An improved cartridge assembly for an aerosol generating device

Abstract

The disclosed aerosol generating device (102) includes a cartridge (106) having a liquid storage tank (124) to store an aerosol generating substrate and facilitate controlled transmission of the aerosol generating substrate to a heating element (110) through a capillary material (208). A heater bracket (206) holds the heating element (110) and the capillary material (208). The heating element (110) is coiled around the capillary material (208) to enable thermal contact of the transmitted aerosol generating substrate. A heater receptacle (112) is mechanically connected to the heater bracket (206) to direct aerosol generating substrate to heating element (110) for aerosolization upon reaching a boiling point, generating an aerosol. A pod base (218) is positioned beneath the heater receptacle (112) with a central air channel (220) to restrict the entry of the aerosol generating substrate upon overflow into a power control unit (120) thereby minimizes chances of aerosol generating substrate leaking out.

Description

AN IMPROVED CARTRIDGE ASSEMBLY FOR AN AEROSOL GENERATING DEVICETECHNICAL FIELD

[0001] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to an aerosol generating device enabling efficient heat distribution and addressing aerosol generating liquid leakage issues.BACKGROUND

[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.

[0003] Aerosol generating devices designed to aerosolize an aerosol generating liquid for inhalation. Said devices typically consist of a rechargeable power source and a cartridge or pod containing an aerosol generating liquid reservoir. The main goal of the aerosol generating device is to provide a satisfying user experience, ensuring the safety and reliability of the device. Additionally, there is a focus on creating devices that are user-friendly and cost-effective to produce.

[0004] One of the primary challenges in achieving the goal is the issue of aerosol generating liquid leakage from the cartridge reservoir. Leakage can lead to consumer dissatisfaction, as leakage not only affects the performance of the device but also poses a risk of damage to the device and potential exposure to the aerosol generating liquid. Furthermore, improper alignment and assembly of the heating system can result in uneven heat distribution, further compromising the device's performance and user experience.

[0005] An aerosol generating device is generally operated through a battery to generate aerosol upon heating the aerosol generating substrate. The aerosol generating devices generally are rechargeable type with replaceable cartridges. The replaceable cartridges of the aerosol generating devices are found to have an inherent issue of leaking, when it contains the aerosol generating substrate in a liquid form, from either one of the ends of the said device. In order to address thesaid issue, various other types of cartridges have been developed with varying internal designs.

[0006] Patent document “WO 2,019,134,883 A2 titled “cartridge and e- vaping device” discloses a sinusoidal heating member extended between first ring and second ring within the device. The absorbent material is surrounding the heating sinusoidal member. Further, a sheath comprising an end wall and a lateral wall integrally formed with the inner tube.

[0007] Another patent document “WO2, 021, 123, 017 Al”, titled “A cartridge for an aerosol-generating system, an aerosol-generating system including a cartridge, and a method of manufacturing a heater assembly and cartridge for an aerosol-generating system” The said prior art discloses a heating element formed from a heater sheet and the electrical contacts are integral to the heating element made from the sheet. The heating element is positioned between the upper housing and lower housing, while the upper and lower housings are placed in the outer housing with a sleeve. However, none of the prior arts teaches the solution described in the present disclosure.

[0008] Currently, the aerosol generating device available in the market encounters the following limitations: The aerosol generating liquid (also referred to as aerosol generating substrate, substrate, liquid or liquid substrate) leakage occurring from one of the ends of the cartridge is high. The aerosol generating substrate flows down into the mouth of the user while usage of the aerosol generating device. The aerosol generating substrate gets deposited inside the cartridge part of the aerosol generating device due to leakage. Thus, there arises a need for frequent cleaning of the cartridge. In addition, the heating chamber in closed system is usually located at the extreme downstream side of the aerosol generating substrate storage tank comprising two or more components of the heater chamber. More components in the cartridge leads to higher contact area to the aerosol generating substrate resulting in higher leakage points during the assembly and usage.

[0009] There is therefore need in the art to develop a cost effective and portable aerosol generating device enabling efficient heat distribution. More particularly, in the present disclosure, heater is positioned in a heater recessor / receptacle which is integrated as a part of the cartridge reservoir. Theintegrated part of the recessor is benefit to have and aids to eliminate one such additional component. Eliminating one or multiple components reduces the contact points of the aerosol generating substrate to the opening surfaces in the cartridge, hence helps in reducing the leakage.OBJECTS OF THE PRESENT DISCLOSURE

[0010] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[0011] It is general object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution.

[0012] It is an object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution, with a leak proof cartridge, which is lightweight, portable and reliable.

[0013] It is another object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution, which eliminates the gaps in the cartridge which reduces leakage of aerosol generating substrate and improper heat distribution in the heater.

[0014] Yet another object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution, which eliminates the multiple components thereby reducing the contact points of the aerosol generating substrate to the opening surfaces in the cartridge, hence helps in reducing the leakage.

[0015] Yet another object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution, where the heater receptacle is positioned substantially below the center of the cartridge which is substantially away from the downstream end of cartridge. Thus, it separates the aerosol generating substrate containing reservoir from overflowing the aerosol generating substrate towards the device side.

[0016] Yet another object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution, which provides zero leakage of the aerosol generating substrate, thereby providing enhanced life of the aerosol generating device.

[0017] Yet another object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution, which prevents messy leaks that can occur with the known cartridges.

[0018] Yet another object of the present disclosure is to provide an aerosol generating device enabling efficient heat distribution, which reduces the maintenance of the aerosol generating device and increases the longevity of the device.

[0019] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.SUMMARY

[0020] Within the scope of this application, it is expressly envisaged that the various aspects, embodiments, examples, and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

[0021] Aspects of the present disclosure relate generally to the field of aerosol generating devices. More specifically, an improved cartridge structure for aerosol generating systems that addresses liquid leakage issues. An aerosol-generating device can include a cartridge having a liquid storage tank to store a substrate and facilitate controlled transmission of the substrate to a heating element through a capillary material. A heater bracket together with a recessor can hold the heating element and the capillary material, where the heating element is coiled around the capillary material to enable thermal contact of the transmitted substrate. A heater receptacle can be mechanically coupled to the heater bracket to direct the liquid substrate to the heating element for aerosolization upon reaching a boiling point, thereby generating an aerosol. A pod base can be positioned beneath the heater receptacle and include a plurality of air channels to restrict entry of the liquid substrate upon overflow into a power control unit. The power control unit can be removably coupled to the cartridge to provide electrical energy to the heatingelement. An aerosol carrying tube can be coupled to the heater receptacle to transport the generated aerosol to a mouthpiece.

[0022] In another aspect, the aerosol-generating device can further include a sensor to detect inhalation by the user through the mouthpiece and generate an activation signal. A control circuit can be operatively coupled to the sensor and can receive the activation signal. The control circuit can transmit the received signal to a battery for obtaining electrical energy. The battery can be operatively coupled to the control circuit. The control circuit can regulate the obtained electrical energy and transmit the regulated electrical energy to the heating element to heat the substrate for aerosolization.

[0023] In yet another aspect, the mouthpiece can be coupled to the aerosol carrying tube, and the aerosol carrying tube can be coupled to the heater receptacle. The substrate can be selected from any or a combination of propylene glycol, vegetable glycerin, a flavoring agent, and an active ingredient.BRIEF DESCRIPTION OF DRAWINGS

[0024] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.

[0025] FIGs. 1 A- IB illustrate an exemplary block diagram and architecture, respectively, representing the proposed aerosol generating device, in accordance with an exemplary embodiment of the present disclosure.

[0026] FIGs. 2A-2B illustrate exemplary representations of cross section architecture, representing the cartridge cross section of the proposed aerosol generating device, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION

[0027] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detailoffered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0028] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without some of these specific details.

[0029] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0030] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0031] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0032] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified, thus fulfilling the written description of all groups used in the appended claims.

[0033] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplaryembodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

[0034] The present disclosure relates to the field of aerosol generating device. More particularly, the present disclosure relates to an aerosol generating device enabling efficient heat distribution.

[0035] FIGs. 1A-1B illustrate an exemplary block diagram 100A and architecture 100B, respectively, representing the proposed aerosol generating device 102, in accordance with an exemplary embodiment of the present disclosure.

[0036] As illustrated, in an embodiment, referring to FIG. 1A, the proposed aerosol generating device 102, is a battery-powered device that aerosolizes the aerosol generating liquid (i.e aerosol generating substrate).

[0037] In an embodiment, an aerosol-generating device 102 can include a cartridge 106 and a power control unit 120. The cartridge 106 can include a liquid storage tank 124, a heater bracket 206, a heating element 110, a capillary material 208, a heater receptacle 112, a pod base 218, and an aerosol carrying tube 204. The power control unit 120 can be removably coupled to the cartridge 106 to supply electrical energy to the heating element 110.

[0038] The liquid storage tank 124 can be configured to store a substrate and facilitate controlled transmission of the substrate to the heating element 110 through the capillary material 208. The liquid storage tank 124 can be constructed of a material resistant to the stored substrate, thereby preventing unwanted chemical reactions. The capillary material 208 can be positioned to extend into the liquid storage tank 124 to enable capillary action, ensuring continuous substrate flow toward the heating element 110. The capillary material 208 can be a fibrous or porous structure such as a wick can be made from cotton, ceramic, silica, metalmesh or synthetic fibers. The dimensions and porosity of the capillary material 208 can be optimized to regulate the substrate flow rate.

[0039] The heater bracket 206 can be configured to hold the heating element 110 and the capillary material 208. The heating element 110 can be coiled around the capillary material 208 to enable thermal contact with the transmitted substrate. The heating element 110 further comprises an electrically resistive portion 110A and an electrically conductive portion HOB. The electrically resistive portion 110A enables heating due to joule heating in the center of the heater assembly while the electrically conductive portion HOB allows the current to pass through without heating. In such embodiment, the electrically resistive portion 110A of the heating element 110 can be a resistive heating coil formed from materials can include, but not limited to, kanthal, Nichrome, stainless steel, ceramic, graphene-based heater or other electrically resistive alloys. Upon receiving electrical energy from the power control unit 120, the heating element 110 can generate heat, thereby elevating the temperature of the substrate absorbed within the capillary material 208. The electrically conductive portion HOB can be formed from materials can include but not limited to nickel, tungsten, silver, tin, etc.

[0040] The heater receptacle 112 can be mechanically connected to the heater bracket 206 and can direct the liquid substrate to the heating element 110. The heater receptacle 112 can be positioned below a central section of the cartridge 106 and spaced apart from a downstream end of the cartridge 106 to optimize liquid flow and minimize leakage. The heater receptacle 112 can be made from a heat- resistant material to withstand prolonged exposure to elevated temperatures. Upon reaching the boiling point, the liquid substrate can undergo phase transition to generate an aerosol.

[0041] The pod base 218 can be positioned beneath the heater receptacle 112 and can be configured to manage any excess liquid substrate. The pod base 218 can include a central air channel 220. The air channel can facilitate proper airflow within the aerosol-generating device 102, optimizes aerosol production and prevents unintended liquid accumulation that may interfere with device operation. The material of the pod base 218 can be selected to prevent absorption or degradation due to substrate exposure. Further, the pod base 218 can include aliquid absorption material to retain and prevent overflow of the substrate into the cartridge 106 or the power control unit 120. The liquid absorption material can include, but are not limited to, porous ceramics, silica gel, superabsorbent polymers (SAPs), cotton or natural fibers, glass fiber mats, foamed polymers, activated carbon cloth or felt, cellulose-based material, microporous polyethylene or polypropylene sheet, or hydrophilic nonwoven fabric.

[0042] The aerosol carrying tube 204 can be coupled to the heater receptacle 112 to transport the generated aerosol to a mouthpiece 104. The aerosol carrying tube 204 can have a defined inner diameter and length to maintain aerosol integrity and minimize condensation before reaching the mouthpiece 104. The material selection of the aerosol carrying tube 204 can be made to resist temperature changes and ensure consistent aerosol delivery.

[0043] The power control unit 120 can be removably coupled to the cartridge 106 and can supply electrical energy to the heating element 110. The power control unit 120 can include a battery 118, a control circuit 116, and a sensor 108 to regulate power delivery based on user actuation. The control circuit can regulate voltage or electrical energy to the heating element 110, ensures efficient substrate aerosolization while preventing overheating. The sensor 108 can detect user activation, either through airflow detection or a manual switch, to initiate the heating process. In such embodiment, the sensor 108 is a breath-activated sensor that generates the activation signal upon inhalation by the user.

[0044] The aerosol-generating device 102 can function by drawing the substrate from the liquid storage tank 124 through the capillary material 208 by capillary action. The heating element 110 can heat the absorbed substrate, converting it into an aerosol. The generated aerosol can be transported through the aerosol carrying tube 204 to the mouthpiece 104 for user inhalation. The heater receptacle 112 can support the heater wick assembly and facilitate controlled aerosolization, while the pod base 218 can manage excess liquid to prevent undesired leakage into the power control unit 120. The power control unit 120 can ensure efficient energy transfer to the heating element 110, thereby enabling consistent aerosol generation.

[0045] In such embodiment, the capillary material, typically cylindrical, absorbs and transports the aerosolisable material to the heating element 110, ensuring efficient aerosolization.

[0046] Further, the pod base 218 can be designed with the central air channel 220. The feature can be maintained the integrity of the device 102 and ensures a pleasant user experience by preventing leakage into the power control unit 120 and improve the longevity of the device. The cartridge 106 can include aerosol carrying tube 204 which is connected to the heater receptacle 112, which extends to the mouthpiece 104. This configuration can ensure that the aerosol produced is efficiently delivered to the user. Further, the cartridge 106 is equipped with electrical contact pins that can provide power to the heating element 110, facilitates the aerosolization process.

[0047] By integrating the heater receptacle 112 into the liquid storage tank 124 and positioning it centrally, the structure can significantly reduce the risk of liquid leakage further ensuring the heater wick assembly is properly aligned during the assembly ensuring reliability. The reduction in the number of components can simplify the manufacturing and assembly process, make it more cost-effective. Proper alignment and positioning of heating element 110 can ensure uniform heat distribution, leading to consistent device performance. The disclosed device 102 can prevent liquid from entering to the device 102, thereby can reduce the risk of damage and enhances user satisfaction. Overall, the disclosure offers a robust solution to the challenges faced by existing aerosol generating systems, provides a more reliable and user-friendly inhalation experience.

[0048] In another embodiment, the aerosol generating device 102 is divided into two parts, viz., the cartridge 106 (the terms “cartridge” and “leak-proof cartridge”, “aerosol generating substrate containing reservoir, and a reservoir are used interchangeably hereinafter) and the power control unit 120 and the said cartridge 106 which is leak proof by structure, includes the mouthpiece 104, the liquid storage tank 124, heating element 110 and heater receptacle 112. The said power control unit 120 includes sensor 108, a light-emitting diode (LED) indicator 114, control circuit 116, battery 118, end cap 126 and an external casing 122. A leak-proof cartridge 106 of the aerosol generating device 102 can include a cartridge design that minimizes the chances of aerosol generating substrate leakingout. The said substrate can include, but are not limited to, a base mixture of propylene glycol (PG) and vegetable glycerin (VG) along with flavoring agent, or active ingredient (that are both natural / synthetic) which help to generate aerosol upon heating.

[0049] In such embodiment, the LED indicator 114 can display one or more alerts to provide real-time information to the user regarding the operation and status of the aerosol-generating device 102. The alerts can include, but are not limited to, power status alerts that includes power on, power off, low battery warning, charging status, inhalation detection alerts that includes activation confirmation, session duration indicator, short circuit warning, overheating alert, fault detection, cartridge and substrate level alert that includes low substrate warning, cartridge replacement alert, or safety and locking alerts that includes child lock activation, auto shut-off notification.

[0050] In such embodiment, as illustrated in FIG. 1A, the aerosol generating device 102 can include the cartridge 106 which can be configured to hold the substrate. The cartridge 106 is a refillable tank in certain aerosol generating dcviccs-102, while in the other aerosol generating device 102, the cartridge 106 is a disposable cartridge. The cartridge 106 holds the substrate, which can include, but not limited to: a mixture of propylene glycol (PG), a vegetable glycerin (VG), flavorings, and, actives which can be natural and / or synthetic in nature.

[0051] In an embodiment, as illustrated in FIG. 1A, the aerosol generating device 102 can include the sensor 108 which enables automatic activation of the heating element 110 of the aerosol generating device 102. In some aerosol generating device 102, the sensor 108, can be replaced by a manual button or a mechanical switch which is pressed by the user to activate the aerosol generating device 102. The mechanical switch can be triggered the heating element 110 upon operated by the user.

[0052] In such embodiment, as illustrated in FIG. IB, 2 A and the architecture 150 of the aerosol generating device 102 can include the mouthpiece 104 which can be configured at the proximal end of the cartridge 106, where the aerosolized substrate is drawn into the user's mouth. The mouthpiece 104 is connected to liquid storage tank 124 by mechanical means. The liquid storage tank comprises an open end 222 which is closed with a top sleeve 224 that connects tothe aerosol carrying tube 204, and the aerosol carrying tube 204 is connected to the heater receptacle 112 via heater bracket 206.

[0053] In such embodiment, the structure of the mouthpiece 104 can vary depending on the style and usage of the aerosol generating device 102, the structure of the mouthpiece 104 can include, but not limited to: a narrow and tube-like structure, a wider structure, a flat structure, and the like. The mouthpiece 104 is often removable for cleaning or replacement and can be made of materials which include, but not limited to a plastic, a metal, a silicone, and the like.

[0054] In such embodiment, as illustrated in FIG. 1A, the aerosol generating device 102 can include the heating element 110 configured for aerosolizing the substrate. The heating element 110 is typically a coil made of a resistance wire which includes, but not limited to: a kanthal, a nichrome, a stainless steel, and the like, which can be wrapped into a coil shape.

[0055] In another embodiment, the aerosol generating device 102 is activated by the sensor 108 when the user inhales through the mouthpiece 104, by sending an electrical current from the battery 118 through the heating element 110 controlled by the control circuit 116, causing it to heat up rapidly. The heat is then transferred to the surrounding substrate absorbed in the capillary material 208, causing it to generate an aerosol. The design and material of the heating element 110 can affect the performance and safety of the device 102, as different materials and coil configurations can produce different levels of heat and aerosol production.

[0056] In such embodiment, the sensor 108 can be configured to detect inhalation by the user through the mouthpiece 104 and generate an activation signal. The sensor 108 can be positioned within the aerosol-generating device 102 to enable accurate detection of the inhalation force applied by the user. The activation signal generated by the sensor 108 can be transmitted to the control circuit 116 to facilitate further processing. The control circuit 116 connected to the sensor 108 and can be configured to receive the activation signal. The control circuit 116 can process the received activation signal and transmit it to the battery 118 for obtaining electrical energy. The battery 118 can be connected to the control circuit 116 and can provide the required electrical energy upon receiving the activation signal. The control circuit 116 can regulate the obtained electrical energy to ensure optimal power delivery to the heating element 110.

[0057] The heating element 110 can be configured to heat the substrate stored within the liquid storage tank 124 for aerosolization. The control circuit 116 can be designed to transmit the regulated electrical energy to the heating element 110, ensuring efficient heating of the substrate. The heating element 110 can be coiled around capillary material 208, which can facilitate the controlled transmission of the liquid substrate from the liquid storage tank 124. The heating element 110 can heat the substrate upon activation until it reaches a temperature sufficient for aerosolization, thereby generating an aerosol. The generated aerosol can be directed through aerosol carrying tube 204 towards the mouthpiece 104, enabling the user to inhale the aerosol. The placement of the sensor 108 within the aerosol-generating device 102 can be optimized to ensure accurate detection of the inhalation force, triggering the activation of the heating element 110 in real-time.

[0058] In such embodiment, the control circuit 116 can also include safety mechanisms to regulate power delivery to the heating element 110, preventing overheating and ensuring consistent aerosol generation. The overheating of the liquid substrate can be eliminated by operating the heater at a constant temperature. The temperature of the heater can be maintained constant by controlling the resistance of the heating element with a feedback mechanism while varying the power delivered to the heater. The battery 118 can be a rechargeable power source, enabling prolonged usage of the aerosol-generating device 102. The integration of the sensor 108 with the control circuit 116 can allow automatic activation of the heating element 110 without requiring any external switches or buttons, ensuring a seamless user experience.

[0059] In yet another embodiment, as illustrated in FIG. 1A, the aerosol generating device 102 can include the heater receptacle 112 configured to hold the heating element 110 securely in place and provide a path for the substrate to come into contact with the heated coil. The structure of the heating receptacle 112 can vary depending on the type of aerosol generating device 102. The primary function of the heating receptacle 112 is to ensure that there is a firm support to a heater assembly and substrate is aerosolized efficiently and safely to produce said aerosol. The aerosol generating device 102 can include the light emitting diode (LED) which displays a light indicating one or more state of the aerosol generating device 102.In an embodiment, the one or more state can include, but not limited to: a usage state, a charging state, a low battery state, and the like.

[0060] FIGs. 2A-2B illustrate exemplary representations 200A, 200B of cross section architecture of the cartridge 106, in accordance with an embodiment of the present disclosure.

[0061] In another embodiment, as illustrated in FIG. 2A, the location of the heater receptacle 112 positioned substantially below the centre of the cartridge 106 or substantially away from the downstream end of cartridge 106 benefits to separate a substrate storage portion 202 from overflowing the aerosol generating substrate towards the power control unit 120. The pod base 218 is located to hold the overflown substrate. Additionally, the pod base 218 will not allow the aerosol generating substrate to flow to the power control unit 120. This eliminates the failure of the said power control unit 120.

[0062] In another embodiment, the aerosol generating device 102, can include the airflow control which is a mechanism that allows the user to adjust the airflow through the aerosol generating device 102. Thus, it allows the users to customize the device by controlling the amount of air that mixes with the aerosol to be generated. The airflow control typically involves a ring or dial on the aerosol generating device 102 that can be adjusted to open or close inlet vents (not shown).

[0063] In yet another embodiment, referring to FIG. IB which illustrates the architecture of the proposed aerosol generating device 102. The aerosol generating device comprises of portion of cartridge 106, the top portion of the aerosol generating device 102 discloses the portion of the cartridge 106, along with mouthpiece 104, the power control unit 120 of the aerosol generating device 102 along with the external casing 122 and an end cap 126.

[0064] In yet another embodiment, the aerosol generating device 102 (referring to FIG. IB) can include the battery 118 which is the power source of the aerosol generating device 102, usually a rechargeable lithium-ion battery. The battery 118 provides the electricity required to heat the coil and aerosolize the substrate. The external casing 122 of the power control unit 120 refers to the outer shell or housing that encloses the control circuit 116, battery 118, LED 114, sensor 108. Further, the external casing 122 plays a crucial role in managing functionalityand aesthetics of the aerosol generating device 102 while protecting the internal components of the power control unit 120 from external damage.

[0065] In yet another embodiment, referring to FIG. 2A and 2B disclose cross section architecture 200 of the cartridge 106. The cartridge 106 can include the mouthpiece 104, a central air channel 220, a liquid storage tank 124, substrate storage portion 202, aerosol carrying tube 204, a heater bracket 206, the heater assembly includes the capillary material 208 and heating element 110 or coil wound on the capillary material 208, a base sealing 210, a pin sealing part 212, one or more electrical contact pins 214, and pod base 218.

[0066] In yet another embodiment, referring to Fig. 2A, the proposed cross section architecture 200 of the cartridge 106 includes the substrate storage portion 202 which can be configured to hold the material to be aerosolised. The substrate material storage portion 202 is often made of glass or plastic and is refillable, allowing users to fill with their preferred substrate but more preferably the cartridge is disposable. Further, the substrate storage portion 202 has openings or ports that allow the substrate to flow to the capillary material 208, where the substrate is heated to generate aerosol. The design and capacity of the substrate storage portion can vary depending on the cartridge 106, with larger substrate storage portion 202 based on the requirements.

[0067] In yet another embodiment, the proposed cross section architecture 200 of the cartridge 106 (referring to FIG. 2A) includes the aerosol carrying tube 204 which is the pathway through which the aerosol travels from the heater assembly to the user. The aerosol carrying tube 204 can be connected to the heater assembly comprising capillary material 208 through the heater bracket 206 where the aerosol is produced and extends to the mouthpiece 104 of the cartridge 106.

[0068] In yet another embodiment, the proposed cross section architecture 200 of the cartridge 106 (FIG. 2 A) includes the heater bracket 206 which can be configured to hold and support the capillary material 208. The heater bracket 206 is more preferably made of any plastic material, or any heat-resistant materials, such as ceramic or metal alloys, to withstand the high temperatures generated by the heating element 110. The heater bracket 206 is designed to securely hold the capillary material 208 with the heating element 110 in position to ensure proper contact with the substrate.

[0069] In yet another embodiment, the proposed cross section architecture 200 of the aerosol cartridge 106 (Fig. 2A) includes the capillary material 208 which serves as a wicking material to deliver the substrate to the heating element 110. The capillary material 208 is typically surrounded by the heating element 110 or near it and is designed to absorb the substrate and transport it to the heating element 110 to generate aerosol.

[0070] In yet another embodiment, the proposed cartridge 106 (referring to FIG. 2A) includes the base sealing 210 which seals the base of the liquid storage tank 124 to eliminate the substrate leakage towards the power control unit 120 during the engagement of cartridge 106 and the power control unit 120. The pod base 218 comprises a slot in which the base sealing 210 is positioned that runs across the circumference of the pod base. The base sealing 210 prevents leaks and ensures that the substrate remains contained within the cartridge 106. The proposed cartridge assembly includes the pin sealing part 212 to allow the electrically conductive portion 110A of the heating element 110 to pass through and establish connection with electrical contact pins 214. The pin sealing part 212 prevents substrate from leaking out of the heater assembly area through the connection pin and ensuring that the electrical connection between the cartridge 106 and the power control unit 120 (bottom portion not shown) remains secure.

[0071] In yet another embodiment, the proposed cartridge 106(FIG. 2A) includes the electrical contact pins 214 which can be configured to establish the electrical connection between the battery 118 and the heating element 110. The electrical contact pins 214 are typically located at bottom end of the cartridge 106 and connect to corresponding pins or contacts on the battery 118 or control circuit 116.

[0072] In yet another embodiment, referring to FIG. 2B, the heating element 110 is coiled around the absorbing material / capillary material 208 resting on the heater receptacle 112, which forms into the cartridge 106. Further, positioning of the heating system (wick and heating element 110) in the cartridge 106 is very critical. Thus, appropriate alignment and assembling leads to elimination of gaps, which leads to efficient heat distribution in the heater receptacle 112. The heater assembly comprising heating element 110, and capillary material 208, is positioned in the heater receptacle 112, which is integrated as a partof the liquid storage tank 124. The integrated part of the heater receptacle 112 aids in eliminating one such additional component. Further, elimination of one or multiple components reduces the contact points of the substrate to the opening surfaces in the cartridge hence helps in reducing the leakage, thereby avoiding the substrate leakage from the cartridge 106.

[0073] In yet another embodiment, the heater receptacle 112 is located substantially closer to the centre of the cartridge 106 and integrated as a part of the cartridge 106. The heating system to assemble from the upstream end of the cartridge 106 on the heater receptacle 112 is located between the centre of the substrate storage portion 202 and the downstream end of the cartridge 106. The integrated heater receptacle 112 in the substrate storage portion 202 helps in reducing the number of associated parts for manufacturing and the complexing of assembling process of the heater. The heating system is highly resilient and can undergo structural changes if the support structure is not mechanically stable. The structural changes in the heater during the usage can cause inconsistent performance of the product. The heater receptacle 112 of the present disclosure advantageously aids the heater to address the said problem. The location of the heater receptacle 112 is positioned closer to the centre of the cartridge 106 which also supports to separate the substrate storage portion 202 from overflowing the leaked substrate towards the device 102. The pod base 218 is located to hold the overflown substrate material. Additionally, the pod base 218 is having a central air channel 220 allows the substrate flow to resist further and helps to stop flowing the substrate to enter the power control unit 120.

[0074] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the disclosure is determined by the claims that follow. The disclosure is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when combined with information and knowledge available to the person having ordinary skill in the art.ADVANTAGES OF THE DISCLOSURE

[0075] The proposed disclosure provides an aerosol generating device enabling efficient heat distribution.

[0076] The proposed disclosure provides an aerosol generating device with a leak proof cartridge, which is lightweight, portable and reliable.

[0077] The proposed disclosure eliminates the gaps in the cartridge which reduces leakage of substrate and improper heat distribution in the heater.

[0078] The proposed disclosure eliminates the multiple components which reduces the contact points of the substrate to the opening surfaces in the cartridge, hence helps in reducing the leakage.

[0079] The proposed disclosure enables positioning of the heater receptacle substantially below the center of the cartridge which is substantially away from the downstream end of cartridge.

[0080] The proposed disclosure provides zero leakage of the substrate, thereby providing enhanced life of the aerosol generating device.

[0081] The proposed disclosure reduces the maintenance of the aerosol generating device and increases the longevity of the aerosol generating device.

[0082] The proposed disclosure incorporates a pod base with set of air channels that resist liquid flow, prevents the liquid from entering the device and causing potential damage.

[0083] The proposed disclosure provides an aerosol generating device that offers a satisfying and reliable user experience, free from the common issues associated with liquid leakage and device malfunction.

Claims

We Claim:

1. An aerosol-generating device (102) comprising: a cartridge (106) comprising: a liquid storage tank (124) to store a substrate; and a heater receptacle (112) to receive a heater assembly integrated within the liquid storage tank (124), wherein the heater receptacle (112) is positioned below a central section of the cartridge (106) and spaced apart from a downstream end of the cartridge (106).

2. The aerosol generating device (102) as claimed in claim 1, wherein the heater assembly is securely suspended on the heater receptacle (112) from an open end (222) of the liquid storage tank (124).

3. The aerosol generating device (102) as claimed in claim 1, wherein the cartridge (106) comprises a heater bracket (206) to hold the heating assembly comprising a heating element (110) and a capillary material (208), wherein the heating element (110) is coiled around the capillary material (208).

4. The aerosol generating device (102) as claimed in claim 3, wherein the cartridge (106) further comprises a pin sealing part (212) to allow a portion of the heating element (110) to pass through and establish connection with electrical contact pins (214).

5. The aerosol generating device (102) as claimed in claim 1, wherein the cartridge further comprising a pod base (218) positioned beneath the heater receptacle (112), wherein the pod base having a central air channel (220) to restrict entry of the substrate upon overflow into a power control unit (120).

6. The aerosol generating device (102) as claimed in claim 1, wherein an aerosol carrying tube (204) is coupled to the heater bracket (206) to transport the generated aerosol to a mouthpiece (104).

7. The aerosol-generating device (102) as claimed in claim 1, wherein the aerosol-generating device (102) further comprising: a sensor (108) to detect inhalation and generate an activation signal; and a control circuit (116) operatively coupled to the sensor (108), wherein the control circuit (116) to:receive the activation signal; transmit the received signal to a power source (118) for obtaining electrical energy, wherein the power source (118) operatively coupled to the control circuit (116); regulate the obtained electrical energy; and transmit the regulated electrical energy to the heating element (110) to heat the substrate for aerosolization.

8. The aerosol-generating device (102) as claimed in claim 1, wherein the mouthpiece (104) is securely coupled to the liquid storage tank (124) by one or more mechanical means.

9. The aerosol-generating device (102) as claimed in claim 1, wherein the substrate is selected from any or a combination of propylene glycol (PG), vegetable glycerin (VG), flavoring agent, and active ingredient.

10. The aerosol-generating device (102) as claimed in claim 7, wherein the sensor (108) is a breath-activated sensor generates the activation signal upon inhalation by the user.

11. The aerosol-generating device (102) as claimed in claim 3, wherein a mechanical switch triggers the heating element (110) upon actuation by the user.

12. The aerosol-generating device (102) as claimed in claim 5, the pod base (218) comprises a liquid absorption material to retain and prevent overflow of the substrate into the cartridge (106) or the power control unit (120).

13. The aerosol-generating device (102) as claimed in claim 5, wherein the power control unit (120) further comprises a light emitting diode (LED) indicator (114) to display one or more alerts.

14. The aerosol-generating device (102) as claimed in claim 3, wherein the capillary material (208) is selected from any or a combination of cotton, ceramic, silica, and metal mesh.

15. The aerosol-generating device (102) as claimed in claim 3, wherein the heating element (110) is selected from any or a combination of metal coil including nichrome, kanthal, stainless steel, ceramic, and graphene-based heater.

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