Aerosol delivery system

Abstract

An aerosol delivery system (10) is described, comprising a cartridge (30) for use in generating an aerosol from an aerosol generating substrate. The cartridge comprises an insertion portion that at least partially defines an aerosol chamber and a substrate area, and the insertion portion is defined by a longitudinal axis corresponding to the insertion direction. The cartridge also comprises a susceptor (34) provided within the insertion portion, and the susceptor comprises a planar surface that separates the aerosol chamber from the substrate area. The planar surface is provided parallel to the longitudinal axis. Furthermore, a guide assembly (40), a mouthpiece and device component (20) for use in the aerosol delivery system, and a method for generating an aerosol from an aerosol generating substrate in the aerosol delivery system are described.

Description

Technology Field

[0001] The present disclosure relates to an aerosol delivery system, a guidance assembly for use in the aerosol delivery system, a cartridge comprising a susceptor, a device component for use with the guidance assembly, and a method for operating the aerosol delivery system. Background Technology

[0002] Many electronic vapor delivery systems, such as e-cigarettes and other electronic nicotine delivery systems that deliver nicotine through vaporized liquids, are formed by two main components or sections: a cartridge or cartomizer section and a control unit (battery section). The cartomizer generally includes a liquid reservoir and an atomizer for vaporizing the liquid. These components can be collectively designated as an aerosol source. The atomizer generally combines a porous or wicking function with a heating function to transport the liquid from the reservoir to a location where it is heated and vaporized. For example, the atomizer may be implemented as an electric heater, which may be a coil for resistive (Joule) heating or a resistive wire formed in a different shape, or a susceptor for induction heating; or it may be a porous element with capillary or wicking capabilities that, in proximity to the heater, absorbs the liquid from the reservoir and transports it to the heater. The control unit typically includes a battery to supply power for operating the system. Electric power from the battery is supplied to activate a heater, which heats a small amount of liquid supplied from a reservoir to vaporize it. The vaporized liquid is then inhaled by the user.

[0003] Since the components of a cartomizer may be intended for short-term use only, the cartomizer is a disposable component of the system and is also referred to as a consumable. In contrast, the control unit is typically intended for multiple uses, along with a series of cartomizers that the user replaces when each one is depleted. Consumable cartomizers are supplied to the consumer with a reservoir pre-filled with liquid and are intended to be discarded when the reservoir is empty. For convenience and safety, the reservoir is sealed and designed not to be easily refilled, as handling the liquid can be difficult. It is simpler for the user to replace the entire cartomizer when a new supply of liquid is required.

[0004] In this context, it is desirable for atomizers to be simple to manufacture and contain few parts, while still providing an appropriate amount of vapor upon activation of the heater. Therefore, atomizers can be manufactured efficiently in large quantities at low cost, minimizing waste without compromising the user's vaping experience. Consequently, atomizers with simple designs that enable efficient heating are of interest.

[0005] Various approaches intended to help solve some of these problems are described.

[0006] According to a first aspect of specific embodiments, a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate is provided. The cartridge comprises an insert that at least partially defines an aerosol chamber and a substrate region, the insert being defined by a longitudinal axis corresponding to the insertion direction; and the cartridge comprises a susceptor provided within the insert, the susceptor comprising a planar surface separating the aerosol chamber from the substrate region, the planar surface being provided parallel to the longitudinal axis.

[0007] In some examples according to the first aspect, the planar surface extends through the center of the cross-section of the insert, which is perpendicular to the longitudinal axis.

[0008] In some examples according to the first aspect, the cross-section of the insert includes an elliptical or circular periphery, and the planar surface is parallel to the diameter of the cross-section.

[0009] In some examples according to the first aspect, the planar surface is defined by length and width, the length is greater than the width, the length is parallel to the longitudinal axis, the length is in the range of 5 mm to 50 mm, and the width is in the range of 2 mm to 15 mm.

[0010] In some examples according to the first aspect, the susceptor includes a plurality of apertures that extend through the susceptor.

[0011] In some examples according to the first aspect, the susceptor is formed of a material having a capillary structure configured to wick a liquid aerosol generating substrate.

[0012] In some examples according to the first aspect, the susceptor comprises a planar element, and the planar element has a thickness within one or more ranges of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm.

[0013] In some examples according to the first aspect, the cartridge includes a reservoir for a liquid aerosol generating material, and the cartridge is configured to supply the liquid aerosol generating material from the reservoir to the susceptor.

[0014] In some examples according to the first aspect, the substrate region includes a liquid transport element configured to walk a liquid aerosol generating substrate toward a susceptor. Optionally, in some of these examples, the liquid transport element is formed of a susceptor material.

[0015] In some examples according to the first aspect, the substrate area includes one or more liquid flow channels for guiding a liquid aerosol generating substrate from a reservoir. Optionally in some of these examples, the insert includes a plurality of ribs, each of which is configured to abut an individual part of the liquid transport element, and one or more liquid flow channels are defined between individual pairs of ribs among the plurality of ribs.

[0016] In some examples according to the first aspect, the cartridge includes a sub-reservoir provided at or toward the opposite end of the susceptor relative to the reservoir, the sub-reservoir is configured to hold a liquid aerosol generating material with a volume smaller than that of the reservoir, and the cartridge is configured to supply liquid from the sub-reservoir to the susceptor.

[0017] According to a second aspect of specific embodiments, a mouthpiece for use with a cartridge according to a first aspect is provided. The mouthpiece includes an outlet and a cavity configured to receive at least a portion of the cartridge.

[0018] In some examples according to the second aspect, the mouthpiece includes an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration, in the first configuration, a cavity is at least partially exposed to allow a cartridge to be inserted and / or removed, and the second configuration is configured to retain a cartridge provided within the cavity.

[0019] According to a third aspect of specific embodiments, an induction assembly for use with a cartridge according to a first aspect is provided. The induction assembly comprises an induction element positioned about a longitudinal axis corresponding to the insertion direction of the insertion portion of the cartridge; the induction element is operable to induce a current flow in a susceptor, thereby inductively heating the susceptor to aerosolize a portion of an aerosol generating substrate near the susceptor.

[0020] According to a fourth aspect of specific embodiments, an aerosol delivery system for generating an aerosol from an aerosol generating substrate is provided. The aerosol delivery system includes a cartridge according to a first aspect and an induction assembly according to a third aspect.

[0021] In some examples according to the fourth aspect, the aerosol delivery system includes a mouthpiece according to the second aspect.

[0022] In some examples according to the fourth aspect, the aerosol delivery system comprises a device component including a control circuit for controlling the supply of power to an induction element, and the control circuit is configured to drive an induction element of an induction assembly to induce a current flow to a susceptor, thereby inductively heating the susceptor and consequently vaporizing a portion of the aerosol generating substrate near the susceptor.

[0023] According to a fifth aspect of specific embodiments, a method for generating an aerosol from an aerosol generating substrate in an aerosol delivery system is provided, wherein the aerosol delivery system comprises a cartridge and an induction assembly, wherein the cartridge comprises an insertion portion that at least partially defines an aerosol chamber and a substrate region, wherein the insertion portion is defined by a longitudinal axis corresponding to the insertion direction, and the induction assembly comprises an induction element positioned around the longitudinal axis. The method comprises: inserting the insertion portion into a receiving cavity of the induction assembly ― a susceptor provided within the insertion portion, wherein the susceptor comprises a planar surface separating the aerosol chamber from the substrate region, wherein the planar surface is provided parallel to the longitudinal axis ―; and driving the induction element to induce a current flow in the susceptor so as to inductively heat the susceptor and thereby vaporize a portion of the aerosol generating substrate near the susceptor.

[0024] These aspects and additional aspects of specific embodiments are presented in the appended independent and dependent claims. It will be recognized that the features of the dependent claims may be combined with one another and with the features of the independent claims in combinations other than those explicitly stated in the claims. Furthermore, the approach described herein is not limited to specific embodiments such as those described below, but includes and considers any suitable combination of the features presented herein. For example, a heater for a steam supply system or a steam supply system including a heater may be provided according to the approaches described herein, which appropriately include any one or more of the various features described below. Brief explanation of the drawing

[0025] Various embodiments of the present invention will now be described in detail only by example with reference to the following drawings. FIG. 1 illustrates a schematic diagram of an exemplary aerosol / vapor delivery system according to aspects of the present disclosure. FIG. 2 illustrates an exploded perspective view of an exemplary induction assembly according to aspects of the present disclosure. FIG. 3 illustrates an exploded perspective view of an exemplary cartridge according to aspects of the present disclosure. FIG. 4a illustrates a schematic cross-sectional view parallel to the longitudinal axis of an exemplary cartridge according to aspects of the present disclosure. FIG. 4b illustrates a schematic cross-sectional view perpendicular to the longitudinal axis of an exemplary cartridge according to aspects of the present disclosure. FIG. 5 illustrates a schematic diagram of an exemplary cartridge and induction assembly according to aspects of the present disclosure. FIG. 6 illustrates a flowchart depicting a method of generating an aerosol from an aerosol generating substrate in an aerosol delivery system according to the present disclosure. Specific details for implementing the invention

[0026] Aspects and features of specific examples and embodiments are discussed and described herein. Some aspects and features of specific examples and embodiments may be implemented in a conventional manner and are not discussed or described in detail for the sake of brevity. Accordingly, it will be recognized that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented according to any conventional techniques for implementing such aspects and features.

[0027] According to the present disclosure, a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate is described, wherein the cartridge comprises an insertion portion that at least partially defines an aerosol chamber and a substrate area—the insertion portion is defined by a longitudinal axis corresponding to the insertion direction—and a susceptor provided within the insertion portion, wherein the susceptor comprises a planar surface that separates the aerosol chamber from the substrate area, the planar surface being provided parallel to the longitudinal axis. The cartridge as described above comprises a susceptor that can be efficiently heated due to the positioning of the susceptor with respect to the insertion direction, thereby improving the positioning of the susceptor within the induction element when the insertion portion is inserted into the induction assembly. Furthermore, the cartridge is relatively simple to manufacture due to the parallel arrangement of the aerosol chamber and the substrate area created by positioning the planar surface to separate the aerosol chamber and the substrate area.

[0028] As used herein, the term “delivery system” is intended to include systems for delivering at least one substance to a user, and includes non-combustible aerosol providing systems that release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as electronic cigarettes, tobacco heating products, and hybrid systems for generating aerosols using a combination of aerosol-generating materials.

[0029] According to the present disclosure, a "non-combustible" aerosol delivery system is such that the constituent aerosol generating material of the aerosol delivery system (or a component of the aerosol delivery system) does not burn or burn during use in order to enable the delivery of at least one material to a user.

[0030] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0031] In some embodiments, the non-flammable aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it is noted that the presence of nicotine in the aerosol generating material is not a requirement.

[0032] In some embodiments, the non-flammable aerosol providing system is an aerosol-generating material heating system also known as a heat-not-burn system. An example of such a system is a cigarette heating system.

[0033] In some embodiments, the non-flammable aerosol providing system is a hybrid system that generates an aerosol using a combination of aerosol generating materials, one or more of which may be heated. Each of the aerosol generating materials may be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material may include, for example, tobacco or non-tobacco products.

[0034] Typically, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

[0035] In some embodiments, the present disclosure relates to consumables comprising an aerosol-generating material and configured to be used with non-flammable aerosol-providing devices. These consumables are sometimes referred to as articles throughout the present disclosure.

[0036] In some embodiments, a non-flammable aerosol providing system, such as a non-flammable aerosol providing device of a non-flammable aerosol providing system, may include a power source and a controller. The power source may be, for example, an electric power source.

[0037] In some embodiments, the non-flammable aerosol delivery system may include an area for receiving consumables, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0038] In some embodiments, consumables for use with a non-flammable aerosol providing device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0039] In some embodiments, the material to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Where appropriate, either material may comprise one or more active components, one or more flavors, one or more aerosol-forming materials, and / or one or more other functional materials.

[0040] In some embodiments, the material to be delivered includes an active material.

[0041] The active substance used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, nutraceuticals, nootropics, and psychoactives. The active substance may occur naturally or be obtained by synthesis. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other herbal medicines.

[0042] In one embodiment, the active substance is a legally permissible recreational drug.

[0043] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0044] As mentioned in the present specification, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0045] The active substance may be CBD or a derivative of CBD.

[0046] As mentioned herein, the active substance may comprise or be derived from one or more plant medicinal substances or their constituents, derivatives, or extracts. As used herein, the term “plant medicinal substance” includes any material derived from plants, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise an active compound naturally present in the plant medicinal substance obtained by synthesis. The material may be in the form of liquid, gas, solid, powder, granules, crushed particles, granules, pellets, shreds, strips, sheets, etc.

[0047] Examples of herbal medicines include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (e.g., green or black tea), thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, and nutmeg. Oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, Maca, Ashwagandha, Damiana, Guarana,It is chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: Mentha arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0048] In some embodiments, the active substance comprises or is derived from one or more plant medicinal substances or their constituents, derivatives, or extracts, and the plant medicinal substance is tobacco.

[0049] In some embodiments, the active substance comprises or is derived from one or more herbal medicines or their constituents, derivatives, or extracts, and the herbal medicine is selected from eucalyptus, star anise, cocoa, and hemp.

[0050] In some embodiments, the active substance comprises or is derived from one or more herbal medicines or their constituents, derivatives, or extracts, and the herbal medicine is selected from rooibos and fennel.

[0051] In some embodiments, the substance to be delivered includes flavor.

[0052] As used herein, the terms “flavor” and “flavoring agent” refer to materials that, where permitted by local regulations, may be used to produce a desired taste, aroma, or other somatosensorial sensation in products for adult consumers. These include naturally occurring flavoring ingredients, medicinal plants, extracts of medicinal plants, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (licorice candy), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, *Lysimachia vulgaris*, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway,Cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, mate, orange peel, rose, tea (e.g., green tea or black tea), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander, myrtle, cassis, valerian, pimento, mace, demi-en-the-wisp, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, It may include limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives, such as charcoal, chlorophyll, minerals, herbal medicines or breath freshening agents. These may be artificial, synthetic, or natural ingredients or blends thereof. They may be in any suitable form, e.g., liquids such as oils, solids such as powders,Or it could be gas.

[0053] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus, and / or red berry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0054] In some embodiments, the flavor may comprise a sensate intended to achieve a somatic sensation that is perceived by stimulation of the fifth cranial nerve (trigeminal nerve) and generally chemically induced, in addition to or instead of the aroma or taste nerves, and these may comprise formulations that provide heating, cooling, tingling, or numbing effects. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0055] An aerosol-generating material is a material capable of generating an aerosol when, for example, heated, irradiated, or energized in any other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, for example, which may or may not contain active substances and / or flavoring agents. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material capable of retaining some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% of an amorphous solid to about 90 wt%, 95 wt%, or 100 wt% of an amorphous solid.

[0056] The aerosol-generating material may include one or more active substances and / or flavors, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0057] The aerosol-forming agent material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0058] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0059] A consumable is an article containing or constituting an aerosol-generating material, some or all of which is intended to be consumed during use by a user. The consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. Additionally, the consumable may include an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may include a susceptor.

[0060] A susceptor is a material capable of being heated by penetration by a variable magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, and accordingly, penetration by the variable magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and accordingly, penetration into this heating material through the variable magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may possess both electrical conductivity and magnetism, and accordingly, the susceptor may be heated by both heating mechanisms. A device configured to generate a variable magnetic field is referred to herein as a magnetic field generator.

[0061] An aerosol modifier is typically a substance located downstream of the aerosol generation region and is configured to modify the generated aerosol by, for example, changing the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be provided within an aerosol modifier release component operable to selectively release the aerosol modifier.

[0062] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring agent, a coloring agent, water, and a carbon absorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, thread, or granules. The aerosol modifier may not contain a filter material.

[0063] An aerosol generator is a device configured to generate an aerosol from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to an aerosol generating material to release one or more volatile substances from the aerosol generating material to form an aerosol.

[0064] FIG. 1 is a highly schematic (not in scale) drawing of an exemplary aerosol / vapor delivery system (10) according to the present disclosure. The system (10) in this example has a generally elongated shape extending along the longitudinal axis and comprises two main components: a control or power component, section or unit (20) (sometimes referred to as an aerosol / vapor delivery device), and a cartridge assembly or section (30) (sometimes referred to as a cartomizer or clearomiser) that carries an aerosolizable substrate material and operates as a vapor generating component.

[0065] The cartridge (30) comprises a reservoir (33) containing a source liquid (sometimes referred to as a liquid aerosol generating material) or other aerosolizable substrate material containing, for example, nicotine, comprising a formulation such as a liquid or gel from which an aerosol is to be generated. For example, the source liquid may contain about 1 to 3% nicotine and 50% glycerol, with the remainder comprising roughly equal amounts of water and propylene glycol, and possibly other components such as flavoring agents. A source liquid without nicotine may also be used, for example, to deliver flavor. A solid substrate (not exemplified), such as a part of tobacco or other flavor element through which the vapor generated from the liquid passes, may also be included.

[0066] The reservoir (33) takes the form of a storage tank and is a container or receiver in which the source liquid can be stored so that the source liquid can move and flow freely within the boundaries of the tank. In the case of a consumable cartridge, the reservoir (33) may be sealed after filling during manufacturing so that it becomes disposable after the source liquid is consumed, or the reservoir (33) may have an inlet port or other opening that allows new source liquid to be added by the user. In some examples, the cartridge (30) also includes a susceptor (34) for generating an aerosol by vaporizing the source liquid stored in the reservoir tank (33) (sometimes called a heater, susceptor heater, or susceptor heating element). The susceptor (34) is intended for heating via induction, which will be further described below.

[0067] A liquid transport or delivery arrangement, such as a wick or other porous element (35) (sometimes referred to as a liquid transport element or liquid delivery element), may be provided to deliver source liquid from a reservoir (33) to a heater (34). The wick (35) may have one or more parts located inside the reservoir (33), or it may be possible to fluidly communicate with the liquid in the reservoir (33) to absorb source liquid and deliver the source liquid by wicking or capillary action to other parts of the wick (35) that are close to or in contact with the heater (34). This liquid is thereby heated and vaporized, and replaced by new source liquid from the reservoir for delivery to the heater (34) by the wick (35). The wick may be considered as a bridge, path, or conduit between the reservoir and the heater that delivers or delivers liquid from the reservoir (33) to the heater (34). Terms including conduit, liquid conduit, liquid transfer path, liquid delivery path, liquid transfer mechanism or element, and liquid delivery mechanism or element may all be used interchangeably in this specification to refer to a wick or a corresponding component or structure.

[0068] A combination of a heater and a wick (or similar) is sometimes referred to as an atomizer or atomizer assembly, and a reservoir containing the source liquid and an atomizer may be collectively referred to as an aerosol source. Other terms may include a liquid transfer assembly or a liquid transport assembly, and in this context, these terms may be used interchangeably to refer to a vapor generating element (vapor generator) and a wick or similar component or structure (liquid transport element) that transfers or transports the liquid obtained from the reservoir to the vapor generator for vapor / aerosol generation. Various designs are possible in which the parts may be arranged differently from the very schematic representation in FIG. 1.

[0069] In some examples, the wick (35) may be an element completely separate from the heater (34). In other examples, the heater (34) may be porous and configured to directly perform at least part of the wicking function (e.g., metallic mesh or foam). For example, the susceptor (34) (sometimes referred to as a susceptor heating element or heater) may include a capillary structure configured to wick a liquid aerosol generating substrate.

[0070] The vapor generating element may be an induction heating susceptor element (34) operated by induction heating to heat and vaporize the aerosol generating material. Thus, generally, an atomizer may be considered as one or more elements that implement the function of a vapor generating or vaporizing element capable of generating vapor from a source liquid delivered to the atomizer, and a liquid transport or delivery element capable of delivering or transporting liquid from a reservoir or similar liquid reservoir to the vapor generator by wicking / capillary force. The atomizer is typically housed in a cartridge component of a vapor generating system. In some designs, liquid may be dispensed directly from the reservoir to the vapor generator without the need for a separate wicking or capillary element. Embodiments of this disclosure are applicable to all and any such configurations consistent with the examples and descriptions of this specification.

[0071] The liquid transfer element (35) may comprise any suitable wicking material. For example, it may be made of fibers that are grouped, bundled, clumped, woven, or unwoven into a fabric or fibrous mass, with gaps between the fibers to provide a capillary effect for absorbency and wicking. Examples of fibrous materials include cotton (including organic cotton), ceramic fibers, and silica fibers. Other suitable materials are not excluded and will be obvious to those skilled in the art. In some examples (as an alternative to fiber-based materials), the liquid transfer element (35) comprises a solid porous element such as a porous ceramic material or a porous foam. For example, a porous ceramic material comprises a network of fine pores or gaps that can support capillary action and thus provide a wicking ability to absorb liquid from a reservoir and transfer it to the vicinity of a heater for vaporization.

[0072] Returning to FIG. 1, the cartridge (30) includes a housing (36) defining a mouthpiece or mouthpiece portion having an opening or air outlet (12) that allows a user to inhale an aerosol generated by the susceptor (34). In these examples, the outer surface of the housing (36) may be shaped to accommodate the user's lips so that the user can more easily form a seal around the air outlet (12) with their mouth. In other examples (not illustrated), the cartridge (30) may not include or define a mouthpiece. Instead, in some examples, the mouthpiece may be connected to the cartridge (30), or the cartridge (30) may be received within a cavity of a device portion (20) (e.g., defined by the induction assembly (40)) so that the cartridge (30) is completely surrounded by a device portion (20) that provides the mouthpiece itself or is attached to the mouthpiece.

[0073] A power component or device component (20) (which is sometimes referred to as a device or control component because it typically includes a control circuit) includes a power supply (25) that may be rechargeable and such as a cell or battery, for providing power to the electrical components of the system (10), particularly for applying power to an induction element or working coil (42) (described in more detail below) to induce heating of the susceptor (34).

[0074] Additionally, there is a controller (28), such as a printed circuit board and / or other electronic devices or circuits, for generally controlling the aerosol delivery system (10). The control electronic devices / circuits (28) use power from a power supply (25) to operate an induction element (42) in response to a signal from an air pressure sensor (not shown) or an air flow sensor that detects inhalation in the system (10) while air is entering through one or more air inlets (14) (e.g., provided at the junction between the device component (20) and the cartridge (30)), indicating that steam is needed, for example, when a user presses a button (not shown), or while air is entering through one or more air inlets (14) provided between the device component (20) and the cartridge (30).

[0075] When the induction element (42) is activated, the induction element (42) inductively heats the susceptor (34) to a suitable temperature to vaporize the source liquid delivered from the reservoir (33) by the liquid delivery element (35) to generate an aerosol, which is then inhaled by the user through the opening (12) of the mouthpiece of the cartridge housing (36). The aerosol is transported from the aerosol source to the mouthpiece outlet (12) along one or more air channels (e.g., see arrows depicted in FIG. 1) that define an air path (16) connecting the air inlet (14) to the aerosol source and connecting the aerosol source to the air outlet when the user inhales through the air outlet (12).

[0076] In some examples, the device component (20) includes a frame or support structure (22) configured to support, hold, or position various components of the device component (20), including a power supply (25) and a control circuit (28). The frame (22) may also support other components not shown, such as a wired connection port for charging (and optionally, communication) and a PCB, user interface elements (e.g., buttons, LEDs, display screens, haptic feedback units) and / or wireless communication components. The frame (22) may be provided by a single component or may include a plurality of frame components combined to form the frame (22).

[0077] In some examples, the device component (20) includes an outer housing (24) and / or an end cap (26). For example, the outer housing (24) may be a tubular structure or a wrap configured to contain components of the device component (20). For example, a frame (22) containing a power supply (25) and a control circuit (28) may be inserted into the outer housing (24), or the outer housing (24) may be provided around the outside of the frame (22). In some examples, the end cap (26) is provided at one end of the outer housing (24) (e.g., after insertion of the frame (22) containing the power supply (25) and the control circuit (28)) to seal the outer housing (24) (e.g., protect components inside the outer housing (24) from the ingress of water and dust).

[0078] An induction element or work coil (42) may be provided as part of an induction assembly (40) comprising a support structure or housing (44) configured to position or contain the induction element or work coil (42) (i.e., the support structure (44) supports the induction element (42). In some examples, the induction assembly (40) is formed by integrally molding the support structure (44) around the induction work element (42), whereas in other examples, the support structure (44) provides a scaffolding to which the induction work element is attached or fixed.

[0079] In some examples, the induction assembly (40) includes a support (44) having a tube portion positioned around the longitudinal axis of the induction element (42), the tube portion including an inner wall and an outer wall, and the induction element (42) is provided between the inner wall and the outer wall of the tube portion, and the inner wall defines a receiving cavity (49) in which the susceptor (34) (or a part of the susceptor (34)) is at least partially located when a part of the cartridge (30) (i.e., an insertion part) containing the susceptor (34) (or a part of the susceptor (34)) is inserted into the receiving cavity (49).

[0080] In some examples, the induction assembly (40) includes a ferrite shield (48), such as a film, foil, or sheet, which can be held in place by a support structure (44). For example, the ferrite shield may be inserted or embedded within the support structure (44) or wrapped around the outer surface of the support structure (44). The ferrite shield may be used to suppress magnetic flux from the induction element (42) toward the shield when power is supplied to the induction element (42).

[0081] In some examples, the ferrite shield (48) is positioned around the circumference of the induction element (42). In some examples, the ferrite shield (48) comprises a film, foil, or sheet. In some examples, the ferrite shield (48) is inserted or embedded within a support (44) for the induction element (42). In some examples, the ferrite shield (48) comprises a sleeve that surrounds the support (44) for the induction element (42).

[0082] In some examples, the induction assembly (40) is a fixed or permanent component of the device component (20). For example, the support structure (44) may be formed integrally with the frame (22) of the device component (20). In other examples, the induction assembly (40) and the device component (20) are separate connectable components that can be separated from each other by separation in a direction parallel to the longitudinal axis of the aerosol delivery system (10). For example, the components (20, 40) are joined together by cooperative fastening elements (e.g., screws or bayonet fittings) that provide mechanical and electrical connections between the power section (20) and the induction assembly (40) when the system (10) is in use.

[0083] An electrical connection may be required to provide electric power to the induction element (42) when the control circuit (28) determines that power should be supplied to the induction element (42). The control circuit is at least for controlling the supply of power to the induction element, and the control circuit is configured to drive the induction element to induce a current flow to the susceptor, thereby inductively heating the susceptor and consequently vaporizing a portion of the aerosol generating material near the susceptor.

[0084] The use of an interchangeable induction assembly (40) not only improves the ease of replacing the induction assembly (40) in the event of damage or wear, but also potentially enables customization of the system (10) by allowing the user to replace the induction assembly with a different induction assembly having an alternative configuration for operation using a different array of susceptors (34) (e.g., provided by a cartridge (30) having a different configuration).

[0085] In some examples, the induction assembly (40) may seal the end of the outer housing (24) (e.g., to protect components inside the outer housing (24) from the ingress of water and dust). For example, the induction assembly (40) may be provided at the end of the outer housing (24) opposite the end having the end cap (26). The induction assembly (40) may be connected to the frame (22) and / or the outer housing (24) in such a way that a liquid seal is formed to prevent liquid from flowing into the cavity formed by the outer housing (24), the end cap (26), and the induction assembly (40). Alternatively, in some examples, the device component includes a second end cap that is secured to the outer housing (24) and / or the frame (22) between the frame (22) and the induction assembly (40). In some of these examples, the second end cap may be configured to facilitate attaching the induction assembly (40) to the device component (20).

[0086] The device component (power section or control unit) (20) and the cartridge (cartridge assembly) (30) are separate connectable components that can be separated from each other by separation in a direction parallel to the longitudinal axis of the aerosol delivery system (10). In some examples, the components (20, 30) are joined together by cooperating fastening elements (e.g., screws or bayonet fittings) that provide a mechanical connection (and in some examples, an electrical connection) between the power section (20) and the cartridge assembly (30) when the system (10) is in use. For example, a part of the outer housing (24) may be a fastening element (not shown) configured to be connected to a corresponding fastening part (not shown) of the cartridge (30) provided by a part of the cartridge housing (36).

[0087] In some other examples, the induction assembly (40) may facilitate a connection between the device component (20) and the cartridge (30). For example, the induction assembly (40) and the cartridge (30) may include cooperating fastening elements (e.g., screws or bayonet fittings) that provide a mechanical (and optionally electrical) connection between the induction assembly (40) and the cartridge (30) to indirectly connect the cartridge (30) to the device component (20) through the induction assembly (40) (including an electrical connection if necessary).

[0088] In systems using induction heating, if components requiring electric power are not located in the cartridge (30), the electrical connection between the cartridge (30) and the device component (20) may be omitted.

[0089] In some examples, the cartridge (30) and the induction assembly (40) are shaped such that there is a suitable exposure of the susceptor (34) to the magnetic flux generated by the induction element (42) for the purpose of generating current flow in the material of the heater when they are connected (e.g., the cartridge housing (36) and the induction support (44), respectively).

[0090] In examples, the cartridge (30) includes an insert (61) that at least partially defines the aerosol chamber (63) and the substrate area (65). The insert (61) is defined by a longitudinal axis corresponding to the insertion direction. In other words, the insert (61) is inserted into the induction assembly (40) by aligning the insert (61) with the corresponding cavity or recess of the induction assembly (40) and moving the insert (61) toward the induction assembly (40) in the insertion direction. The insert (61) may, for example, alternatively be called a fastener. Furthermore, in some examples, the cartridge (30) may be separated from the induction assembly (40) by moving the cartridge in the opposite direction of the insertion direction.

[0091] In examples, a susceptor (34) is provided within the insert (61). The susceptor includes a planar surface (341) that separates the aerosol chamber (63) from the substrate area (65). The planar surface (341) is provided parallel to the longitudinal axis. The planar surface (341) that separates the aerosol chamber (63) from the substrate area (65) means that the planar surface defines the boundary of the aerosol chamber (63) on the side adjacent (or closest) to the substrate area (65).

[0092] As will be discussed below, in some examples, the susceptor (34) comprises a planar element (e.g., a thin metal sheet of about 20 µm to 70 µm) acting as a wall between the aerosol chamber (63) and the substrate area (65); in other examples, the susceptor (34) comprises a block of material additionally configured to hold and / or transport the aerosol-generating substrate. In these examples, the block comprises a planar surface (341) that extends into (and can fill) the substrate area (65) and is adjacent to the aerosol chamber (63), and this planar surface marks the extent of the substrate area (65) toward the aerosol chamber (63).

[0093] Accordingly, the susceptor (34) divides the aerosol chamber (63) from the substrate area (65) within the insertion portion (61). In some examples, the aerosol chamber (63) includes a channel (a channel forming part of the air path (16)) that extends through (at least) the insertion portion (61) of the cartridge (30), and the periphery of the aerosol chamber (63) is defined by the housing (36) providing the insertion portion (61) and the flat surface (341) of the susceptor (34). Similarly, in some examples, the periphery of the substrate area (65) is defined by the housing (36) providing the insertion portion (61) and the susceptor (34) (e.g., a first flat surface (341) if the susceptor (34) is a block for holding the substrate, or a second flat surface opposite the first flat surface (341) if the susceptor (34) is a flat sheet).

[0094] In some examples, the planar surface (341) extends through the center of the cross-section of the insert (61) perpendicular to the longitudinal axis. For example, the insert (61) may be considered to be defined by a peripheral boundary or circumference having a cross-sectional shape perpendicular to the longitudinal axis (i.e., the insertion direction). In some examples, the external cross-sectional shape of the insert (61) perpendicular to the longitudinal axis may be constant for substantially the entire length of the insert (61). For example, the external cross-sectional shape may be constant except for the end of the insert (61) that is joined or connected to the remainder of the cartridge housing (36) (e.g., the mouse end or storage portion), or the end of the insert (61) that defines the end of the cartridge (30) (e.g., the end of the insert (61) that is first inserted into the induction assembly (40).

[0095] The center of the cross-section of the insert (61) perpendicular to the longitudinal axis may be defined as the geometric center of the periphery boundary or circumference. In some examples where the susceptor (34) is a planar element, the planar element may extend through the center of the cross-section of the insert (61) perpendicular to the longitudinal axis. Extending through the center of the cross-section means that the planar surface (341) is positioned within the insert (61) such that the center of the cross-section of the insert (61) intersects the planar surface (341) (or the susceptor (34) in the form of a planar element). This ensures that the aerosol generating zone of the susceptor (34) is substantially centered on the induction element (42) (e.g., a spiral coil coiled around the longitudinal axis) surrounding the insert (61).

[0096] In some examples, the cross-section of the insert (61) includes an elliptical or circular periphery, and the flat surface is parallel to the diameter of the cross-section. For example, the insert (61) may be formed in a rod shape having a circular or elliptical shape perpendicular to the direction of extension. The part of the susceptor (34) providing the flat surface (341) is aligned with the diameter such that the flat surface intersects the center of the circular or elliptical shape. As above, this can ensure that the aerosol generating zone of the susceptor (34) is substantially centered on the guiding element (42) surrounding the insert (61).

[0097] In some examples, the insert (61) includes an air inlet for introducing air into the aerosol chamber (63) and / or an outlet that allows the aerosol to exit the aerosol chamber (63) (the aerosol chamber (63) provides part of the air path (16). When in use, air in the air path (16) is guided to the air inlet (e.g., from a channel between the induction assembly (40) and the cartridge (30), passes through the aerosol chamber (63) where the aerosol can be formed, and then the aerosol (or vapor) accompanied by the air is drawn out of the aerosol chamber (63) toward the outlet (12) of the system (10). In other examples, the air inlet for introducing air into the aerosol chamber (63) may be provided by a different part of the housing (36).

[0098] As described above, aspects of the present disclosure relate to induction heating. This is a process in which an electrically conductive item, typically made of metal, is heated by electromagnetic induction through eddy currents flowing through the item to generate heat. An induction element (42) (e.g., a working coil) acts as an electromagnet when a high-frequency alternating current from an oscillator passes through it; this generates a magnetic field. When a conductive item (i.e., a susceptor (34)) is placed within the magnetic flux of the magnetic field, the magnetic field penetrates the item and induces electric eddy currents. These flow through the item and generate heat according to the flow of current against the electrical resistance of the item through Joule heating, in the same way that heat is generated in a resistive electric heating element by a direct supply of current.

[0099] An attractive feature of induction heating is that it does not require electrical connections to conductive items; instead, the requirement is that sufficient magnetic flux density be generated in the area occupied by the item. In the context of vapor delivery systems requiring heat generation near a liquid, this is advantageous because it allows for more effective separation of the liquid and the current. Assuming that other electrically powered items are not placed in the atomizer, no electrical connection is required between the cartridge and its power section, and a more effective liquid barrier can be provided by the atomizer walls, thereby reducing the possibility of leakage.

[0100] As described above, induction heating is effective for the direct heating of electrically conductive items, but it can also be used to indirectly heat non-conductive items. In a vapor delivery system, it is necessary to provide heat to the liquid within the porous wicking part of the atomizer to cause vaporization. For indirect heating via induction, an electrically conductive item is placed close to or in contact with the item requiring heating, and between the working coil and the item to be heated. The working coil directly heats the conductive item by induction heating, and heat is transferred to the non-conductive item by thermal radiation or thermal conduction. In this arrangement, the conductive item is called a susceptor. Therefore, in the atomizer, the heating component may be provided by an electrically conductive material (typically metal) used as an induction susceptor to transfer thermal energy to the liquid in close proximity to the atomizer (e.g., held by the wick (35) and / or the susceptor (34) itself).

[0101] The susceptor (34), sometimes called a heater or susceptor heating element, may be formed from a suitable material that is electrically resistive / conductive, that is, capable of carrying current. This allows the heater to raise its temperature by being exposed to a magnetic field generated by a high-frequency alternating current in a working coil, which induces eddy currents in the heater material through the inductive effects as mentioned above.

[0102] In some examples, the susceptor (34) comprises a sheet of suitable material that is appropriately dimensioned and shaped to form a heater. The element suitable for the heater (34) (susceptor) is made of an electrically conductive material having sufficient resistance to enable heating by inductive effect through induced eddy currents. In some examples, the susceptor (34) is provided by a flat element such as a sheet. For example, the susceptor (34) is a sheet or foil of metallic material, wherein suitable metals include mild steel, ferritic stainless steel, aluminum, nickel, cupronickel, nichrome (nickel-chrome alloy), and alloys of these materials. In some examples, the sheet may be a laminate of two or more layers of materials. In some examples, the sheet thickness must be thin enough to allow a portion having a curved shape to be formed to create a heater without requiring excessive force, and thick enough to maintain the curved shape once the sheet is formed without the sheet returning to its original configuration (e.g., a flat sheet).

[0103] It may be necessary to balance the need to provide a thickness of planar element that satisfies these requirements and a sufficient volume of resistant material to provide sufficient heating (recalling that in some examples the amount of material is reduced by perforations). Accordingly, in some examples, the susceptor comprises a planar element, and the planar element has a thickness within one or more of the ranges of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm.

[0104] In some examples, the thickness of the sheet providing the susceptor (34) may be in the range of about 20 µm to about 70 µm, for example, about 30 µm to about 60 µm, or about 40 µm to about 55 µm. These values ​​may be the total thickness of the sheet including any support elements or coatings. If the thickness is insufficient, the heater may lack sufficient structural integrity, but this can be compensated for by additional components (e.g., support components).

[0105] In some examples, the susceptor for the heater (34) has a simple rectangular shape or profile. For example, the susceptor (34) may be formed from a rectangular sheet having a length (e.g., 5 mm to 50 mm) and width (e.g., 2 mm to 15 mm) that are significantly larger than the thickness of the sheet (e.g., 20 µm to 70 µm). In other examples, the element providing the susceptor may have an alternative shape, such as a non-rectangular, polygonal shape, or a circular or elliptical shape. This may be particularly useful when heating is intended to be concentrated on specific zones or parts within the cartridge (30). In some of these examples, the susceptor may be provided in a shape corresponding to the zones where a relatively large magnetic flux from the induction element is incident.

[0106] In some other examples, the susceptor (34) is not provided by a sheet (i.e., defined by two dimensions and a thickness that is a relatively small order of magnitude compared to the two dimensions), but, for example, may instead be provided by a block element having a thickness similar to two dimensions defining the planar surface of the susceptor (34); this element or block is formed of a suitable electrically conductive material having sufficient resistance to enable heating by inductive effects through induced eddy currents. For example, the susceptor (34) may comprise an induction-heatable material such as wire wool or mesh (e.g., (ferritic) stainless steel mesh) or a metal foam formed into a suitable shape (e.g., nickel foam or cupronickel foam). In contrast to the sheet providing the susceptor (34), the block (provided by, for example, stainless steel mesh or nickel foam) may have a thickness in the range of 0.5 mm to 5 mm. In some examples, the stainless steel mesh or nickel foam may have a thickness within the range of 1.5 mm to 3 mm.

[0107] In some examples, the block element may have a shape such as a flat slab (e.g., a rectangular prism) having the thickness described above. In some examples, the block element may be formed in the shape of a semicircular rod (e.g., a rod having a semicircular cross-section perpendicular to the direction of extension of the rod). Such a semicircular rod may have a profile or shape that matches the corresponding cavity within the insert (61) (e.g., the substrate area (65)). In some examples, the suitable block element may be formed by pressing a steel mesh into the required shape or by forming a nickel foam within a mold having the required shape.

[0108] In some examples, the susceptor (34) (sometimes referred to as a susceptor heating element (34) or a heater (34)) includes a plurality of apertures extending through the susceptor (34). These apertures may be referred to as perforations or holes. In some examples, the plurality of perforations may be holes cut or punched through the material of the susceptor (34) formed from a flat element (e.g., a sheet of material). Each hole is small compared to the total external surface area of ​​the susceptor (34) (e.g., the plane of the sheet). In some examples, the holes are relatively densely packed and uniformly distributed over the surface of the susceptor (34) so ​​that many holes are included. The holes may be, for example, circular, elongated, or slotted. The purpose of the holes is to allow the generated vapor to more easily escape from the atomizer (e.g., wick and susceptor) into the aerosol chamber and be collected by the airflow through the aerosol chamber. For example, when the liquid in the wick (35) in the atomizer is vaporized by heat from the heater (34), the generated vapor can flow through the holes into the free space of the air path (16) near the heater (34).

[0109] When designing the heater (34), it may be necessary to strike a balance between the increased ease of steam flow provided by additional perforations and the reduced amount of heater material available for heating. Accordingly, an optimal total area for the perforations can be considered relative to the area of ​​the heater material that generates heat and provides heat for vaporization. If the total heater material area without any holes is defined, the range for the total area occupied by the perforations may be, for example, about 5% to 30% of the total heater material area, for example, about 20%. In any case, it is useful that the total area of ​​the perforations does not exceed about 50% due to manufacturing constraints. Furthermore, too large an open area (total area of ​​the perforations) can lead to poor induction coupling when induction heating is used, while too small an open area makes it difficult for the generated steam to escape from the wick (35).

[0110] In some examples, the planar surface (341) of the susceptor (34) is defined by its length and width (e.g., if the planar surface is rectangular), and the length is greater than the width. In some of these examples, the length is parallel to the longitudinal axis of the induction element (42). The susceptor (34) is inserted into the induction element (42) along its length, so that the size of the induction element (42) must accommodate the smaller width between the individual faces of the induction element (42) (e.g., the diameter of the spiral coil providing the induction element (42) must be large enough to accommodate the width of the susceptor (34) defined by the planar surface (341), but not necessarily the length).

[0111] In some examples, the number density of multiple apertures varies along the length and / or width of the planar surface. Number density refers to the number of apertures per unit area. In some examples, the number density of multiple apertures increases monotonically along the length of the susceptor (34). For example, the number density may increase from the end of the susceptor (34) near the reservoir (33) toward the end of the susceptor (34) far from the reservoir (33).

[0112] In some examples, the number density of multiple apertures increases or decreases along the width from the edges of the planar surface (341) toward the center of the planar surface (341). In other words, the number density of multiple apertures increases from the edges of the susceptor (34) (perpendicular to the ends defining the length) toward the center of the susceptor (34).

[0113] In some examples, the wick (35) comprises an induction-heatable material such as stainless steel mesh or nickel foam. The wick (35) formed from the induction-heatable material may also provide a heater (34) component (e.g., a combined wick-heater atomizer) or may be added to the heater (34) (e.g., a wick portion of an atomizer formed by the wick (35) and the heater (34)). When the wick (35) is placed within the magnetic flux of a magnetic field, the magnetic field penetrates the item and induces electric eddy currents. These flow through the item and generate heat according to the flow of current against the item's electrical resistance through Joule heating, in the same way that heat is generated in a resistive electric heating element by a direct supply of current. In some examples, particularly when the wick (35) is used with a separate susceptor (34), the wick (35) can contribute to heating the liquid and can also retain residual heat or latent heat between puffs, which can act to reduce the amount of time or energy required to heat the susceptor (34) to the vaporization temperature on subsequent puffs. In particular, the wick (35) may have a large mass relative to the susceptor (34), which acts to store latent heat, while the relatively low mass of the susceptor (34) enables rapid heating of the susceptor (34).

[0114] In some examples, the stainless steel mesh or nickel foam providing the wick (35) has a shape corresponding to the susceptor (34). For example, the wick (35) and the susceptor (34) may include abutting surfaces configured to ensure proper contact between the wick (35) and the susceptor (34) when the wick (35) and the susceptor (34) are provided in the insertion portion (61). If the susceptor (34) is a flat element, the wick (35) may abut a second susceptor surface of the susceptor (34) on the opposite side of the susceptor (34) with respect to the flat surface (341). In some examples, the wick (35) may assist in the positioning of the susceptor (34) by applying a holding force to the susceptor (34) caused by the positioning of the susceptor (34) between the element of the housing (36) and the wick (35) to push the susceptor (34) into the element of the housing (36) defining the compression and insertion portion (61) of the wick (35).

[0115] In some examples, a liquid transport element (35) (or wick) provides liquid to a second susceptor surface opposite to the first susceptor surface of the susceptor (34). In some examples, the liquid may be supplied to the susceptor (34) through the liquid transport element (35) and subsequently, when the liquid vaporizes, and the liquid may pass through the susceptor (34) from the second susceptor surface to the first planar surface (341) (e.g., by one or more apertures extending through the susceptor (34)).

[0116] In some examples, the liquid transport element (35) comprises a semicircular rod, the flat surface of which abuts the surface of the second susceptor. A semicircular rod means a rod having a semicircular cross-section perpendicular to the direction of extension of the rod. It will be recognized that such a rod has a flat surface defining the diameter of the circle and a curved surface defining the 180° arc of the circle. In some examples, the curved surface is configured to correspond to the shape of the substrate area (65), so that an interference fit is provided between the liquid transport element (35) and at least a portion of the housing defining the substrate area (65), thereby assisting in holding the liquid transport element (35) in place. In other examples, it will be recognized that a rod may be provided that comprises a flat surface for abutting the susceptor (34) but does not have a curved surface or a semicircular cross-section. For example, the rod may be a rectangular prism or may have a cross-section defined by a plurality of curved surfaces and / or linear surfaces in addition to the flat surface.

[0117] Returning to FIG. 1 in more detail, in the illustrated example, the cartridge (30) and the induction assembly (40) are shaped such that when the cartridge (30) and the induction assembly (40) are connected, a portion of the cartridge (30) is received within a cavity or void (49) of the induction assembly (40). The cavity or void (49) may be referred to as a receiving cavity (49). In some examples, the receiving cavity (49) is defined by a housing or support (44) of the induction assembly (40). For example, the support (44) may include an inner surface that defines the shape of the receiving cavity (49). A portion of the support (44) that defines a portion of the receiving cavity (49) may be a tubular support.

[0118] In examples such as those according to FIG. 1, the induction element (42) is provided in the form of a spiral or helical induction element (42). In these examples, the induction element (42) is substantially formed as a coil that surrounds the axis and extends along the axis. In examples such as those according to FIG. 1, the axis on which the induction element (42) is formed is parallel to the longitudinal axis of the system (10).

[0119] In some examples, the induction element (42) is formed by a conductive element or component embedded within the surface of the support (44) defining the receiving cavity (49) (e.g., within the tubular portion of the support (44)) or provided on the surface. The induction element (42) is provided so that a portion of the cartridge (30) inserted into the receiving cavity (49) is within the coil of the induction element (42). In particular, a portion of the cartridge (30) containing the susceptor (34) is provided within the coil of the induction element (42) when the cartridge (30) is received in the receiving cavity. When in use, an AC current passes through the helical induction coil (42), causing the generation of a changing magnetic field, which rapidly heats the susceptor (34) by generating eddy currents within the susceptor (34) of the cartridge (30), which can cause an aerosol to be generated.

[0120] As such, in some examples, the support member (44) comprises a substantially tubular or annular body having a size corresponding to the induction element (42). For example, the inner diameter of the tubular support member (44) may be equal to the required diameter of the induction element (42) received on the inner surface of the tubular portion of the support member (44), or the outer diameter of the tubular support member (44) may be equal to the required diameter of the induction element (42) received on the outer surface of the tubular portion of the support member (44) (e.g., the induction element (42) deposited on the surface or embedded within grooves provided on the surface, as discussed below).

[0121] In some examples, the coil of the induction element (42) may have a fixed number of windings per unit length (i.e., along the axis), or the number of windings per unit length may differ in different sections of the coil of the induction element (42). In some examples, the coil may be considered to have a total length that can be subdivided into two or more sections. In some examples, the coil comprises two identical sections (i.e., the length of the first section is equal to the length of the second section, and the number of windings per unit length in the first section is equal to the number of windings per unit length in the second section). However, in other examples, the number of windings per unit length may be greater in the first section than in the second section, or vice versa.

[0122] In some examples, the coil may comprise multiple sections, and at least some of the sections may have different or identical numbers of windings per unit length. Likewise, in some examples, the induction element (42) comprises two or more separate coils, each of which may have the same or different number of windings per unit length and / or a total length. A change in the number of windings may increase or decrease the rate at which the susceptor (34) is heated (e.g., the rate at which the susceptor can reach its maximum operating temperature). If desired, this arrangement may provide asymmetric heating of the susceptor materials within the cartridge along the length of the cartridge (30) accommodated in the receiving cavity (49).

[0123] In some examples, the induction assembly (40) includes a first induction element (42) and a second induction element, both of which are positioned around the same longitudinal axis. In these examples, a first portion of the susceptor (34) is located at least partially within the first induction element, and a second portion of the susceptor (34) is located at least partially within the second induction element. The first induction element and the second induction element are operable to induce a current flow in the second portion of the susceptor to induce heating of the first portion and the second portion of the susceptor (34), respectively.

[0124] As described above, in some examples, the first induction element and the second induction element may have the same length, diameter, and number of windings per unit length (including any variation in the number of windings per unit length), or alternatively, one or more of the length, diameter, and number of windings per unit length (including variation in the number of windings per unit length) may differ between different induction elements. Furthermore, in some systems having additional induction elements, each additional induction element may be the same as or different from one or more other induction elements.

[0125] In some examples, the first part of the susceptor (34) and the second part of the susceptor (34) are parts of a single susceptor. For example, the susceptor (34) may be a tube component that extends into both the first guiding element and the second guiding element.

[0126] In some examples, the first part of the susceptor (34) is separate and distinct from the second part of the susceptor (34). For example, each part of the susceptor (34) may be a separate component, such as a separate tube component.

[0127] In some examples, the induction element (42) is formed by a resistive wire, such as nickel or cupronickel wire, configured or arranged in a spiral or helix shape (e.g., spiral coil or helical coil). In some examples, the induction element is a Litz coil. In some examples, the resistive wire providing the induction element (42) is provided to a support (44) that acts to maintain the resistive wire in a specific shape (e.g., three-dimensional spiral). In some of these examples, the resistive wire may be embedded within the support. In other examples, the resistive wire providing the induction element (42) is substantially self-supporting in that the resistive wire can support orientation and configuration for an anchor position (i.e., where the resistive wire is connected to the support (44)). For example, the resistive wire may be a material that is sufficiently rigid to maintain configuration throughout continuous use (e.g., a suitably thick wire).

[0128] In some examples, the induction element (42) may be printed or deposited on a portion of the substrate or support (44). In some examples, a laser is used to activate the surface of the support (44), and the support (44) may comprise a thermoplastic material such as polyetheretherketone (PEEK) which may be doped with a metallic inorganic compound. The laser creates one or more laser-activated zones on the support (44), which may then be further metallized, for example, using an electroless plating process to build one or more conductive layers of copper. For example, the induction element (42) may be deposited on a tubular portion of the support (44) to form a spiral induction coil or a helical induction coil (i.e., a spiral coil or a helical coil).

[0129] Forming an inductive element (42) by printing or depositing a conductive layer on the support (44), for example using a laser direct structuring process as described above, results in the formation of an inductive element (42) that is integrated with or within the support (44). This advantageously allows for a reduction in the size of the required support (44) compared to the support (44) suitable for holding the resistive wire providing the inductive element (42), and thus enables the inductive assembly (40) to be provided in a more compact arrangement.

[0130] In the example of FIG. 1, the portion of the induction assembly (40) containing the induction element (42) is a portion of the support structure (44) or housing of the induction assembly (40) (sometimes referred to as the support portion (44) as above). In some examples, the support structure (44) surrounds the induction element (42), thereby providing a protective housing for the induction element and / or supporting or maintaining the position of the induction element (42) within the induction assembly (40). In some other examples not illustrated, at least a portion of the induction element (42) may not be covered by the support structure (44). In these examples, the induction element (42) may be exposed to ambient air. Additionally, the support portion (44) may provide other functions, such as facilitating the attachment of the induction assembly (40) to the control portion (20).

[0131] As mentioned above, the susceptor (34) is configured to provide a planar surface that is accommodated within the helical or helical shape of the induction element (42). By providing the susceptor (34) within the induction element (42), there is a suitable exposure of the susceptor (34) to the magnetic flux generated by the induction element (42) for the purpose of generating current flow in the material of the susceptor (34). In this way, the susceptor (34) responds to the magnetic field generated by the induction element (42).

[0132] The distance separating the susceptor (34) (e.g., the outer surface of the susceptor (34)) from the inductive element (42) (e.g., the inner diameter of the spiral shape of the inductive element (42)) is sometimes called the coupling distance. Without being bound by theory, the susceptor (34) and the inductive element (42) effectively form a pair capable of transmitting or transferring energy to the susceptor (34) when the inductive element (42) is inductively coupled to the susceptor and current is applied to the inductive element (42). The coupling distance is related to the distance over which energy is transferred from the inductive element (42) to the susceptor. The further the susceptor (34) is (i.e., the greater the coupling distance), the greater the energy loss.

[0133] In examples, the coupling distance is based on the diameter of the induction element (42) (e.g., because the susceptor (34) is received within the induction element (42)) and the width of the susceptor within the induction element (42). In some examples, the susceptor (34) is configured to provide a planar surface (341) substantially centered with respect to the induction coil (42) when the insert (61) is received in the induction assembly (40). For example, the susceptor (34) may be a planar element that intersects the center of the induction element (42).

[0134] In these examples, the coupling distance differs for different parts of the susceptor (34), the central part of the planar surface (341) has a maximum distance from the induction element (42), and the edge part (which defines the width of the planar surface (341)) has a reduced coupling distance. In some examples, where the susceptor (34) is provided by a block element, parts of the susceptor (34) far from the planar surface (341) also have a reduced coupling distance. The coupling distance away from the center of the planar surface (341) may depend on the thickness of any peripheral housing of the insert (61) and the induction element (42) (e.g., support (44)), and also on the width of any air gap between the insert (61) and the induction assembly (40), as these factors limit the possible width of the susceptor (34). Thus, without being bound by theory, different parts of the susceptor (34) having different coupling distances are heated differently by the magnetic field.

[0135] In some examples, the coupling distance is within a range of less than 5 mm for all parts of the susceptor (34). In some examples, the coupling distance is within a range of less than 3 mm for all parts of the susceptor (34).

[0136] As illustrated in FIG. 1, in some examples, the aerosol delivery system (10) includes an air path (16) partially defined by the volume between the surface of the induction assembly (40) defined by the insert (61) received within the receiving cavity (49) and the support (44). The portion of the air path (16) is provided between the inlet (14) and the vapor / aerosol generating portion of the air path provided within the cartridge (30). As mentioned above, in these examples, the separation (e.g., coupling distance) between the susceptor (34) and the induction assembly (40) can be at least partially determined by the width or size of the portion of the air path (16) formed between the cartridge (30) and the induction assembly (40), and the air path (16) in this portion of the system (10) needs to be sized to enable an appropriate airflow. In some examples, the separation between the cartridge (30) and the induction assembly (40) is within the range of 0.2 mm to 1 mm.

[0137] In some other examples, where the air path (16) does not extend between the longitudinal portions of the insert (61) and the support (44), the separation between the insert (61) and the guide assembly (40) is within a range of up to 0.5 mm and preferably less than 0.2 mm. A small separation between the insert (61) and the guide assembly (40) can form a press fit that helps hold the cartridge (30) together with the guide assembly (40).

[0138] The design of FIG. 1 is merely an exemplary arrangement, and various parts and features may be distributed differently between the power section (20) and the cartridge assembly section (30), and other components and elements may be included. The two sections may be connected end-to-end in a longitudinal configuration as in FIG. 1, or in different configurations such as a parallel arrangement. The system may generally be cylindrical and / or generally have a longitudinal shape, or may generally not be cylindrical and / or generally not have a longitudinal shape. Any one or both of the sections or components may be intended to be discarded and replaced when depleted (e.g., when the reservoir is empty or the battery is discharged), or may be intended for multiple uses made possible by operations such as reservoir refilling and battery recharging. In other examples, the system (10) may be a monolithic entity in that the parts of the device component (20) (including the induction assembly (40)) and the cartridge (30) are contained in a single housing and cannot be separated. The embodiments and examples of the present disclosure are applicable to any of these configurations and other configurations known to those skilled in the art.

[0139] FIG. 2 is an exploded view of an exemplary induction assembly (40) according to the present disclosure. The exploded view of the induction assembly (40) depicts an exemplary support structure or housing (44) (sometimes referred to as a support), an induction coil (42) (e.g., an example of an induction element (42)), and a ferrite shield (48). The exemplary housing (44) includes a (tubular) receiving portion (46) and a base portion (45). Aspects of the induction assembly (40) may be as described in relation to FIG. 1.

[0140] The induction assembly (40) is intended to be used with the cartridge (30) according to the present disclosure. The induction assembly (40) includes an induction element (42) positioned around a longitudinal axis corresponding to the insertion direction of the insertion portion (61) of the cartridge (30). The induction element (42) can be operated to induce a current flow in the susceptor (34) to induce heating of the susceptor (34), thereby aerosolizing a portion of the aerosol generating material near the susceptor (34).

[0141] The receiving portion (46) is configured to define a receiving cavity (49) in which a portion of the cartridge (30) including the susceptor (34) is received when the cartridge (30) and the induction assembly (40) are combined. The receiving portion (46) may have a tubular or annular shape in which an internal void is configured to define the receiving cavity (49).

[0142] In some examples, the configuration of the receiving portion (46) corresponds to the configuration of the portion of the cartridge (30) received in the cavity (49) of the receiving portion (46). For example, if the portion of the cartridge (30) is cylindrical, the receiving portion (46) may be in the shape of a circularly symmetrical tube. Alternatively, if the portion of the cartridge (30) is not cylindrical and, for example, has an elliptical cross section, the receiving portion (46) may be configured to provide a cavity (49) having a cross section of the same shape. In some examples, the cross section of the receiving portion (46) may be slightly larger than the cross section of the portion of the cartridge (30) to enable airflow between the receiving portion (46) and the cartridge (30).

[0143] The receiving portion (46) of FIG. 2 additionally includes a helical recess (47) for receiving a helical coil. In the illustrated example, the induction assembly (40) is formed by providing an induction element (42) (i.e., a helical coil in this example) suitable for the helical recess (47) (and optionally by surrounding or sleeving it with a ferrite shield (48). The helical recess (47) of the receiving portion (46) may extend between the first opposing face and the second opposing face as illustrated, or the helical recess (47) may be inside the housing (44) (i.e., to encapsulate the induction element (42)). In other examples, if the induction element (42) does not include a helical coil, it will be recognized that the receiving portion (46) will not include a helical recess (47) and instead may include a surface on which a recess of a different configuration or an induction element (42) can be formed.

[0144] In some examples, the thickness of the receiving portion (46) (e.g., the thickness of the tubular walls) is selected to be equal to or approximately equal to the width of the induction element (42) received in the spiral recess (47) (e.g., the diameter of the wire providing the spiral coil). Being approximately equal means that the thickness may be slightly smaller than the width of the induction element (42) (more than 95% of the width) or slightly larger than the width of the induction element (42) (less than 105% of the width). In some examples, the thickness of the receiving portion (46) is selected to provide structural rigidity to the induction assembly (40) and / or support for the induction element (42).

[0145] The base (45) includes attachment features (43) configured to facilitate the connection of the housing (44) to the control unit (20) (i.e., the control unit (20) of FIG. 1) having corresponding attachment features. In some examples, the attachment features (43) allow the induction assembly (40) to be reversibly connected to the control unit, so that the induction assembly (40) can be removed and replaced without damaging the control unit or the induction assembly (40). In some other examples, where the induction assembly (40) is an integral component of the control unit, the attachment features (43) may be omitted (e.g., the housing (44) may be formed integrally with the housing of the control unit), or the attachment features (43) may be configured to provide a permanent attachment that is not intended to be reversible (i.e., detached).

[0146] The base (45) can also facilitate the electronic connection of the induction element (42) to the control unit (20). In some examples, the base (45) includes through holes (41) for individual ends of the wire coil providing the induction element (42), or for electrodes connected to the induction element (42). In some examples, the through holes (41) extend from the top surface of the base (45) to the bottom surface so that the wire ends or electrodes can pass through the base (45) toward the interface with the device component (20).

[0147] In some examples, the base (45) further includes one or more channels that provide part of the air path (16). The channels may guide or facilitate airflow, for example, through the base (45) and into the receiving cavity (49) defined by the receiving portion (46). A suitable channel may be aligned with a corresponding channel provided by the cartridge (30) (i.e., a channel partially defined by the susceptor (34)) so that air may flow from the induction assembly (40) into the channel of the cartridge (30). In some examples, the channel may extend into a recessed cavity on the lower side of the base (opposite the receiving portion (46)) configured to enable airflow between the base (45) and the device part (e.g., the surface of the housing of the device part as shown in FIG. 1).

[0148] According to some examples, FIG. 2 depicts an inductive element (42) comprising a wire coil. The wire coil is a wire of a defined length that is composed of a spiral coil or has a specific shape. In practice, the wire coil can be shaped into the required form by winding the wire of the coil onto the outer surface of the receiving portion (46) (e.g., by winding the wire within the spiral recess (47)). The wire coil further comprises two individual ends (421) configured to enable the formation of a circuit for transmitting power through the wire coil providing the inductive element (42). The individual ends (421) can be inserted into the through holes (41) of the base portion (45) when the wire coil is combined with the support portion (44).

[0149] According to some examples, FIG. 2 depicts a ferrite shield (48). In the example of FIG. 2, the ferrite shield (48) includes a sleeve provided over the receiving portion (46) and the induction element (42) (i.e., the receiving portion (46) and the induction element (42) are inserted into the sleeve of the ferrite shield (48), or the ferrite shield (48) is wound around the receiving portion (46) and the induction element (42). The ferrite shield (48) acts to block or suppress magnetic flux in an outward direction from the induction element (42) when current is applied through the induction element (42).

[0150] FIG. 3 is an exploded perspective view of an exemplary cartridge (30) according to the present disclosure. The cartridge (30) may be intended for use with an induction assembly (40) including a support (44) of FIG. 2. The cartridge (30) includes an upper housing (361), a lower housing (362), a seal (363), a susceptor (34), and a liquid transport element (35) (sometimes called a wick). Various aspects of the cartridge (30) may be as described in relation to FIG. 1.

[0151] The susceptor (34) of FIG. 3 comprises a planar element provided with a plurality of apertures (345). The susceptor (34) of FIG. 3 may be formed from a sheet of material (e.g., nickel, cupronickel, aluminum). The planar element provides a planar surface (341) defined by its length and width, where the length is greater than the width. The susceptor (34) is received together with the insertion part (61) such that its length is parallel to the longitudinal axis of the insertion part (61) of the cartridge (30) corresponding to the insertion direction. In some examples, the length is within the range of 5 mm to 50 mm. In some examples, the width is within the range of 2 mm to 15 mm.

[0152] The liquid transport element or wick (35) of FIG. 3 comprises a rod formed of a suitable wicking material (e.g., cotton or synthetic material). In the example of FIG. 3, the rod is a semicircular rod in which the cross-sectional shape of the rod perpendicular to the direction of extension of the rod is semicircular. The susceptor (34) of FIG. 3 is positioned close to the flat surface of the wick (35) of FIG. 3 (defined over the diameter of the semicircle) so that the wick (35) can supply liquid to the surface of the susceptor (34) opposite the flat surface (341). The flat surface (341) of the susceptor (34) opposite the surface to which the liquid is supplied defines a part of the (not shown) aerosol chamber (63) within the insert (61).

[0153] The susceptor (34) of FIG. 3 includes a plurality of apertures, holes, or perforations (345) that extend through the material of the susceptor (34). The plurality of perforations (345) may be provided by cutting or drilling holes through the material of the susceptor (34). Each hole is small relative to the surface area of ​​the susceptor. The purpose of the holes (345) is to allow the generated vapor to more easily escape through the susceptor (34) into the air path (16) (i.e., aerosol chamber) within the susceptor (34) and be collected by the airflow through the air path (16). For example, when the liquid in the wick (35) near the susceptor (34) is vaporized by heat from the susceptor (34), the generated vapor may flow inward through the perforations (345) into the free space of the air path (16) defined by the surface of the susceptor (34).

[0154] As discussed in relation to FIG. 1, in some examples, the liquid transport element (35) is formed of a magnetically heatable material such as steel mesh or nickel foam. In these examples, the liquid transport element (35) may be further heated in response to the generation of a magnetic field by the induction element (42). In other words, the liquid transport element may be formed of a susceptor material. Compared to the susceptor (34), the volume and mass of the liquid transport element (35) are significantly larger (for example, the liquid transport element (35) has a width of 0.5 mm to 2 mm, whereas the susceptor (34) has a width of 20 µm to 70 µm). The liquid transport element (35) takes longer to heat up compared to the susceptor (34) due to the mass of the liquid transport element (35) (e.g., requires more energy), but it may be possible to retain greater thermal energy (e.g., due to the larger mass of the liquid transport element (35). This can advantageously raise the temperature of the liquid near the liquid transport element (35), thereby reducing the difference between the liquid temperature at the start of the next activation of the induction element (42) and the target temperature of the susceptor (34) during the next activation of the induction element (42) (assuming the time between activations is not too long for the system (10) to cool to ambient conditions).

[0155] Considering the above, the susceptor (34) can provide rapid heating to the vaporization temperature due to the low mass and preferential position of the susceptor (34), while the magnetically heatable liquid transport element (35) can absorb energy and latent heat that would be lost if not absorbed, which can increase the ambient temperature of the aerosol generating material between vaporizations, leading to a reduction in the amount of heating required for the susceptor (34) to reach the vaporization temperature for the suitable aerosol generating material.

[0156] The cartridge (30) of FIG. 3 further comprises a housing (36) formed by an upper housing (361), a lower housing (362), and a sealing portion (363). The upper housing (361) may instead be referred to as a downstream or mouse end housing in that the upper housing (361) provides a portion of the housing facing the mouthpiece outlet (12). In particular, the upper housing (361) is configured to have a mouthpiece shape including an outlet (12) for the user to inhale. The lower housing (362) may instead be referred to as an upstream or device end housing in that the lower housing (362) provides a portion of the housing facing the inlet (14) of the system (10) and a position of the device or control unit (20) when the cartridge (30) is connected to the control unit (20). The sealing portion (363) may instead be referred to as an intermediate portion in that the sealing portion (363) is provided between the upper housing (361) and the lower housing (362). The sealing portion (363) seals the storage (33) and accommodates a liquid path to the material area (65) of the insertion portion (61), while facilitating the connection of the upper housing (361) to the lower housing (362).

[0157] The upper housing (361) defines an internal volume configured to hold a liquid aerosol generating material. In other words, the upper housing (361) provides a reservoir. The lower housing (362) defines a volume (or void) configured to accommodate a susceptor (34) and a liquid transport element (35). The volume is separated into a substrate area (65) and an aerosol chamber (63) by a planar surface (341) of the susceptor (34) provided within the volume (and aligned with the longitudinal axis corresponding to the insertion direction). Accordingly, the lower housing (362) defines or includes an insertion portion (61).

[0158] A sealing portion (363) is configured to be inserted into an upper housing (361) to seal a reservoir (33) and to suppress the movement of liquid from the reservoir (33) except through a liquid path (367) (which may or may not include a liquid transport element (35). For example, the sealing portion (363) may be configured to suppress the movement of liquid between the walls of the upper housing (361) defining the reservoir (33) that are in contact with the walls of the sealing portion (363) (e.g., both the outer wall of the upper housing (361) defining the external shape of the cartridge (30) and the inner wall defining the airflow channel through the upper housing (361)).

[0159] In some examples, such as those according to FIG. 3, the seal (363) includes an outlet (365) for the aerosol chamber (63). For example, the outlet (365) is configured to be aligned with the airflow channel of the upper housing (361) when the seal (363) is connected to the upper housing (361).

[0160] The upper housing (361) and the lower housing (362) may be formed from plastic materials using, for example, conventional materials and manufacturing methods (e.g., injection molding). The seal (363) may be formed from plastic materials as described above, or may be formed from a material such as silicone. FIG. 3 is only one example of a cartridge (30), and it will be recognized that in other examples, a suitable housing (36) may be provided by different components of different configurations (e.g., a reservoir (33) provided to the lower housing (362) only by the recording area (65), or a housing (36) that does not require a seal because the features of the seal (363) are provided by the lower housing (362).

[0161] The lower housing (362) is configured to define an insertion portion of the cartridge (30) that is received within the receiving cavity (49) of the induction assembly (40). A susceptor (34) (and optionally a liquid transport element (35)) is provided in the lower housing (362) such that when the cartridge (30) is connected to the induction assembly (40), at least a portion of the susceptor (34) is provided within the induction element (42) (e.g., within the spiral coil of the induction element (42)). As discussed above in relation to FIGS. 1 and 2, the induction element (42) is configured to generate a magnetic field that extends mainly (or predominantly) within the coil of the induction element (42). Consequently, induction heating is strongest for the susceptor placed within the induction element (42).

[0162] FIG. 4a is a schematic cross-sectional view parallel to the longitudinal axis of an exemplary cartridge (30) for use in an aerosol / vapor delivery system (10) according to the present disclosure. FIG. 4b shows a schematic cross-sectional view perpendicular to the longitudinal axis of the exemplary cartridge shown in FIG. 4a. The cross-sectional view of FIG. 4b corresponds to a cross-sectional plane penetrating the insertion portion (61) of the cartridge (30) shown in FIG. 4a, provided with arrows labeled "A" at each end of the dotted line.

[0163] In addition to the features described in connection with FIGS. 1 and 3, the cartridge (30) of FIGS. 4a and 4b includes one or more liquid flow channels (37) and an auxiliary reservoir (331). As described herein, one or more liquid flow channels (37) and an auxiliary reservoir (331) may be implemented with any of the embodiments of the cartridge (30) described in connection with FIGS. 1 and 3. The remaining aspects of the exemplary cartridge (30) of FIGS. 4a and 4b are as described in connection with FIGS. 1 through 3 and may not be described again in detail.

[0164] One or more liquid flow channels (37), which may be called liquid paths or conduits, are provided near the liquid transport element (35) (or the susceptor (34) if the susceptor (34) is configured to provide the function of the liquid transport element). One or more liquid flow channels (37) extend along the surface of the liquid transport element (35) from the reservoir (33) and serve to facilitate the inflow of liquid aerosol generating material into the liquid transport element (35). For example, one or more liquid flow channels (37) may include a liquid passage (367) provided by the seal (363) or extend from the liquid passage (367). Advantageously, the provision of one or more liquid flow channels (37) can improve the liquid supply to the entire liquid transport element (35) by increasing the surface area through which the liquid aerosol generating material can enter the liquid transport element (35). In other words, in some examples where the liquid flow channel (37) is not present, the liquid can enter the liquid transport element (35) only through the part of the liquid transport element (35) that is in contact with the reservoir (33), whereas in examples where the liquid flow channel (37) (or a plurality of channels) is present, the liquid can additionally enter the liquid transport element (35) along the surface of the liquid transport element (35) near the channel (37).

[0165] Each liquid flow channel (37) functions to provide a suitable path for the conduction of liquid. For example, the liquid flow channel (37) may include a cavity or void where the liquid can be contained. For example, liquid may flow from the reservoir (33) into the liquid flow channel (37) to fill the channel (37); the susceptor (34) is heated via induction heating, and the liquid in the liquid transport element (35) near the susceptor (34) is vaporized; and the liquid in the liquid flow channel (37) and the reservoir (33) is drawn into the liquid transport element (35) along the entire surface of the liquid transport element (35) in contact with the reservoir (33) or the liquid flow channel (37). The increased surface area allows the liquid transport element (35) to return to a saturated liquid state more quickly.

[0166] In some examples, one or more of the liquid flow channels (37) are elongated channels (e.g., cavities or voids having a length significantly greater than the width). In some examples, the liquid flow channels (37) are elongated channels extending from the reservoir (33) toward the end of the cartridge (30) near the control unit (20) when in use. In some examples, the liquid flow channels (37) are elongated channels extending from the reservoir (33) along the entire length of the liquid transport element (35), or from the reservoir (33) to the farthest end of the liquid transport element (35). In some examples, one or more of the liquid flow channels (37) are linear channels (i.e., extending in a straight line). In some examples, one or more of the liquid flow channels (37) include curves and bends (e.g., meandering channels).

[0167] In some examples, each liquid flow channel (37) is configured to induce a capillary effect on the liquid aerosol generating material to draw the liquid into the liquid flow channel (37). For example, the liquid flow channel (37) may have a width in the range of 0.1 mm to 1 mm (the width is perpendicular to the extension direction of the channel (37). Without being bound by theory, the capillary effect of the channel (37) on the liquid aerosol generating material may be defined by the capillary driving force of the channel (37) related to the ability of the liquid flow channel (37) to draw the liquid aerosol generating material by the capillary effect. In some examples, to ensure that the liquid is drawn into the liquid transport element (35), the liquid transport element (35) is configured to induce a capillary effect having a capillary driving force stronger than the capillary driving force of the liquid flow channel (37). For example, the liquid transport element (35) may be formed from a material of a porous network consisting of channels or pores having dimensions (e.g., width) smaller than the width of one or more liquid flow channels (37).

[0168] In some examples, as illustrated in FIG. 4b, the liquid transport element (35) comprises a semicircular rod. The flat surface of the semicircular rod contacts a susceptor (34) on a second surface opposite the flat surface (341). In some examples, one or more liquid flow channels (37) are provided radially outward of the semicircular rod. For example, one or more liquid flow channels (37) are provided close to the curved surface of the rod so that they provide liquid to different individual parts of the semicircular rod.

[0169] In some examples, the insert (61) includes a plurality of ribs (39), each of which is configured to abut (e.g., contact or touch) an individual part of the curved surface of the semicircular rod. In some examples, one or more liquid flow channels (37) are defined between individual pairs of ribs among the plurality of ribs (39).

[0170] For example, the lower housing (362) may include a plurality of ribs (39) defining liquid flow channels (37). For example, each liquid flow channel (37) may be defined by two adjacent ribs of the plurality of ribs (39). The ribs (39) define the path of the channel (37). The width of the channel (37) may be the separation distance of the two ribs (e.g., two adjacent ribs (39) may be separated by a distance of 0.1 mm to 1 mm). Likewise, each rib (39) may have a width within the range of 0.1 mm to 1 mm.

[0171] FIG. 4b depicts a cartridge (30) having six liquid flow channels (37) and seven ribs (39) (including two end ribs (39) adjacent to the susceptor (34), but in other examples there may be fewer than six liquid flow channels (37) (e.g., four or fewer) or more than six liquid flow channels (37) (e.g., eight or more, or twelve or more).

[0172] In some examples, a plurality of ribs (39) additionally serve to position the liquid transport element (35) within the insert (61). For example, the plurality of ribs (39) are configured to abut (e.g., contact or touch) individual parts of the curved surface of the liquid transport element (35) and to provide an interference fit with the liquid transport element (35). In some examples, the liquid transport element (35) may be (slightly) compressed by the ribs (39).

[0173] In other examples, it will be recognized that the ribs (39) may be configured to provide liquid flow channels (37) and to position the liquid transport element (35) even if the liquid transport element (35) is not a semicircular rod. For example, the lower housing (362) defining the insert (61) may be configured to provide ribs (39) that protrude to contact a liquid transport element (35) of a different shape (e.g., a square rod or another polygonal rod).

[0174] In addition, in some examples, the lower housing (362) includes at least two shoulders (368), and the at least two shoulders are configured to support the susceptor (34) such that the flat surface extends across the distance between the at least two shoulders. For example, each of the at least two shoulders (368) may contact an individual part of the susceptor (34) (e.g., a part of the flat surface (341)). In some examples, a wick (35) may assist in positioning the susceptor (34) by holding the susceptor (34) against the at least two shoulders (368). For example, ribs (39) may position the liquid transport element (35) within the insert (61), which can ultimately position the susceptor (34) against the shoulders (368). The liquid transport element (35) and the susceptor (34) may be held in place by a press fit and / or a compression fit. For example, in some examples, the liquid transport element (35) holds the susceptor (34) in place by compressing the liquid transport element (35) so that the liquid transport element (35) exerts force on the ribs (39) and also on the susceptor (34).

[0175] In some other examples where the liquid transport element (35) is not present (not shown), the ribs (39) may be configured to make direct contact with the susceptor (34) so ​​that the ribs (39) act to position the susceptor (34) between the ribs (39) and the shoulders (368).

[0176] An auxiliary reservoir (331), sometimes referred to as a secondary reservoir or supplementary reservoir, includes a cavity or void configured to hold a certain amount of liquid aerosol generating material. In some examples, the auxiliary reservoir (331) is provided at the opposite end of the liquid transport element (35) (or the susceptor (34) if the susceptor (34) is configured to provide the function of the liquid transport element (35)) relative to the reservoir (33). The auxiliary reservoir (331) is positioned so that the liquid transport element (35) can absorb or receive liquid from both the reservoir (33) and the auxiliary reservoir (331) after the aerosol generating material has vaporized. This can improve the distribution of the liquid aerosol generating material along the length of the liquid transport element (35) (e.g., in contact with the susceptor (34)). In particular, this can prevent the portion of the liquid transport element (35) located far from the reservoir (33) from becoming insufficiently saturated (e.g., saturated below optimal level) during subsequent activation of the induction element (42), especially when the duration between puffs by the user (e.g., activations of the induction element (42)) is relatively short.

[0177] Accordingly, in some examples, the cartridge (30) includes an auxiliary reservoir (331) provided at or toward the opposite end of the susceptor (34) relative to the reservoir (33), the auxiliary reservoir (331) is configured to hold a liquid aerosol generating material with a smaller volume than the reservoir (33), and the cartridge (30) is configured to supply liquid from the auxiliary reservoir (331) to the susceptor (34). For example, the cartridge (30) is configured such that the auxiliary reservoir (331) can supply liquid to the distal end of the susceptor (34) relative to the end of the susceptor closest to the reservoir (33).

[0178] The auxiliary reservoir (331) may be provided by the housing (36) of the cartridge (30) or by other structural components of the cartridge (30). For example, the auxiliary reservoir (331) may be provided by injection molding the housing (36) to have a shape defining the auxiliary reservoir (331). In some examples, the auxiliary reservoir (331) may be an annular reservoir extending around the air path (16), similar to the reservoir (33). In some examples, there may be more than one auxiliary reservoir (331) (e.g., two auxiliary reservoirs on opposite sides of the cartridge (30).

[0179] In some examples, the auxiliary reservoir (331) is configured to hold a liquid volume (e.g., the total volume of the auxiliary reservoir (331)) in the range of 0.005 ml to 0.1 ml. In some examples, the auxiliary reservoir (331) is configured to hold a liquid volume in the range of 0.01 ml to 0.05 ml. In some examples, the auxiliary reservoir (331) is configured to hold a liquid volume in the range of 0.015 ml to 0.02 ml.

[0180] In some examples, the auxiliary reservoir (331) is configured to hold a volume of liquid corresponding to the amount of liquid aerosol generating material vaporized in multiple puffs (or fractions of a single puff). For example, an exemplary system can vaporize approximately 0.09 ml of liquid aerosol generating material during an average puff (e.g., over a 3-second period during which the induction element (42) is activated to heat the susceptor (34). Accordingly, the auxiliary reservoir (331), configured to hold a liquid volume in the range of 0.015 ml to 0.02 ml, can hold enough liquid for approximately two puffs. In some examples, the auxiliary reservoir (331) is configured to hold a volume of liquid corresponding to the amount of liquid aerosol generating material vaporized in an average of 0.5 to 5 puffs. In some examples, the auxiliary storage (331) is configured to hold a volume of liquid corresponding to the amount of liquid aerosol generating material vaporized in an average of 1 to 3 puffs.

[0181] In some examples, the reservoir (33) is configured to hold about 2 ml of liquid (e.g., the total volume of the reservoir (33)). For example, the reservoir (33) may be configured to hold a liquid volume in the range of 1 ml to 4 ml. In some examples, the auxiliary reservoir (331) is configured to hold a liquid volume corresponding to a fraction of the total volume of the reservoir (33). In some examples, the auxiliary reservoir (331) is configured to hold a liquid volume in the range of 0.2% to 2.5% of the total volume of the reservoir (33). In some examples, the auxiliary reservoir (331) is configured to hold a liquid volume in the range of 0.5% to 1.5% of the total volume of the reservoir (33).

[0182] In some examples, one or more liquid flow channels (37) fluidly connect the reservoir (33) to the auxiliary reservoir (331). For example, the liquid flow channels (37) may be connected to the reservoir through a liquid passage (367). In these examples, the liquid aerosol generating material may flow between the reservoir (33) and the auxiliary reservoir (331) through one or more liquid flow channels (37).

[0183] In some examples, the auxiliary reservoir (331) includes a capillary material or is formed of a capillary material. For example, the auxiliary reservoir (331) may include a structure having capillary channels, or a capillary material may be inserted into the auxiliary reservoir (331). As described in relation to the liquid flow channels (37), the capillary material of the auxiliary reservoir (331) may apply a lower capillary driving force than the capillary driving force applied by the liquid transport element (35) to allow liquid to be drawn from the auxiliary reservoir (331) into the liquid transport element (35).

[0184] In some examples not illustrated, the cartridge (30) includes one or more liquid flow channels (37) for guiding liquid aerosol generating material from the reservoir (33) and does not include an auxiliary reservoir (331). In some examples, the cartridge (30) includes an auxiliary reservoir (331) configured to hold liquid aerosol generating material of a smaller volume than the reservoir, and the cartridge is configured to supply liquid from the auxiliary reservoir to the susceptor; and does not include liquid flow channels (37) (e.g., liquid can be transported from the reservoir (33) to the auxiliary reservoir (331) via a liquid transport element (35).

[0185] In some examples, such as those according to FIG. 4, the cartridge (30) includes one or more liquid flow channels (37) and an auxiliary reservoir (331). In some of these examples, one or more liquid flow channels (37) are configured to guide a liquid aerosol generating material from the reservoir (33) to the auxiliary reservoir (331).

[0186] As previously discussed, the aerosol chamber (63) forms part of the air path (16) through the system (10). As illustrated in FIG. 4a, in some examples, the cartridge (30) may include an air inlet (366) providing an opening (or openings) for air to enter the aerosol chamber (63), and an aerosol outlet (365) providing an opening (or openings) for aerosols accompanied by air to exit the aerosol chamber (63). In some examples, as illustrated in FIG. 4a, the air inlet (366) may be provided to the insert (61) by a lower housing (362). In some examples, as illustrated in FIG. 4a, the air inlet (366) includes a plurality of openings, such as two linear slots aligned perpendicularly to the flat surface (341). In some examples, as shown in FIG. 4a, the aerosol outlet may be provided by a seal (363).

[0187] FIG. 5 is an (unscaled) schematic diagram of an example of a mouthpiece (50), a cartridge (30), and an induction assembly (40) for use in an aerosol / vapor delivery system (10) according to the present disclosure. The cartridge (30) differs from the cartridges (30) shown in FIG. 1, FIG. 3, and FIG. 4 in that the cartridge (30) is configured to be received within a separate mouthpiece component (50) (referred to herein as mouthpiece (50)). The susceptor (34), liquid transport element (35), and reservoir (33) of the cartridge (30) in FIG. 5, as well as the induction assembly (40), are as described in relation to FIG. 1 and will not be described again in detail. Alternative embodiments of the cartridge (30) suitable for use with the mouthpiece (50) as disclosed in FIG. 5 may include aspects described in relation to FIG. 3 and FIG. 4 (e.g., liquid flow channels (37), auxiliary reservoir (331)).

[0188] The cartridge (30) of FIG. 5 may be called a pod or capsule and is configured to be received inside the cavity or void of the mouthpiece (50). For example, the housing (36) of the cartridge (30) is not configured to define the shape of the mouthpiece, but instead is configured to define a structure that can be received within the component providing the mouthpiece (50) and can receive components such as a reservoir (33), a susceptor (34), and a liquid transport element (35).

[0189] As depicted in FIG. 5, the housing (36) may be a body having a passage, which extends between two openings in the opposing end faces of the body. The passage provides part of the air path (16) of the system (10) and includes an aerosol chamber (63). The susceptor (34) provides a planar surface (341) that defines the boundary of the aerosol chamber (63). For example, the susceptor (34) may include a planar element aligned to intersect the center of the cartridge (30) and parallel to the longitudinal axis corresponding to the insertion direction. The openings in the opposing end faces of the body may be circular or elliptical apertures or any other shape (e.g., polygonal, or a combination of curved edges and straight edges), and the outer surface of the passage may be defined by walls (including the planar surface (341) provided by the susceptor (34)) that extend between the periphery of each of the openings.

[0190] The cartridge (30) includes a liquid transport element (35) provided (fluidically connected) between the susceptor (34) and the reservoir (33). The reservoir (33) is provided by cavities defined by the housing (36) and optionally by the liquid transport element (35) and / or the susceptor (34). For example, the reservoir (33) may be an annular cavity extending from the liquid transport element (35) downstream of the housing (36) or toward the end of the mouse.

[0191] A mouthpiece (50) for use with a separate cartridge (30) includes a cavity (51) (e.g., a void or volume) suitable for accommodating the cartridge (30). In the example of FIG. 5, the cavity (51) is an internal space or volume defined by a housing that also defines the external shape of the mouthpiece (50). For example, the mouthpiece defines an outlet (12) of an air path (16) through which a user can inhale. In some examples, the housing is formed of a metal or plastic material (e.g., the housing may be formed by a plastic injection molding process).

[0192] In some examples, the cavity (51) has a shape and size that corresponds to the external shape defined by the cartridge (30) but is larger than the external shape defined by the cartridge (30) (e.g., slightly larger, e.g., 1% larger). This allows the cartridge (30) to be inserted or placed within the cavity (51), thereby allowing the cartridge (30) to be retained within the cavity (51). In some examples, the size of the cartridge (30) and the size of the cavity (51) may be substantially similar so that a press fit is formed between the housing defining the cavity and the housing (36) defining the cartridge (30).

[0193] In some examples, such as those according to FIG. 5, the housing comprises two parts: a first, upper, downstream or mouth end part (52) (which also defines the external shape of the mouthpiece configured to form a seal when the user is inhaling) and a second, lower, upstream or device end part (54) (configured to be inserted at least partially into the receiving cavity (49) of the induction assembly (40). The cavity (51) may be formed by one or both of the upper part (52) and the lower part (54). In these examples, the mouthpiece (50) may include an opening mechanism (56) and a connecting mechanism (58).

[0194] The opening mechanism (56) is configured to enable movement of the first part (52) relative to the second part (54), or vice versa. In some examples, the opening mechanism (56) is a hinge or a flexible connector. If the opening mechanism (56) is a hinge, the opening mechanism (56) may enable rotation of the first part (52) relative to the second part (54). In some examples, the rotation may be about an axis perpendicular to the longitudinal axis of the system (10), whereas in other examples, it may be about an axis parallel to the longitudinal axis of the system (10).

[0195] The opening mechanism (56) allows the mouthpiece (50) to move between a first configuration in which the cavity (51) is at least partially exposed to allow the cartridge (30) to be inserted and / or removed, and a second configuration in which the cavity (51) is substantially closed (except through openings for the air path (16)) to retain and / or protect the cartridge (30) provided within the cavity (51). The first configuration may be called an open or accessible configuration because the cavity (51) is open and accessible to the user, and the second configuration may be called a closed or inaccessible configuration because the cavity (51) is closed and inaccessible to the user.

[0196] Accordingly, in some examples, the mouthpiece includes an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration, in which a cavity is at least partially exposed to allow a cartridge to be inserted and / or removed, and the second configuration is configured to retain a cartridge provided within the cavity.

[0197] Advantageously, the opening mechanism (56) improves user accessibility by allowing the user to open the cavity (51) without complete separation of the first part (52) and the second part (54), so that the user does not need to hold each part (52, 54) separately while inserting or removing the cartridge (30) from the cavity (51). However, in some other examples, the opening mechanism (56) may not be included, and instead, it will be recognized that the first part (52) and the second part (54) can be completely separated from each other when changing the mouthpiece configuration from the second configuration to the first configuration.

[0198] The connecting mechanism (58) acts to hold the first part (52) in contact with the second part (54) of the housing. For example, the connecting mechanism (58) may be a latch or locking device that prevents or inhibits the first part (52) from moving relative to the second part (54), and vice versa. The connecting mechanism (58) is configured to prevent or inhibit the mouthpiece (50) from moving from a closed configuration to an open configuration to prevent the cartridge (30) from unintentionally moving out of the cavity (51) before the user intends to remove the cartridge (30).

[0199] In some examples, a connecting mechanism (58) is provided in one or both of the first part (52) and the second part (54). For example, the connecting mechanism (58) may include a corresponding component in each of the first part (52) and the second part (54) configured to be joined together to prevent or inhibit movement of the first part (52) and the second part (54) relative to each other. In some examples, the connecting mechanism (58) includes a mechanical mechanism comprising a latch or clip in one of the first part (52) and the second part (54), and a corresponding component (e.g., a second clip or ridge) for holding the latch or clip in the other of the first part (52) and the second part (54). In some examples, the connecting mechanism (58) includes a first magnet in the first part (52) and a second magnet (having an attractive force toward the first magnet) in the second part (54), and the two magnets generate a force that must be overcome to move the first part (52) toward the second part (54).

[0200] In some examples, the connection mechanism (58) is user-operable so that the user can directly interact with the connection mechanism (58) to prevent the connection mechanism (58) from holding the mouthpiece in a second configuration. In other words, the connection mechanism (58) is user-operable so that the user can directly interact with the connection mechanism (58) to allow the first part (52) to move relative to the second part (54) (e.g., the user can move or bend the latch in a position relative to the corresponding clip, or apply force to overcome the attractive force between the two magnets).

[0201] In some examples, the connection mechanism (58) is electronically controlled (e.g., electrically operated by the control circuit (28)). For example, although not illustrated, at least part of the connection mechanism (58) may be electrically connected to the control circuit (28) and may be operable by the control circuit (28) (e.g., in response to electrical signals) to activate or deactivate the connection mechanism (58). In some examples, the connection mechanism (58) may include an electromagnet and a permanent magnet, wherein the electromagnet is configured to generate a magnetic field when current is supplied through the electromagnet, which creates an attractive force between the permanent magnet and the electromagnet. In some examples, the connection mechanism (58) includes an actuator movable in response to an electrical signal to engage a latch or similar (such latch and actuator may be positioned out of sight to the user when the mouthpiece (50) is in the second configuration).

[0202] Advantageously, the connection mechanism (58) can be used to delay the user when the user wants to replace the cartridge (30). For example, when the susceptor (34) is heated by induction, the susceptor (34) can be heated to a high temperature. In particular, in cases where the user activates the induction element multiple times within a short period (e.g., 10 puffs per minute), the elements of the cartridge (30) (especially the susceptor and those near the susceptor) can become hot. If the user removes the cartridge (30) immediately after a puff, the user (or their clothing or nearby items, such as a table) may be burned.

[0203] The provision of the connection mechanism (58) delays the user's immediate access to the cartridge (30) and instead allows heat (thermal energy) to be dissipated across the cartridge (30) and surrounding elements of the system (10). Even if the connection mechanism (58) is a simple mechanical mechanism such as a latch, it will be recognized that it can still delay the user's access to the cartridge by a few seconds (e.g., at least 2 to 3 seconds). In some examples, where the connection mechanism (58) is electronically controlled, the control circuit (28) may implement a timer that prevents the connection mechanism (58) from being disconnected for a certain period of time after the most recent activation of the inductive element (42) (e.g., the time period is within the range of more than 3 seconds, preferably more than 5 seconds). In some examples, the time period may be fixed, whereas in other examples, the time period may be calculated based on the use of the system up to the last puff (e.g., increased use prior to the last activation makes the time period longer).

[0204] In some examples not illustrated, the lower portion (54) may not be a component of the mouthpiece (50). Instead, in these examples, the induction assembly (40) or device (20) defines or otherwise provides at least a portion of the cavity (51) for the cartridge (30) (e.g., at least the induction assembly (40) or device (20) may define the end surface of the cavity together with the remaining surfaces defined by a single mouthpiece housing component). In these examples, as described above, the connection mechanism (58) and / or opening mechanism (56) may be provided by the induction assembly (40) or device (20). For example, the mouthpiece (50) may be connected to the induction assembly (40) or device (20) by a hinge (opening mechanism (56)). Accordingly, in some examples, the mouthpiece (50) includes at least one component of the connection mechanism, and the connection mechanism is configured to hold the mouthpiece in a second configuration.

[0205] In addition, in some examples, a connection mechanism (58) as described above is provided to directly connect the cartridge (30) to the device part (20) and / or the induction assembly (40) without the presence of a separate mouthpiece (50). For example, the connection mechanism (58) can fasten or lock the cartridge (30) to the device part (20) and / or the induction assembly (40) to prevent the cartridge (30) from being unintentionally detached.

[0206] FIG. 6 is a flowchart illustrating a method (100) for generating an aerosol from an aerosol generating substrate in an aerosol delivery system (10) according to the present disclosure. The aerosol delivery system (10) comprises a cartridge (30) and a device component (20) (sometimes referred to as a device, control unit, or control section), wherein the cartridge (30) comprises a susceptor (34), and the control section (20) comprises an induction element (42), a power supply (25), and a control circuit (28). The system (10) and the components of the system (10) (e.g., induction assembly (40), cartridge (30), and control section (20)) may be as described in connection with any of FIGS. 1 to 5 and will not be described again in detail.

[0207] In some examples, a device component (20) for use with an induction assembly (40) according to the present disclosure (for use with a cartridge (30)) comprises a control circuit (28) configured to perform the method (100). The device component (20) comprises a control circuit (28) for controlling the supply of power to an induction element (42), and the control circuit (28) is configured to drive the induction element (42) of the induction assembly (40) so as to induce a current flow to the susceptor (34) to induce heating of the susceptor (34) and thereby vaporize a portion of the aerosol generating substrate near the susceptor (34).

[0208] The method (100) begins with a first step (110) of inserting an insert (61) into a receiving cavity (49). By inserting the insert (61) into the receiving cavity (49), the susceptor positioned within the insert (61) is at least partially inserted into the induction element (42). The cartridge (30) is connected to the induction assembly (40) (or device part (20)) to position the susceptor (34) within the induction element (42) (e.g., within a volume defined by the helical coil forming the induction element (42)). At least a portion of the susceptor (34) is provided in the portion of the cartridge (30) to be inserted into the receiving cavity (49) of the induction assembly when the cartridge (30) is connected to the induction assembly (40), for example, as described in connection with FIGS. 1 through 6. In some examples, inserting the susceptor (34) into the receiving cavity (49) includes inserting the entire susceptor (34) into the receiving cavity (49). In some examples, inserting the susceptor (34) into the receiving cavity (49) includes inserting a portion of the susceptor (34) into the receiving cavity (49).

[0209] The first step (110) may alternatively be described as engaging the receiving cavity (49) of the guide assembly with the cartridge (30) to surround at least a portion of the susceptor (34). In other words, it will be recognized that the relative movement (i.e., insertion) of the susceptor (34) into the receiving cavity (49) can also be described as the relative movement of the receiving cavity (49) with respect to the susceptor (34). Furthermore, the first step (110) may additionally be described as providing the susceptor (34) (at least a portion of it) within the receiving cavity (49).

[0210] In some examples, the method (100) continues to step (120) of driving an induction element (42) to induce a current flow in the susceptor (34) to induce heating the susceptor (34) to a first temperature and thereby vaporizing a portion of the aerosol-generating substrate near the susceptor (34). For example, the induction element (42) may be driven to heat the susceptor (34) to at least the vaporization temperature of the aerosol-generating component of the aerosol-generating substrate (e.g., liquid from the reservoir (33)). The temperature at which the susceptor is driven to vaporize a portion of the aerosol-generating substrate near the susceptor (34) may be considered as the first temperature, or the vaporization temperature, or the aerosolization temperature. In some examples, the first temperature is within the range of 150°C to 300°C. In some examples, the first temperature is within the range of 190°C to 220°C.

[0211] In some examples, step (120) is triggered by user input. For example, the user may engage a user input element. For example, the user may interact with a user-operable element such as a button, or the user may trigger a puff sensor by inhaling into the system (e.g., through the outlet (12)). In addition to the user input element being a user-operable element such as a button or a puff sensor, the user input element may also be any sensor capable of identifying user interaction (e.g., a capacitance sensor, a motion sensor, or a light sensor). The user input element may be configured to transmit a signal to the control circuit (28) indicating that user input has occurred, and the control circuit (28) may trigger step (120) (i.e., drive the induction element (42)). For example, a user inhales through the outlet (12), and the puff sensor transmits a signal identifying the user input corresponding to the inhalation (e.g., a signal identifying a pressure drop) to the control circuit, and the control circuit (28) triggers the operation of the induction element (42) to induce heating of the susceptor (34) to a first temperature by inducing current flow to the susceptor (34) to induce heating of the susceptor (34).

[0212] In some examples, the system (10) includes a temperature sensor for measuring the temperature of the susceptor (34). The temperature sensor may be configured to measure a value representing the temperature of the susceptor (34) rather than directly measuring the susceptor (34). For example, a suitable temperature sensor may be able to determine the temperature of the susceptor (34) based on the resistance of an element near the susceptor (34) (e.g., a thermocouple near the susceptor (34)). In some examples, an inductive element (42) may be used to measure the temperature of the susceptor (34) based on the strength and frequency of the inductive coupling between the susceptor and the inductive element (42). Measurements or signals related to the temperature of the susceptor (34) (directly or indirectly) may be transmitted to a control circuit (28) and may be used to control how the inductive element (42) is driven (i.e., to achieve or maintain the temperature).

[0213] In some examples, the method ends after driving the induction element (42) to induce current flow in the susceptor to induce heating the susceptor to a first temperature. For example, the control circuit (28) may stop driving the induction element (42) to induce current flow in the susceptor (34) to induce heating the susceptor (34) to a first temperature after a time period corresponding to the user's puff and / or the predicted amount of aerosol generated (e.g., based on knowledge of the energy input to the system and the energy required to vaporize the aerosol generating material, which is actively calculated during use or based on predetermined data for a specific system (10) configuration, such as a lookup table).

[0214] In some examples, the method ends after driving the induction element (42) to induce a current flow in the susceptor for a fixed time period to induce heating of the susceptor to a first temperature. In some examples, the fixed time period may be a time period within the range of 1.5 seconds to 5 seconds. In some examples, the fixed time period may be a time period within the range of 2.5 seconds to 4 seconds.

[0215] In some examples, the method terminates after driving the induction element (42) to induce a current flow in the susceptor to induce heating of the susceptor to a first temperature when user input (e.g., inhalation, button pressing, or similar as described above) is stopped. For example, the user stops inhaling the system (10), the puff sensor transmits a signal indicating that the air pressure has increased, and the control circuit (28) stops driving the induction element (42). Alternatively, the user stops pressing the button of the system (10), the button transmits a signal indicating that the button is not being pressed, and the control circuit (28) stops driving the induction element (42). In some examples, the control circuit (28) implements a maximum activation period even when the user continues to trigger the user input mechanism. This can prevent overheating of the system (10), for example, if the user input element malfunctions. In some examples, the maximum activation period is a period within the range of 6 to 15 seconds. In some examples, the maximum activation period is a period within the range of 7 to 12 seconds. In some examples, the method (100) may be terminated after step (120).

[0216] In some examples, the method (100) includes an additional step (115) of driving an induction element (42) to induce a current flow in the susceptor (34) to induce heating the susceptor (34) to a second temperature that is lower than the first temperature and is not sufficient to vaporize a portion of the aerosol-generating substrate near the susceptor (34). In other words, the second temperature is lower than the temperature required to vaporize a portion of the aerosol-generating substrate near the susceptor. The second temperature may be considered as a preheating temperature. In some examples, the second temperature is within the range of 80°C to 200°C. In some examples, the second temperature is within the range of 120°C to 170°C.

[0217] Accordingly, in some examples, according to step (115), the method (100) comprises the step of driving an induction element to induce a current flow in the susceptor to induce heating the susceptor to a first temperature in order to vaporize a portion of the aerosol generating substrate near the susceptor, and the method further comprises the step of driving an induction element to induce a current flow in the susceptor to induce heating the susceptor to a second temperature lower than the first temperature and lower than the temperature required to vaporize a portion of the aerosol generating substrate near the susceptor.

[0218] It will be recognized that the control circuit (28) can drive the induction element (42) to induce a current flow in the susceptor (34) and induce heating of the susceptor (34) to a specific temperature by modifying the power supplied through the induction element. For example, the control circuit (28) can monitor the temperature of the susceptor by a suitable sensor (e.g., a thermocouple, or based on a shift in the resonant frequency detectable by the induction element (42)) and can change the power supplied through the induction element. For example, the control circuit (28) can supply power in periodic pulses at a set frequency (e.g., 500-50 Hz) until the required temperature is reached. As long as the susceptor (34) is above the required temperature, the control circuit (28) can stop supplying power during the next scheduled pulse. When the susceptor drops below the required temperature, the control circuit (28) can resume supplying pulses to drive the induction element (42).

[0219] Providing a preheating temperature may be particularly advantageous when used with a susceptor (34) formed of a high-mass element, such as a block element formed of steel mesh or nickel foam, and / or when a susceptor (34), such as a sheet, is used with a wick (35) formed of an induction-heatable material (e.g., steel mesh or nickel foam). Although such a susceptor (34) and / or wick (35) may take a relatively long time to heat due to their high mass, they can store latent heat between activations. Therefore, by maintaining the susceptor (34) and / or wick at a temperature higher than the ambient temperature, the time required to heat the susceptor (34) to a first temperature to vaporize a portion of the aerosol-generating substrate near the susceptor (34) is reduced. Furthermore, the high mass of the susceptor (34) and / or wick (35) increases the time it takes for the temperature of the susceptor (34) to return to ambient conditions, because the susceptor (34) and / or wick (35) has an increased bulk heat capacity that is not easily dissipated to the surrounding system (10) due to a reduced ratio of external surface area to volume compared to a flat element such as a thin metal sheet.

[0220] In some examples, the induction element (42) is driven to induce a current flow in the susceptor (34) in response to a stimulus to induce heating of the susceptor (34) to a second temperature. In some examples, the control circuit (28) is configured to drive the induction element to induce a current flow in the susceptor in response to a stimulus to induce heating of the susceptor to a second temperature, and the stimulus includes one or more of a signal indicating the insertion of at least a portion of the susceptor into the induction element and a signal indicating the user's intention to start a usage session.

[0221] In some examples, a signal indicating the insertion of at least a portion of the susceptor (34) into the induction element (42) is based on the detection that the induction heating element has moved toward the induction element (42). In other examples, a signal indicating the insertion of at least a portion of the susceptor (34) into the induction element (42) is indirectly based on the detection of the connection of the cartridge (30) to the induction assembly (40) and / or device (20).

[0222] In some examples, the stimulus may be the detection of the connection of the cartridge (30) to the induction assembly (40) and / or the device (20). In some examples, the control circuit (28) may be able to determine that the cartridge (30) was already attached (i.e., is currently attached) based on a measurement or sensor reading (e.g., from a sensor for detecting the attachment of the cartridge (30), such as a light sensor or a resistive sensor, or based on a signal from the induction element (42) indicating that the induction heating element has moved toward the induction element). In some examples, the stimulus may be the user pressing a button on the device (20) or the user taking the first puff from the device (20) (triggering the puff sensor if one is present).

[0223] The stimulus may indicate a user's intention to start a usage session (e.g., a user's intention to take a series of puffs from the system (10) (a puff means that the user will inhale through the outlet (12) of the system (10)). In some examples, the method (100) includes the step of driving an induction element (the control circuit (28)) to induce a current flow in the susceptor in response to the stimulus to induce heating of the susceptor to a second temperature, wherein the stimulus includes one or more of a signal indicating the insertion of at least a portion of the susceptor into the induction element and a signal indicating a user's intention to start a usage session.

[0224] In some examples, the control circuit (28) is configured to maintain the susceptor (34) at a second temperature before raising the temperature to a first temperature during activation (e.g., puffing) of the device (20) by the user, and / or the control circuit (28) is configured to maintain the susceptor (34) at a second temperature between activations of the device (20) by the user. In other words, the control circuit is configured to maintain the susceptor at a second temperature before raising the temperature to a first temperature in response to a signal indicating that the user is interacting with a user input element, and / or the control circuit is configured to maintain the susceptor at a second temperature between signals indicating that the user is interacting with a user input element. By maintaining the temperature of the susceptor (34) at a second temperature, the time required to raise the temperature to a first temperature may be reduced, which may lead to faster generation of vapor (if an aerosol generating material is present). As discussed above, the user input element may include one or more of a button, a capacitance sensor, a motion sensor, a light sensor, and a pressure sensor, or any other suitable input mechanism.

[0225] Accordingly, in some examples, the method (100) includes the step of driving an induction element (42) to induce a current flow in the susceptor (34) to induce heating the susceptor (34) from a second temperature to a first temperature in response to a signal indicating that the user is interacting with a user input element. For example, while the control circuit (28) is driving the induction element (42) to induce a current flow in the susceptor (34) to induce heating the susceptor (34) from the second temperature, the user may press a button or inhale into the system (10), and the control circuit (28) may switch to driving the induction element to induce a current flow in the susceptor (34) to induce heating the susceptor from the second temperature.

[0226] In some examples, the control circuit (28) is configured to perform step (120) (a step of driving the induction element (42) to induce heating the susceptor (34) to a first temperature by inducing current flow in the susceptor (34) to induce heating the susceptor (34) to a second temperature which is lower than the first temperature) after performing step (120) (a step of driving the induction element (42) to induce heating the susceptor (34) to a second temperature which is lower than the first temperature by inducing current flow in the susceptor (34) to a second temperature which is lower than the first temperature). In some examples, this is done in addition to driving the induction element (42) to induce heating the susceptor (34) to a second temperature which is lower than the first temperature by inducing current flow in the susceptor (34) before the first puff (e.g., in response to a stimulus such as the detection of insertion of the susceptor (34) into the receiving cavity (49) and / or the induction element (42)).

[0227] In some examples, the control circuit (28) is further configured to alternate between driving the induction element (42) to heat the susceptor (34) to a first temperature and driving the induction element (42) to heat the susceptor (34) to a second temperature in response to receiving user input and not receiving user input, respectively. For example, when the user inhales or indicates that they are inhaling (e.g., pressing a button), the susceptor (34) is heated to a first temperature, and when the user stops inhaling or stops indicating that they are inhaling (e.g., stopping pressing a button), the susceptor (34) is heated to a second temperature (it will be recognized that this may involve stopping driving the induction element (42) until the susceptor (34) cools from the first temperature to the second temperature, and then periodically driving the induction element (42) to maintain the susceptor (34) at the second temperature).

[0228] Thus, in some examples, the method includes the step of maintaining the susceptor at a second temperature after a signal indicating that the user is interacting with a user input element is interrupted, and / or between signals indicating that the user is interacting with a user input element.

[0229] In some examples, where the method includes step (115), the method (100) additionally includes step (125) of ceasing to drive the induction element (42) after an inactivity period. The control circuit (28) may be configured to maintain the susceptor at a second temperature for a certain period of time in response to stimulation, and to cease driving the induction element (42) if no input from the user is received before the end of the time period. In other words, in some examples, the control circuit is configured to cease driving the induction element after an inactivity period to induce a current flow in the susceptor to maintain the susceptor at a second temperature. As described above, the input (i.e., an action indicating activity) may be a puff (measured by a puff sensor) or a button press indicating that the user is inhaling or intends to inhale into the system (10). In some examples, the inactivity period is within the range of 10 seconds to 120 seconds. In some examples, the inactivity period is within the range of 20 seconds to 60 seconds. In some examples, the method (100) may end after step (125).

[0230] When the method (100) is terminated, the system (10) may enter a standby mode or a low-power sleep mode. For example, after step (120) or after step (125), the control circuit (28) may enter a standby mode in which the control circuit (28) periodically looks up any user input elements for indications that the user is inhaling or intends to inhale into the device (or for other interactions related to system control, such as checking battery levels, changing heater temperature, and turning off or resetting the device). In some examples, if user inputs are not received for a certain period of time (e.g., 5 to 10 minutes), the control circuit (28) may turn off the system (10) or place the system (10) into a low-power sleep mode.

[0231] In some examples, there is a connection mechanism (58) configured to hold a cartridge (30) as part of an aerosol delivery system (10) (e.g., as described in connection with FIG. 5). The method may additionally include the step of engaging and disengaging the connection mechanism (58), and the connection mechanism (58) may be operated electronically (e.g., by a control circuit (28)). In some examples, the connection mechanism (58) connects different parts of a mouthpiece (50) defining a cavity (51), or the connection mechanism (58) connects the mouthpiece (50) to a device component (20) and / or an induction assembly (40) (the cavity (51) for the cartridge (30) is provided by one or more of the mouthpiece (50), the device component (20), and the induction assembly (40), or the connection mechanism (58) directly connects the cartridge to the device component (20) and / or the induction assembly (40) (e.g., no separate mouthpiece (50)).

[0232] In some examples, the method (100) further comprises the steps of engaging a connecting mechanism (58) configured to hold a cartridge as part of an aerosol delivery system, and disengaging the connecting mechanism (not shown). By disengaging the connecting mechanism, the user can remove and / or attach the cartridge (30) (e.g., by inserting the cartridge (30) into the cavity (51) as described in relation to FIG. 5). By implementing such a connecting mechanism (58), the risk of injury to the user or damage to the surrounding environment may be reduced because disengaging or disengaging the connecting mechanism may delay the user removing the cartridge for a few seconds; during that time, the susceptor (34) may be cooled to a lower temperature.

[0233] In some examples, the method includes the step of engaging the connection mechanism (58) in response to the control circuit (28) determining that the cartridge is attached to the system. In some examples, the method includes the step of engaging the connection mechanism (58) in response to the control circuit (28) receiving input from a user indicating that the connection mechanism (58) should be engaged, that the cartridge is attached to the system. For example, the connection mechanism (58) may be engaged in response to a first activation of the aerosol delivery system (10).

[0234] In some examples, the method includes the step of disconnecting the connection mechanism (58) in response to the control circuit (28) receiving input from a user (e.g., a button press or a combination of button presses) indicating that the connection mechanism (58) should be disconnected. In some examples, the method includes the step of disconnecting the connection mechanism (58) in response to the control circuit (28) entering a standby mode or a low-power sleep mode. In some examples, the method includes the step of disconnecting the connection mechanism (58) in response to the control circuit (28) ceasing to drive the induction element (42) after a period of inactivity. In some examples, the method includes the step of disconnecting the connection mechanism (58) in response to the control circuit (28) determining that a certain amount of time has elapsed since the last activation (e.g., time since the control circuit (28) heated the susceptor to a first temperature). In some of these examples, the amount of time since the last activation may be within the range of 2 to 10 seconds or 3 to 5 seconds. In some examples, the method includes the step of disconnecting the connection mechanism (58) in response to the control circuit (28) determining that the susceptor (34) is below a critical temperature.

[0235] Accordingly, an aerosol delivery system comprising a cartridge for use in generating an aerosol from an aerosol generating substrate is described. The cartridge comprises an insert that at least partially defines an aerosol chamber and a substrate region, and the insert is defined by a longitudinal axis corresponding to the insertion direction. The cartridge also comprises a susceptor provided within the insert, and the susceptor comprises a planar surface that separates the aerosol chamber from the substrate region. The planar surface is provided parallel to the longitudinal axis. Furthermore, a guidance assembly, a mouthpiece, and device components for use in the aerosol delivery system, and a method for generating an aerosol from an aerosol generating substrate in the aerosol delivery system are described.

[0236] As noted, the heater according to the present disclosure is a susceptor for induction heating of a liquid aerosol generating material, as described in relation to the cartridges shown in FIGS. 1, 3, 4 and 5. In some other examples, the heater according to the present disclosure may be used for induction heating of alternative aerosol generating materials, such as a gel aerosol generating material (e.g., a thermoreversible gel).

[0237] In conclusion, to solve various problems and advance technology, the present disclosure illustrates various embodiments in which the claimed invention(s) may be practiced. The advantages and features of the present disclosure are merely representative samples of the embodiments and are not limited thereto and / or exclusive. These advantages and features are presented only to aid in understanding and teaching the claimed invention(s). It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure are not to be considered as limitations on the disclosure or equivalents to the claims as defined by the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claims. Various embodiments may appropriately include, be composed of, or constitute essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc., in addition to those specifically described herein, and thus it will be recognized that the features of the dependent claims may be combined with the features of the independent claims in combinations other than those explicitly described in the claims. The present disclosure may include other inventions that are not currently claimed but will be claimed in the future.

[0238] Furthermore, there is considerable flexibility in the design and configuration of the entire aerosol delivery system, as exemplified by the various possibilities of features outlined in the set of provisions following at least this paragraph. To avoid any doubt, it will be correspondingly understood that any features from these provisions may be combined as needed in any combination beyond those explicitly described in these provisions, noting the great flexibility and interchangeability in the use of such features clearly provided by this disclosure.

[0239] Clauses

[0240] 1. As a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate, the cartridge is:

[0241] An insertion that at least partially defines the aerosol chamber and the substrate region — the insertion is defined by a longitudinal axis corresponding to the insertion direction —; and

[0242] It includes a susceptor provided within an insert, wherein the susceptor includes a planar surface separating the aerosol chamber from the substrate region, and the planar surface is provided parallel to the longitudinal axis.

[0243] 2. In the cartridge of Clause 1, the flat surface extends through the center of the cross-section of the insert, which is perpendicular to the longitudinal axis.

[0244] 3. In the cartridge of Clause 2, the cross-section of the insert includes an elliptical or circular periphery, and the flat surface is parallel to the diameter of the cross-section.

[0245] 4. In the cartridge of any preceding clause, the insert includes an air inlet for introducing air into the aerosol chamber.

[0246] 5. In any cartridge of the preceding clause, the flat surface is defined by its length and width, the length is greater than the width, and the length is parallel to the longitudinal axis.

[0247] 6. In the cartridge of Clause 5, the length is within the range of 5 mm to 50 mm.

[0248] 7. In the cartridge of Clause 5 or Clause 6, the width is within the range of 2 mm to 15 mm.

[0249] 8. In any prior clause cartridge, the susceptor includes a plurality of apertures extending through the susceptor.

[0250] 9. In the cartridge of Clause 8 subject to Clause 5, the number density of multiple apertures varies along the length and / or width of the planar surface.

[0251] 10. In the cartridge of Clause 9, the number density of multiple apertures increases monotonically along the length of the susceptor.

[0252] 11. In the cartridge of Clause 9 or Clause 10, the number density of multiple apertures increases or decreases along the width from the edges of the planar surface toward the center of the planar surface.

[0253] 12. In the cartridge of any one of clauses 9 through 11, multiple apertures are arranged in a pattern.

[0254] 13. In the cartridge of any preceding clause, the susceptor is formed of a material having a capillary structure configured to work a liquid aerosol generating substrate.

[0255] 14. In the cartridge of Clause 13, the susceptor is formed from one of wire wool, mesh, or metal foam.

[0256] 15. In the cartridge of Clause 14, the susceptor contains nickel foam or cupronickel foam.

[0257] 16. In the cartridge of Clause 14, the susceptor includes a stainless steel mesh.

[0258] 17. In a cartridge of any one of provisions 1 to 12, the susceptor comprises a planar element, and the planar element has a thickness within one or more ranges of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm.

[0259] 18. In the cartridge of Clause 17, the flat element includes a sheet or foil.

[0260] 19. In the cartridge of Clause 17 or Clause 18, the flat element comprises one or more of mild steel, ferritic stainless steel, aluminum, nickel, cupronickel, and nichrome.

[0261] 20. In any of the cartridges of the preceding clause, the cartridge comprises a reservoir for a liquid aerosol generating material, and the cartridge is configured to supply the liquid aerosol generating material from the reservoir to the susceptor.

[0262] 21. In the cartridge of Clause 20, the substrate area includes a liquid transport element configured to work a liquid aerosol generating substrate toward the susceptor.

[0263] 22. In the cartridge of Clause 21, the liquid transport element is formed of susceptor material.

[0264] 23. In the cartridge of Clause 21 or Clause 22, the liquid transport element provides liquid to the surface of the second susceptor on the opposite side of the susceptor with respect to the flat surface.

[0265] 24. In the cartridge of Clause 23, the liquid transport element includes a semicircular rod, and the flat surface of the semicircular rod contacts the surface of the second susceptor.

[0266] 25. In the cartridge of any one of provisions 20 through 24, the material area includes one or more liquid flow channels for guiding liquid aerosol generating material from a reservoir.

[0267] 26. In the cartridge of Clause 25, the insert includes a plurality of ribs, each of which is configured to abut an individual part of the liquid transport element.

[0268] 27. In the cartridge of Clause 25 or Clause 26, one or more liquid flow channels are provided radially outward of the semicircular rod, and optionally, if subject to Clause 26, ribs are configured to abut individual parts of the curved surface of the semicircular rod.

[0269] 28. In the cartridge of Clause 26, one or more liquid flow channels are defined between individual pairs of ribs among the plurality of ribs.

[0270] 29. In a cartridge of any one of provisions 25 through 28 that is subordinate to any one of provisions 21 through 24, one or more liquid flow channels are configured to guide a liquid aerosol generating material from a reservoir to a liquid transport element.

[0271] 30. In the cartridge of any one of provisions 25 to 30, one or more liquid flow channels include capillary channels.

[0272] 31. In the cartridge of any one of provisions 20 to 30, the cartridge comprises an auxiliary reservoir provided at or toward the opposite end of the susceptor relative to the reservoir, the auxiliary reservoir is configured to hold a liquid aerosol generating material of a smaller volume than the reservoir, and the cartridge is configured to supply liquid from the auxiliary reservoir to the susceptor.

[0273] 32. In the cartridge of Clause 31, the auxiliary reservoir is configured to hold a liquid volume within the range of 0.2% to 2.5% of the volume of the reservoir.

[0274] 33. In the cartridge of Clause 32, the auxiliary reservoir is configured to hold a liquid volume within the range of 0.5% to 1.5% of the volume of the reservoir.

[0275] 34. In the cartridge of any one of provisions 31 to 33, the auxiliary reservoir is configured to hold a liquid volume within the range of 0.005 ml to 0.1 ml.

[0276] 35. In a cartridge of any one of provisions 31 through 34 that is subordinate to any one of provisions 25 through 30, one or more liquid flow channels are configured to guide a liquid aerosol generating material from a reservoir to an auxiliary reservoir.

[0277] 36. In the cartridge of any preceding clause, the insertion part includes at least two shoulders, and the at least two shoulders are configured to support a susceptor such that a flat surface extends across the distance between the at least two shoulders.

[0278] 37. In any of the cartridges of the preceding clause, the cartridge includes a seal, and the seal is configured to provide a liquid path from the reservoir toward the susceptor.

[0279] 38. In the cartridge of Article 37 subject to any one of Articles 21 through 24, the liquid transport element extends into the liquid path defined by the seal.

[0280] 39. In the cartridge of Clause 37 or Clause 38, the seal is configured to provide an outlet for the aerosol chamber.

[0281] 40. In any of the cartridges of the preceding clause, the cartridge is configured to provide a mouthpiece for the user to inhale an aerosol generated from an aerosol generating substrate.

[0282] 41. A mouthpiece for use with a cartridge according to any one of provisions 1 through 39, wherein the mouthpiece comprises an outlet and a cavity configured to receive at least a portion of the cartridge.

[0283] 42. In the mouthpiece of Clause 41, the mouthpiece comprises an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration, wherein in the first configuration, a cavity is at least partially exposed to allow a cartridge to be inserted and / or removed, and the second configuration is configured to retain a cartridge provided within the cavity.

[0284] 43. In the mouthpiece of Clause 41 or Clause 42, the mouthpiece comprises at least one component of a connecting mechanism, and the connecting mechanism is configured to maintain the mouthpiece in a second configuration.

[0285] 44. In the mouthpiece of Clause 43, the connection mechanism is user-operable so that the user can directly interact with the connection mechanism to prevent the connection mechanism from maintaining the mouthpiece in a second configuration.

[0286] 45. A guide assembly for use with a cartridge according to any one of provisions 1 to 40, wherein the guide assembly comprises a guide element arranged around a longitudinal axis corresponding to the insertion direction of the insertion portion of the cartridge;

[0287] The induction element can operate to aerosolize a portion of the aerosol generating substrate near the susceptor by inducing a current flow in the susceptor and inductively heating the susceptor.

[0288] 46. In the guiding assembly of Clause 45, the guiding assembly comprises a support having a tube portion positioned around the longitudinal axis, the tube portion comprising an inner wall and an outer wall, a guiding element provided between the inner wall and the outer wall of the tube portion, and the inner wall defines a receiving cavity in which a susceptor is at least partially located.

[0289] 47. In the induction assembly of Clause 45 or Clause 46, the induction element is formed of a resistive wire.

[0290] 48. In the induction assembly of Clause 45 or Clause 46, the induction element comprises one or more conductive layers deposited on a support.

[0291] 49. In the inductive assembly of Clause 48, one or more conductive layers comprise a metal or a metal alloy.

[0292] 50. In the inductive assembly of Clause 48 or Clause 49, one or more conductive layers comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0293] 51. In the induction assembly of any one of Clauses 45 to 50, the induction element comprises a helical coil or a spiral coil.

[0294] 52. In an induction assembly of any one of provisions 45 to 51, the induction element is a first induction element, and the induction assembly includes a second induction element positioned around the longitudinal axis, and when the induction assembly is attached to a cartridge, a first part of the susceptor is at least partially located within the first induction element, and a second part of the susceptor is at least partially located within the second induction element, and the second induction element is operable to induce a current flow in the second part of the susceptor to induce heating of the second part of the susceptor.

[0295] 53. In any one of provisions 45 to 52, the induction assembly includes a ferrite shield disposed around the circumference of the induction element.

[0296] 54. In the induction assembly of Clause 53, the ferrite shield comprises a film, foil, or sheet.

[0297] 55. In the induction assembly of Clause 53 or Clause 54, the ferrite shield is inserted or embedded within the support for the induction element.

[0298] 56. In the induction assembly of Clause 53 or Clause 54, the ferrite shield includes a sleeve that surrounds a support for the induction element.

[0299] 57. A device component for use with an induction assembly according to any one of provisions 45 to 56, wherein the device component comprises a control circuit for controlling the supply of power to an induction element, and the control circuit is configured to drive an induction element of the induction assembly to induce a current flow to a susceptor, thereby inductively heating the susceptor and thereby vaporizing a portion of an aerosol generating substrate near the susceptor.

[0300] 58. In the device component of Clause 57, the device component includes a power supply unit for supplying power to an induction element, and a control circuit is configured to control the power supply from the power supply unit to the induction element.

[0301] 59. In the device part of Clause 57 or Clause 58, the induction assembly is detachably attached to the device part.

[0302] 60. In a device component of any one of provisions 57 to 59, the control circuit is configured to drive an induction element to induce current flow in the susceptor to induce heating the susceptor to a first temperature in order to vaporize a portion of the aerosol generating substrate near the susceptor, and the control circuit is configured to drive an induction element to induce current flow in the susceptor to induce heating the susceptor to a second temperature lower than the first temperature and lower than the temperature required to vaporize a portion of the aerosol generating substrate near the susceptor.

[0303] 61. In the device component of Clause 60, the second temperature is a temperature within the range of 80°C to 200°C.

[0304] 62. In the device component of Clause 60 or Clause 61, the control circuit is configured to drive an induction element to induce current flow in the susceptor in response to a stimulus to induce heating of the susceptor to a second temperature, the stimulus comprising one or more of a signal indicating insertion of at least a portion of the susceptor into the induction element and a signal indicating a user's intention to start a session of use.

[0305] 63. In the device component of any one of provisions 60 to 62, the control circuit is configured to drive an induction element to induce a current flow in the susceptor in response to a signal indicating that the user is interacting with the user input element, thereby inducing the susceptor to heat the susceptor from a second temperature to a first temperature.

[0306] 64. In the device component of Clause 63, the control circuit is configured to maintain the susceptor at a second temperature after the signal indicating that the user is interacting with the user input element is interrupted, and / or between signals indicating that the user is interacting with the user input element.

[0307] 65. In the device component of Clause 63 or Clause 64, the device component includes a user input element, and the user input element includes one or more of a button, a capacitance sensor, a motion sensor, a light sensor, and a pressure sensor.

[0308] 66. In the device component of any one of provisions 60 to 65, the control circuit is configured to stop driving the induction element to induce current flow in the susceptor to maintain the susceptor at a second temperature after a period of inactivity.

[0309] 67. In the device component of Clause 66, the inactivity period is in the range of 10 seconds to 120 seconds.

[0310] 68. As an aerosol delivery system for generating an aerosol from an aerosol generating substrate, the aerosol delivery system comprises:

[0311] A cartridge of any one of Articles 1 through 40, or a mouthpiece of any one of Articles 41 through 44, and a cartridge of any one of Articles 1 through 39; and

[0312] Includes an induction assembly of any one of clauses 45 to 56.

[0313] 69. In the aerosol delivery system of Clause 68, the aerosol delivery system further comprises a device component of any one of Clauses 57 through 67.

[0314] 70. A method for generating an aerosol from an aerosol generating substrate in an aerosol delivery system, wherein the aerosol delivery system comprises a cartridge and an induction assembly, the cartridge comprises an insertion portion that at least partially defines an aerosol chamber and a substrate area, the insertion portion is defined by a longitudinal axis corresponding to the insertion direction, and the induction assembly comprises an induction element arranged around the longitudinal axis, and the method comprises:

[0315] Step of inserting an insertion into a receiving cavity of a guide assembly ― a susceptor is provided within the insertion, the susceptor includes a planar surface separating the aerosol chamber from the substrate region, and the planar surface is provided parallel to the longitudinal axis ―;

[0316] The method includes the step of driving an induction element to induce a current flow in the susceptor, thereby inductively heating the susceptor and vaporizing a portion of the aerosol generating substrate near the susceptor.

[0317] 71. In the method of Clause 70, the method comprises the step of driving an induction element to induce a current flow in the susceptor to induce heating the susceptor to a first temperature so as to vaporize a portion of the aerosol generating substrate near the susceptor, and the method further comprises the step of driving an induction element to induce a current flow in the susceptor to induce heating the susceptor to a second temperature lower than the first temperature and lower than the temperature required to vaporize a portion of the aerosol generating substrate near the susceptor.

[0318] 72. In the method of Clause 71, the second temperature is a temperature within the range of 80°C to 200°C.

[0319] 73. In the method of Clause 71 or Clause 72, the method comprises the step of driving an induction element to induce a current flow in the susceptor in response to a stimulus to induce heating of the susceptor to a second temperature, wherein the stimulus comprises one or more of a signal indicating insertion of at least a portion of the susceptor into the induction element and a signal indicating a user's intention to start a session of use.

[0320] 74. In the method of any one of provisions 71 through 73, the method comprises the step of driving an induction element to induce a current flow in the susceptor in response to a signal indicating that the user is interacting with a user input element, so as to induce heating of the susceptor from a second temperature to a first temperature.

[0321] 75. In the method of Clause 74, the method includes the step of maintaining the susceptor at a second temperature after a signal indicating that the user is interacting with a user input element is interrupted, and / or between signals indicating that the user is interacting with a user input element.

[0322] 76. In the method of any one of provisions 71 through 75, the method includes the step of ceasing to drive the induction element to induce a current flow in the susceptor to maintain the susceptor at a second temperature after an inactive period.

[0323] 77. In the method of Clause 76, the inactivity period is within the range of 10 to 120 seconds.

[0324] 78. In the method of any one of provisions 70 through 77, the method comprises the steps of engaging a connecting mechanism configured to hold a cartridge as part of an aerosol delivery system, and disengaging the connecting mechanism, wherein the connecting mechanism is electronically operable.

Claims

Claim 1 A cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate, comprising: an insertion portion that at least partially defines an aerosol chamber and a substrate region—said the insertion portion is defined by a longitudinal axis corresponding to the insertion direction—and a susceptor provided within the insertion portion, wherein the susceptor comprises a planar surface separating the aerosol chamber from the substrate region, and wherein the planar surface is provided parallel to the longitudinal axis. Claim 2 In claim 1, the planar surface extends through the center of the cross-section of the insertion part perpendicular to the longitudinal axis, a cartridge. Claim 3 In claim 2, the cross-section of the insertion part includes an elliptical or circular periphery, and the planar surface is parallel to the diameter of the cross-section, a cartridge. Claim 4 A cartridge according to any one of claims 1 to 3, wherein the planar surface is defined by a length and a width, wherein the length is greater than the width, the length is parallel to the longitudinal axis, the length is within the range of 5 mm to 50 mm, and the width is within the range of 2 mm to 15 mm. Claim 5 A cartridge according to any one of claims 1 to 3, wherein the susceptor comprises a plurality of apertures extending through the susceptor. Claim 6 A cartridge according to any one of claims 1 to 3, wherein the susceptor is formed of a material having a capillary structure configured to wick a liquid aerosol generating substrate. Claim 7 A cartridge according to any one of claims 1 to 3, wherein the susceptor comprises a planar element, and the planar element has a thickness within one or more of the ranges of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm. Claim 8 A cartridge according to any one of claims 1 to 3, wherein the cartridge comprises a reservoir for a liquid aerosol generating material, and the cartridge is configured to supply the liquid aerosol generating material from the reservoir to the susceptor. Claim 9 In claim 8, the aforementioned description area comprises a liquid transport element configured to walk the liquid aerosol generating material toward the susceptor, and optionally, the liquid transport element is formed of a susceptor material, cartridge. Claim 10 In claim 8, the aforementioned section comprises one or more liquid flow channels for guiding a liquid aerosol generating material from the reservoir, optionally, the insert comprises a plurality of ribs, each of which is configured to abut an individual part of the liquid transport element, and the one or more liquid flow channels are defined between the ribs of individual pairs of the plurality of ribs, cartridge. Claim 11 In claim 8, the cartridge comprises a sub-reservoir provided at or toward the opposite end of the susceptor relative to the reservoir, wherein the sub-reservoir is configured to hold a liquid aerosol generating material having a smaller volume than the reservoir, and the cartridge is configured to supply liquid from the sub-reservoir to the susceptor. Claim 12 A mouthpiece for use with a cartridge according to any one of claims 1 to 3, comprising an outlet and a cavity configured to accommodate at least a portion of said cartridge; and optionally, said mouthpiece comprises an opening mechanism configured to allow said mouthpiece to move between a first configuration and a second configuration, wherein in the first configuration, said cavity is at least partially exposed to allow a cartridge to be inserted and / or removed, and said second configuration is configured to retain a cartridge provided within said cavity. Claim 13 An induction assembly for use with a cartridge according to any one of claims 1 to 3, comprising an induction element arranged around a longitudinal axis corresponding to the insertion direction of the insertion portion of the cartridge; wherein the induction element is operable to induce a current flow in the susceptor, thereby inducing heating of the susceptor to aerosolize a portion of the aerosol generating substrate near the susceptor. Claim 14 An aerosol delivery system for generating an aerosol from an aerosol generating substrate, comprising: a cartridge of claim 1; an induction assembly of claim 13; a device component comprising a control circuit for controlling the supply of power to the induction element ― said control circuit is configured to drive the induction element of the induction assembly so as to induce a current flow to the susceptor, thereby inductively heating the susceptor and thereby vaporizing a portion of the aerosol generating substrate near the susceptor ―; and optionally, an aerosol delivery system comprising a mouthpiece of claim 12. Claim 15 A method for generating an aerosol from an aerosol generating substrate in an aerosol delivery system, wherein the aerosol delivery system comprises a cartridge and an induction assembly, wherein the cartridge comprises an insertion portion that at least partially defines an aerosol chamber and a substrate area, wherein the insertion portion is defined by a longitudinal axis corresponding to the insertion direction, and the induction assembly comprises an induction element arranged around the longitudinal axis, and the method comprises: Step of inserting the above-described insertion portion into a receiving cavity of the above-described induction assembly ― a susceptor is provided within the above-described insertion portion, said susceptor includes a planar surface separating the aerosol chamber from the above-described region, said planar surface is provided parallel to the longitudinal axis ―; A method comprising the step of driving the induction element to induce a current flow in the susceptor, thereby inducing heating of the susceptor and, accordingly, vaporizing a portion of the aerosol generating substrate near the susceptor.

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