A cartridge with side contacts

Abstract

There is provided a cartridge (500) for use with an aerosol-generating device (600). The cartridge (500) comprises a housing (100) comprising an upstream portion (130) defining an air inlet (110), a downstream portion (140) defining an air outlet (120), and a body (145) extending between the upstream portion (130) and the downstream portion (140). The body (145) defines at least one sidewall (150) of the housing (100). The housing (100) defines a substrate compartment (400) between the air inlet (110) and the air outlet (120). The cartridge (500) also comprises an aerosol-generating substrate (300) positioned within the substrate compartment (400) and an electric heater (500) positioned within the substrate compartment (400). The electric heater (500) comprises a first electrical contact (210) arranged on the at least one sidewall (150) of the housing (100), a second electrical contact (220) arranged on the at least one sidewall (150) of the housing (100), and a common electrical contact (522) arranged on the upstream portion (130) of the housing (100). The electric heater (500) also comprises a first heating element (530) extending between the first electrical contact (210) and the common electrical contact (522), and a second heating element (531) extending between the second electrical contact (220) and the common electrical contact (522).

Description

[0001] A CARTRIDGE WITH SIDE CONTACTS

[0002] The present disclosure relates to a cartridge for use with an aerosol-generating device, the cartridge comprising at least one heating element. 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] 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 may impede airflow through the aerosol-generating substrate. This may lead to an undesirable increase in resistance to draw and may result in non-uniform extraction of aerosol from the aerosol-generating substrate.

[0007] It would be desirable to provide a cartridge for use with an aerosol-generating device, the cartridge facilitating improved airflow through the cartridge.

[0008] According to the present disclosure there is provided a cartridge for use with an aerosolgenerating device. The cartridge may comprise a housing. The housing may comprise an upstream portion defining an air inlet. The housing may comprise a downstream portion defining an air outlet. The housing may comprise a body extending between the upstream portion and the downstream portion. The body may define at least one sidewall of the housing. The housing may define 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 at least one sidewall of the housing. The electric heater may comprise a second electrical contact arranged on the at least one sidewall of the housing. The electric heater may comprise at least one heating element extending between the first electrical contact and 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 comprising an upstream portion defining an air inlet, a downstream portion defining an air outlet, and a body extending between the upstream portion and the downstream portion. The body defines at least one sidewall of the housing. The housing defines a substrate compartment between the air inlet and the air outlet. The cartridge also comprises an aerosol-generating substrate positioned within the substrate compartment and an electric heater positioned within the substrate compartment. The electric heater comprises a first electrical contact arranged on the at least one sidewall of the housing, a second electrical contact arranged on the at least one sidewall of the housing, and at least one heating element extending between the first electrical contact and the second electrical contact.

[0010] Advantageously, cartridges according to the present disclosure comprise at least one heating element extending between first and second electrical contacts, wherein the first and second electrical contacts are arranged on at least one sidewall of a housing of the cartridge. Advantageously, this arrangement may position the first and second electrical contacts away from a central airflow through the substrate compartment. Advantageously, this may reduce a resistance to draw through the cartridge and may lead to a more uniform airflow through the substrate compartment. Advantageously, arranging the first and section electrical contacts on the at least one sidewall may facilitate increasing or maximising the size of the air inlet through the upstream portion. Advantageously, this may further reduce the resistance to draw through the cartridge and further increase the uniformity of airflow through the substrate compartment.

[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 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.

[0016] As used herein, the term “length of a heating element” refers to the conductive length of the heating element between the electrical contacts at each end of the heating element. 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 electrical contacts.

[0017] Preferably, the at least one heating element is a resistive heating element.

[0018] The heating element may be a single heating element extending between the first electrical contact and the second electrical contact.

[0019] The electric heater may comprise a common electrical contact, wherein the at least one heating element comprises a first heating element extending between the first electrical contact and the common electrical contact, and a second heating element extending between the second electrical contact and the common electrical contact.

[0020] Advantageously, providing the cartridge with first and second heating elements may facilitate improved heating of the aerosol-generating substrate when compared to known cartridges comprising a single heater. For example, the first and second heating elements may be controlled to provide heating of different parts of the aerosol-generating substrate at different times to provide consistent aerosol generation over the full duration of a user experience. In another example, the first heating element may be heated to a relatively high temperature for a first time period to rapidly provide an initial aerosol delivery, and the second heating element may be heated to a lower temperature for a subsequent second time period to provide consistent aerosol generation for the remainder of the user experience. Advantageously, providing first and second heating elements provides increased flexibility with regard to heating profiles during a user experience.

[0021] Advantageously, providing first, second, and common electrical contacts facilitates independent control of the first and second heating elements. More specifically, the first heating element may be heated by passing an electric current through the first heating element using the first and common electrical contacts, and the second heating element may be heated independently of the first heating element by passing an electric current through the second heating element using the second and common electrical contacts. Furthermore, the first and second heating elements may be heated concurrently by passing a single electric current through the first and second heating elements using only the first and second electrical contacts. Advantageously, this provides increased flexibility in terms of heating the aerosol-generating substrate when compared to known cartridges comprising a single electric heater.

[0022] Each of the first heating element and the second heating element may have a planar shape. Advantageously, a planar shape may increase or maximise a surface area of each heating element in contact with the aerosol-generating substrate. Advantageously, a planar shape may facilitate positioning of each heating element within the aerosol-generating substrate. Advantageously, positioning each heating element within the aerosol-generating substrate may maximise the transfer of heat from each heating element to the aerosol-generating substrate.

[0023] Preferably, the planar shape of the first heating element and the planar shape of the second heating element extend within a common plane.

[0024] The first heating element may have a length extending from the first electrical contact to the common electrical contact, and the second heating element may have a length extending from the second electrical contact to the common electrical contact.

[0025] The length of the first heating element may be the same as the length of the second heating element. Advantageously, providing the first and second heating elements with the same length may simplify the manufacture of the cartridge.

[0026] The length of the first heating element may be different to the length of the second heating element. Advantageously, providing different lengths of the first and second heating elements may facilitate the first and second heating elements reaching different temperatures during use, and / or the first and second heating elements heating different sized portions of the aerosolgenerating substrate.

[0027] The first heating element may have a first electrical resistance and the second heating element may have a second electrical resistance, wherein the first electrical resistance is different to the second electrical resistance.

[0028] The first heating element may have a first cross-sectional area and the second heating element may have a second cross-sectional area, wherein the first cross-sectional area is different to the second cross-sectional area.

[0029] The first heating element may have a first resistivity and the second heating element may have a second resistivity, wherein the first resistivity is different to the second resistivity.

[0030] The common electrical contact may be arranged on the upstream portion of the housing. Preferably, the common electrical contact is positioned at a centre of the upstream portion.

[0031] The air inlet may comprise a first inlet aperture extending through the upstream portion of the housing and a second inlet aperture extending through the upstream portion of the housing, wherein the common electrical contact is positioned between the first inlet aperture and the second inlet aperture.

[0032] In examples and embodiments in which the first and second heating elements having a planar shape and extend in a common plane, the first heating element may have a first width in the common plane and perpendicular to a length of the first heating element, and the second heating element may have a second width in the common plane and perpendicular to a length of the second heating element, wherein the first width is different to the second width.

[0033] Advantageously, providing the first and second heating elements with at least one of different electrical resistances, different cross-sectional areas, different resistivities, and / or different widths may facilitate heating of the first and second heating elements to different temperatures during use.

[0034] The upstream portion may have a length corresponding to the largest dimension of the upstream portion. The air inlet may have a length corresponding to the largest dimension of the air inlet. The length of the air inlet may be at least 50 percent of the length of the upstream portion, preferably at least 60 percent of the length of the upstream portion, preferably at least 70 percent of the length of the upstream portion, preferably at least 80 percent of the length of the upstream portion. The air inlet may comprise a single inlet aperture, wherein the length of the single inlet aperture is the length of the air inlet.

[0035] A cross-sectional area of the air inlet may be at least 50 percent of a cross-sectional area of the upstream portion, preferably at least 60 percent of a cross-sectional area of the upstream portion, preferably at least 70 percent of a cross-sectional area of the upstream portion, preferably at least 80 percent of a cross-sectional area of the upstream portion. The air inlet may comprise a plurality of inlet apertures, wherein the cross-sectional area of the air inlet is the total combined cross-sectional area of the plurality of inlet apertures.

[0036] The air inlet may have a length corresponding to the largest dimension of the air inlet. The air outlet may have a length corresponding to the largest dimension of the air outlet. The length of the air inlet may be larger than the length of the air outlet. The length of the air outlet may be no more than 80 percent of the length of the air inlet, preferably no more than 70 percent of the length of the air inlet, preferably no more than 60 percent of the length of the air inlet, preferably no more than 50 percent of the length of the air inlet.

[0037] A cross-sectional area of the air outlet may be no more than 80 percent of a cross- sectional area of the air inlet, preferably no more than 70 percent of a cross-sectional area of the air inlet, no more than 60 percent of a cross-sectional area of the air inlet, no more than 50 percent of a cross-sectional area of the air inlet. The air inlet may comprise a plurality of inlet apertures, wherein the cross-sectional area of the air inlet is the total combined cross-sectional area of the plurality of inlet apertures. The air outlet may comprise a plurality of outlet apertures, wherein the cross-sectional area of the air outlet is the total combined cross-sectional area of the plurality of outlet apertures.

[0038] The upstream portion may define an upstream end face of the housing. The downstream portion may define a downstream end face of the housing. Preferably, the at least one sidewall extends perpendicular to the upstream end face and the downstream end face. Preferably, the first electrical contact and the second electrical contact are positioned on opposite sides of the substrate compartment. Preferably, the at least one heating element extends across the substrate compartment between the first electrical contact and the second electrical contact.

[0039] Preferably, the at least one heating element extends within a plane between the first electrical contact and the second electrical contact.

[0040] The at least one 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 at least one heating element in contact with the aerosol-generating substrate. Advantageously, a planar shape may facilitate positioning of the at least one heating element within the aerosol-generating substrate. Advantageously, positioning the at least one heating element within the aerosolgenerating substrate may maximise the transfer of heat from the at least one heating element to the aerosol-generating substrate.

[0041] The at least one heating element may have a thickness in a direction perpendicular to the heater plane, wherein the at least one heating element has a uniform thickness along the length of the at least one heating element. Advantageously, providing the at least one heating element with a uniform thickness may facilitate manufacture of the at least one heating element. For example, the at least one heating element may be stamped or cut from a sheet of electrically conductive material.

[0042] The at least one heating element may have any suitable shape. Preferably, the at least one heating element has a serpentine shape. Advantageously, a serpentine shape may provide the at least one 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 at least one heating element has a planar shape, preferably the serpentine shape of the at least one heating element extends within the heater plane.

[0043] Preferably, the first electrical contact and the second electrical contact extend through the at least one sidewall 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. In examples and embodiments in which the electric heater comprises a common electrical contact, preferably the common electrical contact extends through the housing to an exterior surface of the cartridge.

[0044] Preferably, the at least one heating element extends into the substrate compartment so that the at least one heating element is positioned at least partially inside the aerosol-generating substrate. Advantageously, this may maximise the transfer of heat from the at least one heating element to the aerosol-generating substrate. The at least one heating element may be embedded within the aerosol-generating substrate. For example, the aerosol-generating substrate may be formed around the at least one heating element during manufacture of the cartridge.

[0045] The aerosol-generating substrate may define a heater cavity within the substrate, wherein the at least one heating element is positioned within the heater cavity. Advantageously, a heater cavity may facilitate forming of the aerosol-generating substrate separately from the at least one heating element and subsequent insertion of the at least one heating element into the aerosolgenerating substrate during assembly of the cartridge.

[0046] The at least one heating element may be formed from an iron-based alloy. The at least one heating element may be formed from a nickel alloy. The at least one heating element may be formed from a ceramic. The at least one heating element may be formed from stainless steel. The at least one heating element may be formed from SS316L stainless steel iron aluminides. The at least one heating element may be formed from nichrome. The at least one heating element may be formed from a ceramic coated metal.

[0047] In embodiments in which the at least one heating element comprises a first heating element and a second heating element having a different resistivity to the first heating element, preferably the second heating element is formed from a different material to the first heating element.

[0048] The housing may comprise a material selected from one or more of a metal, a metal alloy, a composite, a ceramic and a thermoplastic.

[0049] 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.

[0050] The housing may be non-porous.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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. 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] When referring to the housing, the term “thickness” is used to describe the smallest transverse dimension of the housing.

[0062] The cartridge may have a planar shape. The cartridge may have a parallelepiped shape. The cartridge may have a rectangular parallelepiped shape.

[0063] The air inlet may comprise a single air inlet aperture. The air inlet may comprise a plurality of air inlet apertures.

[0064] The air outlet may comprise a single air outlet aperture. The air outlet may comprise a plurality of air outlet apertures.

[0065] The aerosol-generating substrate may be a liquid aerosol-generating substrate.

[0066] Preferably, the aerosol-generating substrate is a solid aerosol-generating substrate.

[0067] 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.

[0068] 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.

[0069] As used herein, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof. 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] Suitable aerosol-generating films for use as the aerosol-generating substrate are described in WC-A-2020 / 207733 and WO-A-2022 / 074157. 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.

[0078] Suitable gel compositions for use as the aerosol-generating substrate are described in WO-A-2021 / 170642.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] The mouthpiece may be configured for removable attachment to the body.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] The aerosol-generating device may comprise a device air inlet. The aerosol-generating device may comprise a device air outlet.

[0095] The device air inlet may be disposed at a distal end of the aerosol-generating device. The mouthpiece may comprise the device air outlet. The device air outlet may be disposed at a proximal end of the aerosol-generating device.

[0096] 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.

[0097] 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.

[0098] Example Ex1 : A cartridge for use with an aerosol-generating device, the cartridge comprising: a housing comprising an upstream portion defining an air inlet, a downstream portion defining an air outlet, and a body extending between the upstream portion and the downstream portion, wherein the body defines at least one sidewall of the housing, and wherein the housing defines 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 at least one sidewall of the housing; a second electrical contact arranged on the at least one sidewall of the housing; and at least one heating element extending between the first electrical contact and the second electrical contact.

[0099] Example Ex2: A cartridge according to Example 1 , wherein the at least one heating element is a single heating element extending between the first electrical contact and the second electrical contact.

[0100] Example Ex3: A cartridge according to Example 1 , wherein the electric heater comprises a common electrical contact, and wherein the at least one heating element comprises a first heating element extending between the first electrical contact and the common electrical contact, and a second heating element extending between the second electrical contact and the common electrical contact.

[0101] Example Ex4: A cartridge according to Example 3, wherein the common electrical contact is arranged on the upstream portion of the housing.

[0102] Example Ex5: A cartridge according to Example 4, wherein the air inlet comprises a first inlet aperture extending through the upstream portion of the housing and a second inlet aperture extending through the upstream portion of the housing, and wherein the common electrical contact is positioned between the first inlet aperture and the second inlet aperture. Example Ex6: A cartridge according to any preceding Example, wherein the upstream portion has a length corresponding to the largest dimension of the upstream portion, wherein the air inlet has a length corresponding to the largest dimension of the air inlet, and wherein the length of the air inlet is at least 50 percent of the length of the upstream portion, preferably at least 60 percent of the length of the upstream portion, preferably at least 70 percent of the length of the upstream portion, preferably at least 80 percent of the length of the upstream portion.

[0103] Example Ex7: A cartridge according to Example 6, wherein the air inlet comprises a single inlet aperture, and wherein the length of the single inlet aperture is the length of the air inlet.

[0104] Example Ex8: A cartridge according to any preceding Example, wherein the air inlet has a length corresponding to the largest dimension of the air inlet, wherein the air outlet has a length corresponding to the largest dimension of the air outlet, and wherein the length of the air inlet is larger than the length of the air outlet.

[0105] Example Ex9: A cartridge according to Example 8, wherein the length of the air outlet is no more than 80 percent of the length of the air inlet, preferably no more than 70 percent of the length of the air inlet, preferably no more than 60 percent of the length of the air inlet, preferably no more than 50 percent of the length of the air inlet.

[0106] Example Ex10: A cartridge according to any preceding Example, wherein the upstream portion defines an upstream end face of the housing, wherein the downstream portion defines a downstream end face of the housing, and wherein the at least one sidewall extends perpendicular to the upstream end face and the downstream end face.

[0107] Example Ex11 : A cartridge according to any preceding Example, wherein the first electrical contact and the second electrical contact are positioned on opposite sides of the substrate compartment.

[0108] Example Ex12: A cartridge according to Example 11 , wherein the at least one heating element extends across the substrate compartment between the first electrical contact and the second electrical contact.

[0109] Example Ex13: A cartridge according to any preceding Example, wherein the at least one heating element has a serpentine shape.

[0110] Example Ex14: A cartridge according to any preceding Example, wherein the at least one heating element extends within a plane between the first electrical contact and the second electrical contact.

[0111] Example Ex15: A cartridge according to any preceding Example, wherein the at least one heating element extends into the substrate compartment so that the at least one heating element is positioned at least partially inside the aerosol-generating substrate.

[0112] Example Ex16: A cartridge according to any preceding Example, wherein the at least one heating element is a resistive heating element. Example Ex17: A cartridge according to any preceding Example, wherein the aerosolgenerating substrate is a solid aerosol-generating substrate.

[0113] Example Ex18: 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 Ex19: An aerosol-generating system according to Example 18, wherein the aerosol-generating 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.

[0114] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0115] Figure 1 is a perspective view of a cartridge according to a first embodiment of the disclosure;

[0116] Figure 2 is a cross-sectional view of the cartridge of Figure 1 ;

[0117] Figure 3 is a cross-sectional view of a cartridge according to a second embodiment of the disclosure; and

[0118] Figure 4 is a cross-sectional view of an aerosol-generating system according to the present disclosure.

[0119] Figure 1 shows a perspective view of a cartridge 10 according to a first 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.

[0120] The housing 100 defines a substrate compartment 400. The aerosol-generating substrate 300 is positioned within the substrate compartment 400.

[0121] The housing 100 has a distal or upstream end 101 and a proximal or downstream end 102. The housing 100 comprises an upstream portion 130 formed by an upstream end plug and a downstream portion 140 formed by a downstream end plug. The housing 100 also comprise a body 145 comprising a plurality of sidewalls 150 extending between the upstream portion 130 and the downstream portion 140. An air inlet 110 comprising a plurality of inlet apertures extends through the upstream portion 130. An air outlet 120 comprising a plurality of outlet apertures extends through the downstream portion 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.

[0122] The body 145 defines a first open end in which the upstream portion 130 is received and a second open end in which the downstream portion 140 is received. The upstream and downstream portions 130, 140 are retained by an interference fit with the body 145.

[0123] The body 145 extends from the upstream end 101 of the housing 100 to the downstream end 102 of the housing 100. The body 145 surrounds the substrate compartment 400. The substrate compartment 400 extends between the upstream portion 130 and the downstream portion 140.

[0124] The electric heater 200 is fixedly attached to the housing 100. More specifically, the electric heater 200 is fixedly attached to two of the sidewalls 150 on opposite sides of the substrate compartment 400 and extends into the heater cavity 310 defined by the aerosol-generating substrate 300.

[0125] The electric heater 200 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 opposite sidewalls 150 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.

[0126] Advantageously, positioning the first and second electrical contacts 210, 220 on opposite sidewalls 150 of the housing 100 instead of the upstream portion 130 minimises the obstruction to airflow through the substrate compartment 400 and facilitates a large air inlet 110 extending across almost the entire length of the upstream portion 130. Advantageously, this may reduce or minimise the resistance to draw of the cartridge 10 and provides a more uniform airflow across substantially the entire width of the aerosol-generating substrate 300.

[0127] Figure 3 shows an alternative cartridge 500 according to a second embodiment of the disclosure. The cartridge 500 is similar to the cartridge 10 of Figure 2 and like reference numerals designate like parts.

[0128] The cartridge 500 differs from the cartridge 10 by the configuration of the electric heater 500. More specifically, the electric heater 500 additionally comprises a common electrical contact 522 arranged on the upstream portion 130 and extending through the upstream portion 130 to an exterior surface of the cartridge 500. The electric heater 500 also comprises a first heating element 530 extending between the first electrical contact 210 and the common electrical contact 522, and a second heating element 531 extending between the second electrical contact 220 and the common electrical contact 522.

[0129] Advantageously, the first and second heating elements 530, 531 can be separately controlled during heating of the aerosol-generating substrate 300. For example, the first heating element 530 may be heated by applying a voltage across the first electrical contact 210 and the common electrical contact 522, and the second heating element 531 may be heated by applying a voltage across the second electrical contact 220 and the common electrical contact 522. Furthermore, the first and second heating elements 530, 531 can be heated together as a single heating element by applying a voltage across the first electrical contact 210 and the second electrical contact 220.

[0130] Figure 4 shows a cross-sectional view of an aerosol-generating system 700 comprising the cartridge 10 and an aerosol-generating device 600. Although the following description concerns the use of the aerosol-generating device 600 with the cartridge 10, the skilled person will appreciate that the aerosol-generating device 600 can also be used in the same manner with the cartridge 500 of Figure 3.

[0131] 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.

[0132] The cartridge 10 is configured to be received in the device cavity 610 and the mouthpiece 612 of the aerosol-generating device 600.

[0133] 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.

[0134] The aerosol-generating device 600 comprises a device air inlet 608, a device air outlet 609, a power supply 630, and a controller 640.

[0135] 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.

[0136] 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. The power supply 630 is in the form of a battery. 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 is on or off, and to control the temperature of the electric heater 200.

[0137] 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. The electric heater 200 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.

[0138] 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 comprising an upstream portion defining an air inlet, a downstream portion defining an air outlet, and a body extending between the upstream portion and the downstream portion, wherein the body defines at least one sidewall of the housing, and wherein the housing defines 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 at least one sidewall of the housing; a second electrical contact arranged on the at least one sidewall of the housing; a common electrical contact arranged on the upstream portion of the housing; a first heating element extending between the first electrical contact and the common electrical contact; and a second heating element extending between the second electrical contact and the common electrical contact.

2. A cartridge according to claim 1 , wherein the air inlet comprises a first inlet aperture extending through the upstream portion of the housing and a second inlet aperture extending through the upstream portion of the housing, and wherein the common electrical contact is positioned between the first inlet aperture and the second inlet aperture.

3. A cartridge according to claim 1 or 2, wherein a total cross-sectional area of the air inlet is at least 50 percent of a total cross-sectional area of the upstream portion.

4. A cartridge according to claim 1 , 2 or 3, wherein the upstream portion defines an upstream end face of the housing, wherein the downstream portion defines a downstream end face of the housing, and wherein the at least one sidewall extends perpendicular to the upstream end face and the downstream end face.

5. A cartridge according to any preceding claim, wherein the first electrical contact and the second electrical contact are positioned on opposite sides of the substrate compartment.

6. A cartridge according to any preceding claim, wherein each of the first heating element and the second heating element has a serpentine shape.

7. A cartridge according to any preceding claim, wherein each of the first heating element and the second heating element has a planar shape.

8. A cartridge according to claim 7, wherein the planar shape of the first heating element and the planar shape of the second heating element extend within a common plane.

9. A cartridge according to any preceding claim, wherein the first heating element and the second heating element extend into the substrate compartment so that each of the first heating element and the second heating element is positioned at least partially inside the aerosolgenerating substrate.

10. A cartridge according to any preceding claim, wherein each of the first heating element and the second heating element is a resistive heating element.

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

12. 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.

Images