Cartridge for use in an aerosol-generating device

Abstract

There is provided a cartridge (10) for use with an aerosol-generating device (600). The cartridge (10) comprises: a housing (100) defining a substrate compartment (400), the housing (100) having a first thermal conductivity; an aerosol-generating substrate (300) received within the substrate compartment (400); and a layer (160) having a second thermal conductivity. The layer (160) at least partially overlies the housing (100). The layer (160) at least partially defines an external surface of the cartridge (10). The second thermal conductivity is greater than the first thermal conductivity. The cartridge (10) comprises a heater element (200). There is also provided an aerosol-generating system (800) comprising: the cartridge (10) and an aerosol-generating device (600). The aerosol-generating device (600) comprises a power supply (630).

Description

[0001] CARTRIDGE FOR USE IN AN AEROSOL-GENERATING DEVICE

[0002] The present disclosure relates to a cartridge for use with an aerosol-generating device. The present disclosure also relates to an aerosol-generating system comprising the cartridge and an aerosol-generating device.

[0003] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobaccocontaining substrate, is heated rather than combusted, are known in the art. Typically, in such heated smoking articles an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0004] A number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosolgenerating devices in which an aerosol is generated by the transfer of heat from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of a heated aerosol-generating article. For example, electrically heated aerosol-generating devices have been proposed that comprise an internal heater blade which is adapted to be inserted into the aerosol-generating substrate.

[0005] Use of an aerosol-generating article in combination with an external heating system is also known. For example, WO 2020 / 115151 describes the provision of one or more heating elements arranged around the periphery of the aerosol-generating article when the aerosol-generating article is received in a cavity of the aerosol-generating device. As an alternative, inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor arranged within the aerosol-generating substrate have been proposed by WO 2015 / 176898.

[0006] Handheld electrically operated aerosol-generating systems comprising a cartridge comprising a substrate compartment containing an aerosol-generating substrate and an electrically operated heater configured to heat the aerosol-generating substrate to generate an aerosol, and a device portion comprising control electronics and a power supply for supplying power to the electrically operated heater, are known.

[0007] However, during operation of aerosol-generating systems comprising a cartridge, the cartridge may accumulate significant amounts of heat. As a result, the cartridge may reach elevated temperatures that may render the cartridge too hot for immediate handling, removal, or replacement by the user after use of the cartridge, which may present potential safety and usability concerns. Furthermore, excessive accumulation of heat in the cartridge may compromise the longevity and structural integrity of internal cartridge components, and adjacent components of an aerosol-generating device used with the cartridge.

[0008] In addition, excessive accumulation of heat in the cartridge may thermally degrade the aerosol-generating substrate over time. As a result, the consistency and quality of aerosol generated may be adversely affected over prolonged use or in subsequent uses of the cartridge.

[0009] There is a need to provide a cartridge for use with an aerosol-generating device with enhanced user safety when handling, removing, or replacing the cartridge after use of the cartridge.

[0010] There is a need to provide a cartridge for use with an aerosol-generating device with an improved lifespan over prolonged use or subsequent uses of the cartridge.

[0011] There is a need to provide a cartridge for use with an aerosol-generating device with improved consistency and quality of the generated aerosol over prolonged use or subsequent uses of the cartridge.

[0012] There is also a need to provide a cartridge for use with an aerosol-generating device with improved heating efficiency during operation.

[0013] According to a first aspect of the present disclosure there is provided a cartridge for use with an aerosol-generating device. The cartridge may comprise a housing defining a substrate compartment. The housing may have a first thermal conductivity. An aerosol-generating substrate may be received within the substrate compartment. The cartridge may comprise a layer having a second thermal conductivity. The layer may at least partially overlie the housing. The layer may at least partially define an external surface of the cartridge. The second thermal conductivity may be greater than the first thermal conductivity. The cartridge may comprise a heater element.

[0014] According to a first aspect of the present invention there is provided a cartridge for use with an aerosol-generating device. The cartridge comprises a housing defining a substrate compartment. The housing has a first thermal conductivity. An aerosol-generating substrate is received within the substrate compartment. The cartridge comprises a layer having a second thermal conductivity. The layer at least partially overlies the housing. The layer at least partially defines an external surface of the cartridge. The second thermal conductivity is greater than the first thermal conductivity.

[0015] According to a particularly preferred embodiment of a first aspect of the present invention there is provided a cartridge for use with an aerosol-generating device. The cartridge comprises a housing defining a substrate compartment. The housing has a first thermal conductivity. An aerosol-generating substrate is received within the substrate compartment. The cartridge comprises a layer having a second thermal conductivity. The layer at least partially overlies the housing. The layer at least partially defines an external surface of the cartridge. The second thermal conductivity is greater than the first thermal conductivity. The cartridge comprises a heater element.

[0016] Advantageously, providing the housing having the first thermal conductivity and the layer at least partially overlying the housing having the second thermal conductivity which is greater than the first thermal conductivity may contain heat within the substrate compartment of the cartridge during use whilst also rapidly dissipating any residual heat that reaches an external surface of the cartridge into the surrounding environment, thereby improving heating efficiency whilst also minimising the risk of overheating of the cartridge during use and enhancing user safety during handling of the cartridge.

[0017] In particular, advantageously, providing the housing having the first thermal conductivity and the layer at least partially overlying the housing having the second thermal conductivity which is greater than the first thermal conductivity may reduce the transfer of heat from the substrate compartment to the external surface of the cartridge, for example as the aerosol-generating substrate is heated during use of the cartridge. In addition, providing the housing having the first thermal conductivity and the layer at least partially overlying the housing having the second thermal conductivity which is greater than the first thermal conductivity may enhance the cooling rate of the external surface of the cartridge during and after use. As a result, the external surface of the cartridge may decrease in temperature more quickly after use as a result of an accelerated rate of thermal dissipation of heat from the external surface of the cartridge. The improved thermal dissipation of heat from the external surface of the cartridge may also help to distribute heat more evenly across the cartridge, which may reduce or prevent the occurrence of localised hot spots on the cartridge during use. As a result, the cartridge may experience improved thermal regulation during use, and a more stable and uniform cooling process after use.

[0018] Without wishing to be bound by theory, providing the housing having the first thermal conductivity that is less than the second thermal conductivity may reduce the transfer of heat from the substrate compartment to the external surface of the cartridge during use by having a reduced thermal diffusivity of the housing such that the rate of heat transfer from the substrate compartment through the housing is reduced.

[0019] Without wishing to be bound by theory, providing the layer having the second thermal conductivity that is greater than the first thermal conductivity may facilitate rapid heat transfer from the layer to the surrounding environment, thereby enabling any heat that reaches the external surface of the cartridge to spread out and quickly disperse into the surrounding environment.

[0020] Advantageously, reducing the transfer of heat from the substrate compartment to the external surface of the cartridge during use, in combination with the enhanced cooling rate of the external surface of the cartridge, may reduce the temperature of the external surface of the cartridge reached during and after use, which may allow the user to handle, remove, or replace the cartridge more safely within a shorter period of time following use. As a result, this may improve the overall convenience and usability of the cartridge by minimising any required wait time between cartridge use and cartridge replacement, especially in high-use scenarios where the cartridge may need frequent replacement. In other words, the cartridge may be more readily removed and replaced following use which may enhance convenience and usability of the cartridge. Furthermore, the likelihood of thermal injury from touching the external surface of the cartridge after use may be prevented. Additionally, maintaining a reduced temperature of the external surface of the cartridge may enhance the overall user experience and may allow an aerosol-generating system comprising the cartridge to be held more comfortably by the user.

[0021] Advantageously, reducing the transfer of heat from the substrate compartment to the external surface of the cartridge during use, in combination with an enhanced cooling rate of the external surface of the cartridge may enhance the energy efficiency of heating the aerosolgenerating substrate received within the substrate compartment during use. As a result, there may be an increased effectiveness of heating of the aerosol-generating substrate during use of the cartridge which may lead to a faster heating response, reduced energy usage, and an improved consistency and quality of aerosol generated. At the same time, as discussed above, the layer having the second thermal conductivity may improve dissipation of heat that reaches the external surface of the cartridge during operation, thereby ensuring improved performance of the cartridge without overheating.

[0022] Advantageously, reducing the transfer of heat from the substrate compartment to the external surface of the cartridge during use, in combination with an enhanced cooling rate of the external surface of the cartridge may provide a cartridge with an improved lifespan over prolonged use or subsequent uses of the cartridge. In particular, during use, the improved heating efficiency, reduced loss of heat from the substrate compartment and the enhanced cooling rate of the external surface of the cartridge may lower the operational temperature of the cartridge during use which may minimise thermal stress on the cartridge and adjacent components, including those in an aerosol-generating device used with the cartridge. As a result, any negative effects on the structural integrity of cartridge components and adjacent components of an aerosolgenerating device, such as electronic components, may be reduced. As a result, the lifespan of both the cartridge and an aerosol-generating device used with the cartridge may be improved. Furthermore, the reliability and durability of the cartridge and an aerosol-generating device used with the cartridge may be improved. In other words, exposure to consistently high temperatures during and after use may degrade the integrity of materials of cartridge components and an accompanying aerosol-generating device over time. However, providing the improved heating efficiency, reduced loss of heat from the substrate compartment and the enhanced cooling rate of the external surface of the cartridge may reduce or prevent premature degradation of these components. Advantageously, providing the improved heating efficiency, reduced loss of heat from the substrate compartment and enhanced cooling rate of the external surface of the cartridge may improve the consistency and quality of the generated aerosol over prolonged use or subsequent uses of the cartridge. In particular, overheating of the cartridge may be reduced which may reduce or prevent thermal degradation of the aerosol-generating substrate over time.

[0023] The layer at least partially defines an external surface of the cartridge. In other words, at least part of the external surface of the cartridge may be defined by the layer.

[0024] At least a portion of the layer may be in direct contact with the housing.

[0025] The layer may be in indirect contact with the housing. In other words, there may be an intervening component between the housing and the layer.

[0026] As used herein, the term “cartridge” relates to a component that interacts with an aerosolgenerating device to generate an aerosol.

[0027] As used herein, the term “aerosol-generating device” relates to a device that interacts with a cartridge to generate an aerosol.

[0028] As used herein, the term “aerosol-generating substrate” relates to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds can be released by heating the aerosol-generating substrate.

[0029] As used herein, the term “aerosol” is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0030] A heater element may be configured to heat the aerosol-generating substrate to generate an aerosol. Preferably, the cartridge is configured to interact with the heater element to heat the aerosol-generating substrate to generate an aerosol.

[0031] Preferably, the cartridge comprises the heater element. In other words, preferably the heater element is provided as part of the cartridge. In particular, preferably the heater element is arranged in the substrate compartment.

[0032] The heater element may be an internal heater element. The internal heater element may be embedded in or at least partially surrounded by the aerosol-generating substrate. The internal heater element may be a pin or a blade.

[0033] The heater element may be a planar heater element. The heater element may comprise one or more heating surfaces for heating the aerosol-generating substrate to form an aerosol. The one or more heating surfaces may be planar heating surfaces. The heater element may be substantially or entirely planar. The heater element may be oriented so that a plane of the heater element is aligned with the width of the cartridge. The heater element may have a serpentine shape. The heater element may comprise a plurality of segments. The heater element may comprise a plurality of parallel segments extending along the substrate compartment. The heater element may be a self-supporting track which extends through the substrate compartment.

[0034] The heater element may be a resistive heater element. The heater element may comprise an electrically resistive material.

[0035] The heater element may be formed from an iron-based alloy. The heater element may be formed from a nickel alloy. The heater element may be formed from a ceramic. The heater element may be formed from stainless steel. The heater element may be formed from SS316L stainless steel iron aluminides. The heater element may be formed from nichrome. The heater element may be formed from a ceramic coated metal.

[0036] The heater element may have a length of greater than or equal to 13 millimetres, greater than or equal to 14 millimetres, greater than or equal to 15 millimetres, or greater than or equal to 16 millimetres.

[0037] The heater element may have a length of less than or equal to 20 millimetres, less than or equal to 19 millimetres, less than or equal to 18 millimetres, or less than or equal to 17 millimetres.

[0038] For example, the heater element may have a length of between 13 millimetres and 20 millimetres, between 14 millimetres and 19 millimetres, between 15 millimetres and 18 millimetres, or between 16 millimetres and 17 millimetres.

[0039] The heater element may comprise a susceptor element.

[0040] As used herein, the term “susceptor” denotes a material that is capable of being heated when penetrated by a varying magnetic field.

[0041] The susceptor element may be embedded in or at least partially surrounded by the aerosol-generating substrate.

[0042] The susceptor element may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. For example, the susceptor element may comprise a metal or carbon. The susceptor element may comprise or consist of a ferromagnetic material, for example a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel. A suitable material may be, or comprise, aluminium. The susceptor element may be formed from 400 series stainless steels, for example grade 410, or grade 420, or grade 430 stainless steel.

[0043] Where a susceptor element is provided, the cartridge or an aerosol-generating device may comprise an antenna or inductor coil arranged to inductively heat the susceptor element. The inductor coil may at least partly circumscribe the susceptor element. For example, the cartridge may comprise an internal susceptor element configured to interact with an inductor coil. The heater element may comprise a dielectric heater element. In particular, the dielectric heater element may comprise a dielectric material. The dielectric heater element may be configured to use radio-frequency (RF) electric waves that cause a dipole interaction with the dielectric material to heat the aerosol-generating substrate.

[0044] The heater element may comprise an infrared heater element. The infrared heater element may be configured to heat the aerosol-generating substrate using infrared electromagnetic radiation.

[0045] The first thermal conductivity may be less than or equal to 50 Watts per metre Kelvin, less than or equal to 45 Watts per metre Kelvin, less than or equal to 40 Watts per metre Kelvin, less than or equal to 35 Watts per metre Kelvin, less than or equal to 30 Watts per metre Kelvin, less than or equal to 25 Watts per metre Kelvin, less than or equal to 20 Watts per metre Kelvin, less than or equal to 15 Watts per metre Kelvin, less than or equal to 10 Watts per metre Kelvin, less than or equal to 5 Watts per metre Kelvin, less than or equal to 3 Watts per metre Kelvin, or less than or equal to 1 Watt per metre Kelvin.

[0046] The first thermal conductivity may be greater than or equal to 0.05 Watts per metre Kelvin, greater than or equal to 0.1 Watts per metre Kelvin, greater than or equal to 0.2 Watts per metre Kelvin, greater than or equal to 0.5 Watts per metre Kelvin, greater than or equal to 1 Watt per metre Kelvin, greater than or equal to 2 Watts per metre Kelvin, greater than or equal to 5 Watts per metre Kelvin, greater than or equal to 10 Watts per metre Kelvin, greater than or equal to 15 Watts per metre Kelvin, or greater than or equal to 20 Watts per metre Kelvin.

[0047] For example, the first thermal conductivity may be between 0.1 Watts per metre Kelvin and 50 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 45 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 40 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 35 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 30 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 25 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 20 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 15 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 10 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 5 Watts per metre Kelvin, between 0.1 Watts per metre Kelvin and 3 Watts per metre Kelvin, or between 0.1 Watts per metre Kelvin and 1 Watt per metre Kelvin.

[0048] The second thermal conductivity may be greater than or equal to 100 Watts per metre Kelvin, greater than or equal to 200 Watts per metre Kelvin, greater than or equal to 300 Watts per metre Kelvin, greater than or equal to 500 Watts per metre Kelvin, greater than or equal to 1000 Watts per metre Kelvin, or greater than or equal to 3000 Watts per metre Kelvin.

[0049] The second thermal conductivity may be less than or equal to 5000 Watts per metre Kelvin, less than or equal to 3000 Watts per metre Kelvin, less than or equal to 1000 Watts per metre Kelvin, less than or equal to 800 Watts per metre Kelvin, less than or equal to 500 Watts per metre Kelvin, less than or equal to 400 Watts per metre Kelvin, less than or equal to 300 Watts per metre Kelvin, or less than or equal to 250 Watts per metre Kelvin.

[0050] For example, the second thermal conductivity may be between 100 Watts per metre Kelvin and 5000 Watts per metre Kelvin, between 100 Watts per metre Kelvin and 3000 Watts per metre Kelvin, between 100 Watts per metre Kelvin and 1000 Watts per metre Kelvin, between 100 Watts per metre Kelvin and 800 Watts per metre Kelvin, between 100 Watts per metre Kelvin and 500 Watts per metre Kelvin, between 100 Watts per metre Kelvin and 400 Watts per metre Kelvin, between 100 Watts per metre Kelvin and 300 Watts per metre Kelvin, or between 100 Watts per metre Kelvin and 250 Watts per metre Kelvin.

[0051] Preferably, the ratio of the second thermal conductivity to the first thermal conductivity is greater than or equal to 2: 1 , greater than or equal to 3: 1 , greater than or equal to 4: 1 , greater than or equal to 5: 1 , greater than or equal to 10:1 , greater than or equal to 25: 1 , greater than or equal to 50: 1 , greater than or equal to 100: 1 , or greater than or equal to 250: 1 .

[0052] Preferably, the ratio of the second thermal conductivity to the first thermal conductivity is less than or equal to 50000: 1 , less than or equal to 30000: 1 , less than or equal to 10000: 1 , less than or equal to 5000:1 , less than or equal to 3000:1 , less than or equal to 1000:1 , or less than or equal to 500:1.

[0053] For example, the ratio of the second thermal conductivity to the first thermal conductivity may be between 2:1 and 50000:1 , between 3:1 and 3000:1 , between 4:1 and 1000:1 , or between 5:1 and 500:1.

[0054] It will be appreciated that thermal conductivity of a material, in particular each of the first thermal conductivity and second thermal conductivity, may be measured by any suitable method. For example, the thermal conductivity may be measured by providing a resistive heater in contact with a sample of the material to be measured, an opposing end of the sample may be kept at a constant temperature such as by using a circulating fluid, and the lateral surfaces of the sample may be kept insulated. A differential thermometer may then be used to read the temperature drop across a length of the sample. The electrical power consumed by the resistive heater, the length of the sample, a cross-sectional area of the sample and the measured temperature difference across the length of the sample may then be used to obtain a thermal conductivity of the material.

[0055] The housing may comprise a material selected from one or more of a metal, a metal alloy, a composite, a ceramic, an aerogel and a thermoplastic.

[0056] The metal alloy may be selected from one or both of a nickel based alloy and an iron based alloy. The iron based alloy may be stainless steel, such as 316L stainless steel. The nickel based alloy may be a nickel-copper alloy such as Monel. The nickel based alloy may be a nickelchromium alloy such as Inconel. The Inconel may be Inconel 625.

[0057] The composite may be selected from one or both of a Carbon Fiber Reinforced Polymer and a Glass Fiber Reinforced Polymer. The ceramic may be selected from one or both of aluminium oxide and zirconium oxide. The ceramic may be a closed pore ceramic.

[0058] The thermoplastic may be selected from one or more of polyetheretherketone, polyphenylene sulfide and polyamide.

[0059] Where the housing comprises an aerogel, preferably the housing comprises an internal protective material between the aerogel and the substrate compartment.

[0060] For example, the housing may comprise a material selected from one or more of polyetheretherketone, polyphenylene sulfide, polyamide, Carbon Fiber Reinforced Polymer, Glass Fiber Reinforced Polymer, an aerogel, aluminium oxide (alumina), zirconium oxide (zirconia), alumina, a nickel based alloy and an iron based alloy.

[0061] The housing may have a porosity of less than or equal to 1 percent. The housing may have a porosity of less than or equal to 0.5 percent. The housing may comprise a material having a closed-pore structure. The housing may be non-porous.

[0062] Advantageously, providing a housing have a porosity as described herein may reduce the absorption of substances by the housing which may minimise the risk of degradation of the housing during use.

[0063] The layer may comprise a material selected from one or more of a carbon allotrope, a ceramic and a metal.

[0064] Preferably, the metal is selected from one or more of copper, aluminium, silver and gold.

[0065] Preferably, carbon allotrope is selected from one or both of graphene and carbon nanotube.

[0066] Preferably, the ceramic is boron nitride.

[0067] The layer may have a uniform thickness.

[0068] The layer may have a thickness of greater than or equal to 0.05 micrometres, greater than or equal to 0.1 micrometres, greater than or equal to 0.5 micrometres, greater than or equal to 1 micrometre, greater than or equal to 5 micrometres, greater than or equal to 10 micrometres, or greater than or equal to 50 micrometres.

[0069] The layer may have a thickness of less than or equal to 500 micrometres, preferably less than or equal to 200 micrometres, more preferably less than or equal to 50 micrometres, more preferably less than or equal to 20 micrometres, more preferably less than or equal to 5 micrometres, or most preferably less than or equal to 1 micrometre.

[0070] For example, the layer may have a thickness of between 0.05 micrometres and 500 micrometres, between 50 micrometres and 500 micrometres, between 5 micrometres and 50 micrometres, between 1 micrometre and 20 micrometres, between 0.5 micrometres and 20 micrometres, between 0.5 micrometres and 5 micrometres, between 0.1 micrometres and 5 micrometres, or between 0.05 micrometres and 1 micrometre. Advantageously, providing a layer having the thickness as described herein may improve the dissipation of heat that reaches the external surface of the cartridge during operation without significantly affecting the external dimensions of the cartridge.

[0071] Preferably, the layer is a coating. The coating may be a solid coating.

[0072] Preferably, the coating at least partially defines an external surface of the cartridge. In other words, preferably at least part of the external surface of the cartridge is defined by the coating.

[0073] The coating may be in direct contact with the housing.

[0074] The coating may be in indirect contact with the housing. In other words, there may be an intervening component between the housing and the coating.

[0075] The coating may be formed by one or more of electroplating, thermal spraying, physical vapor deposition, chemical vapor deposition, spray coating, dip coating, inkjet printing, sol-gel processing, and spin coating.

[0076] As used herein, the term “electroplating” refers to a coating process in which a metal layer is deposited using an electric current to reduce the cations of the metal in the metal layer.

[0077] Advantageously, forming the coating by electroplating may provide a uniform and durable coating. Advantageously, forming the coating by electroplating may provide a coating that enhances corrosion resistance of the cartridge.

[0078] As used herein, the term “thermal spraying” refers to a coating process in which heated or melted coating materials are sprayed onto a surface.

[0079] The thermal spraying may be one or both of plasma spraying or high velocity oxygen fuel (HVOF) coating.

[0080] As used herein, the term “plasma spraying” refers to a form of thermal spraying in which the coating material is introduced into a plasma jet to heat the coating material.

[0081] As used herein, the term “high velocity oxygen fuel” refers to a form of thermal spraying in which a mixture of fuel and oxygen is ignited to heat and propel the coating material onto the surface.

[0082] Advantageously, forming the coating by thermal spraying may provide a coating that is securely adhered to the housing and may provide wear resistance.

[0083] As used herein, the term “physical vapor deposition” refers to a coating process using a vacuum deposition method in which the coating material transitions from a condensed phase to a vapor phase before forming a condensed phase to form a coating.

[0084] The physical vapor deposition may be thermal evaporation.

[0085] As used herein, the term “thermal evaporation” refers to a form of physical vapor deposition in which the vapor phase is formed by heating the coating material. As used herein, the term “chemical vapor deposition” refers to a coating process using a vacuum deposition method in which one or more volatile precursors react and / or decompose on a surface to form the coating.

[0086] Advantageously, forming the coating by physical vapor deposition or chemical vapor deposition may provide a coating that is uniform, durable, textured and wear resistant. In particular, advantageously, forming the coating by physical vapor deposition may form a coating that is securely adhered to the housing.

[0087] As used herein, the term “spray coating” refers to forming the coating by applying a fine coating mist to a surface.

[0088] Advantageously, forming the coating by spray coating may form a uniform coating.

[0089] As used herein, the term “dip coating” refers to forming the coating by immersing the surface in a coating solution.

[0090] Advantageously, forming the coating by dip coating may form a uniform coating, in particular even on complex surfaces.

[0091] As used herein, the term “inkjet printing” refers to a coating process in which droplets of coating material are propelled onto a surface.

[0092] Advantageously, forming the coating by inkjet printing may allow the formation of a controlled coating pattern.

[0093] As used herein, the term “sol-gel processing” refers to a coating process in which a ceramic layer is formed by converting monomers in solution into a colloidal solution that then transitions to a solid coating.

[0094] Preferably, the layer is thermally stable at 200 degrees Celsius. Preferably, the housing is thermally stable at 200 degrees Celsius. Preferably, the housing is configured to withstand a temperature of 200 degrees Celsius without degrading, warping or melting.

[0095] Preferably, the layer is substantially corrosion resistant. Preferably, the housing is substantially corrosion resistant.

[0096] As used herein, the term “corrosion resistant” refers to the ability of a component to withstand degradation from exposure to environment factors such as moisture and chemical substances. Corrosion resistance may be determined as described in ASTM B117.

[0097] Preferably, the layer is substantially resistant to oxidation. Preferably, the housing is substantially resistant to oxidation.

[0098] Preferably, the layer is biocompatible. Preferably, the housing is biocompatible.

[0099] As used herein, the term “biocompatible” refers to the compatibility of a component with the generated aerosol such that the user is not exposed to toxicity during use. Biocompatibility may be determined as described in ISO 10993-1 :2018. The housing may comprise a first portion and a second portion. The housing may comprise a peripheral wall extending between the first portion and the second portion. The first portion may be a proximal end plug. The second portion may be a distal end plug.

[0100] In other words, the housing may comprise a proximal end plug and a distal end plug, and the housing may comprise a peripheral wall extending between the proximal end plug and the distal end plug.

[0101] As used herein, the terms “proximal” and “distal” are used to describe the relative positions of components, or portions of components, of cartridges, aerosol-generating devices and aerosolgenerating systems according to the disclosure. Cartridges, aerosol-generating devices and aerosol-generating systems may comprise a proximal end through which, in use, an aerosol exits. Cartridges, aerosol-generating devices and aerosol-generating systems may comprise a distal end opposite the proximal end. The proximal end may also be referred to as the mouth end or downstream end. The distal end may also be referred to as the upstream end.

[0102] As used herein, the terms “upstream” and “downstream” describe the relative positions of elements, or portions of elements, of the cartridges, aerosol-generating devices or aerosolgenerating systems in relation to the direction in which the aerosol is transported through the cartridges, aerosol-generating devices and aerosol-generating systems during use.

[0103] The proximal end plug may define the proximal end of the housing.

[0104] The distal end plug may define the distal end of the housing.

[0105] The peripheral wall may extend from the proximal end of the housing to the distal end of the housing. The peripheral wall may surround the substrate compartment. The proximal end plug, the distal end plug and the peripheral wall may define the substrate compartment.

[0106] The proximal end plug may be received in the peripheral wall. The proximal end plug may be received in the peripheral wall by an interference fit.

[0107] The distal end plug may be received in the peripheral wall. The distal end plug may be received in the peripheral wall by an interference fit.

[0108] The housing may comprise a peripheral wall defining a first open end in which the proximal end plug is received and a second open end in which the distal end plug is received.

[0109] The proximal end plug may extend into the peripheral wall. The distal end plug may extend into the peripheral wall.

[0110] The substrate compartment may extend between the distal end plug and the proximal end plug.

[0111] The layer may overlie one or more of the proximal end plug, the distal end plug and the peripheral wall.

[0112] The layer may overlie the peripheral wall. The layer may overlie the entirety of the peripheral wall. At least a portion of the layer may be in direct contact with the peripheral wall. The layer may overlie one or both of the proximal end plug and the distal end plug. The layer may overlie the entirety of the proximal end plug. The layer may overlie the entirety of the distal end plug. At least a portion of the layer may be in direct contact with the proximal end plug. At least a portion of the layer may be in direct contact with the distal end plug.

[0113] The layer may overlie the peripheral wall, the proximal end plug and the distal end plug.

[0114] The heater element may be fixedly attached to the housing.

[0115] The distal end plug may comprise the heater element. Preferably, the heater element extends from the distal end plug into the substrate compartment. The heater element may be fixedly attached to the distal end plug.

[0116] The distal end plug may comprise one or more electrical contacts arranged at an external surface of the cartridge. The one or more electrical contacts may be connected to the heater element. The one or more electrical contacts may be configured to interact with an aerosolgenerating device.

[0117] The housing may comprise one or more air inlets. Preferably, the one or more air inlets are in the distal end plug. Preferably the one or more air inlets extend through the layer. The one or more air inlets may be a single air inlet. The one or more air inlets may be a plurality of air inlets.

[0118] The housing may comprise one or more air outlets. Preferably, the one or more air outlets are in the proximal end plug. Preferably the one or more air outlets extend through the layer. The one or more air outlets may be a single air outlet. The one or more air outlets may be a plurality of air outlets.

[0119] The substrate compartment may extend between the one or more air inlets and the one or more air outlets.

[0120] The housing may have a length of greater than or equal to 10 millimetres, preferably greater than or equal to 12 millimetres, or most preferably greater than or equal to 14 millimetres.

[0121] The housing may have a length of less than or equal to 40 millimetres, preferably less than or equal to 30 millimetres, or most preferably less than or equal to 20 millimetres.

[0122] For example, the housing may have a length of between 10 millimetres and 40 millimetres, preferably between 10 millimetres and 30 millimetres, or most preferably between 14 millimetres and 20 millimetres.

[0123] As used herein, the term “length” is used to describe the maximum dimension of elements, or portions of elements, of cartridges, aerosol-generating devices and aerosol-generating systems according to the disclosure. The length may be defined in the longitudinal direction or along a longitudinal axis of the cartridge. In particular, the length of the housing may refer to the distance between the proximal end of the proximal end plug and the distal end of the distal end plug of the cartridge. As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the cartridges, aerosol-generating devices and aerosol-generating systems according to the disclosure, which extends between the upstream and downstream ends of the cartridges, aerosol-generating devices and aerosol-generating systems.

[0124] The housing may have a width of greater than or equal to 5 millimetres, preferably greater than or equal to 6 millimetres, or most preferably greater than or equal to 7 millimetres.

[0125] The housing may have a width of less than or equal to 20 millimetres, preferably less than or equal to 15 millimetres, or most preferably less than or equal to 12 millimetres.

[0126] For example, the housing may have a width of between 5 millimetres and 20 millimetres, preferably between 5 millimetres and 15 millimetres, or most preferably between 7 millimetres and 12 millimetres.

[0127] As used herein, the term “width” is used to describe the maximum transverse dimension of elements, or portions of elements, of cartridges, aerosol-generating devices and aerosolgenerating systems according to the disclosure. In particular, the width of the housing may be perpendicular to the length of the housing.

[0128] As used herein, the term “transverse” is used to describe the direction perpendicular to the longitudinal direction or the length of cartridges, aerosol-generating devices and aerosolgenerating systems according to the disclosure.

[0129] The housing may have a thickness of greater than or equal to 2 millimetres, preferably greater than or equal to 3 millimetres, or most preferably greater than or equal to 4 millimetres.

[0130] The housing may have a thickness of less than or equal to 15 millimetres, preferably less than or equal to 10 millimetres, or most preferably less than or equal to 8 millimetres.

[0131] For example, the housing may have a thickness of between 2 millimetres and 15 millimetres, preferably between 3 millimetres and 10 millimetres, or most preferably between 4 millimetres and 8 millimetres.

[0132] As used herein, the term “thickness” is used to describe the smallest transverse dimension of elements, or portions of elements, of cartridges, aerosol-generating devices and aerosolgenerating systems according to the disclosure.

[0133] The peripheral wall of the housing may have a thickness of greater than or equal to 1 millimetre, preferably greater than or equal to 2 millimetre, or most preferably greater than or equal to 3 millimetre.

[0134] The peripheral wall of the housing may have a thickness of less than or equal to 7 millimetres, preferably less than or equal to 5 millimetres, or most preferably less than or equal to 4 millimetres.

[0135] For example, the peripheral wall of the housing may have a thickness of between 1 millimetre and 7 millimetres, preferably between 1 millimetre and 5 millimetres, or most preferably between 1 millimetre and 4 millimetres. The proximal end plug may have a length along a longitudinal axis of the cartridge of greater than or equal to 2 millimetres, preferably greater than or equal to 3 millimetres, or most preferably greater than or equal to 4 millimetres.

[0136] The proximal end plug may have a length along a longitudinal axis of the cartridge of less than or equal to 15 millimetres, preferably less than or equal to 10 millimetres, or most preferably less than or equal to 8 millimetres.

[0137] For example, the proximal end plug may have a length along a longitudinal axis of the cartridge of between 2 millimetres and 15 millimetres, preferably between 3 millimetres and 10 millimetres, or most preferably between 4 millimetres and 8 millimetres.

[0138] The distal end plug may have a length along a longitudinal axis of the cartridge of greater than or equal to 2 millimetres, preferably greater than or equal to 3 millimetres, or most preferably greater than or equal to 4 millimetres.

[0139] The distal end plug may have a length along a longitudinal axis of the cartridge of less than or equal to 10 millimetres, preferably less than or equal to 8 millimetres, or most preferably less than or equal to 6 millimetres.

[0140] For example, the distal end plug may have a length along a longitudinal axis of the cartridge of between 2 millimetres and 10 millimetres, preferably between 3 millimetres and 8 millimetres, or most preferably between 4 millimetres and 6 millimetres.

[0141] The length of the proximal end plug along a longitudinal axis of the cartridge is preferably greater than the length of the distal end plug along a longitudinal axis of the cartridge.

[0142] The aerosol-generating substrate may be a liquid aerosol-generating substrate.

[0143] Preferably, the aerosol-generating substrate is a solid aerosol-generating substrate.

[0144] As used herein, the term “solid” refers to an aerosol-generating substrate that is not a liquid or a gas and which does not flow such that it retains its shape and form at room temperature. In the context of the present invention, the term “solid” encompasses gel materials and compositions.

[0145] The aerosol-generating substrate may be in the form of one or more sheets of a solid aerosol-generating substrate. Preferably, the one or more sheets of solid aerosol-generating substrate comprise at least one aerosol former and at least one of nicotine and tobacco.

[0146] As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof.

[0147] The one or more sheets of solid aerosol-generating substrate may be provided on a suitable carrier element. For example, the one or more sheets of solid aerosol-generating substrate may be deposited onto at least one surface a sheet of an inert carrier material, such as paper or cardboard. This may provide improved rigidity to the one or more sheets of solid aerosolgenerating substrate, which may facilitate the process of filling the cartridge with the one or more sheets during production. The one or more sheets of solid aerosol-generating substrate may be in the form of one or more gathered sheets. As used herein, the term “gathered” denotes that a sheet is convoluted, folded, or otherwise compressed or constricted substantially transversely to a defined axis.

[0148] Alternatively or in addition, the one or more sheets of solid aerosol-generating substrate may be in the form of one or more crimped sheets, preferably, one or more gathered crimped sheets. As used herein, the term “crimped” denotes a sheet having a plurality of substantially parallel ridges or corrugations.

[0149] The one or more sheets of solid aerosol-generating substrate may comprise one or more sheets of homogenised plant material, preferably homogenised tobacco material. The aerosol former content of the homogenised tobacco material is preferably within the ranges defined above for aerosol-generating substrate having a relatively low aerosol former content.

[0150] Alternatively or in addition, the one or more sheets of solid aerosol-generating substrate may comprise one or more sheets comprising an aerosol-generating film comprising a cellulosic based film forming agent, nicotine and the aerosol former. The aerosol-generating film may further comprise a cellulose based strengthening agent. The aerosol-generating film may further comprise water, preferably 30 percent by weight of less of water.

[0151] As used herein, the term “film” is used to describe a solid laminar element having a thickness that is less than the width or length thereof. The film may be self-supporting.

[0152] The aerosol former content of the aerosol-generating film is within the ranges defined above for aerosol-generating substrates having a relatively high aerosol former content.

[0153] In the context of the present invention the term “cellulose based film-forming agent” is used to describe a cellulosic polymer capable, by itself or in the presence of an auxiliary thickening agent, of forming a continuous film. Preferably, the cellulose based film-forming agent is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methyl cellulose (HEMC), hydroxyethyl cellulose (HEC), hydroxypropyl cellulose (HPC), and combinations thereof. In particularly preferred embodiments, the cellulose based film-forming agent is HPMC.

[0154] Suitable aerosol-generating films for use as the aerosol-generating substrate are described in WC-A-2020 / 207733 and WO-A-2022 / 074157.

[0155] Alternatively or in addition, the one or more sheets of solid aerosol-generating substrate may comprise one or more sheets comprising a gel composition that includes nicotine, at least one gelling agent and the aerosol former. The gel composition is preferably tobacco free.

[0156] Suitable gel compositions for use as the aerosol-generating substrate are described in WO-A-2021 / 170642.

[0157] In other embodiments, the aerosol-generating substrate may be in the form of a shredded aerosol-generating substrate. Preferably, the shredded aerosol-generating substrate comprises at least one aerosol former and at least one of tobacco and nicotine. As used herein, the term “shredded” describes an aerosol-generating substrate that is in the form of a plurality of shreds or strips. In general, the shredded aerosol-generating substrate is formed by the cutting or shredding of a larger portion of the aerosol-generating substrate, such as a sheet, leaf or other piece of plant material. The individual strips or strands are typically elongate in form, with a length that is greater than the width and thickness.

[0158] The shredded aerosol-generating substrate may be in the form of shredded tobacco material, such as cut filler. Alternatively, the shredded aerosol-generating substrate may be in the form of a shredded sheet of homogenised plant material, such as a homogenised tobacco material. Alternatively, the shredded aerosol-generating substrate may be in the form of a shredded non-tobacco material, as described in more detail below.

[0159] As used herein, the term “cut filler” is used to describe to a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0160] According to a second aspect of the present disclosure there is provided an aerosolgenerating system. The aerosol-generating system may comprise a cartridge according to the first aspect of the present disclosure. The aerosol-generating system may comprise an aerosolgenerating device. The aerosol-generating device may comprise a power supply.

[0161] According to a second aspect of the present invention there is provided an aerosolgenerating system. The aerosol-generating system comprises a cartridge according to the first aspect of the present disclosure. The aerosol-generating system comprises an aerosolgenerating device. The aerosol-generating device comprises a power supply.

[0162] Since the aerosol-generating system of this disclosure comprises a cartridge described herein, the advantages specified above for the cartridge also apply to the aerosol-generating system itself.

[0163] The power supply may be configured to provide power to the heater element to heat the aerosol-generating substrate to generate an aerosol. The power supply may be a DC power supply. The power supply may a battery. The power supply may require recharging and may have a capacity that allows for the storage of enough energy for one or more user operations, for example one or more aerosol-generating experiences.

[0164] The aerosol-generating device may further comprise a device cavity configured to receive at least a part of the cartridge. The device cavity may have a closed end and an open end. The cartridge may be insertable into the device cavity via the open end. The device cavity may have substantially the same cross-sectional shape as the cartridge.

[0165] The device cavity of the aerosol-generating device may be at least partially defined by a device housing.

[0166] The device housing may comprise one or more of a metal, a plastic, a composite and a metal alloy. Preferably, the device housing comprises one or more of polycarbonate (PC), acrylonitrile butadiene styrene (ABS), liquid crystalline polymer (LCP), copolyester, polyetheretherketone (PEEK), cyclic olefin copolymer (COC), aluminium, an aluminium alloy, magnesium and carbon fibre reinforced polymer.

[0167] As discussed above, the cartridge is preferably configured to interact with the heater element to heat the aerosol-generating substrate to generate an aerosol.

[0168] The aerosol-generating device may comprise the heater element. In other words, the heater element may be provided as part of the aerosol-generating device. The heater element may be configured for insertion into the substrate compartment of the cartridge.

[0169] Alternatively or in addition, the heater element may be located around the periphery of the device cavity. The heater element may circumscribe the cartridge when the cartridge is at least party received in the device cavity.

[0170] The heater element may comprise one of a resistive heater element, a susceptor element, an infrared heater element or a dielectric heater element as described herein.

[0171] Where a susceptor element is provided either as part of the cartridge or the aerosolgenerating device, the aerosol-generating device may comprise the inductor coil arranged to inductively heat the susceptor element. Where the aerosol-generating device comprises a device cavity, the inductor coil may at least partly circumscribe the device cavity. The inductor coil may be arranged to coaxially circumscribe the device cavity.

[0172] The aerosol-generating device may further comprise a controller. The controller may be configured to control the supply of power from the power supply to the heater element. The controller may be electrically connected to the power supply. The controller may be configured to control the power output from the power supply to control whether the heater element is on or off. The controller may be configured to control the power output from the power supply to control the temperature of the heater element.

[0173] The aerosol-generating device may further comprise a mouthpiece. During use, a user may draw on the mouthpiece to receive aerosol generated in the cartridge.

[0174] The cartridge may be configured to be at least partially received in the device cavity and at least partially received in the mouthpiece.

[0175] The mouthpiece may be configured to move between an open position and a closed position. When the mouthpiece is in the open position, the cartridge may be inserted into or removed from the device cavity. When the mouthpiece is in the closed position, the cartridge may be secured within the aerosol-generating device. When the mouthpiece is in the closed position, the cartridge may be contained within and surrounded by the mouthpiece and the device cavity.

[0176] The mouthpiece may comprise one or more of a metal, plastic and a plant based material. Preferably, the mouthpiece comprises one or more of polycarbonate (PC), acrylonitrile butadiene styrene (ABS), liquid crystalline polymer (LCP), copolyester, polyetheretherketone (PEEK), cyclic olefin copolymer (COC), aluminium, stainless steel, wood and bamboo. The aerosol-generating device may comprise a device air inlet. The aerosol-generating device may comprise a device air outlet.

[0177] The device air inlet may be disposed at a distal end of the aerosol-generating device.

[0178] The mouthpiece may comprise the device air outlet. The device air outlet may be disposed at a proximal end of the aerosol-generating device.

[0179] The cartridge and the aerosol-generating device may be configured such that the one or more electrical contacts of the cartridge electrically connect to corresponding electrical contacts of the aerosol-generating device.

[0180] The electrical contacts of the aerosol-generating device may be electrically connected to the power supply.

[0181] The aerosol-generating system may be configured such that, during use, air passes into the device air inlet, through the device cavity into the one or more air inlets of the cartridge, through the aerosol-generating substrate in the substrate compartment. The aerosol-generating system may be configured such that, during use, aerosol generated in the substrate compartment passes in air flow to the one or more air outlets of the cartridge, and subsequently to the device air outlet.

[0182] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0183] Example EX1 : A cartridge for use with an aerosol-generating device, the cartridge comprising: a housing defining a substrate compartment, the housing having a first thermal conductivity; an aerosol-generating substrate received within the substrate compartment; and a layer having a second thermal conductivity, wherein the layer at least partially overlies the housing, wherein the layer at least partially defines an external surface of the cartridge, and wherein the second thermal conductivity is greater than the first thermal conductivity.

[0184] Example EX2: A cartridge according to example EX1 , wherein the cartridge comprises a heater element, preferably wherein the heater element is configured to heat the aerosolgenerating substrate to generate an aerosol.

[0185] Example EX3: A cartridge according to example EX2, wherein the heater element is arranged in the substrate compartment.

[0186] Example EX4: A cartridge according to example EX3, wherein the heater element is embedded in or at least partially surrounded by the aerosol-generating substrate.

[0187] Example EX5: A cartridge according to any preceding example, wherein the first thermal conductivity is less than or equal to 50 Watts per metre Kelvin, optionally less than or equal to 45 Watts per metre Kelvin, optionally less than or equal to 40 Watts per metre Kelvin, optionally less than or equal to 35 Watts per metre Kelvin, optionally less than or equal to 30 Watts per metre Kelvin, optionally less than or equal to 25 Watts per metre Kelvin, optionally less than or equal to 20 Watts per metre Kelvin, optionally less than or equal to 15 Watts per metre Kelvin, optionally less than or equal to 10 Watts per metre Kelvin, optionally less than or equal to 5 Watts per metre Kelvin, optionally less than or equal to 3 Watts per metre Kelvin, or optionally less than or equal to 1 Watt per metre Kelvin.

[0188] Example EX6: A cartridge according to any preceding example, wherein the first thermal conductivity is greater than or equal to 0.05 Watts per metre Kelvin, optionally greater than or equal to 0.1 Watts per metre Kelvin, optionally greater than or equal to 0.2 Watts per metre Kelvin, or optionally greater than or equal to 0.5 Watts per metre Kelvin.

[0189] Example EX7: A cartridge according to any preceding example, wherein the second thermal conductivity is greater than or equal to 100 Watts per metre Kelvin, optionally greater than or equal to 200 Watts per metre Kelvin, optionally greater than or equal to 300 Watts per metre Kelvin, optionally greater than or equal to 500 Watts per metre Kelvin, optionally greater than or equal to 1000 Watts per metre Kelvin, or optionally greater than or equal to 3000 Watts per metre Kelvin.

[0190] Example EX8: A cartridge according to any preceding example, wherein the second thermal conductivity is less than or equal to 5000 Watts per metre Kelvin, optionally less than or equal to 3000 Watts per metre Kelvin, optionally less than or equal to 1000 Watts per metre Kelvin, optionally less than or equal to 800 Watts per metre Kelvin, optionally less than or equal to 500 Watts per metre Kelvin, optionally less than or equal to 400 Watts per metre Kelvin, optionally less than or equal to 300 Watts per metre Kelvin, or optionally less than or equal to 250 Watts per metre Kelvin.

[0191] Example EX9: A cartridge according to any preceding example, wherein the housing has a porosity of less than or equal to 1 percent, preferably less than or equal to 0.5 percent.

[0192] Example EX10: A cartridge according to any preceding example, wherein the housing comprises a material selected from one or more of a metal, a metal alloy, a composite, a ceramic, an aerogel and a thermoplastic.

[0193] Example EX11 : A cartridge according to any preceding example, wherein the housing comprises a material selected from one or more of polyetheretherketone, polyphenylene sulfide, polyamide, Carbon Fiber Reinforced Polymer, Glass Fiber Reinforced Polymer, an aerogel, aluminium oxide (alumina), zirconium oxide (zirconia), alumina, a nickel based alloy and an iron based alloy.

[0194] Example EX12: A cartridge according to any preceding example, wherein the layer comprises a material selected from one or more of a carbon allotrope, a ceramic and a metal, preferably wherein the metal is selected from one or more of copper, aluminium, steel, silver and gold.

[0195] Example EX13: A cartridge according to any preceding example, wherein the layer has a thickness of greater than or equal to 0.05 micrometres, optionally greater than or equal to 0.1 micrometres, optionally greater than or equal to 0.5 micrometres, optionally greater than or equal to 1 micrometre, optionally greater than or equal to 5 micrometres, optionally greater than or equal to 10 micrometres, or optionally greater than or equal to 50 micrometres.

[0196] Example EX14: A cartridge according to any preceding example, wherein the layer has a thickness of less than or equal to 500 micrometres, optionally less than or equal to 200 micrometres, optionally less than or equal to 50 micrometres, optionally less than or equal to 20 micrometres, optionally less than or equal to 5 micrometres, or optionally less than or equal to 1 micrometre.

[0197] Example EX15: A cartridge according to any preceding example, wherein the layer is a coating.

[0198] Example EX16: A cartridge according to example EX15, wherein the coating is formed by one or more of electroplating, thermal spraying, physical vapor deposition, chemical vapor deposition, spray coating, dip coating, inkjet printing, sol-gel processing, and spin coating.

[0199] Example EX17: A cartridge according to any preceding example, wherein one or both of the housing and the layer is thermally stable at 200 degrees Celsius.

[0200] Example EX18: A cartridge according to any preceding example, wherein one or both of the housing and the layer are substantially corrosion resistant.

[0201] Example EX19: A cartridge according to any preceding example, wherein one or both of the housing and the layer are biocompatible.

[0202] Example EX20: A cartridge according to any preceding example, wherein at least a portion of the layer is in direct contact with the housing.

[0203] Example EX21 : A cartridge according to any preceding example, wherein the housing comprises a proximal end plug and a distal end plug, and a peripheral wall extending between the proximal end plug and the distal end plug.

[0204] Example EX22: A cartridge according to example EX21 , wherein the layer overlies one or more of the proximal end plug, the distal end plug and the peripheral wall.

[0205] Example EX23: A cartridge according to example EX21 or EX22, wherein the distal end plug comprises the heater element.

[0206] Example EX24: A cartridge according to any one of examples EX21 to EX23, wherein the distal end plug comprises one or more electrical contacts arranged at an external surface of the cartridge.

[0207] Example EX25: A cartridge according to any preceding example, wherein the housing comprises one or more air inlets. Example EX26: A cartridge according to any preceding example, wherein the housing comprises one or more air outlets.

[0208] Example EX27: A cartridge according to any preceding example, wherein the aerosolgenerating substrate is a solid aerosol-generating substrate.

[0209] Example EX28: A cartridge according to any preceding example, wherein the heater element is a resistive heater element.

[0210] Example EX29: A cartridge according to any preceding example, wherein the housing has a length of between 10 millimetres and 40 millimetres, preferably between 10 millimetres and 30 millimetres, or most preferably between 14 millimetres and 20 millimetres.

[0211] Example EX30: A cartridge according to any preceding example, wherein the housing has a width of between 5 millimetres and 20 millimetres, preferably between 5 millimetres and 15 millimetres, or most preferably between 7 millimetres and 12 millimetres.

[0212] Example EX31 : A cartridge according to any preceding example, wherein the housing has a thickness of between 2 millimetres and 15 millimetres, preferably between 3 millimetres and 10 millimetres, or most preferably between 4 millimetres and 8 millimetres.

[0213] Example EX32: An aerosol-generating system comprising: a cartridge according to any preceding example; and an aerosol-generating device, the aerosol-generating device comprising a power supply.

[0214] Example EX33: An aerosol-generating system according to example EX32, wherein the aerosol-generating device further comprises a mouthpiece.

[0215] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0216] Figure 1 is a perspective view of a cartridge according to an embodiment of the disclosure.

[0217] Figure 2 is a cross-sectional view of the cartridge of Figure 1 according to an embodiment of the disclosure.

[0218] Figure 3 is a cross-sectional view of an aerosol-generating system comprising the cartridge of Figure 1 and an aerosol-generating device.

[0219] Figure 1 shows a perspective view of a cartridge 10 and Figure 2 shows a schematic cross-sectional view of the cartridge 10. The cartridge 10 is configured for use with an aerosolgenerating device 600. As best seen in Figure 2, the cartridge 10 comprises: a housing 100, a heater element 200, and an aerosol-generating substrate 300.

[0220] The housing 100 defines a substrate compartment 400. The aerosol-generating substrate 300 is received within the substrate compartment 400.

[0221] The housing 100 has a thermal conductivity of 1 Watt per metre Kelvin.

[0222] The housing 100 comprises a plurality of air inlets 110 and a plurality of air outlets 120.

[0223] The housing 100 has a distal end 101 and a proximal end 102. The housing 100 comprises an air flow path extending between the plurality of air inlets 110 and the plurality of air outlets 120. The housing 100 defines the plurality of air inlets 110 and the plurality of air outlets 120. The housing 100 is configured such that in use, air can flow from the plurality of air inlets 110, through the substrate compartment 400, towards and out through the plurality of air outlets 120.

[0224] The plurality of air inlets 110 are disposed at the distal end 101. The plurality of air outlets 120 are disposed at the proximal end 102.

[0225] The housing 100 comprises a distal end plug 130. The distal end plug 130 defines the distal end 101 of the housing 100.

[0226] The housing 100 comprises a proximal end plug 140. The proximal end plug 140 defines the proximal end 102 of the housing 100.

[0227] The housing comprises a peripheral wall 150. The peripheral wall 150 defines a first open end in which the proximal end plug 140 is received and a second open end in which the distal end plug 130 is received. The proximal end plug 140 is received in the peripheral wall 150 by an interference fit. The distal end plug 130 is received in the peripheral wall 150 by an interference fit.

[0228] The peripheral wall 150 extends from the proximal end 102 of the housing 100 to the distal end 101 of the housing 100. The peripheral wall 150 surrounds the substrate compartment 400.

[0229] The distal end plug 130 comprises the plurality of air inlets 110.

[0230] The proximal end plug 140 comprises the plurality of air outlets 120.

[0231] The substrate compartment 400 extends between the distal end plug 130 and the proximal end plug 140.

[0232] The cartridge 10 comprises a layer 160 overlying the peripheral wall 150, the distal end plug 130 and the proximal end plug 140. The layer 160 is in direct contact with each of the peripheral wall 150, the distal end plug 130 and the proximal end plug 140. The layer 160 defines an external surface of the cartridge 10. The plurality of air inlets 110 and the plurality of air outlets 120 each extend through the layer 160.

[0233] The layer 160 has a thermal conductivity of 250 Watts per metre Kelvin.

[0234] The heater element 200 is arranged in the substrate compartment 400. The heater element 200 is fixedly attached to the housing 100. More specifically, the heater element 200 is fixedly attached to the distal end plug 130. The heater element 200 extends from the distal end plug 130 into the substrate compartment 400.

[0235] The aerosol-generating substrate 300 is a solid aerosol-generating substrate. The heater element 200 is embedded in the aerosol-generating substrate 300.

[0236] The distal end plug 130 comprises one or more electrical contacts arranged at an external surface of the cartridge 10.

[0237] The heater element 200 is configured to heat the aerosol-generating substrate 300 to generate an aerosol. The heater element 200 is a resistive heater element, which is configured to generate heat upon application of a voltage across the heater element 200. It will be appreciated that the heater element 200 may alternatively be a susceptor element configured to interact with an inductor coil.

[0238] The heater element 200 has a serpentine shape. The heater element 200 comprises a plurality of parallel segments extending along the substrate compartment 400. The heater element 200 is a self-supporting track which extends through the substrate compartment 400. The heater element 200 is substantially or entirely planar. The heater element 200 is oriented so that a plane of the heater element 200 is aligned with the width of the cartridge 10.

[0239] Figure 3 shows a cross-sectional view of an aerosol-generating system 800 comprising the cartridge 10 and an aerosol-generating device 600.

[0240] The aerosol-generating device 600 comprises a device cavity 610 and a mouthpiece 612. The device cavity 610 is defined by a device housing 650.

[0241] The cartridge 10 is configured to be received in the device cavity 610 and the mouthpiece 612 of the aerosol-generating device 600.

[0242] The mouthpiece 612 is configured to move between an open position and a closed position. When the mouthpiece 612 is in the open position, the cartridge 10 can be inserted into or removed from the device cavity 610. When the mouthpiece 612 is in the closed position, the cartridge 10 is secured within the aerosol-generating device 600. When the mouthpiece is in the closed position, the cartridge 10 is contained within and surrounded by the mouthpiece 612 and the device cavity 610.

[0243] The aerosol-generating device 600 comprises a device air inlet 608, a device air outlet 609, a power supply 630, and a controller 640.

[0244] The device air inlet 608 is disposed at a distal end of the aerosol-generating device 600. The mouthpiece 612 comprises the device air outlet 609. The device air outlet 609 is disposed at a proximal end of the aerosol-generating device 600.

[0245] The cartridge 10 and the aerosol-generating device 600 are configured such that the electrical contacts of the cartridge 10 electrically connect to corresponding electrical contacts of the aerosol-generating device 600. The electrical contacts of the aerosol-generating device 600 are electrically connected to the power supply 630, such that power can be supplied from the power supply 630 to the heater element 200. The power supply 630 is in the form of a battery.

[0246] The aerosol-generating device 600 comprises a controller 640, which is electrically connected to the power supply 630. The controller 640 is configured to control the power output from the power supply 630, in particular to control whether the heater element 200 is on or off, and to control the temperature of the heater element 200.

[0247] In use, air passes into the device air inlet 608, through the device cavity 610 into the plurality of air inlets 110 of the cartridge 10, through the aerosol-generating substrate 300 surrounding the heater element 200. The heater element 200 heats the aerosol-generating substrate 300 to generate an aerosol. The aerosol passes in air flow to the plurality of air outlets 120 of the cartridge 100, and subsequently to the device air outlet 609 of the mouthpiece 612. The user can draw on the mouthpiece 612 to receive the aerosol from the device air outlet 609.

[0248] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

- 26 -Claims1 . A cartridge for use with an aerosol-generating device, the cartridge comprising: a housing defining a substrate compartment, the housing having a first thermal conductivity; an aerosol-generating substrate received within the substrate compartment; and a layer having a second thermal conductivity, wherein the layer at least partially overlies the housing, wherein the layer at least partially defines an external surface of the cartridge, wherein the second thermal conductivity is greater than the first thermal conductivity, and wherein the cartridge comprises a heater element.

2. A cartridge according to claim 1 , wherein the heater element is a resistive heater element.

3. A cartridge according to any preceding claim, wherein the first thermal conductivity is less than or equal to 50 Watts per metre Kelvin.

4. A cartridge according to any preceding claim, wherein the first thermal conductivity is greater than or equal to 0.1 Watts per metre Kelvin.

5. A cartridge according to any preceding claim, wherein the second thermal conductivity is greater than or equal to 100 Watts per metre Kelvin.

6. A cartridge according to any preceding claim, wherein the second thermal conductivity is less than or equal to 5000 Watts per metre Kelvin.

7. A cartridge according to any preceding claim, wherein the housing comprises a material selected from one or more of a metal, a metal alloy, a composite, a ceramic, an aerogel and a thermoplastic.

8. A cartridge according to any preceding claim, wherein the housing comprises a material selected from one or more of polyetheretherketone, polyphenylene sulfide, polyamide, Carbon Fiber Reinforced Polymer, Glass Fiber Reinforced Polymer, an aerogel, aluminium oxide (alumina), zirconium oxide (zirconia), alumina, a nickel based alloy and an iron based alloy.

9. A cartridge according to any preceding claim, wherein the layer comprises a material selected from one or more of a carbon allotrope, a ceramic and a metal, preferably wherein the metal is selected from one or more of copper, aluminium, steel, silver and gold.

10. A cartridge according to any preceding claim, wherein at least a portion of the layer is in direct contact with the housing.

11. A cartridge according to any preceding claim, wherein the housing comprises a proximal end plug and a distal end plug, and a peripheral wall extending between the proximal end plug and the distal end plug.

12. A cartridge according to claim 11, wherein the layer overlies one or more of the proximal end plug, the distal end plug and the peripheral wall.

13. A cartridge according to any preceding claim, wherein the aerosol-generating substrate is a solid aerosol-generating substrate.

14. An aerosol-generating system comprising: a cartridge according to any preceding claim; and an aerosol-generating device, the aerosol-generating device comprising a power supply.

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