Aerosol generating device

Abstract

An aerosol generating device (100) includes an atomizer (102) including at least one fluid permeable heater (104) and an aerosol generating substrate (S). The fluid permeable heater (104) includes at least one temperature zone (106) and at least one interior slot structure (116) to define a current path in the fluid permeable heater (104). The temperature zone (106) includes an atomization zone (106-1), a pre-heating zone (106-2), and a cold zone (106-3). The atomization zone (106-1) is configured in a central portion (114) of the fluid permeable heater (104). The pre-heating zone (106-2) is configured adjacent to the cold and atomization zones (106-3, 106-1). The aerosol generating substrate (S) in the atomization zone (106-1) is atomized and volatile compounds are released which mix with an airstream entering the atomization zone (106-1) axially.

Description

AEROSOL GENERATING DEVICETECHNICAL FIELD

[0001] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to an aerosol generating device having a fluid permeable heater which enables uniform and consistent aerosol generation.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 present disclosure, or that any publication specifically or implicitly referenced as prior art.

[0003] Aerosol generating devices (AGDs) are commonly used for delivering inhalable aerosols in various applications. Traditional aerosol generating devices mainly rely on a heaterwick combination to generate an aerosol by heating an aerosol generating substrate, also referred to as an aerosol generating liquid, which contains volatile compounds. The wick, when saturated with the aerosol generating substrate, is heated by the heater to release these volatile compounds, which then mix with an incoming airstream, forming an inhalable aerosol mixture.

[0004] However, these traditional aerosol generating devices have certain drawbacks, such as oversaturation of the wick, thermal degradation of the wick, poor contact between the heater and the wick, heater’s high thermal inertia, and low specific heating area, which affect the performance of the aerosol generating devices.

[0005] In known aerosol generating devices containing the heater, the wick often becomes oversaturated with the aerosol generating substrate. This oversaturation increases the thermal load, as the excess aerosol generating substrate requires additional energy input to fully aerosolize and achieve the targeted aerosol mass. Consequently, this leads to reduction in the overall thermal efficiency and performance of the aerosol generating device due to prolonged heating times and inefficient energy utilization.

[0006] Further, for efficient generation of the aerosol, the contact between the heater and the wick should be completely established. In traditional heater, this contact is not always reliably achieved. This lack of uniform contact introduces additional constraints during manufacturing, as the positioning and attachment of the heater and wick become critical factors. Any variation in their alignment can lead to inconsistent performance and reduced operational effectiveness. Furthermore, the heater-wick combination in the heater operates athigh temperatures during use, subjecting the wick to significant thermal stresses. Over time, these thermal stresses cause the wick to deform negatively, potentially leading to loss of contact with the heater. This can lead to further inefficiencies in heating and, in the worst scenario, can cause heater burnout.

[0007] Additionally, the traditional heater can suffer from a low specific heating area (ratio of heating area to the unit weight of the heater is relatively low). This configuration results in high thermal inertia, which reduces the responsiveness of the heater to changes in demand or operational conditions. As a result, the heater may take longer to reach the desired temperature, and may struggle to maintain consistent temperatures under varying usage conditions.

[0008] Efforts have been made in the past to overcome the limitations of the traditional heater-wick combinations by introducing capillary heaters. One of the key advantages of capillary heaters over traditional wick-heater combinations is their ability to reduce thermal inertia. The capillary heaters effectively transfer the heat to the aerosol generating substrate, resulting in improved heating efficiency. This increased efficiency not only enhances the consistency of the aerosol generation process but also ensures faster response times, improving the overall user experience by providing a more responsive and efficient device. While the introduction of capillary heaters addresses several of the issues associated with the traditional wick-heater system, challenges remain in optimizing the wicking and heating action to ensure consistent aerosol generation. Specifically, the distribution of the aerosol generating substrate in the capillary heating material is more complex than in traditional wicks. In traditional wick designs, the aerosol generating substrate is quickly absorbed and often becomes oversaturated, which can lead to inefficiencies and inconsistent performance. However, in capillary heaters, the distribution of the aerosol generating liquid is slow and non-homogenous, making it more difficult to ensure uniform saturation and heating throughout the material. Another aspect to be considered is the temperature distribution in the capillary heater’s topology. For consistent aerosol generation, the atomizing area temperature should be high and uniform throughout. Any inconsistency in the temperature distribution in the atomizing area leads to uneven heating of the aerosol generating substrate. The uneven heating leads to inconsistent aerosol formation.

[0009] A patent document RU2832542C2 describes a fluid permeable heater assembly for an aerosol generating system. The heater assembly includes a cover, and a flat electrically conductive heating element, wherein the cover is formed by multi-component moulding on edge regions on one side of the heating element. The cover includes a hollow body with first and second openings of the cover, where the first opening of the cover is opposite the secondopening of the cover. The heating element is mounted on the cover in such a way that the heating element extends across the first opening of the cover. RU’542 describes an improved heater assembly for an aerosol generating system that allows for simpler manufacturing at lower cost and provides a more rigid structure to prevent displacement of the heater assembly.

[0010] Another patent document W02017207320A1 describes an electrically conductive flat filament arrangement for a fluid permeable heater assembly for aerosol-generating systems. The flat filament arrangement includes a center portion and two side portions. The two side portions are arranged on opposite sides of the center portion. The center portion defines a heating region of the filament arrangement and the side portions define electrical contact regions of the filament arrangement. The center portion and the two side portions, each include a plurality of openings, each plurality of openings defining an open area of the center portion and an open area of each of the two side portions. The percentage of the total area of the center portion comprising the open area of the center portion is greater than the percentage of the total area of one of the side portions comprising the open area of the side portion. The referred document describes creation of different resistance zones by the way of controlling the open area within the filaments, where the filaments are arranged in transversal and vertical position. The electrical contact region has lesser open area creating a low resistance zone. The center portion is the heating zone, the open area is relatively larger than the electrical contact region creating high resistance zone.

[0011] Yet another patent document WO2016096745A1 describes an aerosol-generating system for guiding an airflow inside an electrically heated aerosol-generating system. The aerosol-generating system includes a liquid storage portion comprising a container holding a liquid aerosol-forming substrate and defining an opening, and a heater assembly which extends across the opening along a transverse plane. The heater assembly includes at least one electrically operated heating element, and a first channel defines a first flow route which brings ambient air into impingement against the heater assembly. A portion of the first channel is arranged orthogonally to the transverse plane such that the at least a portion of the first channel directs ambient air from outside the system to impinge perpendicularly onto a surface portion of the heating element before conveying the ambient air to a downstream end.

[0012] Though, the referred documents talk about the use of the capillary heater in the aerosol generating system, the issue of temperature distribution and the aerosol generating substrate distribution concerns are not addressed in any of the above referred documents.

[0013] There is therefore a need in the art to provide an aerosol generating device having at least one fluid permeable heater to address the limitations associated with the traditional heaterwick combinations, to enable uniform and consistent aerosol generation.OBJECTS OF THE PRESENT DISCLOSURE

[0014] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as listed herein below.

[0015] It is an object of the present disclosure to provide an improved aerosol generating device to address the limitations associated with the traditional heater-wick combinations of a heater.

[0016] It is an object of the present disclosure to provide an aerosol generating device with a fluid permeable heater to enhance overall performance and efficiency of the aerosol generating device.

[0017] It is an object of the present disclosure to design the aerosol generating device to reduce thermal inertia of the fluid permeable heater.

[0018] It is yet another object of the present disclosure to provide an aerosol generating device which ensures uniform and consistent aerosol generation of the aerosol generating substrate in a capillary heating material, thereby improving the overall consistency and quality of the aerosol formed.

[0019] It is yet another object of the present disclosure to reduce the complexity of manufacturing by eliminating the need for separate wick and heater components, by providing a fluid permeable heater thereby simplifying the overall aerosol generating device assembly.

[0020] It is yet another object of the present disclosure to enhance the durability and reliability of the aerosol generating device by mitigating issues such as wick deformation, loss of contact of the wick with the heater, and heater burnout, which are common problems in traditional heater- wick combinations.

[0021] It is yet another object of the present disclosure to improve the user experience by ensuring a responsive and efficient aerosol generation process, delivering consistent quality and quantity of aerosol with reduced waiting times and energy consumption.

[0022] It is still yet another object of the present disclosure to design compact, lightweight, and portable aerosol generating device.SUMMARY

[0023] Aspects of the present disclosure relate generally to the field of aerosol generating devices. In particular, the present disclosure pertains to an aerosol generating device having a fluid permeable heater which enables uniform and consistent aerosol generation.

[0024] According to an aspect of the present disclosure, the disclosed aerosol generating device (simply referred to as “device” herein) includes at least one fluid permeable heater (simply referred to as “fluid permeable heater” herein) and an aerosol generating substrate. The fluid permeable heater includes at least one temperature zone and at least one interior slot structure to define a current path in the fluid permeable heater.

[0025] In one or more embodiments, the at least one temperature zone may include an atomization zone, a pre-heating zone, and a cold zone. The atomization zone may be maintained at a first temperature range. The atomization zone may be positioned at a central portion of the fluid permeable heater to heat the aerosol generating substrate. Further, the preheating zone may be located adjacent to the atomization zone. The pre-heating zone may be maintained within a second temperature range. The second temperature range may be less than the first temperature range.

[0026] The cold zone may be located adjacent to the pre-heating zone. The cold zone may be maintained within a third temperature range. The third temperature range may be lower than the first and second temperature ranges.

[0027] In one or more embodiments, the fluid permeable heater may be positioned such that the airstream traverses the atomization zone in a longitudinal direction of the fluid permeable heater.

[0028] In one or more embodiments, the fluid permeable heater may include a plurality of substantially orthogonally oriented interior slots (simply referred to as “interior slots” herein) connected to each other to form the interior slot structure.

[0029] In one or more embodiments, the cold zone may include a set of electrical contacts (simply referred to as “electrical contacts” herein) configured to supply electrical power from a power source to the fluid permeable heater.

[0030] In one or more embodiments, the fluid permeable heater may include a pair of lateral side portions (simply referred to as “lateral side portions” herein) configured at sides of the central portion. The lateral side portions may include a first side portion, and a second side portion having a plurality of slots to assist in formation of different temperature zones.

[0031] In one or more embodiments, each slot among the plurality of slots may have a height to width ratio ranging from 0.1 to 2. The width being oriented perpendicular to an airflow path, and the height being oriented parallel to the airflow path.

[0032] In one or more embodiments, a width of the interior slot structure formed within a material of the fluid permeable heater may range from 10% to 50% of a width of either the first side portion or the second side portion.

[0033] In one or more embodiments, the first temperature range of the atomization zone may be above 120 C.

[0034] In one or more embodiments, the atomization zone may occupy 40 % to 95 % of a total surface area of the fluid permeable heater.

[0035] In one or more embodiments, the second temperature range of the pre-heating zone may be between 60 C and 120 C.

[0036] In one or more embodiments, the temperature zone may be formed by varying a width of the fluid permeable heater.

[0037] In one or more embodiments, the temperature zone may be formed by providing at least one slit or slot in the fluid permeable heater.

[0038] In one or more embodiments, the third temperature range of the cold zone may be between 25sC to 60 C.

[0039] In one or more embodiments, the cold zone may be formed by increasing the width of the fluid permeable heater, thereby reducing electrical resistance in the cold zone, and inhibiting a rate of temperature rise in the cold zone.

[0040] In one or more embodiments, the fluid permeable heater may be made of a metal fibre felt manufactured from metal fibres or filaments using any of lapping, laminating, or high-temperature diffusion bonding.

[0041] In one or more embodiments, the fluid permeable heater may be made of ceramic material.

[0042] In one or more embodiments, the metal fibres may have porosities ranging from 0.4 to 0.9.

[0043] In one or more embodiments, the fluid permeable heater may include a plurality of interior slots either connected to or not connected to each other to form the interior slot structure.

[0044] In one or more embodiments, the fluid permeable heater may be a circular fluid permeable heater.

[0045] In one or more embodiments, the temperature zone may be radially distributed from a centre of the circular fluid permeable heater.

[0046] In one or more embodiments, the atomization zone may be arranged radially in proximity to the centre of the circular fluid permeable heater.

[0047] In one or more embodiments, the pre-heating zone may be arranged radially adjacent to the atomization zone, and may enclose the atomization zone.

[0048] In one or more embodiments, the cold zone may be formed by at least two lateral side extensions, and the set of electrical contacts may be positioned in the cold zone.

[0049] In one or more embodiments, the plurality of slots may be located circumferentially along a fluid permeable heater path of the circular fluid permeable heater.

[0050] In one or more embodiments, the fluid permeable heater path may include an innermost path, an intermediate path, and an outermost path. In the innermost path, the slots may be located along a first diametric axis of the circular fluid permeable heater, and may be configured opposite to each other. In the intermediate and outermost paths, the slots may be located at an angle to the first diametric axis of the fluid permeable heater.

[0051] In one or more embodiments, a width to length ratio of each slot may vary from 0.1 to 2.BRIEF DESCRIPTION OF DRAWINGS

[0052] 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.

[0053] FIG. 1A illustrate an exemplary block diagram of the proposed aerosol generating device having at least one fluid permeable heater, in accordance with one or more embodiments of the present disclosure.

[0054] FIGs. IB- IE illustrate various exemplary sectional views of the fluid permeable heater of the aerosol generating device, where the fluid permeable heater is of meandering type, in accordance with one or more embodiments of the present disclosure.

[0055] FIGs. 2A-2C illustrate various exemplary sectional views of the fluid permeable heater, where the fluid permeable heater is of circular type, in accordance with another embodiment of the present disclosure.DETAILED DESCRIPTION

[0056] 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 present disclosure.

[0057] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0058] 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.

[0059] As used in the description herein 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.

[0060] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein does not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0061] 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 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 description herein.

[0062] 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 tothe embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skilled 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).

[0063] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to an aerosol generating device having a fluid permeable heater which enable uniform and consistent aerosol generation.

[0064] The traditional heater-wick combination in aerosol generating devices (AGDs) presents several drawbacks that impact overall performance. First, wicks are often oversaturated with the aerosol generating substrate, resulting in lower heating efficiency. Further, establishing complete and consistent contact between the heater and the wick is challenging, adding complexity during manufacturing. Furthermore, the wick is exposed to thermal stresses during operation, which can cause deformation and lead to a loss of contact with the heater, potentially resulting in heater burnout. Lastly, traditional heaters typically have a low specific heating area (heating area per heater weight), which results in high thermal inertia, slowing response time of the aerosol generating device and affecting its overall efficiency.

[0065] To address the aforementioned problems, the traditional heater-wick combination is replaced with a dual-functional material capable of both wicking and heating the aerosol generating substrate simultaneously. This material not only provides capillary action to facilitate the diffusion of the aerosol generating substrate but also possesses sufficient electrical resistance to induce joule heating, effectively heating the substrate. Additionally, the material has lower thermal inertia, i.e. it consumes less heat and transfers more heat to the aerosol generating substrate, thus improving the heating efficiency of the device . These dual-functional materials, known as fluid permeable heaters (or capillary heaters), offer a more efficient and reliable solution. Consequently, the proposed fluid permeable heater can effectively address both temperature distribution and aerosol generating liquid distribution concerns. By addressing these issues, the overall performance of the aerosol generating device can be significantly improved, ensuring better heating efficiency and more consistent aerosol delivery.

[0066] As illustrated, referring to FIGs. 1A-1E, FIGs. 2A-2C, the disclosed aerosol generating device 100 (simply referred to as “device 100” herein) includes an atomizer 102 including at least one fluid permeable heater 104, 204 (simply referred to as “fluid permeable heater 104,204” herein) and an aerosol generating substrate S. An outer boundary of the fluid permeable heater 104, 204 can be in contact with the aerosol generating substrate S. The fluid permeable heater 104, 204 includes at least one temperature zone 106, 206 (individually or collectively referred to as “temperature zone 106, 206” or “temperature zones 106, 206” herein) and at least one interior slot structure 116, 216 (simply referred to as “interior slot structure 116, 216” herein) to define a current path in the fluid permeable heater 104, 204. The fluid permeable heater 104, 204 can be made of metal fibre felt manufactured from metal fibres or filaments through any of but not limited to: lapping, laminating, and high temperature diffusion-bonding. In an embodiment, the metal fibre felt can have porosities ranging from 0.4 to 0.9. Further, in an embodiment, a thickness of the metal fibre felt can vary from 0.1 mm to 0.3 mm. The metal fibre felt can be made of material selected from but not limited to stainless steel, nichrome, and the like. In some embodiments, the fluid permeable heater 104, 204 can be made of ceramic material.

[0067] In an embodiment, the at least one temperature zone 106, 206 may include an atomization zone 106-1, 206-1, a pre-heating zone 106-2, 206-2 and a cold zone 106-3, 206-3. The at least one temperature zone 106-1, 106-2, 106-3, 206-1, 206-2, 206-3 may be formed by varying a width of the fluid permeable heater 104, 204. The fluid permeable heater 104, 204 can be configured such that the airstream traverses the atomization zone 106-1, 206-1 in a longitudinal direction X-X of the fluid permeable heater 104, 204 forming an airflow path AP. As shown in FIGs. IB- IE, in a first embodiment, the atomization zone 106-1 can be configured in a central portion 114 of the fluid permeable heater 104 and can be maintained at a first temperature range. The atomization zone 106-1, 206-1 can be configured to heat the aerosol generating substrate S (also referred as “aerosol generating liquid S” herein). In an embodiment, the aerosol generating substrate S is received from the pre-heating zone 106-2, 206-2 and is transported to the atomization zone 106-1, 206-1 via passing through the preheating zone 106-2, 206-2 where the aerosol generating substrate S is atomized and volatile compounds are released which mix with an airstream flowing above and below the atomization zone 106-1, 206-1 to form an inhalable aerosol mixture. In an embodiment, the aerosol generating substrate S can be selected from but not limited to propylene glycol (PG) and vegetable glycerin (VG), water and active component.

[0068] In an embodiment, the first temperature range of the atomization zone 106-1, 206-1 can be above 12ff C. In the atomization zone 106-1, 206-1, the aerosol generating substrate S is heated and the volatile compounds are released. These volatile compounds can mix with the incoming airstream to form the inhalable aerosol mixture. The incoming mixture can moveeither parallel or non-parallel to the longitudinal axis X-X of the fluid permeable heater 104, 204 and can be isolated from the pre-heating zone 106-2, 206-2 and the cold zone 106-3, 206-3. As the airstream can be concentrated only on the atomization zone 106-1, 206-1, the airstream may be able to carry maximum volatile compounds released upon heating of the aerosol generating substrate S. To achieve atomizing uniform temperatures in the atomization zone 106- 1 , in the first embodiment of the fluid permeable heater 104, the interior slot structure 116 is created by a plurality of substantially orthogonally oriented interior slots 116-1, 116-2 connected to each other. The interior slot structure 116 can assist in creating maximum atomizing region that is lying in an airflow path (AP). There are two types of the interior slots 116-1, 116-2 that are perpendicular 116-1 and parallel 116-2 to the longitudinal axis X-X of the fluid permeable heater 104. The perpendicular interior slots 116-1 and parallel interior slots 116-2 both are joined together thus creating the interior slot structure 116. Increasing the atomizing region area close to the projected planar area of the airflow path (AP) in the atomizer 102 improves the prospect of high aerosol volume. Maximizing the atomizing region in the projected planar area of the airflow path (AP) in the atomizer 102 of the aerosol generating device 100 can improve the prospects of high aerosol volume. In an embodiment, the atomization zone 106-1, 206-1 can occupy between 40% to 95% of total surface area of the fluid permeable heater 104, 204 more preferably 40% to 70% of total surface area of the fluid permeable heater 104, 204 or more preferably between 40% to 60% of total surface area.

[0069] In an embodiment shown in FIGs. 1B-1E, the fluid permeable heater 104 can include lateral side portions 118 configured at sides of the central portion 114. The lateral portions 118 can include a first side portion 118-1, and a second side portion 118-2. The second side portion 118-2 can include a plurality of slots 120 (Refer FIG. 1C) (collectively referred as “slots 120” hereinafter) configured to assist in formation of the different temperature zones 106-1, 106-2, 106-3. Each slot among the plurality of slots 120 can have height to width ratio ranging from 0.1 to 2, considering the width being oriented perpendicular to the airflow path (AP), and the height being oriented parallel to the airflow path (AP). Further, a width of the interior slot structure 116 within a material of the fluid permeable heater 104 can vary from 10% to 50% of a width of the first side portion 118-1 or the second side portion 118-2.

[0070] In an embodiment, the pre-heating zone 106-2, 206-2 can be located adjacent to the atomization zone 106-1, 206-1. The pre-heating zone 106-2, 206-2 can be maintained at a second temperature range, where the second temperature range can be less than the first temperature range. The second temperature range of the pre-heating zone 106-2, 206-2 can be ranging between 60 C and 120 C. In an embodiment, the pre-heating zone 106-2 can occupybetween 20% to 40% of the total surface areaofthe fluid permeable heater 104. The pre-heating zone 106-2, 206-2 can be formed by reducing the width of the fluid permeable heater 104, 204 and / or by providing at least one slit or slot in the fluid permeable heater 104, 204. The planar fluid permeable heater 104 is formed by multiple apertures or slots 124. One such aperture or slot 124-1 is formed starting externally from the left lateral surface (first side portion) 118-1 and another aperture or slot 124-2 starting externally from the right lateral surface (second side portion) 118-2 and extended into the central section 114 of the fluid permeable heater 104 and another aperture path i.e. interior slot 116 formed within the central section 114. The interior slot structure 116 formed in the central section 114 can include interior slots 116-1 formed perpendicular to the longitudinal axis X-X of the fluid permeable heater 104 and another interior slots 116-2 formed parallel to the longitudinal axis X-X of the fluid permeable heater 104. The two interior slots 116-1, 116-2 connected at a common end to form continuous interior slot structure 116 in the central section 114, thus enabling an atomization zone 106-1 and a preheating zone 106-2. As the aerosol generating substrate S is transported from the pre-heating zone 106-2, 206-2 through the atomization zone 106-1, 206-1 one or more intrinsic properties of the aerosol generating substrate S may undergo significant change. The one or more intrinsic properties can include but not limited to viscosity, surface tension, and the like. The decrease in the viscosity and the surface tension of the aerosol generating substrate S can make it to transverse to the atomization zone 106-1, 206-1 of the fluid permeable heater 104, 204 efficiently.

[0071] In an embodiment, the outer boundary of the fluid permeable heater 104, 204 is in contact with the aerosol generating substrate, S. The aerosol generating substrate S, from a storage reservoir 108 of the aerosol generating device 100, is in contact with the fluid permeable heater 104, 204 at the peripheral boundary, preferably along Upper Left (UL), Lower left (LL), Upper Right (UR), and lower Right (LR) as shown in FIG. ID, to ensure efficient distribution of the aerosol generating substrate S within the fluid permeable heater 104.

[0072] In an embodiment, the cold zone 106-3, 206-3 of the fluid permeable heater 104, 204 can be maintained at a third temperature range. The third temperature range can be lower than the first and second temperature ranges. The third temperature range of the cold zone 106-3, 206-3 can be ranging between 25° C to 60 C. In an embodiment, the cold zone 106-3, 206-3 can occupy between 10% to 20% of the total surface area of the fluid permeable heater 104. The cold zone 106-3, 206-3 can be formed by increasing the width of the fluid permeable heater 104, 204 thereby reducing an electrical resistance in the cold zone 106-3, 206-3. In addition,increasing the width of the fluid permeable heater 104, 204 also increases mass of the fluid permeable heater 104, 204 thereby inhibiting the rate of temperature rise in the cold zone 106-3, 206-3. The intrinsic properties of the aerosol generating substrate S don’t undergo significant change in the cold zone 106-3, 206-3. Further, the cold zone 106-3, 206-3 can include a set of electrical contacts 122, 214. (Collectively referred as “electrical contacts 122” hereinafter) As shown in FIG. ID of the first embodiment, the set of electrical contacts 122 may he in the central portion 114 of the fluid permeable heater 104. The electrical contacts 122, 214 can be configured to supply power from a power source 112 to the fluid permeable heater 104, 204. As can be appreciated, the temperature in the cold zone 106-3, 206-3 is maintained less than 60 C, the electrical contacts 122, 214 and any bonding material; adherent to the electrical contacts 122, 214 are immune to any thermal damage. FIG. IE illustrates a current path defined by the at least one interior slot structure 116 in the at least one fluid permeable heater 104 of the first embodiment.

[0073] Referring to FIGs. 2A-2C, in another embodiment, the fluid permeable heater 204 can be of a circular fluid permeable heater 204, where the fluid permeable heater 204 is formed in a circular shape. In the circular fluid permeable heater 204, the at least one temperature zone 206 can be radially distributed from a centre of the circular fluid permeable heater 204. The atomization zone 206-1 can be arranged radially in proximity to the center of the circular fluid permeable heater 204. The pre-heating zone 206-2 is arranged radially adjacent to the atomization zone (206-1), and can enclose the atomization zone 206-1 radially. As shown in FIG. 2B, the cold zone 206-3 can be formed by at least two lateral side extensions 210 and the set of electrical contacts 214 can be positioned in the cold zone 206-3. The air flow path (AP) is such that it covers 100% of the atomization zone 206-1, and covers minimum area of the pre-heating zone 206-2. The electrical contacts 214 can be located on the lateral side extensions 210 forming the cold zone 206-3.

[0074] In an embodiment, the atomization zone 206-1 can cover 40%-95% of the total area of the circular fluid permeable heater 204. In an embodiment, the pre-heating zone 206-2 can cover 20%-40% of the total area of the circular fluid permeable heater 204, and the cold zone 206-3 can occupy remaining 10%-20% of the total area of the circular fluid permeable heater 204. As shown in FIGs. 2A-2C, the circular fluid permeable heater 204 includes a plurality of interior slots either connected to or not connected to each other to form the at least one interior slot structure 216. FIG. 2C illustrates a current path defined by the at least one interior slot structure 216 in the at least one fluid permeable heater 204. Similar to the meandering type fluid permeable heater 104, in this embodiment, the circular fluid permeable heater 204 canalso include the plurality of slots 212 (collectively referred to as “slots 212” herein) located circumferentially along a fluid permeable heater path (FP). The fluid permeable heater path (FP) can be divided into an innermost path (FP-1), an intermediate path (FP-2), and the outermost path (FP-3). In a preferred embodiment, in the innermost path (FP-1), the slots 212 can be located collinearly along a first diametric axis of the circular fluid permeable heater 204, and configured opposite to each other. In the intermediate and outermost paths (FP-2, FP-3), the slots 212 can be located at an angle to the first diametric axis of the circular fluid permeable heater 204. The angle can be ranging from 0 C to 90 C. In a preferred embodiment, the angle can be 45° C. As aspect ratio (width / length) of each slot 212 can vary from 0.1 to 2. Further, the position of the slots 212, the number of slots 212, and the aspect ratio of the slots 212 can vary depending on change in area of the temperature zone 206 and overall resistance of the circular fluid permeable heater 204. The overall resistance of the circular fluid permeable heater 204 can vary from 0.5 ohm to 2.5 ohm. More preferably, the circular fluid permeable heater 204 can vary from 0.8 ohm to 1.2 ohm.

[0075] In an embodiment, the outer boundary of the fluid permeable heater 204 is in contact with the aerosol generating substrate, S. i.e., the aerosol generating substrate, from the storage reservoir 108 of the aerosol generating device 100, is in contact with the fluid permeable heater 204 at the peripheral boundary.

[0076] In an embodiment, the aerosol generating device 100 can include the storage reservoir 108 to store the aerosol generating substrate S. Further, the fluid permeable heater 104, 204 can be fluidically coupled to the storage reservoir 108. The aerosol generating substrate S flows from the storage reservoir 108 to the fluid permeable heater 104, 204 to heat up the aerosol generating substrate S to generate an aerosol.

[0077] In an embodiment, the aerosol generating device 100 can include the power source 112 operatively coupled to the fluid permeable heater 104, 204. The power source 112 can be a battery, including, without limitations, 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 fluid permeable heater 104, 204 and aerosolize the aerosol generating substrate S. Upon actuation of the aerosol generating device 100, the power source 112 can transmit an electric current through the fluid permeable heater 104, 204, which results in heating -up of the heating material of the fluid permeable heater 104.

[0078] In an embodiment, the aerosol generating device 100 can include a control unit 110 operatively coupled to the power source 112 and the fluid permeable heater 104, 204. The control unit 110 draws power from the power source 112 and provides the desired amount ofregulated power to the fluid permeable heater 104, 204 to aerosolize the aerosol generating substrate S. In another embodiment, the control unit 110 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 110. 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.

[0079] Unlike conventional heaters, the fluid permeable heater 104, 204 of the present invention offers a high surface area. Because of the high surface area and low mass of the fluid permeable heater 104, 204, a higher quantity of aerosol can be generated with low power being supplied to the fluid permeable heater 104, 204, thereby improving the overall energy efficiency and performance of the aerosol generating device. Further, the fluid permeable heater 104, 204 reaches the desired temperature quickly, and maintains consistent temperatures. Further, the uniform temperature distribution achieved within the atomization zone 106-1, 206-1 ensures stable and consistent aerosol formation.

[0080] As can be appreciated, the disclosed aerosol generating device 100 with at least one fluid permeable heater 104, 204 enhances the uniformity and efficiency of aerosol generation by implementing a carefully designed temperature distribution. By adjusting geometrical parameters of the fluid permeable heater 104, 204 the temperature zones 106, 206 such as the atomization, pre-heating, and cold zones 106-1, 206-1, 106-2, 206-2 and 106-3, 206-3 are created, each serving a specific function. The cold and pre-heating zones 106-3, 206-3, 106-2, 206-2 ensure a controlled transport of the aerosol generating substrate to the atomization zone 106-1, 206-1 where it is rapidly atomized. This process facilitates the release of volatile compounds, which then mix seamlessly with the air stream to form a uniform aerosol mixture. This innovative approach not only ensures consistent distribution of the aerosol generating substrate S but also significantly improves the speed and efficiency of aerosol generation, ultimately enhancing overall performance of the aerosol generating device 100.

[0081] 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 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

[0082] The present invention provides an improved aerosol generating device to address the limitations associated with the traditional heater-wick combinations of a heater.

[0083] The present invention provides an aerosol generating device with a fluid permeable heater to enhance overall performance and efficiency of the aerosol generating device.

[0084] The present invention provides an aerosol generating device with a fluid permeable heater with reduced thermal inertia.

[0085] The present invention provides the fluid permeable heater of the aerosol generating device to ensure uniform and consistent aerosol generation of the aerosol generating substrate in a capillary heating material, thereby improving the overall consistency and quality of the aerosol formed.

[0086] The present invention reduces the complexity of manufacturing by eliminating the need for separate wick and heater component of the aerosol generating device.

[0087] The present invention enhances the durability and reliability of the aerosol generating device by mitigating issues such as wick deformation, loss of contact with the heater, and heater burnout, which are common problems in traditional heater- wick combinations.

[0088] The aerosol generating device of the present invention improves the user experience by ensuring a responsive and efficient aerosol generation process, delivering consistent quality and quantity of aerosol with reduced waiting times and energy consumption.

[0089] The present invention provides a compact, lightweight, and portable aerosol generating device.

Claims

We Claim:

1. An aerosol generating device (100) comprising:an atomizer (102) comprising at least one fluid permeable heater (104, 204) and an aerosol generating substrate (S),wherein the at least one fluid permeable heater (104, 204) comprises at least one temperature zone (106, 206) and at least one interior slot structure (116, 216) to define a current path in the at least one fluid permeable heater (104, 204).

2. The aerosol generating device (100) as claimed in claim 1, wherein the at least one temperature zone (106, 206) comprising:an atomization zone (106-1, 206-1) maintained at a first temperature range and positioned at a central portion (114) of the fluid permeable heater (104), to heat the aerosol generating substrate (S);a pre-heating zone (106-2, 206-2) located adjacent to the atomization zone (106- 1, 206-1), and maintained within a second temperature range, wherein the second temperature range is less than the first temperature range; anda cold zone (106-3, 206-3) adjacent to the pre-heating zone (106-2, 206-2), the cold zone (106-3, 206-3) maintained within a third temperature range, wherein the third temperature range is lower than the first and second temperature ranges.

3. The aerosol generating device (100) as claimed in claim 2, wherein the at least one fluid permeable heater (104, 204) is positioned such that the airstream traverses the atomization zone (106-1, 206-1) in a longitudinal direction (X-X) of the at least one fluid permeable heater (104, 204).

4. The aerosol generating device ( 100) as claimed in claim 1 , wherein the at least one fluid permeable heater (104) comprises a plurality of substantially orthogonally oriented interior slots (116-1, 116-2) connected to each other to form the at least one interior slot structure (116).

5. The aerosol generating device ( 100) as claimed in claim 2, wherein the cold zone (106- 3, 206-3) comprises a set of electrical contacts (122, 214) being configured to supply electrical power from a power source (112) to the at least one fluid permeable heater (104, 204).

6. The aerosol generating device (100) as claimed in claim 1, wherein the fluid permeable heater (104) comprises a pair of lateral side portions (118) configured at sides of the central portion (114), wherein the pair of lateral side portions (118) comprises a firstside portion (118-1), and a second side portion (118-2) having a plurality of slots (120) to assist in formation of the different temperature zones (106).

7. The aerosol generating device (100) as claimed in claim 6, wherein each slot (120) among the plurality of slots has a height to width ratio ranging from 0.1 to 2, wherein the width being oriented perpendicular to an airflow path (AP), and the height being oriented parallel to the airflow path (AP).

8. The aerosol generating device (100) as claimed in claim 6, wherein a width of the at least one interior slot structure (116) formed within a material of the at least one fluid permeable heater (104) ranges from 10% to 50% of a width of either the first side portion (118-1) orthe second side portion (118-2).

9. The aerosol generating device ( 100) as claimed in claim 2, wherein the first temperature range of the atomization zone (106-1, 206-1) is above 12ff C.

10. The aerosol generating device (100) as claimed in claim 2, wherein the atomization zone (106-1, 206-1) occupies between 40% to 95 % of a total surface area of the at least one fluid permeable heater (104, 204).

11. The aerosol generating device (100) as claimed in claim 2, wherein the second temperature range of the pre-heating zone (106-2, 206-2) is between 60 C and 12ff C.

12. The aerosol generating device (100) as claimed in claim 2, wherein the at least one temperature zone (106-1,106-2, 106-3,206-1,206-2, 206-3) is formed by varying a width of the at least one fluid permeable heater (104, 204).

13. The aerosol generating device (100) as claimed in claim 2, wherein the at least one temperature zone (106-1,106-2,106-3,206-1,206-2,206-3) is formed by providing at least one slit or slot in the fluid permeable heater (104, 204).

14. The aerosol generating device (100) as claimed in claim 2, wherein the third temperature range of the cold zone (106-3, 206-3) is between 25° C to 60 C.

15. The aerosol generating device (100) as claimed in claim 2, wherein the cold zone (106- 3, 206-3) is formed by increasing the width of the fluid permeable heater (104, 204), thereby reducing electrical resistance in the cold zone (106-3, 206-3), and inhibiting a rate of temperature rise in the cold zone (106-3, 206-3).

16. The aerosol generating device (100) as claimed in claim 1, wherein the at least one fluid permeable heater (104, 204) is made of a metal fibre felt manufactured from metal fibres or filaments using any of lapping, laminating, or high-temperature diffusion bonding.

17. The aerosol generating device (100) as claimed in claim 1, wherein the at least one fluid permeable heater (104, 204) is made of ceramic material.

18. The aerosol generating device as claimed in claim 16, wherein the metal fibres of the metal fibre felt have porosities ranging from 0.4 to 0.9.

19. The aerosol generating device (100) as claimed in claim 1, wherein the at least one fluid permeable heater (104, 204) is a circular fluid permeable heater (204).

20. The aerosol generating device (100) as claimed in claim 19, wherein the circular fluid permeable heater (204) comprises a plurality of interior slots either connected to or not connected to each other to form the at least one interior slot structure (216).

21. The aerosol generating device (100) as claimed in claim 19, wherein the at least one temperature zone (206) is radially distributed from a centre of the circular fluid permeable heater (204).

22. The aerosol generating device (100) as claimed in claim 2 or claim 19, wherein the atomization zone (206-1) is arranged radially in proximity to the centre of the circular fluid permeable heater (204).

23. The aerosol generating device (100) as claimed in claim 2 or claim 19, wherein the preheating zone (206-2) of the circular fluid permeable heater (204) is arranged radially adjacent to the atomization zone (206-1), and enclose the atomization zone (206-1).

24. The aerosol generating device (100) as claimed in claim 5 or claim 19, wherein the cold zone (206-3) of the circular fluid permeable heater (204) is formed by at least two lateral side extensions (210), and the set of electrical contacts (214) are positioned in the cold zone (206-3).

25. The aerosol generating device (100) as claimed in claim 19, wherein the plurality of slots (212) are located circumferentially along a fluid permeable heater path (FP) of the circular fluid permeable heater (204).

26. The aerosol generating device (100) as claimed in claim 25, wherein the fluid permeable heater path (FP) comprises an innermost path (FP-1), an intermediate path (FP-2), and an outermost path (FP-3),wherein, in the innermost path (FP-1), the plurality of slots (212) are located along a first diametric axis of the circular fluid permeable heater (204), and configured opposite to each other.wherein, in the intermediate and outermost paths (FP-2, FP-3), the plurality of slots (212) are located at an angle to the first diametric axis of the circular fluid permeable heater (204).

27. The aerosol generating device (100) as claimed in claim 25, wherein a width to length ratio of each slot (212) varies from 0.1 to 2.

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