WO2022049537A1

WO2022049537A1 - Aerosol generating article

Info

Publication number: WO2022049537A1
Application number: PCT/IB2021/058065
Authority: WO
Inventors: Sunkara KOTESWARA RAO; Sriram Srinivasan
Original assignee: Itc Limited
Priority date: 2020-09-03
Filing date: 2021-09-03
Publication date: 2022-03-10

Abstract

Embodiments disclose an aerosol generating article (10) comprising: an outer body (11, 111) extending in a longitudinal direction to operably couple an end cap (12, 112) at one end and a cartridge assembly (13, 118, 20) at the other end; said outer body (11, 111) enclosing a housing (113), said housing (113) comprising electronic circuitry, a battery assembly (114), and a charging mechanism (117) embedded therein; said cartridge assembly (20) enclosing therein: a liquid storage compartment (22) for storing vaporizable liquid material or an aerosol source liquid; a heater assembly comprising: a wick to absorb the vaporizable liquid material; and a heating element wounded on the wick material, wherein the wick is arranged to transfer the vaporizable liquid via capillary action to the wick for vaporizing the vaporizable liquid material, and an air pipe (4103) integrated into liquid storage compartment (22) for carrying the condensed vapor towards the end of said cartridge assembly (20), where a user inhales the condensed vapor through a mouthpiece (21).

Description

AEROSOL GENERATING ARTICLE

TECHNICAL FIELD

The present subject matter described herein generally relates to aerosol generating article and more particularly, the invention relates to a heater assembly to generate aerosol.

BACKGROUND OF THE INVENTION

Aerosol generating articles have been developed more rapidly over the last few years. Such devices comprises generally of two components: Cartridge and a control unit. The cartridge primarily comprises of a reservoir and a heater. The reservoir is generally a liquid reservoir having an aerosol generating medium while the heater comprises a heating element and a wick. In traditional aerosol generating articles comprising liquid substrate, the said liquid is soaked in a cotton, which in turn is arranged to be in contact with the wicking element. Known in the art are also closed system cartridges which are made of cotton less reservoirs. The control unit comprises of a battery to supply desired power to the heater. The supply of the power is by means of a control circuit.

Reference is made to US9854839B2 that discloses an electronic smoking article which includes a liquid supply including liquid material, a heater operable to heat the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol, a wick in communication with the liquid material and in communication with the heater such that the wick delivers the liquid material to the heater, and at least one air inlet operable to establish a predetermined resistance to draw under a prescribed test of the smoking article.

Reference is now made to US10251424B2 that discloses a heater assembly for an electronic vaping device and a method of manufacturing the electronic vaping device. The heater assembly includes a chimney cage extending longitudinally, a heater extending longitudinally within the chimney cage, a heater gauze positioned about an outer circumference of the heater, the chimney case positioned about an outer circumference of the heater gauze, and a cathode clip electrically connected to a first end portion of the heater.

A further reference is made to US20180368479A1 that discloses an e- vaping device that includes a battery section, an e-vaping tank capable of holding a liquid material, and an adapter connecting the battery section to the e-vaping tank. The adapter includes a heater capable of vaporizing the liquid material, and a wick capable of drawing the liquid material from the e-vaping tank to the heater. The adapter is connected to the e-vaping tank and the power source section via threaded connections. The threaded connections between the adapter and the battery section have threads with a non-standard pitch.

Still further, a reference is made to US9888719B2 that discloses a liquid reservoir component of an electronic vaping device which comprises an outer casing extending in a longitudinal direction, an air inlet, and a vapor outlet. An inner tube is within the outer casing defining a central air passage communicates with the inlet and the outlet. A liquid reservoir is in an annular space between the outer casing and the inner tube. A susceptor is adjacent the central air passage, and a wick is in communication with the liquid reservoir and in thermal communication with the susceptor such that the susceptor is operable to heat the liquid material to a temperature to vaporize the liquid material and form a vapor in the central air passage. The liquid reservoir component is configured to connect with a power supply component such that an induction source is operable to generate an inductive field to heat the susceptor when powered by the power source.

Development of aerosol generating articles are more rapid in recent years, and in view of the foregoing prior arts, there is a requirement of such device that can offer enhanced consumer experience such as consistent delivery and no leakage to mouth. There are devices with cotton-less reservoirs are used to be in direct contact with the wick which helps in improving the wicking performance, hence the consistent delivery. However, leakage issue still persists when used with such cotton- less reservoirs.

Therefore, there is a dire need for an aerosol generating article with an improved wicking performance whereby avoiding the e-liquid leakage issues from said article and offers consistent aerosol delivery to the consumers when using such articles. Further, there is a need for an aerosol generating article having ease of manufacturing, which is still an area of concern to the developers in the industry.

SUMMARY OF THE INVENTION

The following disclosure presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the present invention. It is not intended to identify the key /critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form as a prelude to a more detailed description of the invention presented later.

An object of the present invention is to provide an aerosol generating article that does not have the drawbacks of the prior art.

It is also an object of the present invention to provide an aerosol generating article having a cartridge comprising a mouthpiece with an absorbent pad and a liquid storage compartment to hold e-liquid.

It is yet another object of the present invention to provide an aerosol generating article comprising an air pipe, integrated into the liquid storage compartment.

It is also an object of the present invention to provide an aerosol generating article with an improved wicking performance, wherein said wick comprises of at least two or more fiber modules formed into a single-bundle like structure. A further object of the present invention is to provide a uniform heat distribution and eliminates the dry puff behavior.

Yet another object of the present invention is to provide an aerosol generating article that prevents the leakage of the liquid into the mouth of the user and to the distal end of the consumable pod.

Briefly, various aspects of the subject matter described herein are directed an aerosol generating device comprising a cartridge, wherein said cartridge further comprising, a wick, and a heating element, said cartridge further comprising, two cups viz, upper cup and lower cup to hold the wick in between the cups.

The aerosol generating article comprises of a vaporizer or a body comprising electronics. The vaporizer is connected to the body containing printed circuit board comprising micro controller. The heater in the vaporizer is controlled by the control circuitry to desired temperature by sensing the resistance of the heating element. The heating element should be chosen such that it is sensitive to the resistance. The change in resistance will be detected by the advanced control circuit techniques such as voltage amplification method.

An aspect of the present invention discloses an aerosol generating article comprising: an outer body extending in a longitudinal direction to operably couple an end cap at one end and a cartridge assembly at the other end; said outer body enclosing a housing, said housing comprising electronic circuitry, a battery assembly, and a charging mechanism embedded therein; said cartridge assembly enclosing therein: a liquid storage compartment for storing vaporizable liquid material or an aerosol source liquid; a heater assembly comprising: a wick to absorb the vaporizable liquid material; and a heating element wounded on the wick material, wherein the wick is arranged to transfer the vaporizable liquid via capillary action to the wick for vaporizing the vaporizable liquid material, and an air pipe integrated into liquid storage compartment for carrying the condensed vapor towards the end of said cartridge assembly, where a user inhales the condensed vapor through a mouthpiece.

Another aspect of the present invention discloses a heater assembly for an aerosol generating article, said heater assembly comprises: a wick to absorb a vaporizable liquid material stored in the aerosol generating article; and a heating element wounded on the wick material, wherein the wick is arranged to transfer the vaporizable liquid material via capillary action for vaporizing the vaporizable liquid material, wherein the wick comprises of at least two or more fiber modules formed into a single-bundle like structure (5123), wherein each fiber module of the wick has a coiled heating element (5122) running across said individual fiber module.

Other salient features and advantages of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:

Figure 1(a) illustrates the external view of an aerosol generating article, according to the present invention. Figure 1(b) illustrates the exploded diagram of the outer body of an aerosol generating article, according to the present invention

Figure 2 illustrates the external view of the cartridge of the aerosol generating article, according to the present invention.

Figure 3 illustrates the exploded diagram with the internal components of an aerosol generating article, according to the present invention.

Figure 4(a) illustrates cartridge configuration of an aerosol generating article, according to the present invention.

Figure 4(b) illustrates the configuration of the heater housing in the cartridge of an aerosol generating article, according to the present invention.

Figure 4(c) illustrates the sectional view of the cartridge of an aerosol generating article, according to the present invention.

Figure 5 illustrates the configuration of the heater assembly of the cartridge in an aerosol generating article, according to the present invention.

Figure 6 illustrates the configuration of the heater assembly in the cartridge of an aerosol generating article, according to the present invention.

Figure 7 illustrates the configuration of the heater assembly with metal panels in the cartridge of an aerosol generating article, according to the present invention.

Figure 8 illustrates the change in weight of liquid with respect to time, in an aerosol generating article, according to the present invention.

Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary.

Accordingly, those skilled in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by their equivalents.

It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

By the term “substantially” wherever used or will be used later it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide. Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

It should be emphasized that the term “comprises” / ’’comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

In an embodiment of the present invention is disclosed an aerosol generating article (10) as shown in Figure 1(a). The article (10) comprises of a body (11) and an end cap (12) and a cartridge (13), said body (11) is the housing for the electronic control system, battery assembly, and charging mechanism, said end cap (12) is for closing the charging system at the end of the body (11), said cartridge (13) comprising a volume devoted for storing vaporizable liquid material or an aerosol source liquid, a heater assembly comprising a wick and a heating element wherein the wick is configured to transfer the liquid via capillary action to the wick for vaporizing the vaporizable liquid material, an air flow path/channel for carrying the condensed vapor towards the end of the cartridge where the user inhales the condensed vapor through a mouthpiece. Aerosol source liquid may contain several components such as but not limited to Propylene glycol, glycerin, Nicotine, suitable acids, water, and flavors.

In another embodiment of the present invention is disclosed as illustrated in figure 1(b). It comprises of a device body (111), an end cap (112), housing of the electronic components (113). In one embodiment, the end cap (112) and the housing of the electronic component (113) are formed as a single unit. The housing encloses a battery (114), a gasket (115), and slots for electrical contacts (116), and charging port (117) and a cartridge (118). In another embodiment of the present invention is the cartridge which is disclosed as illustrated in Figure 2. The cartridge (20) comprising a mouthpiece (21) and liquid storage compartment (22). In another embodiment of the present invention is disclosed an exploded diagram of the aerosol generating article as illustrated in Figure 3. Wherein said article comprises of a liquid refilling sleeve (3214) to cover a liquid storage tank (3213). There is an upper cup (3215) that holds the aerosol carrying duct present in the liquid storage tank (3213). The aerosol carrying duct is an integral part of the storage tank (3213). The wick (3212) is interposed between the condensation tube holder (3215) and the lower cup (3210) after placing on the heater support (3211). The components are enclosed within a body (3213). The cartridge (20) comprises a mouth piece (3217), adapted to cover the components at the end having the absorbent pad (3216).

Figure 3 further illustrates an exemplary embodiment of the power supply for the vapour generation in the article. It consists of a means (3201) to hold the components of the device. On a chassis (3202) the electronic components are arranged as detailed in the figure. It comprises a rubber gasket (3203), printed circuit board, PCB (3206), adapted to be connected by any connecting means. The connecting means may be electrical pogo pin connectors body side (3208). These connectors will be in contact with the contact pins (3209), when the cartridge is inserted into the cavity of the body (3201). A light guide (3207) to direct the light emitting from a LED source positioned on the PCB. A double sided tape (DST) is added for the assembly of the electronic components and to hold them. The chassis (3202) is adapted to accommodate a means for power supply such as a battery (3205). The battery can be charged using the charging connector (3218). In one embodiment the charging can be done using a magnetic connector. The components are held together by the chassis (3202) and an end cap (3204). In one embodiment the chassis (3202) and the end cap (3204) are formed as a single unit. Further, the body (3201) comprises holes on the sides of the body, through which the air enters into the body and the cartridge (20). The body (3201) further comprises a cavity at one end opposite the charging end of the body in which the cartridge is being inserted. In an embodiment of the present invention, the aerosol generating article (320, Fig 3, 4(c)) consists of means to pass air through the air flow channels (4101) present in the lower cup (4125) through which air enters into cartridge (410, Fig 4(a)), then passes over the heating element (4123, Fig 4b) and carries the vapors generated by heating the liquid vaporizable material stored in the volume (4102) of the storage tank absorbed in the wick (3212, Fig 3). The vaporized material further condenses as liquid droplets to form inhalable aerosol in a vapor condensation pipe or an air pipe (4103) and then delivered to the user through the mouthpiece (3217, Fig 3). The heating element (4123, Fig 4(b)) is connected to the power source via the electrical circuitry (3206, Fig 3) containing a microcontroller. Power is supplied to the heating element controlled by microcontroller and the circuit gets (3206, Fig 3) closed while the user inhales puff.

Figure 4(a) discloses the components of the cartridge assembly comprising a liquid storage tank (411), heater module (412), absorbent pads (413), to be placed inside mouth piece (414), and the air flow channels positioned in the bottom of the lower cup (4125).

Figure 4(b) discloses the assembling sequence of the heater module (4120). It comprises an upper cup (4121), a wick material (4122) to absorb the vaporizable liquid, a heating element (4123) wounded on the wick material, a heater holder (4124), and a lower cup (4125). Wick material (4122) is placed on the heater holder (4124) before placing in the lower cup. In an embodiment of the present invention the operating temperature of the heater may be in a range from about 120 - 300 deg C. In some instances, the temperature may exceed upto 600 deg C when the liquid in the reservoir (411) is depleted.

In another embodiment of the present invention, as shown in Figure 5, the heater assembly housing (5120) comprises the upper cup (5121), said wick material (5123) comprises a single fiber module (4122). Single fiber module is formed from a bundle of fiber filaments which are weaved to form a single structure. More preferably the wick material (5123) comprises of two or more fiber modules bundled together to form a single unit. The fiber modules are arranged in any form of circular pattern. More preferably, the wick is made of three fiber modules, bundled to arrange in triangular shape (5123). Each fiber module of the wick having individual coil (5122) formed from a single and continuous heating element, resulting in more fiber module surface in contact with the coil, preventing the loss of heat energy enabling better thermal diffusion. In one embodiment, the heater module is placed in the lower cup (5124) without the heater holder (4124).

Since in traditional heater assembly only one surface of the coil is in contact with the wick but in this invention, it focusses on utilization of the secondary heating surface enabling in lowering the heat loss due to convection. The fiber modules are squeezed to form a single unit with the help of the coil winding.

In an embodiment of the present invention, the heating element (5122) is a tiny filament of diameter ranging from 0.1 mm to 0.25 mm, and said heating element is made of materials selected from a group consisting of Kanthal wire, alternatively stainless steel, titanium, nickel, tungsten, platinum or more preferably any alloy of Nickel .

The combination of two or more fiber module can improve the liquid absorption rate (Figure 8) due to increased capillary action, resulting in improved availability of liquid, preventing drying of wick.

In another embodiment of the present invention is disclosed a wick (6122) as illustrated in Figure 6. Said wick (6122) comprises of two or more fiber modules bundled together to form a single unit, which may have a single coil.

In an embodiment of the present invention, said heating element (5122) is wound around a wick (5123) made of silica, or cotton, or ceramic material. In some examples, said wick (5123) is also made of natural fibers, metal mesh. The typical resistance of the heating element (5122) is more than sub ohm range 0.5 ohms - 2 ohms. More preferably greater than 0.5 ohm, or more preferably greater than 1.0 ohm or more preferably greater than 1.5 or more preferably between 1.0- 2 . In another embodiment of the present invention is disclosed a detailed diagram of the heating compartment as illustrated in Figure 6 which comprises of the upper cup (6121) and the lower cup (6123). The vapor generating compartment comprises two metal panels (713 in Figure 7) arranged in parallel and opposite to each other in the lower cup (6123), and arranged such that they are perpendicular to the air flow direction in which the heating element (4123) is attached to the panels (713). The panels are rested in the lower cup (4123) or lower cup or to any sides of the lower cup. The panels are connected to the heating wire by any means such as soldering or any mechanical bonding. The upper cup opens (6121) to the aerosol carrying duct. Interposed between the upper cup (6121) and the lower cup (6123) is the wick (6122). The design of the device is such that the leakage of the liquid to the mouth is prevented.

In another embodiment of the present invention as illustrated in Figure 4 discloses a support element for the heater assembly (4124 in Figure 4b) which helps in guiding said heater assembly (4122) into the lower cup (4125) and the terminal points of the heating element are folded outside of the heater support (4124) to form rigid electrical contacts. The supporting material can be made of silicone rubber in one of the embodiments.

In a further advantageous embodiment of the invention, it is provided a supporting structure which is made of porous ceramic. This arrangement has the advantageous effect that the liquid seeping out from the liquid compartment can be filled into the pores of the ceramic unit, which resists the liquid leaking towards the vaporizer body. In another advantageous embodiment the porous ceramic can also acts as heat sink by dissipating the extra heat generated from the heating element.

In another embodiment of the present invention is disclosed a detailed diagram of the vapour chamber (700) as illustrated in Figure 7, said chamber (700) comprises an upper cup (711) and a lower cup (714). A wick element (712) is adapted to be interposed between the two cups. Due to this configuration, the resistance towards the liquid transfer to the wick (712) is minimized. Said upper cup (711), said lower cup (714) and said wick (712) interposed therein are so configured that it averts the dry puff effect. Said upper cup (711) and said lower cup (714) are attached to each other by means of press fit or any means of ultrasonic welding to avoid leakage. The configuration also offers consistent delivery without any e-liquid leakage. It is one of the advantageous method in arranging the heater wick enabling to design an optimal clearance between lower cup (714) and upper cup (711) while allowing the liquid only through the lateral sides of said wick (712).

The aerosol generating article consists of air flow channels through which air entering into device will pass over the heating element and carries the vapors generated by heating the liquid vaporizable material present in the wick. The vaporized material further condenses as liquid droplets to form inhalable aerosol and then delivered to the user through the mouthpiece. Aerosol then forms due to higher rate of evaporation of the liquid into vapor and then rapid cooling of this generated vapor. These dual physical processes increase the partial vapor pressure and reduces the saturation vapor pressure further resulting in higher saturation ratios leading the system to a non-equilibrium state. The system try to attain equilibrium by condensing the supersaturated vapors to liquid droplets by minimizing the free energy until the stable droplets are formed to a droplet sizes of less than or equal to 2.5 micron of mass median.

The heating element wound on the wick is connected to the power source via the electrical circuitry containing a microcontroller. Power is supplied to the heating element controlled by microcontroller and the circuit gets closed while the user inhales puff. The operating temperature of the heater will be about 120° - 300° C. In some instances, the temperature can exceed upto 600° C when the liquid in the reservoir is depleted. The heating element is a tiny filament of diameter ranging from 0.1 mm to 0.25 mm. It is made of Kanthal wire, alternatively Stainless steel, or titanium, or nickel, or tungsten, or platinum or more preferably an alloy of Nickel and Chromium such as Nichrome. The heating element is wound around a wick made of silica, or cotton, or ceramic material. In some examples, the wick is also made of natural fibers, metal mesh. The typical resistance of the heating element is more than sub ohm range such as 0.5 ohms - 2 ohms. More preferably greater than 0.5 ohm, or more preferably greater than 1.0 ohm or more preferably greater than 1.5 or more preferably between 1.0 - 2 0.

The aerosol generating article comprises of vaporizer or a body comprising electronics. The vaporizer is connected to the body containing printed circuit board comprising micro controller. The heater in the vaporizer is controlled by the control circuitry to desired temperature by sensing the resistance of the heating element. The heating element should be chosen such that it is sensitive to the resistance. The change in resistance will be detected by the advanced control circuit techniques such as voltage amplification method.

Some of the noteworthy features of the present invention are mentioned below: a. The design of the device is such that it delivers consistent puffs. b. The device features preclude the liquid leakage which is seen as a perennial problem in all the existing EVD formats.

Some of the non-limiting advantages of the present invention over the prior art are mentioned below: a. The invention offers a unique value proposition to the consumers using the device. b. It is easy to manufacture. c. It is a simple in construction and does not use complex structures.

Although an aerosol generating article has been described in language specific to structural features and/or methods, it is to be understood that the implementations disclosed in the above section are not necessarily limited to the specific features or methods or devices described. Rather, the specific features are disclosed as examples of implementations of the aerosol generating article.

Claims

CLAIMS:

1. An aerosol generating article (10) comprising: an outer body (11, 111) extending in a longitudinal direction to operably couple an end cap (12, 112) at one end and a cartridge assembly (13, 118, 20) at the other end; said outer body (11, 111) enclosing a housing (113), said housing (113) comprising electronic circuitry, a battery assembly (114), and a charging mechanism (117, 3218) embedded therein; said cartridge assembly (20) enclosing therein: a liquid storage compartment (22) for storing vaporizable liquid material or an aerosol source liquid; a heater assembly comprising: a wick to absorb the vaporizable liquid material; and a heating element wounded on the wick material, wherein the wick is arranged to transfer the vaporizable liquid via capillary action to the wick for vaporizing the vaporizable liquid material, and an air pipe (4103) integrated into liquid storage compartment (22) for carrying the condensed vapor towards the end of said cartridge assembly (20), where a user inhales the condensed vapor through a mouthpiece (21).

2. The aerosol generating article as claimed in claim 1, wherein the housing (113) comprises: a chassis (3202) and an end cap (3204), adapted to accommodate the battery assembly (3205), and electronic components embedded therein; a rubber gasket (115, 3203) adapted to fit atop the chassis (3202); a printed circuit board, PCB (3206) coupled to the battery assembly (3205), said PCB is adapted to be connected by electrical connector pins/contacts (116, 3208).

3. The aerosol generating article as claimed in claim 1, wherein the cartridge assembly of the device (320) further comprises: a liquid refilling sleeve (3214) covering the liquid storage compartment (3213); the heater assembly comprising a plurality of cups - an upper cup (3215) and a lower cup (3210) arranged to hold the wick, placed on a heater support/holder (3211, 4124) or without a heater holder, said wick being interposed between said upper cup and lower cup, said upper cup and lower cup are attached to each other by means of press fit or any means of ultrasonic welding to avoid leakage, to form a vapor generating compartment, wherein the upper cup (3215) is further adapted to hold the aerosol carrying duct in the liquid storage compartment (3213), wherein the cartridge assembly comprises the mouth piece (3217), adapted to cover the components at the end having an absorbent pad (3216), wherein the heating element (4123) is connected to the battery assembly via the PCB (3206), said PCB comprising a microcontroller configured to control the power supplied to the heating element and the circuit gets closed while the user inhales puff.

4. The aerosol generating article as claimed in claim 1, wherein the heater support/holder (4124) for the heater assembly, is adapted to guide said heater assembly (4122) into the lower cup (4125) and the terminal points of the heating element (4123) are folded outside of the heater support (4124) to form rigid electrical contacts, wherein the heater support material is made of silicone rubber, and the like. 17 The aerosol generating article as claimed in claim 1, wherein an air flow channel (4101) is adapted to allow passage of air into the cartridge assembly, wherein the air passes over the heating element (4123) and carries the vapors generated by heating the liquid vaporizable material absorbed in the wick (3212), and the condenses the vaporized material as liquid droplets to form inhalable aerosol and is delivered to the user through the mouthpiece (3217). The aerosol generating article as claimed in claim 1, wherein the vapor generating compartment comprises two metal panels (713) arranged in parallel and opposite to each other in the lower cup (6123) in which the heating element (4123) is attached to the panels (713), said panels being rested in the lower cup (4123) or to any sides of the lower cup, wherein the panels (713) are connected to the heating wire by any means such as soldering or any mechanical bonding. The aerosol generating article as claimed in claim 1, wherein the aerosol source liquid contains several components such as propylene glycol, glycerin, nicotine, suitable acids, water, and flavors, and the like. The aerosol generating article as claimed in claim 1, wherein said wick comprises of at least two or more fiber modules formed into a single-bundle like structure (5123), wherein said single-bundle structure of the wick having a heating element coiling the said wick (5122). The aerosol generating article as claimed in claim 1, wherein the wick (5123) comprises of three fiber modules, bundled to arrange in triangular shape, wherein each fiber module of the wick having individual coil (5122) is formed from a single and continuous heating element, resulting in more fiber module surface in contact with the coil, preventing the loss of heat 18 energy enabling better thermal diffusion, wherein the wick is made of silica, or cotton, or ceramic material, or natural fibers, metal mesh, and the heating element (5122) is a tiny filament of diameter ranging from 0.1 mm to 0.25 mm, and the resistance of the heating element (5122) is more than sub ohm range 0.5 ohms - 2 ohms, wherein the heating element is made of materials selected from a group consisting of Kanthal wire, alternatively stainless steel, titanium, nickel, tungsten, platinum or more preferably any alloy of Nickel and Chromium.

10. The aerosol generating article as claimed in claim 1, wherein the device is configured to prevent the leakage of the liquid into the mouth of the user and to the distal end of the consumable pod.

11. The aerosol generating article as claimed in claim 1, wherein the operating temperature of the heater assembly is in a range from about 120°C - 300°C, may exceed upto 600°C when the vaporizable liquid material in the liquid storage compartment (411) is depleted.

12. A heater assembly for an aerosol generating article, said heater assembly comprises: a wick to absorb a vaporizable liquid material stored in the aerosol generating article; and a heating element wounded on the wick material, wherein the wick is arranged to transfer the vaporizable liquid material via capillary action for vaporizing the vaporizable liquid material, wherein the wick comprises of at least two or more fiber modules formed into a single-bundle like structure (5123), wherein each fiber module of the wick has a coiled heating element (5122) running across said individual fiber module. 19 The heater assembly as claimed in claim 12, wherein the heater assembly comprises a heater assembly housing (5120) comprising a plurality of cups - an upper cup (5121) and a lower cup (5124) arranged to hold the wick, said wick being interposed between said upper cup and lower cup, said upper cup and lower cup are attached to each other by means of press fit or any means of ultrasonic welding to avoid leakage, to form a vapor generating compartment, wherein the wick is either placed on a heater support/holder (3211, 4124) or without the heater holder, wherein the upper cup (5121) is further adapted to hold an aerosol carrying duct in a liquid storage compartment of the aerosol generating article. The heater assembly as claimed in claim 12, wherein the wick is formed into any geometrical pattern - a circular pattern and the like, more preferably a triangular pattern (5123). The heater assembly as claimed in claim 12, wherein the wick comprises two or more individual fiber modules with a circumference which is equal or lesser than the circumference of a single unit wick (5123) which is combined with two or more fiber modules integrated.