A cartridge with varying heating
The cartridge with a heating element of varying cross-sectional area and resistivity optimizes heat distribution within the aerosol-generating substrate, addressing inefficiencies and discomfort in existing cartridges by enhancing heating uniformity and reducing exterior heat transfer.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- PHILIP MORRIS PRODUCTS SA
- Filing Date
- 2025-12-17
- Publication Date
- 2026-06-25
AI Technical Summary
Existing aerosol-generating cartridges with electrically operated heaters suffer from non-optimized heating, leading to inefficient heating of the aerosol-generating substrate and discomfort due to excess heat transfer to the exterior.
The cartridge features a heating element with varying cross-sectional area and/or resistivity along its length, allowing for a non-uniform spatial heating profile that matches the geometry of the aerosol-generating substrate, thereby optimizing heat distribution and reducing exterior heating.
This design facilitates efficient heating of the aerosol-generating substrate while minimizing heat loss to the exterior, resulting in more uniform heating and reduced discomfort during use.
Smart Images
Figure EP2025087789_25062026_PF_FP_ABST
Abstract
Description
[0001] A CARTRIDGE WITH VARYING HEATING
[0002] The present disclosure relates to a cartridge for use with an aerosol-generating device, the cartridge comprising a heating element. The present disclosure also relates to an aerosolgenerating 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] 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 also known.
[0006] However, in known cartridges comprising an electrically operated heater, the arrangement of the heater often results in non-optimised heating of the cartridge. For example, known cartridges may result in excess transfer of heat to the outside of the cartridge, which results in inefficient heating of the aerosol-generating substrate and may result in the cartridge or the device becoming uncomfortably warm for a user to hold. In other examples, non-optimised heating of the cartridge may result in portions of the substrate being heated too much or not enough.
[0007] It would be desirable to provide a cartridge for use with an aerosol-generating device, the cartridge facilitating improved heating of an aerosol-generating substrate.
[0008] According to the present disclosure, there is provided a cartridge for use with an aerosolgenerating device. The cartridge may comprise a housing defining an air inlet, an air outlet, and a substrate compartment between the air inlet and the air outlet. The cartridge may comprise an aerosol-generating substrate positioned within the substrate compartment. The cartridge may comprise an electric heater positioned within the substrate compartment. The electric heater may comprise a first electrical contact arranged on the housing. The electric heater may comprise a second electrical contact arranged on the housing. The electric heater may comprise a heating element extending between the first electrical contact and the second electrical contact. At least one of a cross-sectional area of the heating element and / or a resistivity of the heating element may vary along a length of the heating element from the first electrical contact to the second electrical contact.
[0009] According to the present disclosure, there is provided a cartridge for use with an aerosolgenerating device. The cartridge comprises a housing defining an air inlet, an air outlet, and a substrate compartment between the air inlet and the air outlet. The cartridge also comprises an aerosol-generating substrate positioned within the substrate compartment. The cartridge also comprises an electric heater positioned within the substrate compartment. The electric heater comprises a first electrical contact arranged on the housing, a second electrical contact arranged on the housing, and a heating element extending between the first electrical contact and the second electrical contact. At least one of a cross-sectional area of the heating element and / or a resistivity of the heating element varies along a length of the heating element from the first electrical contact to the second electrical contact.
[0010] Advantageously, cartridges according to the present disclosure comprise an electric heater comprising a heating element having at least one of a cross-sectional area and / or a resistivity that varies along a length of the heating element. Advantageously, the variation in the cross-sectional area and / or the resistivity may provide the heating element with a non-uniform spatial heating profile during use. Advantageously, a non-uniform spatial heating profile may allow the distribution of heat generated by the heating element during use to be adapted or matched to the geometry of at least one of the aerosol-generating substrate and / or the substrate compartment. Advantageously, this may facilitate efficient heating of the aerosol-generating substrate and may reduce or minimise heating of the cartridge exterior.
[0011] As used herein, the term “cartridge” relates to a component that interacts with an aerosolgenerating device to generate an aerosol.
[0012] As used herein, the term “aerosol-generating device” relates to a device that interacts with a cartridge to generate an aerosol.
[0013] 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.
[0014] 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.
[0015] As used herein, the term “length of the heating element” refers to the conductive length of the heating element from the first electrical contact to the second electrical contact. Therefore, in examples and embodiments in which the heating element has a non-linear shape, the length of the heating element will be larger than the straight line distance between the first electrical contact and the second electrical contact.
[0016] Preferably, the heating element is a resistive heating element.
[0017] The heating element may comprise a central portion, a first portion extending between the first electrical contact and a first end of the central portion, and a second portion extending between the second electrical contact and a second end of the central portion.
[0018] The central portion may have a larger cross-sectional area than each of the first portion and the second portion.
[0019] The central portion may have a smaller resistivity than each of the first portion and the second portion.
[0020] Providing the central portion with at least one of a larger cross-sectional area and / or a smaller resistivity than each of the first portion and the second portion may increase a ratio of heat generated by each of the first portion and the second portion to the heat generated by the central portion. Advantageously, this may facilitate more uniform heating of the aerosolgenerating substrate. For example, in embodiments in which at least one of the cartridge, the substrate compartment, and / or the aerosol-generating substrate has a planar shape, heat losses from the substrate during use may be greater at the edges of the substrate compared to a central portion of the substrate. Therefore, the increase in relative heat generation by the first and second portions of the heating element may counteract these heat losses, which may result in more uniform heating of the aerosol-generating substrate.
[0021] A ratio of the cross-sectional area of the central portion to the cross-sectional area of the first portion may be at least 1.1 , at least 1.2, at least 1.3, at least 1.4, at least 1.5, at least 1.6, at least 1.7, at least 1.8, at least 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least 2.7, at least 2.8, at least 2.9, or at least 3.
[0022] A ratio of the cross-sectional area of the central portion to the cross-sectional area of the second portion may be at least 1.1 , at least 1.2, at least 1.3, at least 1.4, at least 1.5, at least 1.6, at least 1.7, at least 1 .8, at least 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least 2.7, at least 2.8, at least 2.9, or at least 3.
[0023] The central portion may have a smaller cross-sectional area than each of the first portion and the second portion.
[0024] The central portion may have a larger resistivity than each of the first portion and the second portion. Providing the central portion with at least one of a smaller cross-sectional area and / or a larger resistivity than each of the first portion and the second portion may increase a ratio of heat generated by the central portion to each of the first portion and the second portion. Advantageously, this may facilitate increased heating of a central portion of the aerosolgenerating substrate compared to one or more outer portions of the aerosol-generating substrate. Advantageously, this may result in more efficient aerosol generation in examples and embodiments in which a main airflow pathway extends through a central portion of the aerosolgenerating substrate. Increased heating at the central portion of the heating element compared to the first and second portions of the heating element may also reduce or minimise heat losses at one or more sides of the cartridge. Advantageously, this may reduce or minimise heating of the cartridge exterior.
[0025] A ratio of the cross-sectional area of the first portion to the cross-sectional area of the central portion may be at least 1.1 , at least 1.2, at least 1.3, at least 1.4, at least 1.5, at least 1.6, at least 1.7, at least 1 .8, at least 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least 2.7, at least 2.8, at least 2.9, or at least 3.
[0026] A ratio of the cross-sectional area of the second portion to the cross-sectional area of the central portion may be at least 1.1 , at least 1.2, at least 1.3, at least 1.4, at least 1.5, at least 1.6, at least 1.7, at least 1 .8, at least 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least 2.7, at least 2.8, at least 2.9, or at least 3.
[0027] Preferably, a cross-sectional area of the first portion is the same as a cross-sectional area of the second portion.
[0028] Preferably, a resistivity of the first portion is the same as the resistivity of the second portion.
[0029] Providing the first portion with at least one of the same cross-sectional area and / or the same resistivity as the second portion may facilitate similar or the same generation of heat by the first portion and the second portion. Advantageously, this may facilitate a symmetrical heating profile over the heating element.
[0030] Preferably, the central portion has a uniform cross-sectional area from the first end of the central portion to the second end of the central portion. Advantageously, this may result in uniform heating of the central portion of the heating element during use. Advantageously, this may provide uniform heating of at least part of the aerosol-generating substrate.
[0031] A cross-sectional area of the first portion may vary along at least part of the first portion from the first electrical contact to the first end of the central portion.
[0032] A cross-sectional area of the second portion may vary along at least part of the second portion from the second electrical contact to the second end of the central portion.
[0033] Advantageously, in examples and embodiments in which the central portion has a different cross-sectional area to the first portion and the second portion, varying a cross-sectional area of at least one of the first portion and the second portion may provide a gradual transition into the central portion from each of the first portion and the second portion.
[0034] The first portion may comprise a first constant region having a first constant cross- sectional area that is different to the cross-sectional area of the central portion. The first portion may comprise a first transition region extending between the first constant region and the first end of the central portion. The first transition region may have a varying cross-sectional area that increases or decreases from the first constant cross-sectional area to the cross-sectional area of the central portion.
[0035] The second portion may comprise a second constant region having a second constant cross-sectional area that is different to the cross-sectional area of the central portion. The second portion may comprise a second transition region extending between the second constant region and the second end of the central portion. The second transition region may have a varying cross-sectional area that increases or decreases from the second constant cross-sectional area to the cross-sectional area of the central portion.
[0036] The heating element may have a planar shape extending in a heater plane. Advantageously, a planar shape may increase or maximise a surface area of the heating element in contact with the aerosol-generating substrate. Advantageously, a planar shape may facilitate positioning of the heating element within the aerosol-generating substrate. Advantageously, positioning the heating element within the aerosol-generating substrate may maximise the transfer of heat from the heating element to the aerosol-generating substrate.
[0037] The heating element may have a thickness in a direction perpendicular to the heater plane, wherein the heating element has a uniform thickness along the length of the heating element. Advantageously, providing the heating element with a uniform thickness may facilitate manufacture of the heating element. For example, the heating element may be stamped or cut from a sheet of electrically conductive material.
[0038] The heating element may have a width in a direction perpendicular to the thickness of the heating element and perpendicular to the length of the heating element. The width of the heating element may vary along the length of the heating element from the first electrical contact to the second electrical contact. Advantageously, in examples and embodiments in which the heating element has a cross-sectional area that varies along the length of the heating element, the varying width of the heating element may provide the varying cross-sectional area of the heating element.
[0039] The central portion may have a larger width than each of the first portion and the second portion.
[0040] Providing the central portion with a larger width than each of the first portion and the second portion may increase a ratio of heat generated by each of the first portion and the second portion to the heat generated by the central portion. Advantageously, this may facilitate more uniform heating of the aerosol-generating substrate. For example, in embodiments in which at least one of the cartridge, the substrate compartment, and / or the aerosol-generating substrate has a planar shape, heat losses from the substrate during use may be greater at the edges of the substrate compared to a central portion of the substrate. Therefore, the increase in relative heat generation by the first and second portions of the heating element may counteract these heat losses, which may result in more uniform heating of the aerosol-generating substrate.
[0041] A ratio of the width of the central portion to the width of the first portion may be at least
[0042] 1.1 , at least 1.2, at least 1 .3, at least 1.4, at least 1 .5, at least 1.6, at least 1 .7, at least 1.8, at least
[0043] 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least
[0044] 2.7, at least 2.8, at least 2.9, or at least 3.
[0045] A ratio of the width of the central portion to the width of the second portion may be at least
[0046] 1.1 , at least 1.2, at least 1 .3, at least 1.4, at least 1 .5, at least 1.6, at least 1 .7, at least 1.8, at least
[0047] 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least
[0048] 2.7, at least 2.8, at least 2.9, or at least 3.
[0049] The central portion may have a smaller width than each of the first portion and the second portion.
[0050] Providing the central portion with a smaller width than each of the first portion and the second portion may increase a ratio of heat generated by the central portion to each of the first portion and the second portion. Advantageously, this may facilitate increased heating of a central portion of the aerosol-generating substrate compared to one or more outer portions of the aerosolgenerating substrate. Advantageously, this may result in more efficient aerosol generation in examples and embodiments in which a main airflow pathway extends through a central portion of the aerosol-generating substrate. Increased heating at the central portion of the heating element compared to the first and second portions of the heating element may also reduce or minimise heat losses at one or more sides of the cartridge. Advantageously, this may reduce or minimise heating of the cartridge exterior.
[0051] A ratio of the width of the first portion to the width of the central portion may be at least
[0052] 1.1 , at least 1.2, at least 1 .3, at least 1.4, at least 1 .5, at least 1.6, at least 1 .7, at least 1.8, at least
[0053] 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least
[0054] 2.7, at least 2.8, at least 2.9, or at least 3.
[0055] A ratio of the width of the second portion to the width of the central portion may be at least
[0056] 1.1 , at least 1.2, at least 1 .3, at least 1.4, at least 1 .5, at least 1.6, at least 1 .7, at least 1.8, at least
[0057] 1.9, at least 2, at least 2.1 , at least 2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least
[0058] 2.7, at least 2.8, at least 2.9, or at least 3.
[0059] Preferably, a width of the first portion is the same as a width of the second portion. Providing the first portion with the same width as the second portion may facilitate similar or the same generation of heat by the first portion and the second portion. Advantageously, this may facilitate a symmetrical heating profile over the heating element. Preferably, the central portion has a uniform width from the first end of the central portion to the second end of the central portion. Advantageously, this may result in uniform heating of the central portion of the heating element during use. Advantageously, this may provide uniform heating of at least part of the aerosol-generating substrate.
[0060] A width of the first portion may vary along at least part of the first portion from the first electrical contact to the first end of the central portion.
[0061] A width of the second portion may vary along at least part of the second portion from the second electrical contact to the second end of the central portion.
[0062] Advantageously, in examples and embodiments in which the central portion has a different width to the first portion and the second portion, varying a width of at least one of the first portion and the second portion may provide a gradual transition into the central portion from each of the first portion and the second portion.
[0063] The first portion may comprise a first constant region having a first constant width that is different to the width of the central portion. The first portion may comprise a first transition region extending between the first constant region and the first end of the central portion. The first transition region may have a varying width that increases or decreases from the first constant width to the width of the central portion.
[0064] The second portion may comprise a second constant region having a second constant width that is different to the width of the central portion. The second portion may comprise a second transition region extending between the second constant region and the second end of the central portion. The second transition region may have a varying width that increases or decreases from the second constant width to the width of the central portion.
[0065] The heating element may have any suitable shape. Preferably, the heating element has a serpentine shape. Advantageously, a serpentine shape may provide the heating element with a relatively large length while maintaining a relatively small overall size of the electric heater. In examples and embodiments in which the heating element has a planar shape, preferably the serpentine shape of the heating element extends within the heater plane.
[0066] The housing may comprise a body, an upstream portion, and a downstream portion, wherein the body extends between the upstream portion and the downstream portion. Preferably, the upstream portion defines the air inlet and the downstream portion defines the air outlet.
[0067] 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.
[0068] The first electrical contact and the second electrical contact may be arranged on the upstream portion. The first electrical contact and the second electrical contact may be positioned on opposite sides of the air inlet. Preferably, the first electrical contact and the second electrical contact extend through the upstream portion to an exterior surface of the cartridge. Advantageously, this may facilitate electrical connection of the first electrical contact and the second electrical contact with corresponding electrical contacts on an aerosol-generating device.
[0069] The first electrical contact and the second electrical contact may be arranged on the downstream portion. The first electrical contact and the second electrical contact may be positioned on opposite sides of the air outlet.
[0070] Preferably, the first electrical contact and the second electrical contact extend through the downstream portion to an exterior surface of the cartridge. Advantageously, this may facilitate electrical connection of the first electrical contact and the second electrical contact with corresponding electrical contacts on an aerosol-generating device.
[0071] Preferably, the heating element extends into the substrate compartment so that the heating element is positioned at least partially inside the aerosol-generating substrate. Advantageously, this may maximise the transfer of heat from the heating element to the aerosolgenerating substrate.
[0072] The heating element may be embedded within the aerosol-generating substrate. For example, the aerosol-generating substrate may be formed around the heating element during manufacture of the cartridge.
[0073] The aerosol-generating substrate may define a heater cavity within the substrate, wherein the heating element is positioned within the heater cavity. Advantageously, a heater cavity may facilitate forming of the aerosol-generating substrate separately from the heating element and subsequent insertion of the heating element into the aerosol-generating substrate during assembly of the cartridge.
[0074] The heating element may be formed from an iron-based alloy. The heating element may be formed from a nickel alloy. The heating element may be formed from a ceramic. The heating element may be formed from stainless steel. The heating element may be formed from SS316L stainless steel iron aluminides. The heating element may be formed from nichrome. The heating element may be formed from a ceramic coated metal.
[0075] In embodiments in which the central portion has a different resistivity to each of the first portion and the second portion, preferably the central portion is formed from a different material to each of the first portion and the second portion. Preferably, the first portion and the second portion are formed from the same material.
[0076] The housing may comprise a material selected from one or more of a metal, a metal alloy, a composite, a ceramic and a thermoplastic.
[0077] The housing may comprise a material selected from one or more of one or more of Polyetheretherketone, Polyphenylene Sulfide, Polyamide, Stainless Steel, Carbon Fiber Reinforced Polymer, Glass Fiber Reinforced Polymer, Aluminum Oxide, Zirconium Oxide, Inconel, a nickel based alloy and an iron based alloy.
[0078] The housing may be non-porous.
[0079] 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.
[0080] 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.
[0081] 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.
[0082] When referring to the housing, the term “length” is used to describe the maximum external dimension of the housing. The length may be defined in a longitudinal direction or along a longitudinal axis of the cartridge. As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the cartridge, which extends between upstream and downstream ends of the cartridge.
[0083] 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.
[0084] 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.
[0085] 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.
[0086] When referring to the housing, the term “width” is used to describe the maximum transverse dimension of the housing. In particular, the width of the housing may be perpendicular to the length of the housing. As used herein, the term “transverse” is used to describe the direction perpendicular to the longitudinal direction or the length of housing.
[0087] 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.
[0088] 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.
[0089] 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.
[0090] When referring to the housing, the term “thickness” is used to describe the smallest transverse dimension of the housing.
[0091] The cartridge may have a planar shape. The cartridge may have a parallelepiped shape. The cartridge may have a rectangular parallelepiped shape. The air inlet may comprise a single air inlet aperture. The air inlet may comprise a plurality of air inlet apertures.
[0092] The air outlet may comprise a single air outlet aperture. The air outlet may comprise a plurality of air outlet apertures.
[0093] The aerosol-generating substrate may be a liquid aerosol-generating substrate.
[0094] Preferably, the aerosol-generating substrate is a solid aerosol-generating substrate.
[0095] 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.
[0096] 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.
[0097] As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof.
[0098] 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.
[0099] 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.
[0100] 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.
[0101] 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.
[0102] 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. 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.
[0103] 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.
[0104] 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.
[0105] Suitable aerosol-generating films for use as the aerosol-generating substrate are described in WC-A-2020 / 207733 and WO-A-2022 / 074157.
[0106] 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.
[0107] Suitable gel compositions for use as the aerosol-generating substrate are described in WO-A-2021 / 170642.
[0108] 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.
[0109] 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.
[0110] 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.
[0111] 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.
[0112] According to the present disclosure there is provided an aerosol-generating system comprising a cartridge according to the present disclosure and an aerosol-generating device arranged to receive the cartridge. The aerosol-generating device comprises a power supply arranged to supply power to the electric heater of the cartridge.
[0113] Since the aerosol-generating system according to the present disclosure comprises a cartridge described herein, the advantages specified above for the cartridge also apply to the aerosol-generating system.
[0114] The power supply may be configured to provide power to the electric heater to heat the aerosol-generating substrate to generate an aerosol. The power supply may be a DC power supply. The power supply may be 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.
[0115] The aerosol-generating device may comprise a body housing the power supply and arranged to receive at least part of the cartridge. The body may define 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.
[0116] The body may comprise one or more of a metal, a plastic, a composite and a metal alloy. Preferably, the body 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.
[0117] The aerosol-generating device may comprise a mouthpiece. During use, a user may draw on the mouthpiece to receive aerosol generated in the cartridge. The cartridge may be configured to be at least partially received in the device cavity and at least partially received in the mouthpiece.
[0118] The mouthpiece may comprise one or more of the same material used to form the body. 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.
[0119] The mouthpiece may be configured for removable attachment to the body.
[0120] 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.
[0121] Preferably, the aerosol-generating device comprises a first device contact arranged to engage the first electrical contact of the electric heater and a second device contact arranged to engage the second electrical contact of the electric heater when the cartridge is received within the aerosol-generating device. Preferably, the power supply is configured to supply power to the electric heater via the first device contact and the second device contact.
[0122] The aerosol-generating device may comprise a controller. The controller may be configured to control the supply of power from the power supply to the electric heater. 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 electric heater is on or off. The controller may be configured to control the power output from the power supply to control the temperature of the electric heater.
[0123] The aerosol-generating device may comprise a device air inlet. The aerosol-generating device may comprise a device air outlet.
[0124] The device air inlet may be disposed at a distal end of the aerosol-generating device.
[0125] The mouthpiece may comprise the device air outlet. The device air outlet may be disposed at a proximal end of the aerosol-generating device.
[0126] The aerosol-generating system may be configured such that, during use, air passes into the device air inlet, through the device cavity into the air inlet of the cartridge, through the aerosolgenerating 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 air outlet of the cartridge, and subsequently to the device air outlet.
[0127] 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.
[0128] Example 1 : A cartridge for use with an aerosol-generating device, the cartridge comprising: a housing defining an air inlet, an air outlet, and a substrate compartment between the air inlet and the air outlet; an aerosol-generating substrate positioned within the substrate compartment; and an electric heater positioned within the substrate compartment, the electric heater comprising: a first electrical contact arranged on the housing; a second electrical contact arranged on the housing; and a heating element extending between the first electrical contact and the second electrical contact; wherein at least one of a cross-sectional area of the heating element and / or a resistivity of the heating element varies along a length of the heating element from the first electrical contact to the second electrical contact.
[0129] Example 2: A cartridge according to Example 1 , wherein the heating element comprises a central portion, a first portion extending between the first electrical contact and a first end of the central portion, and a second portion extending between the second electrical contact and a second end of the central portion.
[0130] Example 3: A cartridge according to Example 2, wherein the central portion has a larger cross- sectional area than each of the first portion and the second portion.
[0131] Example 4: A cartridge according to Example 2 or 3, wherein the central portion has a smaller resistivity than each of the first portion and the second portion.
[0132] Example 5: A cartridge according to Example 2, wherein the central portion has a smaller cross-sectional area than each of the first portion and the second portion.
[0133] Example 6: A cartridge according to Example 2 or 5, wherein the central portion has a larger resistivity than each of the first portion and the second portion.
[0134] Example 7: A cartridge according to any of Examples 2 to 6, wherein a cross-sectional area of the first portion is the same as a cross-sectional area of the second portion.
[0135] Example 8: A cartridge according to any of Examples 2 to 7, wherein a resistivity of the first portion is the same as the resistivity of the second portion.
[0136] Example 9: A cartridge according to any of Examples 2 to 8, wherein the central portion has a uniform cross-sectional area from the first end of the central portion to the second end of the central portion.
[0137] Example 10: A cartridge according to any of Examples 2 to 9, wherein a cross-sectional area of the first portion varies along at least part of the first portion from the first electrical contact to the first end of the central portion.
[0138] Example 11: A cartridge according to any of Examples 2 to 10, wherein a cross-sectional area of the second portion varies along at least part of the second portion from the second electrical contact to the second end of the central portion.
[0139] Example 12: A cartridge according to any preceding Example, wherein the heating element has a planar shape extending in a heater plane, wherein the heating element has a thickness in a direction perpendicular to the heater plane, and wherein the heating element has a uniform thickness along the length of the heating element.
[0140] Example 13: A cartridge according to Example 12, wherein the heating element has a width in a direction perpendicular to the thickness of the heating element and perpendicular to the length of the heating element, and wherein the width of the heating element varies along the length of the heating element from the first electrical contact to the second electrical contact.
[0141] Example 14: A cartridge according to Example 13 in combination with Example 2, wherein the central portion has a larger width than each of the first portion and the second portion.
[0142] Example 15: A cartridge according to Example 13 in combination with Example 2, wherein the central portion has a smaller width than each of the first portion and the second portion.
[0143] Example 16: A cartridge according to Example 14 or 15, wherein a width of the first portion is the same as a width of the second portion. Example 17: A cartridge according to any of Examples 14 to 16, wherein the central portion has a uniform width from the first end of the central portion to the second end of the central portion.
[0144] Example 18: A cartridge according to any of Examples 14 to 17, wherein a width of the first portion varies along at least part of the first portion from the first electrical contact to the first end of the central portion.
[0145] Example 19: A cartridge according to any of Examples 14 to 18, wherein a width of the second portion varies along at least part of the second portion from the second electrical contact to the second end of the central portion.
[0146] Example 20: A cartridge according to any preceding Example, wherein the heating element has a serpentine shape.
[0147] Example 21 : A cartridge according to any preceding Example, wherein the housing comprises a body, an upstream portion, and a downstream portion, wherein the body extends between the upstream portion and the downstream portion, wherein the upstream portion defines the air inlet, and wherein the downstream portion defines the air outlet.
[0148] Example 22: A cartridge according to Example 21 , wherein the first electrical contact and the second electrical contact are arranged on the upstream portion.
[0149] Example 23: A cartridge according to any preceding Example, wherein the heating element extends into the substrate compartment so that the heating element is positioned at least partially inside the aerosol-generating substrate.
[0150] Example 24: A cartridge according to any preceding Example, wherein the heating element is a resistive heating element.
[0151] Example 25: A cartridge according to any preceding Example, wherein the aerosol-generating substrate is a solid aerosol-generating substrate.
[0152] Example 26: An aerosol-generating system comprising: a cartridge according to any preceding Example; and an aerosol-generating device arranged to receive the cartridge, the aerosol-generating device comprising a power supply arranged to supply power to the electric heater of the cartridge. Example 27: An aerosol-generating system according to Example 26, wherein the aerosolgenerating device comprises: a body housing the power supply and arranged to receive at least part of the cartridge; and a mouthpiece configured for removable attachment to the body.
[0153] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:
[0154] Figure 1 is a perspective view of a cartridge according to an embodiment of the disclosure;
[0155] Figure 2 is a cross-sectional view of the cartridge of Figure 1 ; Figure 3 shows the electric heater of the cartridge of Figures 1 and 2 removed from the cartridge;
[0156] Figure 4 shows an electric heater according to an alternative embodiment of the present disclosure; and
[0157] Figure 5 is a cross-sectional view of an aerosol-generating system according to the present disclosure.
[0158] Figure 1 shows a perspective view of a cartridge 10 according to an embodiment of the present disclosure and Figure 2 shows a schematic cross-sectional view of the cartridge 10. The cartridge 10 is configured for use with an aerosol-generating device 600. As best seen in Figure 2, the cartridge 10 comprises: a housing 100, an electric heater 200, and an aerosol-generating substrate 300. The aerosol-generating substrate 300 is a solid aerosol-generating substrate that defines a heater cavity 310 in which the electric heater 200 is positioned. The electric heater 200 is configured to heat the aerosol-generating substrate 300 to generate an aerosol. The electric heater 200 is a resistive heater, which is configured to generate heat upon application of a voltage across the electric heater 200.
[0159] The housing 100 defines a substrate compartment 400. The aerosol-generating substrate 300 is positioned within the substrate compartment 400.
[0160] The housing 100 has a distal or upstream end 101 and a proximal or downstream end 102. The housing 100 comprises an upstream portion formed by an upstream end plug 130 and a downstream portion formed by a downstream end plug 140. The housing 100 also comprise a body formed by a peripheral wall 150 extending between the upstream end plug 130 and the downstream end plug 140.
[0161] An air inlet 110 comprising a plurality of inlet apertures extends through the upstream end plug 130. An air outlet 120 comprising a plurality of outlet apertures extends through the downstream end plug 140. The housing 100 defines an air flow path extending between the air inlet 110 and the air outlet 120. The housing 100 is configured such that, in use, air can flow from the air inlet 110, through the substrate compartment 400, and out through the air outlet 120.
[0162] The peripheral wall 150 defines a first open end in which the upstream end plug 130 is received and a second open end in which the downstream end plug 140 is received. The upstream and downstream end plugs 130, 140 are retained by an interference fit with the peripheral wall 150.
[0163] The peripheral wall 150 extends from the upstream end 101 of the housing 100 to the downstream end 102 of the housing 100. The peripheral wall 150 surrounds the substrate compartment 400. The substrate compartment 400 extends between the upstream end plug 130 and the downstream end plug 140. The electric heater 200 is fixedly attached to the housing 100. More specifically, the electric heater 200 is fixedly attached to the upstream end plug 130 and extends into the heater cavity 310 defined by the aerosol-generating substrate 300.
[0164] The electric heater 200, which is more clearly shown in Figure 3 separately from the rest of the cartridge, comprises a first electrical contact 210, a second electrical contact 220, and a heating element 230 extending between the first electrical contact 210 and the second electrical contact 220. The first electrical contact 210 and the second electrical contact 220 extend through the upstream end plug 130 for electrical connection to corresponding device electrical contacts on an aerosol generating device 600. The heating element 230 has a planar serpentine shape and a uniform thickness along the length of the heating element 230.
[0165] The heating element 230 comprises a central portion 240, a first portion 250 extending between the first electrical contact 210 and a first end of the central portion 240, and a second portion 260 extending between the second electric contact 220 and a second end of the central portion 240. A width of the heating element 230 varies along a length of the heating element so that the width of the heating element 230 in the central portion 240 is smaller than the width of the heating element 230 in the first portion 250 and the second portion 260. As a result of the varying width of the heating element 230, the heating element 230 has a smaller cross-sectional area in the central portion 240 than the cross-sectional area of the heating element 230 in each of the first portion 250 and the second portion 260. This arrangement leads to the central portion 240 reaching a higher temperature than each of the first portion 250 and the second portion 260 during use. Advantageously, this may transfer more heat to a central part of the aerosolgenerating substrate 300, which may be more susceptible to faster cooling during puffing by a user in view of the airflow from the air inlet 110 to the air outlet 120. Advantageously, this arrangement may also transfer less heat to the outer parts of the aerosol-generating substrate 300, which may be more susceptible to heat loss to the exterior of the cartridge 10. Advantageously, this may lead to more efficient heating of the aerosol-generating substrate 300 and less heating of the exterior of the cartridge 10.
[0166] Figure 4 shows an alternative electric heater 500 that may be used in the cartridge 10 instead of the electric heater 200. The electric heater 500 is similar to the electric heater 200 and like reference numerals are used to designate like parts.
[0167] The electric heater 500 comprises a first electrical contact 210, a second electrical contact 220, and a heating element 530 extending between the first electrical contact 210 and the second electrical contact 220. The heating element 530 has a planar serpentine shape and a uniform thickness along the length of the heating element 530.
[0168] The heating element 530 comprises a central portion 540, a first portion 550 extending between the first electrical contact 210 and a first end of the central portion 540, and a second portion 560 extending between the second electric contact 220 and a second end of the central portion 540. A width of the heating element 530 varies along a length of the heating element so that the width of the heating element 530 in the central portion 540 is larger than the width of the heating element 530 in the first portion 550 and the second portion 560. As a result of the varying width of the heating element 530, the heating element 530 has a larger cross-sectional area in the central portion 540 than the cross-sectional area of the heating element 530 in each of the first portion 550 and the second portion 560. This arrangement leads to the central portion 540 reaching a lower temperature than each of the first portion 550 and the second portion 560 during use. Advantageously, this may transfer more heat to the outer parts of the aerosol-generating substrate 300, which may be more susceptible to heat loss to the exterior of the cartridge 10. Advantageously, this may lead to more uniform heating of the aerosol-generating substrate 300 and therefore more complete aerosol-generating across the full width of the aerosol-generating substrate.
[0169] Figure 5 shows a cross-sectional view of an aerosol-generating system 700 comprising the cartridge 10 and an aerosol-generating device 600.
[0170] 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.
[0171] The cartridge 10 is configured to be received in the device cavity 610 and the mouthpiece 612 of the aerosol-generating device 600.
[0172] 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.
[0173] The aerosol-generating device 600 comprises a device air inlet 608, a device air outlet 609, a power supply 630, and a controller 640.
[0174] The device air inlet 608 is disposed at a downstream end of the aerosol-generating device 600. The mouthpiece 612 comprises the device air outlet 609. The device air outlet 609 is disposed at an upstream end of the aerosol-generating device 600.
[0175] The cartridge 10 and the aerosol-generating device 600 are configured such that the first and second electrical contacts 210, 220 of the cartridge 10 electrically connect to corresponding electrical contacts of the aerosol-generating device 600. The electrical contacts of the aerosolgenerating device 600 are electrically connected to the power supply 630, such that power can be supplied from the power supply 630 to the electric heater 200 or 500. The power supply 630 is in the form of a battery.
[0176] 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 electric heater 200 or 500 is on or off, and to control the temperature of the electric heater 200 or 500.
[0177] In use, air passes into the device air inlet 608, through the device cavity 610 into the air inlet 110 of the cartridge 10, and through the aerosol-generating substrate 300 surrounding the electric heater 200 or 500. The electric heater 200 or 500 heats the aerosol-generating substrate 300 to generate an aerosol. The aerosol passes in air flow to the air outlet 120 of the cartridge 10, 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.
[0178] 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
Claims1. A cartridge for use with an aerosol-generating device, the cartridge comprising: a housing defining an air inlet, an air outlet, and a substrate compartment between the air inlet and the air outlet; an aerosol-generating substrate positioned within the substrate compartment; and an electric heater positioned within the substrate compartment, the electric heater comprising: a first electrical contact arranged on the housing; a second electrical contact arranged on the housing; and a heating element extending between the first electrical contact and the second electrical contact, wherein the heating element comprises a central portion, a first portion extending between the first electrical contact and a first end of the central portion, and a second portion extending between the second electrical contact and a second end of the central portion; wherein a cross-sectional area of the heating element varies along a length of the heating element from the first electrical contact to the second electrical contact, and wherein the central portion has a larger cross-sectional area than each of the first portion and the second portion.
2. A cartridge according to claim 1 , wherein a cross-sectional area of the first portion is the same as a cross-sectional area of the second portion.
3. A cartridge according to claim 1 or 2, wherein the heating element has a planar shape extending in a heater plane, wherein the heating element has a thickness in a direction perpendicular to the heater plane, and wherein the heating element has a uniform thickness along the length of the heating element.
4. A cartridge according to claim 3, wherein the heating element has a width in a direction perpendicular to the thickness of the heating element and perpendicular to the length of the heating element, and wherein the width of the heating element varies along the length of the heating element from the first electrical contact to the second electrical contact.
5. A cartridge according to claim 4, wherein the central portion has a larger width than each of the first portion and the second portion.
6. A cartridge according to claim 5, wherein a width of the first portion is the same as a width of the second portion.
7. A cartridge according to any preceding claim, wherein the heating element has a serpentine shape.
8. A cartridge according to any preceding claim, wherein the housing comprises a body, an upstream portion, and a downstream portion, wherein the body extends between the upstream portion and the downstream portion, wherein the upstream portion defines the air inlet, and wherein the downstream portion defines the air outlet.
9. A cartridge according to claim 8, wherein the first electrical contact and the second electrical contact are arranged on the upstream portion.
10. A cartridge according to any preceding claim, wherein the heating element extends into the substrate compartment so that the heating element is positioned at least partially inside the aerosol-generating substrate.
11. A cartridge according to any preceding claim, wherein the heating element is a resistive heating element.
12. A cartridge according to any preceding claim, wherein the aerosol-generating substrate is a solid aerosol-generating substrate.
13. An aerosol-generating system comprising: a cartridge according to any preceding claim; and an aerosol-generating device arranged to receive the cartridge, the aerosol-generating device comprising a power supply arranged to supply power to the electric heater of the cartridge.