A cartridge for an aerosol-generating system

Abstract

A cartridge (100) for an aerosol generating system, wherein the cartridge comprises: a housing (105) having a mouse end opening (110) and an air inlet (150); a storage compartment (135) configured to contain a liquid aerosol forming material (131) within the housing; an airflow passage (140) extending from the air inlet to the mouse end opening; a fluid-permeable aerosol generating element (121) having a first surface and a second surface facing the first surface, wherein the second surface is in fluid communication with the storage compartment; and a removable seal (310) having a seal portion (320) and a tab portion (330) connected to the seal portion, wherein the seal portion is located in the airflow passage over the first surface of the fluid-permeable aerosol generating element and the tab portion extends outwardly from the housing through the air inlet. An aerosol generation system comprising a cartridge and a control body (200) connected to the cartridge, wherein the control body is configured to control the power supply to a fluid-permeable aerosol generating element.

Description

Technology Field

[0001] The present invention relates to a cartridge for an aerosol generating system configured to generate an aerosol by heating a liquid aerosol forming substrate. In particular, the present invention relates to a portable aerosol generating system, for example, an electronically operated smoking system. Background Technology

[0003] In many portable aerosol generation systems, an electric heater is used to vaporize a liquid aerosol-forming substrate to generate aerosols. The liquid substrate is typically contained in a replaceable cartridge having a mouth end for the user to inhale the generated aerosol and a connecting end facing the mouth end. For example, the electric heater is a fluid-permeable mesh provided at the connecting end to connect to a control unit containing a control circuit and a power supply. The liquid is held in a storage compartment between the heater element and the mouth end of the cartridge. Such replaceable cartridges allow the user to replace the consumed liquid substrate without discarding other parts of the system, such as the power supply, and allow for a simple connection of the heater to the power supply. However, during use, due to the orientation of the heater and the storage compartment, the liquid substrate may leak through the heater element under the influence of gravity.

[0004] To reduce leakage, a cartridge has been developed comprising a storage compartment divided into an upper section for storing liquid bulk and a smaller lower section containing capillary material. The upper and lower sections are connected to allow the liquid to pass from the upper section to the lower section, with a heater element positioned between the two sections and in contact with the capillary material. This allows the liquid to be transferred downward from the upper section to the capillary material by gravity before being drawn into the heater element due to upward capillary motion. This cartridge design ensures that the capillary material is saturated with the liquid substrate while mitigating leakage problems during use.

[0005] However, due to the complex design, it is difficult to economically mass-produce cartridges of this prior art using conventional techniques such as injection molding. Additionally, it would be desirable to further prevent liquid leakage from the cartridge during transportation and storage. means of solving the problem

[0007] In a first aspect of the present invention, a cartridge for an aerosol generating system is provided, said cartridge comprising: a housing having a mouth end opening and an air inlet; a storage compartment within the housing configured to contain a liquid aerosol forming material; an airflow passage extending from the air inlet to the mouth end opening; a fluid-permeable aerosol generating element within the housing having a first surface and a second surface facing the first surface, wherein the second surface is in fluid communication with the storage compartment; and a removable seal having a seal portion and a tab portion connected to the seal portion, wherein the seal portion is located in the airflow passage over the first surface of the fluid-permeable aerosol generating element and the tab portion extends outwardly from the housing through the air inlet.

[0008] The aerosol generating element may be a heater element. The aerosol generating element may be a mesh heater. The mesh heater may allow a liquid aerosol forming material stored in a storage compartment to pass through the gaps of the mesh heater from a second surface to a first surface. Alternatively, the aerosol generating element may be a vibration element.

[0009] A removable seal is positioned in the airflow passage above the first surface of the aerosol generating element during transport and storage of the cartridge. As described herein, storage may refer, for example, to storage in a warehouse and long-term storage at a sales and storage location prior to first use. The seal serves to cut off the fluid communication between the aerosol generating element and the airflow passage. This can be achieved by directly sealing the first surface or by sealing a portion of the housing adjacent to the first surface, for example, the inner wall of the housing. By sealing the fluid communication between the first surface and the airflow passage, leakage and evaporation of the liquid aerosol forming material can be eliminated or at least reduced during transport and storage.

[0010] The tab portion forms part of a removable seal accessible to the user. That is, when the seal portion of the removable seal is located within an airflow passage on a first surface, the tab portion extends past the outer surface of the housing.

[0011] Extracting the seal through the air inlet allows for the use of a shorter, removable seal.

[0012] Optionally, when located within the airflow passage, the sealing portion forms an airtight seal within the airflow passage. For example, to prevent airflow in the airflow passage, the sealing portion may extend across the airflow passage to form an airtight blockage. This prevents dust and dirt from being collected within the airflow passage. Optionally, the sealing portion extends from the mouse end opening to the air inlet. Optionally, the sealing portion is configured to match the dimensions of the airflow passage to completely block the airflow passage.

[0013] Optionally, by applying a pulling force to the tab portion, the seal portion is removed from the first surface, thereby positioning the first surface in fluid communication with the airflow passage. Before initial use, the user can pull the tab portion of the removable seal from the cartridge to extract the removable seal from the airflow passage. Removal of the removable seal establishes fluid communication between the aerosol generating element and the airflow passage. This allows the user to inhale the generated aerosol through the end opening of the mouse. The surface of the tab portion may have indentations and / or protrusions to improve the user's grip on the tab portion. Advantageously, the surface area of ​​the tab portion is sufficiently large to be easily grasped by the user's fingers.

[0014] Optionally, the removable seal is reusable. The removed seal can be reinserted into the airflow passage so as to be positioned in the airflow passage over the first surface of the aerosol generating element. This allows the cartridge to be resealed for additional storage and transport after initial use.

[0015] Optionally, the removable seal comprises a retaining means for retaining the removable seal on a first surface of the aerosol generating element until the pulling force is applied to the tab portion. The retaining means may be any retaining means known to those skilled in the art, for example, a mechanical retaining means such as a spring clip or a latch engaging with the first surface and / or housing, or may be achieved by a bonding technique such as an adhesive seal, a heat seal, or an induction heat seal.

[0016] Optionally, the tab portion extends outwardly from the housing through the mouse end opening. This allows the mouse end opening to be closed by the tab portion and may serve to remind the user to remove the removable seal before operation.

[0017] Optionally, a safety mechanism is provided to prevent the aerosol generating element from operating before the seal is removed from the airflow passage. Such a safety mechanism may be any mechanism known to those skilled in the art, for example, a safety mechanism such as a removable connector seal and an interlock formed integrally with the seal, or a more complex electronic sensor such as an airflow sensor or a pressure-actuated switch communicating with the airflow passage. While the safety mechanism serves to prevent unintended heater operation, the seal is positioned over the heater element.

[0018] Optionally, the removable seal may be made of thermoplastic elastomer (TPE), styrene ethylene butylene styrene (SEBS), polyethersulfone (PESU), rubber, silicone, or any suitable material known to those skilled in the art. The tab portion and the seal portion may be molded or extruded from a single piece of material, or may be made of different materials for different purposes. For example, the seal portion may be made of more elastic material than the tab portion to achieve a better seal, while the tab portion may be made of more elastic material than the elastic material to withstand the pulling force applied by the user while removing the removable seal.

[0019] Optionally, the tab portion is flexible and configured to bend at the air inlet to conform to the external contour of the housing. Alternatively, the tab portion may be hinged at the air inlet to the seal portion, allowing the tab portion to conform to the external contour of the housing. More specifically, the tab portion is arranged to fold at the air inlet during storage and transport, so as to extend along the longitudinal axis of the housing. In other words, the tab portion can be fixed in place before use. In this way, the tab portion causes minimal protrusion, and the cartridge can be packaged in a more compressed package. To remove the removable seal, the user may straighten the tab portion so that it is not parallel to the housing before applying a lateral pulling force to remove the removable seal from the housing.

[0020] Optionally, the sealing portion is arranged to provide a hermetic seal between the aerosol generating element and the airflow passage. Providing a hermetic seal prevents the evaporation and / or loss of the liquid substrate from the storage compartment to the atmosphere through the airflow passage, and furthermore, suppresses the ingress of moisture into the storage compartment which could affect the quality and stability of the liquid substrate.

[0021] Optionally, the storage compartment comprises a first compartment and a second compartment connected to each other by a connector, so that a liquid in the first compartment can pass into the second compartment through a liquid passage of the connector; wherein the first surface of the fluid-permeable aerosol generating element faces the first compartment and the second surface faces the second compartment while fluidly communicating with the second compartment, so that the liquid aerosol generating material in the first compartment can reach the fluid-permeable aerosol generating element only through the second compartment.

[0022] The connector seals two separate compartments and provides one or more liquid passages between them. More specifically, the connector is separated from both the first compartment and the second compartment. The connector may be connected to the first compartment and / or the second compartment by a press fit, which is elastically deformed to provide a seal at the connection. This allows for the formation of more complex cartridge designs by enabling the individual parts to be mass-produced inexpensively by extrusion or molding before assembly. For example, this allows an aerosol generating element to be molded with the second compartment before being assembled onto the first compartment via the connector. The press fit may be any suitable press fit known to those skilled in the art, for example, the press fit may be an interlock or a snap fit.

[0023] Optionally, the connector and the first surface of the fluid-permeable aerosol generating element define at least a portion of the airflow passage. The connector may define a wall of the airflow passage facing the fluid-permeable aerosol generating element. More specifically, the connector allows the seal portion of the removable seal to be positioned in the airflow passage over the first surface of the aerosol generating element before the cartridge is assembled. This improves access to the first surface because the seal portion is fully exposed when placed in position.

[0024] Optionally, the airflow passage extends from the air inlet to the mouse end opening and between the first and second compartments. That is, the connector not only provides a liquid passage to the aerosol generating material but also defines a portion of the airflow passage to guide the airflow over the heater element and toward the mouse end opening.

[0025] Optionally, the airflow passage may extend through the first compartment. For example, the first compartment may have an annular cross-section, and the airflow passage extends from the aerosol generating element through the first compartment to the mouse distal opening. Alternatively, the airflow passage may extend from the aerosol generating element to the mouse distal opening adjacent to the first compartment.

[0026] Optionally, the connector may be manufactured from polypropylene (PP), high-density polyethylene (HDPE), copolyester, thermoplastic elastomer (TPE), polysulfone (PSU), styrene ethylene butylene styrene (SEBS), polyethersulfone (PESU), rubber, silicone, or any suitable material known to those skilled in the art. Optionally, the connector may be manufactured from a material capable of maintaining mechanical integrity at up to 90°C. Optionally, the connector may be manufactured from a material capable of maintaining mechanical integrity at a temperature up to 120°C.

[0027] Optionally, the first compartment has a larger liquid storage capacity than the second compartment. Optionally, the first compartment is larger than the second compartment. In use, the first compartment is typically positioned above the aerosol generating element. Optionally, the first compartment is positioned between the fluid-permeable aerosol generating element and the mouse terminal opening.

[0028] Advantageously, the second compartment contains a capillary material in contact with a second surface of the aerosol generating element. The capillary material delivers a liquid aerosol forming substrate to the aerosol generating element against the force of gravity. By requiring the liquid aerosol forming substrate to move against the force of gravity to reach the aerosol generating element, the possibility of liquid substrate leakage is reduced.

[0029] The capillary material may be made of a material capable of ensuring the presence of a liquid aerosol-forming substrate in contact with at least a portion of the second surface of the aerosol-generating element. The capillary material may extend into a gap or hole in the aerosol-generating element. The aerosol-generating element may draw the liquid aerosol-forming substrate into the gap or hole by capillary action.

[0030] A capillary material is a material that actively transports a liquid from one end of the material to the other. A capillary material may have a fibrous or sponge-like structure. A capillary material preferably comprises a bundle of capillaries. For example, a capillary material may comprise a plurality of fibers, threads, or other microbore tubes. The fibers or threads may be generally aligned so that the liquid aerosol-forming substrate is transported toward an aerosol-generating element. Alternatively, the capillary material may comprise a sponge-like or foam-like material. The structure of the capillary material forms a plurality of small bores or tubes through which the liquid can be transported by capillary action. The capillary material may comprise any suitable material or a combination of materials. Examples of suitable materials include sponge or foam materials, ceramic or graphite-based materials in the form of fibers or calcined powders, foamed metal or plastic materials, and fibrous materials composed of, for example, cellulose acetate, polyester, or combined polyolefins, polyethylene, ethylene or polypropylene fibers, nylon fibers, or spun or extruded fibers such as ceramics. Capillary materials may have any suitable capillary action and porosity to be used with different liquid properties. Liquid aerosol-forming substrates have physical properties including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, which allow the liquid aerosol-forming substrate to be transported through a capillary medium by capillary action.

[0031] Alternatively or additionally, the storage compartment may contain a carrier material for holding a liquid aerosol-forming substrate. The carrier material may be in the first compartment, the second compartment, or both the first and second compartments. The carrier material may be a sponge of foam and fiber assemblies. The carrier material may be formed of a polymer or copolymer. In one embodiment, the carrier material is a spun polymer. The aerosol-forming substrate may be released into the carrier material during use. For example, the liquid aerosol-forming substrate may be provided within a capsule.

[0032] Optionally, the cartridge comprises a heater assembly, the heater assembly comprises a heater element and an electrical contact portion electrically connected to the heater element, wherein the contact portion is exposed through a connection end of the cartridge to make contact with an electrical contact pin within the control body portion of the aerosol generating system. The connection end is located away from the mouse end, which features a mouse end opening. The connection end is configured to be connected to the control body portion of the aerosol generating system. A second side of the aerosol generating element may face the connection end, and a first side of the aerosol generating element may face the mouse end. Power may be transmitted from the connected control body portion to the aerosol generating element through the connection end of the housing.

[0033] Optionally, the electrical contact may be two electrically conductive contact pads. The electrically conductive contact pads may be located at the edge region of the heater element. Optionally, at least two electrically conductive contact pads may be located at the extremes of the heater element. The electrically conductive contact pads may be fixed directly to the electrically conductive filament of the heater element. The electrically conductive contact pads may include a tin patch. Alternatively, the electrically conductive contact pads may be integral with the heater element.

[0034] Optionally, the aerosol generating element is closer to the connection end than to the mouse terminal opening. This allows for a simple and short electrical connection path between the control body and the power source within the aerosol generating element.

[0035] Optionally, the storage compartment may include a heater mounting portion, and the heater mounting portion is formed across the heater assembly.

[0036] Optionally, the first and second surfaces of the aerosol generating element may be substantially flat. The aerosol generating element may be a heater element. The heater element may include a substantially flat heater element so that it can be manufactured simply. Geometrically, the term “substantially flat” heater element is used to refer to a heater element in the form of a substantially two-dimensional surface. Thus, a substantially flat heater element extends in two dimensions along the surface rather than in a substantially third dimension. In particular, the dimension of the substantially flat heater element in the two dimensions within the surface is at least five times larger than the third dimension in the direction normal to the surface. An example of a substantially flat heater element is a structure between two substantially virtual parallel surfaces, and the distance between these two virtual surfaces is substantially smaller than the extension within the surfaces. In some embodiments, the substantially flat heater element is planar. In other embodiments, the substantially flat heater element is curved along one or more dimensions to form, for example, a dome shape or a bridge shape.

[0037] The heater element may include a plurality of gaps or holes extending from the second surface to the first surface through which fluid can pass.

[0038] A heater element may include a plurality of electrically conductive filaments. Throughout the specification, the term “filament” is used to refer to an electrical path arranged between two electrical contacts. The filament may be optionally branched into multiple paths or filaments, or may converge from multiple electrical paths into a single path. The filament may have a circular, square, flat shape, or any other cross-sectional shape. The filament may be arranged in a straight or curved shape.

[0039] The heater element may be, for example, an array of filaments arranged parallel to one another. Preferably, the filaments may form a mesh. The mesh may be a fabric or a non-woven fabric. The mesh may be formed using different types of weave or lattice structures. Alternatively, the electrically conductive heater element consists of a filament array or a filament fabric. The mesh, array, or fabric of electrically conductive filaments may be characterized by the ability to retain liquid, as is well known in the art.

[0040] In a preferred embodiment, the substantially flat heater element may be made of wire formed into a wire mesh. Preferably, the mesh has a plain weave design. Optionally, the heater element is a wire grill made of mesh strips.

[0041] The electrically conductive filament can define gaps between the filaments, and the gaps may have a width of 10 µm to 100 µm. Preferably, the filament causes capillary action within the gaps, so that liquid to be evaporated during use is drawn into the gaps, thereby increasing the contact area between the heater element and the liquid aerosol forming substrate.

[0042] The electrically conductive filaments can form a mesh with a size of 60 to 240 filaments (± 10%) per centimeter. Preferably, the mesh density is 100 to 140 filaments (± 10%) per centimeter. More preferably, the mesh density is approximately 115 filaments per centimeter. The width of the gaps can be 100 µm to 25 µm, preferably 80 µm to 70 µm, more preferably approximately 74 µm. The percentage of the open area of ​​the mesh (the ratio of the gap area to the total area of ​​the mesh) can be 40% to 90%, preferably 85% to 80%, more preferably approximately 82%.

[0043] The electrically conductive filament may have a diameter of 8 µm to 100 µm, preferably 10 µm to 50 µm, more preferably 12 µm to 25 µm, and most preferably about 16 µm. The filament may have a round cross-section or a flattened cross-section.

[0044] The area of ​​the mesh, array, or fabric of electrically conductive filaments may be, for example, 50 mm² or less, preferably 25 mm² or less, and more preferably approximately 15 mm². The size is selected so that the heater element is contained within the portable system. If the size of the mesh, array, or fabric of electrically conductive filaments is 50 mm² or less of the said area, the total amount of power required to heat the mesh, array, or fabric of electrically conductive filaments is reduced while continuously ensuring sufficient contact of the mesh, array, or fabric of electrically conductive filaments with the liquid aerosol-forming substrate. The mesh, array, or fabric of electrically conductive filaments may be, for example, rectangular, with a length of 2 mm to 10 mm and a width of 2 mm to 10 mm. Preferably, the mesh has dimensions of approximately 5 mm × 3 mm.

[0045] The filament of the heater element may be formed from any material having suitable electrical properties. Suitable materials include, but are not limited to: doped ceramics, “conductive” ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, metal alloys, and semiconductors such as composite materials of ceramic and metal materials. Such composite materials may include doped ceramics or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals.

[0046] Examples of suitable metal alloys include stainless steel, Constantan, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, and iron-containing alloys, and superalloys based on nickel, iron, cobalt, and stainless steel, Timetal®, iron-aluminum base alloys, and iron-manganese-aluminum base alloys. Timetal® is a registered trademark of Titanium Metals Corporation. The filament may be coated with one or more insulators. Preferred materials for the electrically conductive filament are stainless steel and graphite, more preferably 300 series stainless steels such as AISI 304, 316, 304L, and 316L. Additionally, the electrically conductive heater element may comprise a combination of the above materials. Combinations of materials can be used to improve the resistance control of substantially flat heater elements. For example, a material with high intrinsic resistance can be combined with a material with low intrinsic resistance. This can be advantageous if one of the materials is more beneficial in other aspects, such as cost, processability, or other physical and chemical parameters. Advantageously, substantially flat filament devices with increased resistance reduce parasitic losses. Advantageously, high-resistance heaters enable more efficient use of battery energy.

[0047] Optionally, the filaments are made of wire. Optionally, the wire is made of metal, most preferably stainless steel.

[0048] The electrical resistance of the mesh, array, or fabric of the electrically conductive filaments of the heater element may be 0.3Ω to 4Ω. Optionally, the electrical resistance is 0.5Ω or greater. More preferably, the electrical resistance of the mesh, array, or fabric of the electrically conductive filaments is 0.6Ω to 0.8Ω, most preferably about 0.68Ω. The electrical resistance of the mesh, array, or fabric of the electrically conductive filaments is preferably at least tens of times, more preferably hundreds of times, greater than the electrical resistance of the electrically conductive contact area. This ensures that the heat generated by passing current through the heater element is confined to the mesh or array of the electrically conductive filaments. When the system is powered by a battery, it is advantageous to have a low overall resistance for the heater element. A low-resistance, high-current system allows high power to be delivered to the heater element. This enables the heater element to rapidly heat the electrically conductive filaments to a desired temperature.

[0049] Alternatively, the heater element may include a heating plate having an array of holes formed therein. The holes may be formed, for example, by etching or machining. The plate may be formed of any material having suitable electrical properties, such as the material described above for the filament of the heater element.

[0050] The first surface of the aerosol generating element may directly face the mouse distal opening. This orientation of the planar aerosol generating element enables simple assembly of the cartridge during manufacturing.

[0051] The storage compartment may include a storage compartment housing. The storage compartment includes a heater mounting portion, wherein the heater mounting portion is formed over the heater assembly. The heater mounting portion may cover a portion of the first surface of the heater assembly to isolate the electrical contact portion from the airflow passage and may cover at least a portion of the second surface of the heater assembly to isolate the electrical contact portion from the liquid aerosol forming substrate.

[0052] The heater mounting portion may include at least one wall surface extending from a second surface of the heater assembly, said at least one wall surface forming part of a second compartment. The heater mounting portion may define a liquid flow path from a first surface of the heater assembly to a second surface of the heater assembly.

[0053] The liquid storage compartment may hold a liquid aerosol-forming substrate. As used herein, the aerosol-forming substrate is a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The volatile compound may be released by moving the aerosol-forming substrate through a passage of a vibrating element.

[0054] The aerosol-forming substrate may be liquid at room temperature. The aerosol-forming substrate may include both liquid and solid components. The liquid aerosol-forming substrate may include nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may include a plant-based material. The liquid aerosol-forming substrate may include tobacco. The liquid aerosol-forming substrate may include a tobacco-containing material containing a volatile tobacco flavor compound that is released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may include a homogenized tobacco material. The liquid aerosol-forming substrate may include a non-tobacco-containing material. The liquid aerosol-forming substrate may include a homogenized plant-based material.

[0055] A liquid aerosol-forming substrate may comprise one or more aerosol-forming agents. An aerosol-forming agent is any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol upon use and substantially resists thermal degradation at the operating temperature of the system. Examples of suitable aerosol-forming agents are glycerin and propylene glycol. Suitable aerosol-forming agents are well known in the art and include, but are not limited to, polyhydric alcohols such as triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. A liquid aerosol-forming substrate may comprise water, a solvent, ethanol, a plant extract, and a natural or artificial flavor.

[0056] The liquid aerosol-forming substrate may comprise nicotine and at least one aerosol-forming agent. The aerosol-forming agent may be glycerin or propylene glycol. The aerosol-forming agent may comprise both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of about 0.5% to about 10%, for example, about 2%.

[0057] The housing may be formed of a moldable plastic material, such as polypropylene (PP) or polyethylene terephthalate (PET). The housing may form part or all of the walls of the storage compartment. The housing and the storage compartment may be formed integrally. Alternatively, the storage compartment may be formed separately from the housing and assembled to the housing.

[0058] The cartridge may include a removable mouthpiece that can be inhaled by the user. The removable mouthpiece may cover the distal opening of the mouse. Alternatively, the cartridge may be configured to allow the user to inhale directly through the distal opening of the mouse.

[0059] The cartridge can be refilled with a liquid aerosol-forming substrate. Alternatively, the cartridge can be designed so that the storage compartment is discarded when the liquid aerosol-forming substrate is emptied.

[0060] In a second aspect of the present invention, a cartridge for an aerosol generating system is provided, and said cartridge is:

[0061] Housing having a mouse end opening and an air inlet;

[0062] A storage compartment located inside the above housing and configured to contain a liquid aerosol-forming material; wherein the storage compartment has a first compartment and a second compartment connected to each other by a connector, so that a liquid in the first compartment can pass into the second compartment through a liquid passage in the connector;

[0063] An airflow passage extending from the air inlet to the mouse end opening, wherein the airflow passage passes between the first compartment and the second compartment of the storage compartment;

[0064] A fluid-permeable aerosol generating element having a first surface and a second surface facing the first surface, wherein the first surface of the fluid-permeable aerosol generating element faces the first compartment and the second surface faces the second compartment, and the second surface is in fluid communication with the second compartment so that a liquid aerosol generating material within the first compartment can reach the fluid-permeable aerosol generating element only through the second compartment, and wherein the first surface and the connector form a part of the airflow passage; and

[0065] Here, the liquid aerosol forming material in the first compartment can reach the fluid-permeable aerosol generating element only through the connector and the second compartment.

[0066] The features of the cartridge of the first aspect of the present invention may be applied to the second aspect of the present invention.

[0067] In a third aspect of the present invention, an aerosol generating system is provided, comprising a cartridge according to either the first or second aspect and a control body connected to the cartridge, wherein the control body is configured to control the power supply to an aerosol generating element.

[0068] The control body may include at least one electrical contact element configured to provide an electrical connection to an aerosol generating element when the control body is connected to a cartridge. The electrical contact element may be elongated. The electrical contact element may be spring-loaded. The electrical contact element may contact an electrical contact pad within the cartridge.

[0069] The control body may include a connection part for engaging with the connection end of the cartridge.

[0070] The control body may include a power supply unit.

[0071] The control body may include a control circuit configured to control the supply of power from the power supply unit to the aerosol generating element.

[0072] The above electrical circuit may include a microcontroller. The microcontroller may preferably be a programmable microcontroller. The control circuit may further include electronic components. The control circuit may be configured to regulate the power supply to the aerosol generating element. Power may be supplied to the aerosol generating element to continuously accompany the activation of the system, or may be supplied intermittently, for example, on a per-puff basis. Power may also be supplied to the aerosol generating element in the form of pulsed current.

[0073] The control body may include a power supply unit arranged to supply power to at least one of the control system and the aerosol generating element. The aerosol generating element may include an independent power supply unit. The aerosol generating system may include a first power supply unit arranged to supply power to a control circuit and a second power supply unit configured to supply power to the aerosol generating element.

[0074] The power supply may be a DC power supply. The power supply may be a battery. The battery may be a lithium-based battery, for example, a lithium-cobalt, lithium-iron-phosphate, lithium titanate, or lithium-polymer battery. The battery may be a nickel-hydrogen alloy battery or a nickel-cadmium battery. The power supply may be another form of charge storage device, such as a capacitor. The power supply may require recharging and may be configured for multiple charge and discharge cycles. The power supply may have a capacity sufficient to store energy for one or more user experiences; for example, the power supply may have a capacity sufficient to continuously generate an aerosol for a period of about 6 minutes, corresponding to the typical time taken to smoke a conventional cigarette, or for a period of several times 6 minutes. In other embodiments, the power supply may have a capacity sufficient to enable a predetermined number of puffings or individual activation of the atomizing assembly.

[0075] The aerosol generating system may be a portable aerosol generating system configured to allow a user to suck on a mouthpiece and inhale an aerosol through the mouthpiece's end opening. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The aerosol generating system may have a total length of about 30 mm to about 150 mm. The aerosol generating system may have an outer diameter of about 5 mm to about 30 mm.

[0076] In any aspect of the present invention, the cartridge or aerosol generating system may include a puff detector in communication with a control circuit. The puff detector may be configured to detect when a user inhales through an airflow passage.

[0077] In any aspect of the present invention, the cartridge or aerosol generating system may include a temperature sensor in communication with a control circuit. The cartridge or aerosol generating system may include a user input such as a switch or a button. The user input may enable the user to turn the system on and off.

[0078] The cartridge or aerosol generating system may also include a display means for displaying to the user a determined amount of liquid aerosol-forming material contained in a liquid reservoir. The control circuit may be configured to activate the display means after determining the amount of liquid aerosol-forming material held in the liquid reservoir.

[0079] The display means may include one or more lights, such as light-emitting diodes (LEDs), a display, such as an LCD display, and auditory display means, such as a loudspeaker or buzzer, and vibration means. The control circuit may be configured to illuminate one or more lights, display a quantity on the display, emit sound through the loudspeaker or buzzer, and vibrate the vibration means.

[0080] In a fourth aspect of the present invention, a housing having a mouse end opening and an air inlet;

[0081] A storage compartment located within the above housing and configured to contain a liquid aerosol-forming substrate;

[0082] An airflow passage extending from the air inlet to the mouse end opening;

[0083] A fluid-permeable aerosol generating element having a first surface and a second surface facing the first surface, wherein the second surface is in fluid communication with the storage compartment;

[0084] A removable seal having a seal portion and a tab portion connected to the seal portion, wherein the tab portion connected to the seal portion is included, the seal portion is located in an airflow passage on the first surface of the aerosol generating element, and the tab portion extends outwardly from the housing through the air inlet; and

[0085] An aerosol generating system is provided, comprising a control body configured to control the power supply to the aerosol generating element.

[0086] Features of one aspect of the present invention may be applied to other aspects of the present invention. Brief explanation of the drawing

[0088] Embodiments of the present invention will be described in detail with reference to the accompanying drawings merely for illustrative purposes, wherein: FIG. 1a is a schematic diagram of an aerosol generating system according to one embodiment of the present invention; FIG. 1b is a schematic diagram of a first cross-section of the cartridge shown in FIG. 1a; FIG. 1c is a schematic diagram of a second cross-section of the cartridge shown in FIG. 1a; FIGS. 2a and 2b illustrate the fit of a removable seal portion to the cartridge of FIGS. 1a to 1c; FIG. 2c illustrates the removal of a removable seal as illustrated in FIG. 2a and FIG. 2b; FIG. 3 is a cross-sectional view of a cartridge according to another embodiment of the present invention; FIGS. 4a and 4b are perspective views of a heater assembly for a cartridge shown in FIG. 3; FIG. 5a is a perspective view of the cartridge shown in FIG. 3; FIG. 5b is an exploded view of the cartridge shown in FIG. 5a; and FIG. 6 is an exploded view of a cartridge according to another embodiment of the present invention. Specific details for implementing the invention

[0089] FIG. 1a is a schematic diagram of an aerosol generating system. The aerosol generating system comprises two main components, a cartridge (100) and a control body (200). A connecting end (115) of the cartridge (100) is removablely connected to a corresponding connecting end (205) of the control body (200). The control body (200) comprises a battery (210), which is a rechargeable lithium-ion battery in this embodiment, and a control circuit (220). The aerosol generating device is portable and has a size comparable to a conventional cigar or cigarette.

[0090] The cartridge (100) comprises a housing (105) containing a spray assembly (120) and a liquid storage compartment having a first part / compartment (130) and a second part / compartment (135). An aerosol-forming material is held in the liquid storage compartment. As can be seen in FIG. 1b, the first part (130) of the liquid storage compartment is connected to the second part (135) of the liquid storage compartment so that liquid within the first part (130) can pass into the second part (135). The spray assembly (120) receives liquid from the second part (135) of the liquid storage compartment. In this embodiment, the spray assembly (120) is generally a planar fluid-permeable heater assembly.

[0091] The airflow passage (140, 145) extends through the cartridge (100) from the air inlet (150) within the cartridge housing (105), through the spray assembly (120), and from the spray assembly (120) to the mouse end opening (110).

[0092] The components of the cartridge (100) are arranged such that the first part (130) of the liquid storage compartment is located between the spray assembly (120) and the mouse end opening (110), and the second part (135) of the liquid storage compartment is located on the side of the spray assembly (120) opposite to the mouse end opening (110). That is, the spray assembly (120) is positioned between the two parts (130, 135) of the liquid storage compartment, receives liquid from the second part (135), and the first part (130) of the liquid storage compartment is closer to the mouse end opening (110) than the second part (135) of the liquid storage compartment. An airflow passage extends through the spray assembly (120) between the first part and the second part (130, 135) of the liquid storage compartment.

[0093] The system is configured so that a user can inhale an aerosol into their mouth by puffing or sucking through the mouse end opening (110) of the cartridge (100). When in operation, when the user puffs through the mouse end opening (110), air is drawn in through an airflow passage from the air inlet (150), through the spray assembly (120), and into the mouse end opening (110). A control circuit (220) controls the power supply from the battery (210) to the cartridge (100) when the system is activated. As a result, it controls the amount and characteristics of the vapor generated by the spray assembly (120). The control circuit (220) may include an airflow sensor, and the control circuit (220) may supply power to the spray assembly (120) detected by the airflow sensor when the user puffs through the cartridge (100). This type of control configuration is well established in aerosol generating systems such as inhalers and electronic cigarettes. Thus, when a user sucks through the mouth end opening (110) of the cartridge (100), the atomizing assembly (120) is activated to generate vapor that is entrained in the airflow passing through the airflow passage (140). The vapor is cooled along with the airflow within the passage (145) to form an aerosol, which is then inhaled into the user's mouth through the mouth end opening (110).

[0094] When in operation, the mouse end opening (110) is typically the highest point of the device. The configuration of the cartridge (100), in particular the arrangement of the spray assembly (120) between the first and second parts (130, 135) of the liquid storage compartment, is advantageous because it utilizes gravity to ensure that the liquid material is delivered to the spray assembly (120) even as the liquid storage compartment is emptied, but prevents oversupply of liquid to the spray assembly (120) which could cause leakage of liquid into the airflow passage (140).

[0095] FIG. 1b is a first cross-sectional view of a cartridge (100) for use in the system of FIG. 1a. FIG. 1c is a second cross-sectional view orthogonal to the cross section of FIG. 1b.

[0096] The cartridge (100) of FIGS. 1b and 1c comprises a mouse end having a mouse end opening (110) and an outer housing (105) having a connecting end facing the mouse end. Within the housing (105) there is a liquid storage compartment holding a liquid aerosol forming material (131). The liquid is contained within the liquid storage compartment by three components: an upper storage compartment housing (137), a heater mounting portion (134), and a terminal cap (138). A heater assembly (120) is held in the heater mounting portion (134). A capillary material (136) is provided in a second portion (135) of the liquid storage compartment and is in contact with a heater element in the central region of the heater assembly (120). The capillary material is oriented to transport the liquid to the heater element. The heater element (121) includes a mesh heater element formed of a plurality of filaments. Details of this type of heater element configuration can be found, for example, in WO2015 / 117702. An airflow passage (140) extends between the first and second parts (130, 135) of the liquid storage compartment. The lowest wall of the airflow passage (140) includes the heater element (121) and the heater mounting part (134), the side walls of the airflow passage (140) include parts of the heater mounting part (134), and the upper wall of the airflow passage (140) includes a part of the upper storage compartment housing (137). The airflow passage (130) has a vertical part (145) extending through the first part (130) of the liquid storage compartment toward the mouse end opening (110), as shown in FIG. 1b.

[0097] The heater assembly (120) is generally flat and has two faces. The first face of the heater assembly (120) faces the first part (130) of the liquid storage compartment and the mouse end opening (110). The second face of the heater assembly (120) is in contact with the capillary material (136) and liquid (131) within the liquid storage compartment and faces the connection end (115) of the cartridge (100). The heater assembly (120) is closer to the connection end so that, as described, an electrical connection to the power supply of the heater assembly (120) can be easily and securely achieved. The first part (130) of the liquid storage compartment is larger than the second part (135) of the liquid storage compartment and occupies the space between the heater assembly (120) of the cartridge (100) and the mouse end opening (110). Liquid within the first part (130) of the liquid storage compartment can move to the second part (135) of the liquid storage compartment through a liquid channel (133) on one side of the heater assembly (120). Even if only one channel is required, two channels are provided in this embodiment to provide a symmetrical structure. The channel is an enclosed liquid flow path defined between the upper storage compartment housing (137) and the heater mounting part (134).

[0098] FIGS. 2a, 2b, and 2c illustrate an embodiment of the present invention for a cartridge illustrated in FIGS. 1a through 1c. In FIG. 2a, a heater assembly (120) is illustrated as being assembled on a first part (130) of a storage compartment so as to seal a first side of a heater element (121) that is exposed to an airflow passage (140) by having a seal portion (320) of a removable seal portion (310) positioned over the heater element (121). FIGS. 2b and 2c illustrate an assembled heater assembly (120) having a first part (130) of a storage compartment and a final cartridge, respectively. A tab portion (330) of the removable seal portion (310) is illustrated as extending outward from the airflow passage and protruding from the outer surface of the housing (105). The tab portion (330) allows the user to remove the seal portion (320) of the removable seal portion (310) from the airflow passage (140) by pulling the tab portion (330), thereby establishing fluid communication between the heater element and the airflow passage (140).

[0099] FIG. 3 is a cross-sectional view of another embodiment of the present invention. In this embodiment, a sealing joint (410) is provided between a first part (130) of a storage compartment and a second part (135) of a storage compartment and a heater assembly (120) that is molded. Since the sealing joint (410) can be created individually before the second part (135) and the first part (130) of the storage compartment are sealed together to form a liquid channel (133), it not only simplifies the manufacturing process, but also the sealing joint (410) also defines part of the airflow passage (140), which allows the sealing part (320) of the removable seal (310) to be more easily attached to the heater element (121). The sealing joint (410) can also be formed to induce airflow over the heater element (121), for example, to generate turbulence across the surface of the heater element (121) to improve vaporization.

[0100] FIGS. 4a and 4b are perspective views of the exterior and cross-section of a heater assembly (120) connected to a sealing joint (410). The sealing joint (410) forms part of an airflow passage (140) extending from the air inlet end (440) toward the cartridge end (420). The cartridge end (420) is configured to cooperate in a sealing manner with a corresponding connection in the housing (105) to complete the airflow passage (140). As shown in FIGS. 4a and 4b, the connection between the sealing joint (410) and the heater assembly (120), as well as the connection between the sealing joint (140) and the housing (105), are all made by an interference fit to provide a sealed connection. A pair of ribs protruding from and along the circumference of the outer surface of the sealing joint (410) as shown in FIG. 4b are compressed when the sealing joint is paired with the housing (105) to provide a seal upon connection. A similar rib (not shown) is positioned to protrude from and along the circumference of the inner surface of the sealing joint (410) to form a seal upon connection with the heater assembly (120). In the illustrated embodiment, the rib (450) is formed integrally with the sealing joint (410), wherein both the rib and the sealing joint (410) are made of the same material. However, the rib (450) may be replaced with an elastomer O-ring or any other material different from that of the sealing joint (410).

[0101] In a specific embodiment illustrated in FIG. 4b, the seal portion (320) of the removable seal portion (310) is engaged with the heater assembly (120) by a mechanical seal portion (340). That is, the ring of the protrusion on the mechanical seal portion (340) engages with the corresponding grooved ring on the heater assembly (120) to secure the seal portion (320) in place. The mechanical seal portion (340) is made of an elastic material, and its attachment to the grooved ring creates a hermetic seal between the heater element (121) and the airflow passage (140). The use of such a mechanical seal portion (340) prevents leakage of the liquid material during transport and storage, as well as preventing evaporation of the liquid material from the second portion (135) of the storage compartment. The mechanical seal portion (340) is configured to be released from the heater assembly when a pulling force is applied to the tab portion (330).

[0102] The sealing portion (320), when located in the airflow passage (140), not only covers and seals the first side of the heater element (121) from the airflow passage, but also blocks the airflow passage (140) to prevent dust and contaminants from being collected therefrom.

[0103] The sealing joint (410) also includes a fluid passage connection (430) for being sealedly connected to a corresponding connector in the first part (130) of the storage compartment by means of an interference seal, thereby providing a sealed liquid passage between the first part (130) and the second part (135) of the storage compartment.

[0104] FIG. 5a is a perspective view of the assembled cartridge shown in FIG. 3, while its exploded view is also provided in FIG. 5b. In FIG. 5a, the removable seal (310) is positioned in an air passage (140) having a seal (320) located over a heater element (121), and in a tab portion (330) extending through the cartridge housing. As shown in FIG. 5b, the removable seal (310) is shown having an “L” shaped contour. That is, the removable seal (310) is curved so that the tab portion (330) is aligned perpendicularly to the seal portion (320) to fit the outer contour of the cartridge housing (105). This allows for the production of a more compact cartridge.

[0105] Before first use, to remove the removable seal (310) from the air passage, the user may grasp the tab portion (330) and pull it outward from the housing (105). This separates the hermetic seal between the seal portion (320) and the heater element (121), and allows the liquid material from the second portion (135) of the storage compartment to be exposed to the atmosphere. Once the removable seal is removed, the connection end (115) of the cartridge (100) can be connected to the corresponding connection end (205) of the control body portion (200).

[0106] The removable seal also prevents contamination and dust from being collected in the airflow passage (140) and the heater element. Additionally, the tab portion (330) also prevents the cartridge from being accidentally connected to the control body portion (200) before removal, because the tab portion (330) can be connected in a different way. More specifically, the tab portion (330) prevents the heater element from being activated before the removable seal is removed.

[0107] FIG. 5b illustrates an exploded view of the exemplary cartridge of FIG. 3. A first portion of the storage compartment is manufactured integrally with the cartridge housing (105) by an injection molding process. A heater assembly (120) is first created by molding a heater element into a heater assembly (120), which is formed integrally with a second portion of the storage compartment (135). The heater assembly (120) includes an electrical contact pad to provide an electrical connection to a control circuit (220).

[0108] Then, the retaining material (139) and the capillary material (136) are inserted into the second part (135) of the storage compartment before the second part (135) is closed by the end cap (138). The retaining material (139) is a fibrous material provided to receive any incoming liquid material from the first part (130) before it is drawn toward the capillary material and consumed by the heater element. The end cap (138) is sealedly attached to the second part (135) by a press fit, not only to retain the capillary material within the second part but also to prevent leakage and evaporation of the liquid material from the second part (135) of the storage compartment.

[0109] Subsequently, a removable seal is positioned over a heater element to seal it in place. While a mechanical sealing means (340) is used in this exemplary embodiment, the sealing portion (320) of the removable seal (310) may be secured on the heater element by other cap sealing mechanisms, such as an induction seal or an adhesive seal. The sealing joint (410) may then be installed on the heater assembly (120) by an interference fit to form an embodiment as illustrated in FIGS. 4a and 4b. The use of the sealing joint (410) is particularly advantageous because it provides sufficient free space for an induction sealer or a heat sealer to operate on the cap sealer, as the heater element is fully exposed during the application of the cap sealer.

[0110] A finished heater assembly (120) with a sealing joint (410) attached is attached to a cartridge housing (105) by a press fit to form a cartridge as shown in FIG. 3 and FIG. 5a.

[0111] FIG. 6 shows another embodiment according to the present invention in which the removable seal (310) is not in place. The cartridge (100) as shown in FIG. 6 has a configuration similar to the embodiment shown in FIG. 3 to 5, and thus the removable seal (310) can be applied in a similar manner. More specifically, the embodiment shown in FIG. 6 includes a first portion (130) of a storage compartment formed integrally with the housing (105), a heater assembly formed integrally with the second portion (135) of the storage compartment, and an end cap (138) designed to work directly with the housing (105) through a press fit. That is, the end cap (138) of FIG. 6 is designed to be submerged on the housing (105) instead of the heater assembly as shown in FIG. 3 and 5. This further simplifies the manufacturing process.

[0112] In addition, it should be apparent that alternative geometric structures are possible within the scope of the present invention. The cartridge and liquid storage compartment may have different cross-sectional shapes, and the heater assembly may have different shapes and configurations.

Claims

Claim 1 A cartridge for an aerosol generating system, wherein the cartridge comprises: an air inlet and a mouse end opening; a storage compartment configured to accommodate an aerosol forming material; an airflow passage extending from the air inlet to the mouse end opening; an aerosol generating element fluidly communicating with the storage compartment; and a removable seal comprising a sealing portion and a tab portion connected to the sealing portion, wherein the sealing portion seals fluid communication between the aerosol generating element and the airflow passage, and the tab portion extends outwardly through the air inlet. Claim 2 A cartridge according to claim 1, wherein the cartridge comprises a housing, and the sealing portion of the removable sealing portion seals a portion of the housing adjacent to the first surface of the aerosol generating element to seal a fluid communication between the first surface of the aerosol generating element and the airflow passage. Claim 3 A cartridge according to claim 1, wherein the removable seal portion is located in the airflow passage above the first surface of the aerosol generating element, and the first surface is fluidly connected to the airflow passage by applying a pulling force to the tab portion to remove the seal portion from the first surface. Claim 4 In paragraph 3, the cartridge comprises a removable seal portion having a retaining means for holding the removable seal portion over the airflow passage until the pulling force is applied to the tab portion. Claim 5 In any one of claims 1 to 4, the removable seal portion is removable from the airflow passage through the air inlet portion, the cartridge. Claim 6 In any one of paragraphs 1 to 4, the tab portion is a flexible cartridge. Claim 7 A cartridge according to any one of claims 1 to 4, wherein the sealing portion is arranged to provide a hermetic seal between the aerosol generating element and the airflow passage. Claim 8 A cartridge according to any one of claims 1 to 4, wherein the storage compartment comprises a first compartment and a second compartment connected to each other by a connector, so that a liquid in the first compartment can pass into the second compartment through a liquid passage of the connector; and the first surface of the aerosol generating element faces the first compartment, and the second surface of the aerosol generating element is in fluid communication with the second compartment and faces the second compartment, so that a liquid aerosol forming material in the first compartment can reach the aerosol generating element only through the second compartment. Claim 9 In claim 8, the first surface of the connector and the aerosol generating element forms at least a portion of the airflow passage, the cartridge. Claim 10 In paragraph 8, the airflow passage extends from the air inlet to the mouse end opening and between the first compartment and the second compartment, a cartridge. Claim 11 In paragraph 8, the first compartment is a cartridge located between the aerosol generating element and the mouse terminal opening. Claim 12 In paragraph 8, the connector is a cartridge connected to the first compartment and / or the second compartment by an interference fit. Claim 13 In any one of paragraphs 1 to 4, the aerosol generating element is a heater element, a cartridge. Claim 14 In paragraph 13, a cartridge comprising a heater assembly, wherein the heater assembly comprises a heater element and an electrical contact portion electrically connected to the heater element, and the contact portion is exposed through the connection end of the cartridge. Claim 15 In paragraph 14, the storage compartment comprises a heater mounting portion, wherein the heater mounting portion is formed over the heater assembly, a cartridge. Claim 16 A cartridge for an aerosol generating system comprising: a storage compartment configured to accommodate an aerosol forming material, wherein the storage compartment has a first compartment and a second compartment connected to each other by a connector; an aerosol generating element having a first surface and a second surface facing the first surface, wherein the first surface of the aerosol generating element faces the first compartment and the second surface faces the second compartment, wherein the second surface is in fluid communication with the second compartment, and the aerosol forming material in the first compartment can reach the aerosol generating element only through the connector and the second compartment. Claim 17 An aerosol generating system comprising a cartridge according to claim 1 or 16 and a control body connected to said cartridge, wherein the control body is configured to control the power supply to said aerosol generating element. Claim 18 An aerosol generating system comprising: a mouth end opening and an air inlet; a storage compartment configured to accommodate an aerosol forming material; an airflow passage extending from the air inlet to the mouth end opening; an aerosol generating element fluidly communicating with the storage compartment; a removable seal having a sealing portion and a tab portion connected to the sealing portion, wherein the sealing portion seals fluid communication between the aerosol generating element and the airflow passage, and the tab portion extends outwardly through the air inlet; and a control body configured to control power supply to the aerosol generating element.

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