A cartridge for an aerosol generating device

Abstract

The disclosed cartridge (200) for an aerosol generating device (100), includes a heater assembly (300, 400, 500). The heater assembly (300, 400, 500) further includes a heater (300a, 400a, 500a), and a wick (304, 404, 504). The heater (300a, 400a, 500a) includes at least one heating portion (302, 402, 502), and at least one supporting section (306, 406, 506). The 5 supporting section (306, 406, 506) is configured to form a gripping member defining a wick conforming space to receive the wick (304, 404, 504). The gripping member is further configured to exert compressive force against the wick (304, 404, 504), when the wick (304, 404, 504) is positioned in the wick conforming space.

Description

A CARTRIDGE FOR AN AEROSOL GENERATING DEVICETECHNICAL FIELD

[0001] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to a cartridge for an aerosol generating device, having an improved heater assembly which enhances ability of a heater to deliver consistent and efficient heat to a wick and an aerosol generating liquid, thus improving heat transfer efficacy of the aerosol generating device.BACKGROUND

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

[0003] Aerosol generating devices (AGDs) have gained significant popularity due to their ability to deliver aerosolized substances for inhalation. These devices rely on a combination of several components to efficiently generate and deliver aerosol to the user. The components of an AGD includes a control unit, a power source, a cartridge, a condensation chamber and a mouthpiece. The control unit monitors activation and deactivation of the AGD, regulates the temperature of the heater, and tracks user inhalation metrics, such as the number and duration of inhalations. The cartridge houses a reservoir for an aerosol generating substrate (or aerosol generating liquid), and an atomizer / a heater assembly consisting of a wick, and a heater. The aerosol generating liquid is absorbed by the wick and is vaporized by the heater. The resulting vapor mixes with the air and forms an aerosol, which is then inhaled by the user.

[0004] The aerosolization process in the atomizer should be very efficient to deliver necessary Aerosol Collected Mass (ACM). The efficiency depends on factors such as power input, electrical and thermal properties of the heater, properties of the aerosol generating liquid, and the wick-heater contact surface area. For consistent ACM, the wick-heater contact surface area is very crucial factor to maintain. Ensuring good wick-heater contact surface area, and air gap absentia between the wick and the heater improves heat transfer from the heater into the aerosol generating substrate (or aerosol generating liquid) in the wick for aerosolization. Unlike a coil type heater-wick assembly, a flat mesh heater-wick assembly is afflicted by air gaps and depleted wick-heater contact surface area due to resilient nature and manufacturinginconsistencies. These air gaps degrade efficiency of heat transfer from the heater to the wick, resulting in uneven vaporization and inconsistent aerosol generation.

[0005] A patent document WO2017207415A1 describes a heater and wick assembly for an aerosol generating system. The heater and wick assembly includes a capillary body, a heating element arranged on an outer surface of the capillary body, and a pair of spaced apart electrical contacts fixed around the capillary body and coupled with the heating element. Further, the heater and wick assembly include a support member extending along at least part of a length of the capillary body. The referred document solely focuses on a coil heater-wick assembly, where the heater and wick assembly are stabilized using electrical contacts, and a rigid support member in a core of the capillary body.

[0006] Another patent document WO2022270824A1 describes a vaporizer for an aerosol-generating device. The vaporizer includes a storage unit configured to store an aerosolgenerating material, a wick configured to absorb the aerosol-generating material, and an accommodating unit configured to accommodate the wick. The accommodating unit includes at least one storage groove for temporarily storing the aerosol-generating material to deliver the aerosol-generating material to the wick, wherein a maximum width of the storage groove is greater than a maximum width of the support groove. The referred document primarily focuses on abundant and uniform supply of the aerosol-generating material. To stabilize the wick and heater assembly, an accommodating unit with a groove is provided to support the wick.

[0007] Yet another patent document KR102135804B1 describes a coil bracket assembly supporting a coil heater wound around a wick so as to generate an aerosol from the wick, and the wick from which a liquid is immersed. The coil bracket assembly includes a packaging that provides sealing with a main body, including a coil bracket. The coil bracket assembly provides a cartomizer for an electrically heated aerosol generator that prevents the liquid in a liquid reservoir from leaking to an outside by forcibly pressing and assembling the assembly into the main body.

[0008] Thus, there arises a need for modification in design of the heater assembly to improve heat transfer efficacy of the aerosol generating device, and to ensure consistent delivery of the ACM, without need of additional support assembly to support the wick.

[0009] There is therefore a need in the art to develop a cost effective, safe and portable aerosol generating device with an improved heater assembly which improves heat transfer efficacy of the aerosol generating device.OBJECTS OF THE PRESENT DISCLOSURE

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

[0011] It is an object of the present disclosure to provide a cartridge for an aerosol generating device, having an improved heater assembly which improves heat transfer efficacy of the aerosol generating device.

[0012] It is an object of the present disclosure to provide a heater assembly to minimize air gaps between a wick and a heater to ensure uniform wick-heater contact surface area.

[0013] It is an object of the present disclosure to provide a cartridge designed to improve thermal conduction from the heater to an aerosol generating substrate in the wick.

[0014] It is another object of the present disclosure to provide a cartridge having an improved heater assembly designed to generate consistent aerosol, thereby improving the overall performance of the device and user satisfaction.

[0015] It is another object of the present disclosure to provide a cartridge which enables reliable and efficient aerosol generation, resulting in consistent delivery of Aerosol Collected Mass (ACM) to the user.

[0016] It is yet another object of the present disclosure to provide a cartridge for improved aerosol generation without need of significant changes to existing manufacturing processes.SUMMARY

[0017] Aspects of the present disclosure relate generally to the field of aerosol generating devices. In particular, the present disclosure pertains to a cartridge for an aerosol generating device, having an improved heater assembly to improve heat transfer between a wick and a heater.

[0018] According to an aspect of the present disclosure, a cartridge for an aerosol generating device is disclosed. The cartridge includes a heater assembly. The heater assembly further includes a heater, and a wick. The heater includes at least one heating portion (simply referred to as “heating portion” hereinafter), and at least one supporting section (simply referred to as “supporting section” hereinafter). The supporting section is configured to form a gripping member defining a wick conforming space to receive the wick. The gripping member is further configured to exert compressive force against the wick, when the wick is positioned in the wick conforming space.

[0019] In one or more embodiments, the at least one supporting section may include two or more supporting sections (collectively referred as “supporting sections” herein). Each of the supporting sections may be configured to form corresponding gripping members.

[0020] In one or more embodiment, the wick conforming space may be formed between the gripping members and a first surface of the heater. The first surface of the heater may include a portion of each of the supporting sections and the heating portion.

[0021] In one or more embodiments, when the wick is positioned in the wick conforming space, the gripping members may exert compressive force against the wick to maintain uniform thermal contact between the wick and the heating portion of the heater, thereby eliminating air gaps between the wick and the heating portion.

[0022] In one or more embodiments, the supporting sections may be attached to each side of the heating portion, and extending from a periphery of the heating portion. The supporting sections may be initially coplanar with respect to a surface of the heating portion prior to forming the gripping members.

[0023] In one or more embodiments, each of the supporting sections may include a proximal end defining a height of the wick conforming space, and a distal end configured to interface with the wick. The proximal end may be close to the surface of the heating portion. The distal end may be away from the surface of the heating portion.

[0024] In one or more embodiments, the distal ends may be bent inwardly towards the surface of the heating portion to form the gripping members. The distance between the distal ends and the surface of the heating portion may be less than a width of the wick to provide a tensioned grip on the wick.

[0025] In one or more embodiments, the distal ends may be bent such that the bended distal ends or the gripping members may be substantially parallel to the surface of the heating portion.

[0026] In one or more embodiments, each of the supporting sections may include a first supporting section, and a second supporting section. The first and second supporting sections may rotate clockwise and counter-clockwise respectively, to contact against the wick positioned on the heater.

[0027] In one or more embodiments, each of the supporting sections may be made from an elastically deformable structure allowing the distal ends or the gripping members to be deflected away from the first surface of the heater for insertion of the wick and to move toward the first surface of the heater to exert the compressive force against the wick, when the distal ends or the gripping members are released.

[0028] In one or more embodiments, the supporting sections may include a plurality of rib structures to minimize conductive heat loss while maintaining structural contact with the wick.

[0029] In one or more embodiments, the supporting section and the heating portion may be made monolithically from same material.

[0030] In one or more embodiments, the supporting section and the heating portion may be made of different materials. The supporting section may have a lower thermal conductivity than the heating portion.

[0031] In one or more embodiments, the supporting section and the heating portion may be made from an identical or same material. The supporting section may be configured to have a lower electrical resistance relative to the heating portion.

[0032] In one or more embodiments, the supporting section and the heating portion may be made from dissimilar materials. The supporting section may be made of a material having a lower electrical resistivity than the heating portion.

[0033] In one or more embodiments, the supporting sections may be in the form of rectangular straps attached at each side of the heating portion.

[0034] In one or more embodiments, a proximal end of each of the supporting sections may be bent inwardly towards a surface of the heating portion to form a hook structure. A distal end of each of the supporting sections may be configured to lock into the hook structure to define the wick conforming space to enclose the wick.

[0035] In one or more embodiments, a length of the hook structure may extend along the heating portion for a distance ranging from 5% to 95% of a length of the heater.

[0036] In one or more embodiments, the distal end may overlap the hook structure by a length ranging from 5% to 10% to ensure a secure mechanical lock.

[0037] In one or more embodiments, the supporting sections may be oriented either parallel or perpendicular to a direction of airflow.

[0038] In one or more embodiments, the heating portion may be a flat-mesh heating portion.

[0039] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.BRIEF DESCRIPTION OF DRAWINGS

[0040] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.

[0041] FIG. 1 illustrates an exemplary diagram representing of an aerosol generating device having the proposed cartridge, in accordance with an embodiment of the present disclosure.

[0042] FIG. 2 illustrates an exemplary diagram representing a cut-sectional view of the proposed cartridge for the aerosol generating device of FIG. 1, in accordance with an embodiment of the present disclosure.

[0043] FIGs. 3A, 3B, and 3C illustrate exemplary diagrams representing a heater for a heater assembly, a top view of the heater assembly holding a wick, and a bottom view of the heater assembly holding the wick, respectively, in accordance with a first embodiment of the present disclosure.

[0044] FIGs. 4A, 4B, and 4C illustrate another exemplary diagrams representing the heater for a heater assembly, the bottom view of the heater assembly holding the wick, and the top view of the heater assembly holding the wick, respectively, in accordance with a second embodiment of the present disclosure.

[0045] FIGs. 5A, 5B, and 5C illustrate another exemplary diagrams representing the heater for a heater assembly, the top view of the heater assembly holding the wick, and the bottom view of the heater assembly holding the wick, respectively, in accordance with a third embodiment of the present disclosure.DETAILED DESCRIPTION

[0046] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0047] In the following description, numerous specific details are pair forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to oneskilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0048] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0049] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0050] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “a” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0051] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

[0052] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments pair forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

[0053] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to a cartridge for an aerosol generating device,having an improved heater assembly which improves heat transfer efficacy of the aerosol generating device.

[0054] Existing aerosol generating devices (AGDs) face significant drawbacks related to the efficiency of an aerosolization process. In particular, flat mesh heater- wick assemblies are prone to air gaps and inconsistent wick-heater contact surface area due to the variations in manufacturing. These air gaps hinder efficient heat transfer from a heater to an aerosol generating substrate in the wick, leading to uneven vaporization and inconsistent aerosol generation. This lack of consistent contact and heat transfer results in suboptimal aerosol delivery, affecting the overall performance of the device and the quality of the inhaled aerosol.

[0055] To address the aforesaid issue, the proposed cartridge of an aerosol generating device describes an improved heater assembly which utilizes a novel design where a wick rests on a heater having strategically placed arms (also referred as “supporting sections” hereinafter). Each supporting sections extending, from a periphery of the heater contains a proximal end (closer to the heater) and a distal end (away from the heater). The proximal end and the distal end are suitably configured to form a wick conforming space (also referred as “pocket” herein) when folded. The pocket is formed by at least one heating portion of the heater, as the base, and the proximal end and the distal ends of the supporting sections extending from the periphery of the heater. The wick sits in the pocket firmly and securely between the at least one heating portion of the heater and gripping members of the supporting sections. The wick sits firmly enough not to ooze out anaerosol generating liquid (also referred as “aerosol generating substrate” herein). This configuration eliminates air gaps between the wick and the at least one heating portion of the heater, and significantly enhances the wick-heater contact surface area. Pushing the wick firmly against the heater, ensures more efficient heat transfer from the heater to the aerosol generating substrate in the wick, leading to uniform vaporization and consistent aerosol generation. The improved heater assembly of the proposed cartridge also stabilizes the heater’s position relative to the wick, enhancing the overall structural integrity of a heater-wick assembly (the heater assembly) and improving the consistency and efficacy of the aerosolization process.

[0056] FIG. 1 illustrates an exemplary diagram representing an aerosol generating device 100 having a cartridge 200, in accordance with an embodiment of the present disclosure. As illustrated, in an embodiment, referring to FIG. 1, the aerosol generating device 100 (also referred simply as “device 100” hereinafter) includes the cartridge 200, a control unit 104, and a power source 106. The device 100 also includes a condensation chamber and a mouthpiece. The control unit 104 draws power from the power source 106 and provides the desired amountof regulated power to a heater (300a, 400a, 500a) to vaporize the aerosol generating substrate. The vapor condenses upon coming in contact with the incoming airstream from an inlet 202 of the device 100 and an inhalable aerosol mixture (also referred as “aerosol” hereinafter) is formed.

[0057] FIG. 2 illustrates an exemplary diagram representing a cut-sectional view of the proposed cartridge 200 of the aerosol generating device of FIG.l, in accordance with an embodiment of the present disclosure.

[0058] Referring to FIG. 2, a cut-section view of the cartridge 200 of the proposed device 100 is shown. The cartridge 200 includes a heater assembly 300, 400, 500. The heater assembly 300, 400, 500 includes the heater 300a, 400a, 500a and a wick 304, 404, 504. The cartridge 200 can include the inlet 202 having ducts to direct air streams / airflow towards the heater assembly 300, 400, 500 through an airflow path 208. The inlet 202 can have any cross-section geometry shape such as but not limited to rectangle, circular, elliptical, and the like. Further, the cartridge 200 can include an outlet 204 for aerosol inhalation by a user. The outlet 204 can have any cross-section geometry shape such as but not limited to rectangle, circular, elliptical, and the like. The outlet 204 can be present at other side of the heater assembly 300, 400, 500 to direct the aerosol towards the mouthpiece.

[0059] In an embodiment, the cartridge 200 of the device 100 can further include a reservoir 206 for storing the aerosol generating substrate. The aerosol generating substrate is in communication with the heater 300a, 400a, 500a through fluid communication medium such as the wick 304, 404, 504.

[0060] Referring to FIGs. 3A-3C, the heater assembly 300 includes the wick 304, and the heater 300a. The wick 304 draws / absorbs the aerosol generating substrate from the reservoir 206, and the heater 300a vaporizes the aerosol generating substrate. The heater 300a includes at least one heating portion 302 (simply referred to as “heating portion 302” hereinafter) and at least one supporting portion 306 (simply referred to as “supporting section 306” hereinafter). The supporting section 306 is configured to form a gripping member defining a wick conforming space to receive the wick 304. The gripping member is further configured to exert compressive force against the wick 304, when the wick 304 is positioned in the wick conforming space as shown in FIGs. 3B-3C. The wick conforming space can be formed between the gripping members and a first surface of the heater 300a. The first surface of the heater 300a can include a portion of the supporting section 306 and the heating portion 302. In an embodiment, the heating portion 302 can be a flat-mesh heating portion. The heater 300a vaporize the aerosol generating substrate. The resulting vapor then mixes with the air to forman aerosol which may be carried to the user through the condensation chamber (not shown). The condensation chamber serves as a transitional space between the heater assembly 300 and the mouthpiece. As the vapor cools within the condensation chamber, some of the excess vapor may condense into liquid, which either drips back into the reservoir 206 or is reabsorbed into the wick 304.

[0061] In an embodiment, the at least one supporting section 306 can include two or more supporting sections such as 306-1, and 306-2 (collectively referred as “supporting sections 306” hereinafter), where each of the supporting sections 306-1, 306-2 may be configured to form the corresponding gripping members. The supporting sections 306 may be attached at each side of the heating portion 302. The supporting sections 306 can be configured to provide good surface contact between the wick 304 and the heater 300a. The supporting sections 306-1 and 306-2 may be extending from a periphery of the heating portion 302. The supporting sections 306-1, 306-2 may be initially coplanar with respect to a surface of the heating portion 302 prior to forming the gripping members. When the wick 304 is positioned in the wick conforming space, the gripping members can exert compressive force against the wick 304 to maintain uniform thermal contact between the wick 304 and the heating portion 302 of the heater 300a, thereby eliminating air gaps between the wick 304 and the heating portion 302.

[0062] In an embodiment, each of the supporting sections 306-1, 306-2 can include a proximal ends 306-lb, 306-2b, and a distal ends 306-la, 306-2a. The proximal ends 306-lb, 306-2b can be defining a height of the wick conforming space. The proximal ends 306-lb, 306-2b can be close to the surface of the heating portion 302. The distal ends 306-la, 306-2a can be configured to interface with the wick 304, and can be away from the surface of the heating portion 302. The distal ends 306-la, 306-2a can be bent inwardly towards the surface of the heating portion 302 to form the gripping members. The distal ends 306-la, 306-2a can be bent such that the bended distal ends or the gripping members can be substantially parallel to the surface of the heating portion 302. In some embodiments, the distal ends 306-la, 306-2a, and the proximal ends 306-lb, 306-2b can be non-parallel to each other. The distance between the distal ends 306-la, 306-2a and the surface of the heating portion 302 can be less than a width of the wick 304 to provide a tensioned grip on the wick 304. The space between the distal ends 306-la, 306-2a, and the surface of the heating portion 302 can be either equal to the width of the wick 304 in parallel configuration or less than the width of the wick 304 in non-parallel configuration.

[0063] The supporting sections 306 can include a first supporting section 306-1, and a second supporting section 306-2, where the first and second supporting sections 306-1, 306-2 canrotate clockwise and counter-clockwise respectively, to contact against the wick 304 positioned on the heater 300a. The supporting sections 306 can be made of material which exhibits elastic deformation properties such as but not limited to stainless steel, spring steel, silicone, polyurethane, Nitinol, or thermoplastic elastomers. Further, the supporting sections 306 can be made of material with poor thermal conductivity to minimize heat losses from the heating portion 302, and with good electrical conductivity to restrict the joule heating only to the heating portion 302. The supporting sections 306 and the heating portion 302 can be made monolithically from same material.

[0064] In another configuration, to enhance the joule heating points, the support sections 306 can be made with the same material as the heating portion 302 or any other material with similar electrical resistivity. In some embodiments, the supporting section 306 and the heating portion 302 can be made of different materials. The supporting section 306 can have a lower thermal conductivity than the heating portion 302. In certain embodiments, the supporting section 306 and the heating portion 302 can be made from an identical or same material, and where the supporting section 306 can be configured to have a lower electrical resistance relative to the heating portion 302. In various embodiments, the supporting section 306 and the heating portion 302 can be made from dissimilar materials, and the supporting section 306 can be made of a material having a lower electrical resistivity than the heating portion 302.

[0065] The supporting sections 306 as shown in FIGs. 3A-3C can be a ribbed structure or a continuous structure. The supporting sections 306 can have a plurality of rib structures. Cross sections of the rib structures can be rectangular, square, circular, or of any other shape, without any limitations. As can be appreciated, by using these configurations, the supporting sections 306 can ensure that the wick 304 remains firmly in place against the heating portion 302 of the heater 300a, eliminating air gaps and enhancing the overall heat transfer and aerosol generation efficiency. The elastic deformation allows the supporting sections 306 to adapt to assembling process and placement of the wick 304, ensuring consistent performance over time. The supporting sections 306 can be designed with enough surface area for having a low resistance to inhibit resistive heating. In another embodiment, the supporting sections 306 can be designed with enough surface area for having a suitable resistance to exhibit resistive heating to increase the heating area / portion exposed to the wick 304. In configuration, where the resistive heating is restricted to the heating portion 302 only, the heating portion 302 and the supporting sections 306 are connected minimally to minimize the conductive heat transfer from the heating portion 302 to the supporting sections 306. The supporting sections 306 also act as electrical contacts.The supporting sections 306 can be located either parallel or perpendicular to a direction of airflow in the airflow path 208.

[0066] In an embodiment, the first supporting section 306-1 can include a distal first end 306-la, and a proximal first end 306-lb. Similarly, the second supporting section 306-2 can include a distal second end 306-2a, and a proximal second end 306-2b. In the first embodiment, the rotation of the supporting sections 306 can be achieved by pushing the distal ends 306- la, 306-2a of the supporting sections 306 while the proximal ends 306-lb, 306-2b of the supporting sections 306 remain rigid. The wick 304 can be placed between the proximal ends 306-lb, 306-2b and the distal ends 306-la, 306-2a of the supporting sections 306, ensuring good contact with the heating portion 302 as shown in FIG. 3C. The proximal ends 306-lb, 306-2b are closer to the heating portion 302 of the heater 300a, and the distal ends 306-la, 306-2a extend away from the proximal ends 306-lb, 306-2b.

[0067] In an embodiment, rotation of the supporting sections 306 can be simultaneous. For instance, the first supporting section 306-1 can be rotated or folded first, and then the second supporting section 306-2 can be rotated or folded. In another instance, the second supporting section 306-2 can be folded first, and thereafter the first supporting section 306-1 to form the wick conforming space, for the wick 304 to rest within. The wick 304 resting inside the wick conforming space can ensure good contact with the heating portion 302 of the heater 300a for better aerosolization. Further, the supporting sections 306 can possess less contact points with the heating portion 302 of the heater 300a to minimize conductive heating from the heating portion 302 of the heater 300a to the supporting sections 306.

[0068] In another embodiment, the control unit 104 may include one or more processors (interchangeably referred to as processor, hereinafter). The processor may be implemented as one or more microprocessors, microcomputers, microcontrollers, edge or fog microcontrollers, digital signal processors, central processing units, logic circuitries, and / or any devices that process data based on operational instructions. Among other capabilities, the processor may be configured to fetch and execute computer-readable instructions stored in a memory of the control unit 104. The memory may be configured to store one or more computer-readable instructions or routines in a non-transitory computer readable storage medium, which may be fetched and executed to actuate the heating assembly, upon detection of airflow by an inhalation sensor, thereby generating the aerosol for inhalation by the user.

[0069] In an embodiment, the memory may comprise any non-transitory storage device including, for example, volatile memory such as Random-Access Memory (RAM), or non-volatile memory such as Erasable Programmable Read-Only Memory (EPROM), flash memory, and the like.

[0070] In an embodiment, the user can customize the aerosolizing experience by controlling the amount of air that mixes with the aerosol as they inhale.

[0071] In another embodiment, the power source 106 of the aerosol generating device 100 can be a battery, including, without limitation, a rechargeable lithium-ion battery, a lithium polymer battery, Nickel-metal Hydride (NiMH) battery, and the like. The battery provides an electric current required to heat-up the heater 300a and aerosolize the aerosol generating substrate.

[0072] The flexibility of the supporting sections 306, combined with their ability to secure hold the wick 304, ensures that the wick-heater contact is firm and consistent over multiple uses, reducing the chances of poor vaporization or inconsistent generation of the aerosol. The elastic deformation of the supporting sections 306 can also allow for easy assembly and maintenance. In an alternative configuration, the user can easily insert the wick 304 by pulling up the distal ends 306- la, 306-2a of the supporting sections 306, and when the force is released, the wick 304 can be securely held in place without needing complex tools or fasteners. The elimination of air gaps between the wick 304 and the heating portion 302 through the secure and adjustable contact provided by the supporting sections 306 greatly improves the efficiency of heat transfer, leading to better overall performance in terms of aerosol generation and user experience.

[0073] In a second embodiment and referring to FIGs. 4A to 4C, the heater assembly 400 can include a heater 400a, and a wick 404, which perform functions similar to the heater 300a and wick 304 of the first embodiment, but are configured with structural modifications specific to the second embodiment, and are therefore denoted by different reference numerals. The heater 400a can include at least one heating portion 402, and at least two supporting sections 406 such as a first support section 406-1, and a second support section 406-2 (collectively referred as “supporting sections 406” hereinafter) attached at each side of the heating portion 402. In an embodiment, the heating portion 402 can be a flat-mesh heating portion. The supporting sections 406 can be configured to provide good surface contact between the wick 404 and the heating portion 402 of the heater 400a. Each of the supporting sections 406 can include a distal end 406-la, 406-2a, and a proximal end 406-lb, 406-2b. The supporting sections 406 can be bent around a certain bending radius such that the supporting sections 406 can form a gripping member defining a wick conforming space (to receive the wick 404), after bending of the distal ends 406-la, 406-2a of the supporting sections 406-1, 406-2. Each of the supporting sections406 can be made from an elastically deformable structure allowing the distal ends or the gripping members 406- la, 406-2a to be deflected away from a first surface of the heater 400a for insertion of the wick 404 and to move toward the first surface of the heater 400a to exert the compressive force against the wick 404, when the distal ends or the gripping members 406-la, 406-2a are released. The distal ends 406-la, 406-2a can be designed to be pulled up by applying force. This flexibility allows for easy insertion of the wick 404 into the wick conforming space formed between the distal ends 406-la, 406-2a and the proximal ends 406-lb, 406-2b of the supporting sections 406-1, 406-2. When the pulling force is applied to the distal ends 406-la, 406-2a, the supporting sections 406-1, 406-2 can expand or open up, creating space for the wick 404 to be inserted between them. Once the wick 404 is positioned correctly, the applied force can be released, and the distal ends 406-la, 406-2a of the supporting sections 406 return to their initial position, securing the wick 404 in place against the first surface of the heater 400a (Refer 4B-4C). The force applied on the wick 404 after releasing the support sections 406-1, 406-2 is sufficient enough to secure the wick 404 on to a surface of the heating portion 402. The supporting sections 406-1, 406-2 can be a single long continuous structure. The supporting sections 406-1, 406-2 can have a plurality of rib structures. A cross section shape of the rib structures can be selected from not limited to rectangular, square, circular, and the like. The supporting sections 406-1, 406-2 can be located either parallel or perpendicular to a direction of the airflow in the airflow path 208.

[0074] In an embodiment, the supporting sections (406) and the heating portion (402) are made monolithically from same material. In some embodiments, the supporting sections 406-1, 406-2 can be made of different material from that of the heating portion (402). The supporting sections 406 (including 406-1 and 406-2) and the heating portion 402 of the heater 400a can be formed of materials similar to that described above with reference to the supporting sections 306 and the heating portion 302 of the heater 300a. Accordingly, the supporting sections 406 can be made of the same or different material than the heating portion 402, and can have lower thermal conductivity and / or lower electrical resistance relative to the heating portion 402, consistent with the embodiments previously described, and not repeated here for brevity.

[0075] According to a third embodiment and referring to FIGs. 5 A to 5C, the heater assembly 500 can include a heater 500a, and wick 504. Different reference numerals are used in the present embodiment solely for purposes of clarity and distinction between embodiments. The heater 500a can include at least one heating portion 502 (simply referred to as “heating portion 502” hereinafter), and at least one supporting section 506 (simply referred to as “supportingsection 506” hereinafter) including two or more supporting sections such as a first supporting section 506-1, and a second supporting section 506-2 (collectively referred to as “supporting sections 506” herein), attached at each side of the heating portion 502. The supporting section 506 can be configured to provide good surface contact between the wick 504 and the heater 500a. In an embodiment, the heating portion 502 can be a flat-mesh heating portion. The supporting sections 506 can be in form of a rectangular straps as shown in FIG. 5A, where the rectangular straps can be attached at each side of the heating portion 502. The supporting section 506 is configured to form a gripping member defining a wick conforming space to receive the wick 504.

[0076] Each of the supporting sections 506 can include a proximal end 506-lb, 506-2b and a distal end 506-la, 506-2a. The proximal ends 506-lb, 506-2b of the supporting sections 506 can be bent inwards towards a surface of the heating portion 502 to form a hook structure. The distal ends 506-la, 506-2a of the supporting sections 506 can be then bent over the wick 504 and locked in the hook structure (Refer FIGs. 5B-5C). The hook structure can be formed first from the proximal ends 506-lb, 506-2b of the supporting sections 506. The hook structure can be formed simultaneously from first and second supporting sections 506-1, 506-2. The distal ends 506-la, 506-2a of the supporting sections 506 can be thereafter locked into the hook structure simultaneously, defining the wick conforming space to enclose the wick 504. In some embodiments, the hook structure can be formed first on the first supporting section 506-1 and then on the second supporting section 506-2. The distal first end 506-la of the first supporting section 506-1 can be locked first into the hook structure, and then the distal second end 506-2a of the second supporting section 506-2 can be locked into the hook structure. In some embodiments, the hook structure can be first formed on the second supporting section 506-2 and then on the first supporting section 506-1. The distal second end 506-2a of the second supporting section 506-2 can be locked first into the hook structure, and then the distal first end 506-la of the first supporting section 506-1 can be locked into the hook structure.

[0077] In the third embodiment, the supporting sections 506 and the heating portion 502 can be formed and configured in accordance with the material, and electrical and thermal properties described above for the previous embodiments. A length of the hook structure can extend along the heating portion 502 for a distance ranging from 5% to 95% of a length of the heater 500a. Thus, the corresponding strap structures can be varied along the length of the heater 500a from 97% to 7%. The strap structures goes beneath the hook structure and the distal end 506-la, 506-2a can overlap the hook structure by a length ranging from 5% to 10% to ensure a secure mechanical lock. A width of the strap structure can be either greater, equal, or less than a widthof the hook structure. The number of strap structures can be equal to the number of hook structures. The configuration can contain a single strap-hook structure or plurality of straphook structures. The adjacent strap-hook structures can either be parallel or non-parallel to one another. The strap and hook structures provided on a periphery of the heating portion 502 can be located equidistant and non-equidistant to each other with respect to a longitudinal central line of the heating portion502. The supporting sections 506 can be located either parallel to airflow direction in the airflow path 208 or perpendicular to a direction of airflow in the airflow path 208.

[0078] As can be appreciated, the proposed cartridge 200 for an aerosol generating device 100 addresses several inherent challenges faced by existing aerosol generating devices, particularly the issues of inconsistent wick-heater contact and inefficient heat transfer. The proposed cartridge 200, where the wick 304 / 404 / 504 is securely held within a pocket / wick conforming space formed by the strategically bent supporting sections 306 / 406 / 506, not only eliminates air gaps but also increases the surface area over which heat is transferred from the heater 300a / 400a / 500a to the wick 304 / 404 / 504. This enhanced heat transfer ensures that the aerosol generating liquid is vaporized uniformly, improving the consistency of the aerosol collected mass (ACM) and providing a more reliable and efficient user experience. Additionally, the stability of the heater 300a / 400a / 500a relative to the wick 304 / 404 / 504, afforded by the structural integrity of the supporting sections 306 / 406 / 506, mitigates the risk of misalignment or instability during device operation. The design’s simplicity and effectiveness make it a significant advancement over existing devices, offering a solution that improves both the operational reliability and overall performance of the aerosol generation process. This improved heater-wick assembly provides more consistent vaporization, reduces the likelihood of dry hits or inconsistent aerosol production, and enhances the longevity and efficiency of the aerosol generating device 100, resulting in a better-quality user experience.

[0079] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.ADVANTAGES OF THE INVENTION

[0080] The present invention provides a cartridge for an aerosol generating device, having an improved heater assembly which improves heat transfer efficacy of the aerosol generating device.

[0081] The present invention provides a cartridge designed to minimize air gaps between a wick and a heater to ensure uniform wick-heater contact surface area.

[0082] The present invention provides a heater assembly which improves thermal conduction from the heater to an aerosol generating substrate in the wick.

[0083] The present invention provides a heater assembly designed to provide consistent aerosol generation for improving the overall performance of the device and user satisfaction.

[0084] The present invention provides a heater assembly which enables reliable and efficient aerosol generation, resulting in consistent delivery of Aerosol Collected Mass (ACM) to the user.

[0085] The present invention provides a cartridge with an improved heater assembly for improved aerosol generation without need of significant changes to existing manufacturing processes.

Claims

1. We Claim:

1. A cartridge (200) for an aerosol generating device (100) comprising:a heater assembly (300, 400, 500) further comprising:a heater (300a, 400a, 500a); anda wick (304, 404, 504),wherein the heater (300a, 400a, 500a) comprises at least one heating portion (302, 402, 502) and at least one supporting section (306, 406, 506),wherein the at least one supporting section (306, 406, 506) is configured to form a gripping member defining a wick conforming space to receive the wick (304, 404, 504), wherein the gripping member is further configured to exert compressive force against the wick, when the wick (304, 404, 504) is positioned in the wick conforming space.

2. The cartridge (200) as claimed in claim 1, wherein the at least one supporting section (306, 406, 506) comprises two or more supporting sections (306-1, 306-2, 406-1, 406- 2, 506-1, 506-2) and each of the supporting sections (306-1, 306-2, 406-1, 406-2, 506- 1, 506-2) are configured to form corresponding gripping members.

3. The cartridge (200) as claimed in claim 1, wherein the wick conforming space is formed between the gripping members and a first surface of the heater (300a 400a, 500a), the first surface of the heater (300a, 400a, 500a) comprising a portion of each of the supporting sections (306-1, 306-2, 406-1, 406-2, 506-1, 506-2) and the at least one heating portion (302, 402, 502).

4. The cartridge (200) as claimed in claim 1, wherein when the wick (304, 404, 504) is positioned in the wick conforming space, the gripping members exert compressive force against the wick (304, 404, 504) to maintain uniform thermal contact between the wick (304, 404, 504) and the at least one heating portion (302, 402, 502) of the heater (300a, 400a, 500a), thereby eliminating air gaps between the wick (304, 404, 504) and the at least one heating portion (302, 402, 502).

5. The cartridge (200) as claimed in claim 2, wherein the supporting sections (306-1, 306- 2, 406-1, 406-2) are attached to each side of the at least one heating portion (302, 402), extend from a periphery of the at least one heating portion (302, 402) and the supporting sections (306-1, 306-2, 406-1, 406-2) are initially coplanar with respect to a surface of the at least one heating portion (302, 402) prior to forming the gripping members.

6. The cartridge (200) as claimed in claim 2, wherein each of the supporting sections (306- 1, 306-2, 406-1, 406-2) comprises a proximal end (306-lb, 306-2b, 406-lb, 406-2b) defining a height of the wick conforming space and a distal end (306- la, 306-2a, 406- la, 406-2a) configured to interface with the wick (304, 404), the proximal end (306-lb, 306-2b, 406-lb, 406-2b) close to the surface of the at least one heating portion (302, 402) and the distal end (306-la, 306-2a, 406-la, 406-2a) away from the surface of the at least one heating portion (302, 402).

7. The cartridge (200) as claimed in claim 6, wherein the distal ends (306-la, 306-2a, 406- la, 406-2a) are bent inwardly towards the surface of the at least one heating portion (302, 402) to form the gripping members, and wherein the distance between the distal ends (306-la, 306-2a, 406-la, 406-2a) and the surface of the at least one heating portion (302, 402) is less than a width of the wick (304, 404) to provide a tensioned grip on the wick (304, 404).

8. The cartridge (200) as claimed in claim 6, wherein the distal ends (306-la, 306-2a) are bent such that the bended distal ends or the gripping members are substantially parallel to the surface of the at least one heating portion (302).

9. The cartridge (200) as claimed in claim 2, wherein each of the supporting sections (306) comprises a first supporting section (306-1), and a second supporting section (306-2), wherein the first and second supporting sections (306-1, 306-2) rotate clockwise and counter-clockwise respectively, to contact against the wick (304) positioned on the heater (300a, 400a, 500a).

10. The cartridge (200) as claimed in claim 2, wherein each of the supporting sections (406) are made from an elastically deformable structure allowing the distal ends or the gripping members (406-la, 406-2a) to be deflected away from the first surface of the heater (300a, 400a, 500a) for insertion of the wick and to move toward the first surface of the heater (300a, 400a, 500a) to exert the compressive force against the wick, when the distal ends or the gripping members (406-la, 406-2a) are released.

11. The cartridge (200) as claimed in claim 2, wherein the supporting sections (306, 406) comprise a plurality of rib structures to minimize conductive heat loss while maintaining structural contact with the wick.

12. The cartridge (200) as claimed in claim 1, wherein the at least one supporting section (306, 406, 506) and the at least one heating portion (302, 402, 502) are made monolithically from same material.

13. The cartridge (200) as claimed in claim 1, wherein the at least one supporting section (306, 406, 506) and the at least one heating portion (302, 402, 502) are made of different materials, and the at least one supporting section (306, 406, 506) have a lower thermal conductivity than the at least one heating portion (302, 402, 502).

14. The cartridge (200) as claimed in claim 12, wherein the at least one supporting section (306, 406, 506) and the at least one heating portion (302, 402, 502) are made from an identical or same material, and wherein the at least one supporting section (306, 406, 506) are configured to have a lower electrical resistance relative to the at least one heating portion (302, 402, 502).

15. The cartridge (200) as claimed in claim 13, wherein the at least one supporting section (306, 406 and 506) and the at least one heating portion (302, 402, 502) are made from dissimilar materials, and wherein the at least one supporting section (306, 406 and 506) made of a material having a lower electrical resistivity than the at least one heating portion (302, 402, 502).

16. The cartridge (200) as claimed in claim 2, wherein the supporting sections (506-1, 506-2) are in the form of rectangular straps (506) attached at each side of the at least one heating portion (502).

17. The cartridge (200) as claimed in claim 16, wherein a proximal end (506- lb, 506-2b) of each of the supporting sections (506-1, 506-2) is bent inwardly towards a surface of the at least one heating portion (502) to form a hook structure, and a distal end (506-la, 506-2a) of each of the supporting sections (506-1, 506-2) is configured to lock into the hook structure to define the wick conforming space to enclose the wick.

18. The cartridge (200) as claimed in claim 17, wherein a length of the hook structure extends along the at least one heating portion (502) for a distance ranging from 5% to 95% of a length of the heater (300a, 400a, 500a).

19. The cartridge (200) as claimed in claim 17, wherein the distal end (506-la, 506-2a) overlaps the hook structure by a length ranging from 5% to 10% to ensure a secure mechanical lock.

20. The cartridge (200) as claimed in claim 2, wherein the supporting sections (306, 406, 506) are oriented either parallel or perpendicular to a direction of airflow.

21. The cartridge (200) as claimed in claim 1, wherein the at least one heating portion (302, 402, 502) is a flat-mesh heating portion.

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