BR112019023644B1 - AEROSOL GENERATING DEVICE FOR USE IN AN AEROSOL GENERATING SYSTEM - Google Patents

Abstract

ADAPTABLE AEROSOL GENERATOR SYSTEM. The present invention relates to an aerosol generating system (10) comprising a cartridge (200) and an aerosol generating device (100). The cartridge comprises a cartridge body (202) defining a substrate compartment (208, 212) and a heater cavity (216) and an aerosol-forming substrate (210, 214) within the substrate compartment. The aerosol generating device comprises a housing (102) defining a device cavity (104) for receiving at least a portion of the cartridge body; an elongated electric heater (106) located in the device cavity; and a thermally conductive sheath (112) secured over the elongated electric heater such that the electric heater is substantially enclosed within the thermally conductive sheath along at least part of its length. The thermally conductive sheath and electrical heater are configured to extend into the heater cavity of the cartridge when the cartridge is received into the cavity of the device such that, in use, the substrate compartment of the cartridge is heated by the electrical heater through the sheath. thermally conductive.

Description

[0001] The present invention relates to an aerosol generating system comprising a cartridge containing an aerosol-forming substrate and an aerosol generating device. In particular, the invention relates to an aerosol generating system comprising a cartridge having a cartridge body defining a substrate compartment and a heater cavity and an aerosol generating device having a device cavity for receiving at least a portion of the cartridge body; an elongated electrical heater located in the device cavity and configured to extend into the heater cavity when the cartridge is received in the device cavity. The present invention also relates to an aerosol generating device for use in such a system and to a kit for such an aerosol generating system. The present invention further relates to a method of adapting an aerosol generating device for use with a cartridge to form an aerosol generating system.

[0002] Known portable aerosol generating systems typically comprise an aerosol generating device comprising a battery, control electronics and an electric heater for heating an aerosol generating article, such as a cartridge, designed specifically for use with the aerosol generating device. aerosol. In some examples, the aerosol-generating article comprises an aerosol-forming substrate, such as a tobacco column or a tobacco plug, and the heater contained in the aerosol-generating device is inserted into or around the aerosol-forming substrate when the aerosol-generating article of aerosol is inserted into the aerosol generating device. In an alternative aerosol-generating system, the aerosol-generating article may include a capsule containing an aerosol-forming substrate, such as loose tobacco, or a liquid storage portion containing a liquid aerosol-forming substrate.

[0003] In another alternative aerosol generating system, the aerosol generating article may include a cartridge in which the aerosol-forming substrate comprises a nicotine source and an acid source. In use, nicotine and acid are reacted with each other in the gas phase to form an aerosol of nicotine salt particles that is inhaled by the user. Devices for delivering aerosol to a user are known which comprise a source of nicotine and a source of volatile delivery enhancing compound. For example, WO 2008/121610 A1 discloses a device in which nicotine and an acid, such as pyruvic acid, are reacted with each other in the gas phase to form an aerosol of nicotine salt particles that is inhaled by the user.

[0004] Aerosol generating systems comprising a cartridge with a cartridge body defining a substrate compartment and a heater cavity, and an aerosol generating device with an elongated electrical heater configured to extend into the heater cavity of the cartridge are known. Differences in the dimensions of the electric heater and heater cavity may make it difficult to transfer heat from the electric heater to the cartridge. These differences or the structure of the electric heater can also lead to the occurrence of hot spots in the cartridge, which can, in turn, lead to inconsistent heating of the aerosol-forming substrate contained therein. Additionally, existing electric heaters may be damaged during insertion into the cartridge heater cavity unless care is taken to ensure that the electric heater and cartridge are properly aligned and additional force is not used.

[0005] It would be desirable to provide an aerosol generating system comprising a cartridge and an aerosol generating device with an electric heater configured to extend into a heater cavity in the cartridge that allows the cartridge to be heated more uniformly by the electric heater. It would also be desirable to provide an aerosol generating system comprising a cartridge and an aerosol generating device with an electric heater configured to extend into a heater cavity in the cartridge which reduces the risk of damage to the electric heater during insertion into the heater cavity.

[0006] According to a first aspect of the present invention, an aerosol generating system comprising a cartridge and an aerosol generating device is provided. The cartridge comprises a cartridge body defining a substrate compartment and a heater cavity and an aerosol-forming substrate within the substrate compartment. The aerosol generating device comprises a housing defining a device cavity for receiving at least a portion of the cartridge body; an elongated electric heater located in the device cavity; and a thermally conductive sheath secured over the elongated electric heater such that the electric heater is substantially enclosed within the thermally conductive sheath along at least part of its length. The thermally conductive sheath and electrical heater are configured to extend into the heater cavity of the cartridge when the cartridge is received into the cavity of the device such that, in use, the substrate compartment of the cartridge is heated by the electrical heater through the sheath. thermally conductive.

[0007] Advantageously, this can improve the efficiency of heat transfer from the electric heater to the cartridge. The sheath can also act to spread heat from the electric heater over a wider surface area than with the electric heater alone, which can reduce the incidence of hot spots in the cartridge and allow for more, or homogenized, heating of the aerosol-forming substrate. . This can lead to more consistent aerosol delivery. Additionally, the sheath may act as a protective covering over the electric heater to reduce the risk of damage to the electric heater during insertion of a cartridge into the device cavity. This can be enhanced by forming the sheath of material that is harder, stiffer, or harder and more rigid than may be possible with the electric heater.

[0008] Furthermore, using a sheath, the heating performance of the device can be adapted to a given cartridge without the need for redesign of the electric heater or the device itself. This is because the geometry of the sheath used can be varied according to the configuration of the cartridge with which the device is intended to be used, for example according to the dimensions of the heater cavity or the position of the substrate compartment within the cartridge. . This can also improve the ease with which a cartridge can be inserted into the device cavity, since by more closely following the dimensions of the heater cavity than the underlying electric heater, the sheath can act as a guide for correct placement. of the cartridge into the device cavity. The sheath may also allow the size of the heater cavity to be increased for a given thickness of the electric heater. This can be particularly beneficial when a thin electric heater is used, as it can be difficult to consistently manufacture cartridges with the correspondingly narrow heater cavities that would be required for effective heat transfer.

[0009] The system comprises a cartridge. The cartridge is consumable. The cartridge and the aerosol generating device are configured to engage and cooperate with each other to form the aerosol generating system for in situ generation of an aerosol. The cartridge may be removably coupled to the aerosol generating device. As used herein, the term "removably coupled" is used to denote that the cartridge and the device can be coupled and uncoupled from each other without significantly damaging the device or the cartridge. The cartridge may be removed from the aerosol-generating device when the aerosol-forming substrate has been consumed. The cartridge can be disposable. The cartridge can be reusable. The cartridge can be refilled with aerosol-forming substrate. The cartridge may be replaceable in the aerosol generating device.

[00010] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds can be released by heating the aerosol-forming substrate.

[00011] As used herein, the term "aerosol generating device" refers to a device that interacts with a cartridge comprising an aerosol-forming substrate to generate an aerosol.

[00012] As used herein, the term "substantially enclosed" means that the portion of the length of the electric heater that is substantially enclosed within the sheath is covered by the sheath at least 70 percent of the outer surface area of the electric heater, preferably, at least 80 percent of its outdoor area, more preferably at least 90 percent of its outdoor area. This includes casing arrangements that extend around the entire circumference of the electric heater, as well as casing arrangements with one or more openings along its length or around its circumference, for example, an open-sided casing.

[00013] In certain embodiments, the thermally conductive sheath covers at least 30 percent of the outer surface area of the electric heater. For example, the thermally conductive sheath may substantially surround the electric heater for about 30 percent of the length of the electric heater. In other examples, the thermally conductive sheath may extend substantially the entire length of the electric heater and includes one or more windows or openings that reduce the amount of the outer surface area of the electric heater that is covered by the sheath to about 30 percent. Where the thermally conductive sheath covers at least 30 percent of the exterior surface area of the electric heater, it will be understood that the thermally conductive sheath may extend over anywhere from about 30 percent of the length of the electric heater to 100 percent of the length of the electric heater. When the thermally conductive sheath comprises one or more windows or openings, the one or more windows or openings are preferably located in the distal portion of the thermally conductive sheath, for example, towards the distal end of the thermally conductive sheath. In this way, the one or more windows or openings can reduce the amount of thermally conductive material required while ensuring good thermal contact between the electric heater and the cartridge towards the proximal end of the thermally conductive sheath.

[00014] As used herein, the term "thermally conductive sheath" refers to a sheath with a thermal conductivity of at least 40 W/m.K, preferably, or at least 100 W/m.K. Unless otherwise noted, thermal conductivity values referenced herein in this document are thermal conductivity values as measured in accordance with ASTM C1114 - 00.

[00015] The sheath may be thermally coupled to the electric heater through one or more intermediate components. Preferably, the sheath is in direct contact with the electric heater along at least part of the length of the sheath. The sheath may be thermally coupled to the cartridge via one or more intermediate components. Preferably, the sheath is in direct contact with the cartridge along at least part of the length of the sheath. In particularly preferred embodiments, the sheath is in direct contact with the cartridge and the electric heater along at least part of the length of the sheath.

[00016] The sheath substantially surrounds the electric heater along its smallest part of the length of the electric heater. In preferred embodiments, the sheath substantially surrounds the electric heater along the entire length of the portion of the electric heater that is configured to extend into the heater cavity of the cartridge. Preferably, the electric heater is contained substantially within the thermally conductive sheath along substantially the entire length of the electric heater. As used herein, the term "along substantially the entire length of the electric heater" refers to at least 80 percent of the length of the electric heater, preferably at least 90 percent of the length of the electric heater, more preferably at least least 95 percent of the length of the electric heater.

[00017] The thermally conductive sheath can be permanently fixed over the electric heater. Advantageously, the thermally conductive sheath can be removably protected over the electric heater. With this arrangement, the sheath can be removed and replaced with a new sheath independently of the rest of the device, for example after a certain number of uses. This may allow device performance to be maintained without the need to clean the electrical heater or thermally conductive sheath. This may allow the sheath to be interchanged with a sheath in accordance with the requirements of a particular cartridge. For example, the sheath may be replaced with a sheath having different dimensions or which is formed from a different material.

[00018] The sheath can be formed from a plurality of components. For example, the sheath may be formed from two or more discrete sheath segments that are joined together. Preferably, the sheath is formed from a single thermally conductive component.

[00019] In preferred embodiments, the sheath is formed from a single sheet of thermally conductive material that has been curved or folded into a shape. This allows for simple construction and fabrication of the sheath.

[00020] In particularly preferred embodiments, the sheath comprises a sheet of thermally conductive material that has been curved or folded along a single fold line, such that the sheath comprises two opposing sheath walls, between which the electrical heater is substantially enclosed along at least part of its length and from an opening opposite the single fold line. This has been found to provide a particularly simple yet effective framework. The opening can make it easier to place the sheath over the electric heater during fabrication or assembly.

[00021] Preferably, the sheet of thermally conductive material is elastic and curved or folded so that the fold line provides a spring force to tilt the sheath walls spaced apart in the opening. This can improve the ease with which the sheath is positioned over the electric heater, either by a user or during manufacturing. For example, the sheet of thermally conductive material may be curved or folded into a substantially V shape. With this arrangement, the walls of the sheath are angled spaced apart in the opening. The opposite walls of the sheath can then be closed together over the electric heater. For example, where the electric heater is flat, the opposing sheath walls can then be closed together over the electric heater so that the sheath walls are parallel.

[00022] The sheath may have a substantially smooth outer surface. This can reduce the insertion force required to insert the sheath into the heater cavity of a cartridge and, therefore, the insertion force required to insert the cartridge into the device cavity.

[00023] In preferred embodiments, the sheath comprises a plurality of elevations on its outer surface.

[00024] In particularly preferred embodiments, the sheath comprises a corrugated sheet of thermally conductive material. With this arrangement, the corrugated structure allows the sheath to be flexed throughout its thickness to conform to the outer surface of the electric heater and the inner surface of the cartridge heater cavity. This can improve the consistency of thermal contact between the electric heater and cartridge by compensating for manufacturing tolerances of the electric heater, sheath and cartridge. This can allow for more efficient heat transfer between the electric heater and the cartridge. This can also help ensure more consistent performance between different cartridges or devices. It may also allow reliable contact between the sheath and the cartridge by limiting the insertion force between the cartridge and the device. The corrugations can also increase the moment of inertia of the sheath relative to a flat sheet of the same sheet thickness. This increases the rigidity of the sheath and may reduce the risk of bending of the electric heater and sheath during insertion of the cartridge into the device cavity. It can also reduce the amount of material required to manufacture a sheath of a certain stiffness or thickness.

[00025] Preferably, the corrugated sheet of thermally conductive material comprises a first set of corrugations extending along a first direction and a second set of corrugations extending along a second direction that is at an angle to the first sense. With this arrangement, the rigidity of the sheath can be maintained in all directions. This differs from an arrangement in which each corrugation extends in a single direction across the entire width or length of the sheath, in which the sheath may be more susceptible to bending in a bending moment, being applied about an axis that is parallel to the direction of wave. In some embodiments, the corrugations are arranged in a chevron pattern. The sheet may be corrugated so that the ripples in the resulting sheet are symmetrical about one or more axes. For example, the corrugations may be symmetrical about the longitudinal axis of the sheath.

[00026] The thermally conductive sheath can be made of any suitable thermally conductive material. Preferably, the thermally conductive sheath is formed from a metal or alloy. Suitable materials include, but are not limited to, aluminum, copper and steel or combinations thereof.

[00027] The sheath can be of any suitable thickness. In certain preferred embodiments, the sheath has a thickness of approximately 0.20 mm to approximately 0.35 mm, preferably approximately 0.22 mm to approximately 0.30 mm, more preferably approximately 0.25 mm to approximately 0.29 mm, more preferably approximately 0.27 mm. These bands have been found to provide a particularly desirable combination of effective heat transfer and electrical heater protection without excessively increasing the weight of the device or the insertion force required to insert a cartridge into the device cavity.

[00028] As used herein, the term "thickness" in relation to the sheath refers to the thickness of a wall of the sheath, rather than the total width or depth of the sheath as a whole. For example, where the sheath is made from a sheet of thermally conductive material, the term "thickness" refers to the thickness of the sheet itself.

[00029] The sheath can be fixed in the device cavity by any suitable connection. For example, the sheath is removably secured over the electric heater by a clamp or a retaining pin. In preferred embodiments, the sheath has a sheath fitting whereby the sheath is secured over the electric heater. The sheath fitting is preferably at the distal end of the sheath. Preferably, the sheath fitting is configured to press fit against a retainer at the distal end of the device cavity origin point. In such embodiments, the sheath fitting may be of any suitable shape. For example, the sheath fitting may generally be disc-shaped. The retainer may include a clip within which the sheath fitting is retained. The retainer may include a raised tab against which the sheath fitting is press fit.

[00030] When the sheath comprises a sheet of thermally conductive material that has been flexed or bent to a certain shape so that the sheath comprises two or more sheath walls in which the electrical heater is substantially enclosed, fitting of the sheath may be provided at the distal end of one or more of the sheath walls. Advantageously, the sheath fitting comprises a first sheath fitting portion at the distal end of a first sheath wall and a second sheath fitting portion at the distal end of a second sheath wall. With this arrangement, the sheath fitting is formed when the sheath walls are brought together around the electric heater and the sheath fitting portions combine to define the sheath fitting. This can help the sheath fit hold the sheath walls together against the electric heater, as well as keep the sheath within the device cavity.

[00031] The sheath fitting can be made of any suitable high temperature resistant material. Preferably, the sheath fitting is made from a material with low thermal conductivity. For example, the sheath fitting may comprise or be made of PEEK.

[00032] The aerosol generating device according to the present invention comprises an elongated electric heater. The electric heater may be a single electric heater. This advantageously provides a simple construction of the device.

[00033] The electric heater is configured as an internal heater which in use is positioned internally in relation to the cartridge. The aerosol generating device may advantageously further comprise a guide portion configured for engagement with the cartridge to facilitate proper alignment of the electric heater with the heater cavity of the cartridge.

[00034] Advantageously, the electric heater is configured to heat the cartridge to a temperature below approximately 250 degrees Celsius. Preferably, the electric heater is configured to heat the cartridge to a temperature between about 80 degrees Celsius and about 150 degrees Celsius.

[00035] Advantageously, the elongated electric heater is in the form of a heater blade with a width greater than its thickness. In such embodiments, the heater cavity in the cartridge may be configured as an elongated groove.

[00036] The electric heater may be a resistive heater. Alternatively, the electric heater may be an induction heater. Preferably, the electric heater comprises an electric heating element comprising an electrically resistive material. The electrical heating element may comprise a non-elastic material, for example, a sintered ceramic material such as alumina (Al2O3) and silicon nitride (Si3N4) or printed circuit board or silicon rubber. Alternatively, the electrical heating element may comprise an elastic metallic material, for example, an iron alloy or a nickel-chromium alloy.

[00037] Other suitable electrically resistive materials include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metal and metal alloys and materials composites made from a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and platinum group metals. Examples of suitable metal alloys include alloys of stainless steel, nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium and manganese, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal® and iron-manganese-aluminum alloys. Timetal® is a registered trademark of Titanium Metals Corporation, 1999 Broadway Suite 4300, Denver, Colorado. In composite materials, the electrically resistive material can optionally be incorporated, encapsulated or coated with insulating material or vice versa, depending on the kinetics of power transfer and the external physiochemical properties required.

[00038] The electrical heating element can be formed using a metal with a defined relationship between temperature and resistivity. In these embodiments, the metal may be formed as a rail between two layers of suitable insulation materials. An electrical heating element formed in this way can be used as a heater and a temperature sensor.

[00039] Preferably, the electric heater does not project from the aerosol generating device.

[00040] The aerosol generating system may further comprise a power source for supplying power to an electric heater and a controller configured to control a power supply from the power source to the electric heater. Any suitable electronic circuit can be used as a controller. The controller can be programmable.

[00041] The power source can be a DC voltage source. In preferred embodiments, the power supply source is a battery. For example, the power supply source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, e.g., lithium-cobalt, lithium-iron-phosphate, or a polymer polymer battery. lithium. The energy source may alternatively be another form of charge storage device, such as a capacitor. The energy source may require recharging and may have a capacity that allows sufficient energy to be stored for use of the aerosol generating device with one or more aerosol generating articles.

[00042] The aerosol generating device may include one or more temperature sensors configured to detect the temperature of the electric heater and the temperature of the substrate compartment of the cartridge. In these embodiments, the controller may be configured to control the supply of power to the heater based on the detected temperature.

[00043] The cartridge may be received entirely within the device cavity of the aerosol generating device or partially within the device cavity of the aerosol generating device. For example, the length of the device cavity of the aerosol generating device is less than the length of the aerosol generating article so that when the aerosol generating article is received into the cavity of the aerosol generating device, the proximal or downstream end of the cartridge protrudes from the cavity of the aerosol generating device.

[00044] Preferably, the device cavity of the aerosol generating device is substantially cylindrical.

[00045] As used herein with reference to the present invention, the terms "cylinder" and "cylindrical" refer to a substantially straight circular cylinder with a pair of opposing substantially flat end faces.

[00046] Preferably, the device cavity of the aerosol generating device has a diameter substantially equal to or slightly larger than the diameter of the cartridge.

[00047] The cartridge comprises a substrate compartment in which an aerosol-forming substrate is positioned. The substrate compartment may contain a single aerosol-forming substrate. The substrate compartment may contain a plurality of aerosol-forming substrates. When the substrate compartment contains a plurality of aerosol-forming substrates, they can be stored separately or together. In preferred embodiments, the cartridge comprises a nicotine source and an acid source for use in an aerosol generating system for in situ generation of an aerosol comprising nicotine salt particles. As used herein with reference to the present invention, by "in situ" is meant that, in use, the nicotine vapor released from the nicotine source and the lactic acid vapor released from the lactic acid source react with each other in gaseous phase within the aerosol generating system according to the present invention to form an aerosol consisting of nicotine lactate salt particles.

[00048] As used herein with reference to the invention, the term "nicotine" is used to describe nicotine, nicotine base or a nicotine salt. In embodiments in which a carrier material is impregnated with nicotine base or a nicotine salt, the amounts of nicotine dictated herein are the amount of nicotine base or the amount of ionized nicotine, respectively.

[00049] The nicotine source may comprise one or more of nicotine, nicotine base, a nicotine salt, such as nicotine-HCl, nicotine bitartrate or nicotine dictatortrate or a nicotine derivative. The nicotine source may comprise natural nicotine or synthetic nicotine. The nicotine source may comprise pure nicotine, a solution of nicotine in an aqueous or non-aqueous solvent, or a liquid tobacco extract.

[00050] The nicotine source may further comprise an electrolyte-forming compound. The electrolyte-forming compound may be selected from the group consisting of alkali metal hydroxides, alkali metal oxides, alkali metal salts, alkaline earth metal oxides, alkaline earth metal hydroxides, and combinations thereof. For example, the nicotine source may comprise an electrolyte-forming compound selected from the group consisting of potassium hydroxide, sodium hydroxide, lithium oxide, barium oxide, potassium chloride, sodium chloride, sodium carbonate, sodium citrate. , ammonium sulfate and combinations thereof.

[00051] In certain embodiments, the nicotine source may comprise an aqueous solution of nicotine, nicotine base, a nicotine salt or a nicotine derivative and an electrolyte-forming compound. Alternatively or additionally, the nicotine source may further comprise other components including, but not limited to, natural flavors, artificial flavors and antioxidants.

[00052] The nicotine source may include a first carrier material impregnated with nicotine. For example, the first carrier material may be impregnated with between about 1 milligram and about 50 milligrams of nicotine, preferably between about 1 milligram and about 40 milligrams of nicotine, more preferably between about 3 milligrams and about 30 milligrams. of nicotine, more preferably between about 6 milligrams and about 20 milligrams of nicotine, more preferably between about 8 milligrams and about 18 milligrams of nicotine.

[00053] The first carrier material can be impregnated with liquid nicotine or a nicotine solution in an aqueous or non-aqueous solvent. The first carrier material may be impregnated with natural nicotine or synthetic nicotine.

[00054] Advantageously, the first carrier material has a density between approximately 0.1 grams/cubic centimeter and approximately 0.3 grams/cubic centimeter. Advantageously, the first carrier material has a porosity of between approximately 15 percent and approximately 55 percent.

[00055] The first carrier material may comprise one or more of glass, cellulose, ceramics, stainless steel, aluminum, polyethylene (PE), polypropylene, polyethylene terephthalate (PET), poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene terephthalate polybutylene (PBT), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE) and BAREX®.

[00056] The first carrier material acts as a reservoir for nicotine.

[00057] Advantageously, the first carrier material is chemically inert with regard to nicotine.

[00058] The first carrier material can be any appropriate shape and size. For example, the first carrier material may be in the form of a sheet or plug. The shape, size, density and porosity of the first carrier material can be chosen to allow the first carrier material to be impregnated with a desired amount of nicotine.

[00059] Advantageously, the first carrier material may further include a flavoring. Suitable flavorings include, but are not limited to, menthol. Advantageously, the first carrier material may be impregnated with between about 3 milligrams and about 12 milligrams of flavoring.

[00060] The acid source may comprise an organic acid or an inorganic acid.

[00061] Preferably, the acid source comprises an organic acid, more preferably a carboxylic acid, more preferably an alpha-keto or 2-oxo acid or lactic acid

[00062] Advantageously, the acid source comprises an acid selected from the group consisting of 3-methyl-2-oxopentanoic acid, pyruvic acid, 2-oxopentanoic acid, 4-methyl-2-oxopentanoic acid, 3-methyl-2- oxobutanoic acid, 2-oxooctanoic acid, lactic acid and combinations thereof. Advantageously, the acid source comprises pyruvic acid or lactic acid. More advantageously, the acid source comprises lactic acid.

[00063] The acid source may include a second acid-impregnated carrier material. Preferably, the acid source is a lactic acid source comprising a second carrier material impregnated with lactic acid. For example, the second carrier material may be impregnated with about 2 milligrams and about 60 milligrams of lactic acid, between about 5 milligrams and about 50 milligrams of lactic acid, more preferably between about 8 milligrams and about 40 milligrams. of lactic acid, more preferably between about 10 milligrams and about 30 milligrams of lactic acid.

[00064] Advantageously, the second carrier material has a density of between about 0.1 grams/cubic centimeter and about 0.3 grams/cubic centimeter. Advantageously, the second carrier material has a porosity of between about 15 percent and about 55 percent.

[00065] The second carrier material may comprise one or more of glass, cellulose, ceramic, stainless steel, aluminum, polyethylene (PE), polypropylene, polyethylene terephthalate (PET), poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene terephthalate polybutylene (PBT), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE) and BAREX®.

[00066] The second carrier material acts as a reservoir for the acid.

[00067] Advantageously, the second carrier material is chemically inert with respect to the acid.

[00068] The second carrier material can be of any appropriate shape and size. For example, the second carrier material may be in the form of a sheet or plug. The shape, size, density and porosity of the second carrier material can be chosen to allow the second carrier material to be impregnated with a desired amount of acid.

[00069] The first carrier material and the second carrier material may be the same or different.

[00070] Preferably, the substrate compartment comprises a first compartment containing a nicotine source and a second compartment containing an acid source. The nicotine source preferably comprises a first carrier material impregnated with nicotine, as discussed above. Advantageously, the shape of the first carrier material is similar to the shape and size of the first cartridge compartment. The acid source preferably comprises a second acid-impregnated carrier material, such as lactic acid. Advantageously, the shape and size of the second carrier material are similar to the shape and size of the second cartridge compartment.

[00071] Advantageously, the electric heater is configured to heat the first compartment and the second compartment of the cartridge to substantially the same temperature.

[00072] As used herein with reference to the invention, by "substantially the same temperature" it is to be understood that the difference in temperature between the first compartment and the second compartment of the cartridge measured at corresponding locations relative to the heater is less than about 3°C.

[00073] In use, heating the first compartment and the second compartment of the cartridge to a temperature above room temperature advantageously allows the concentrations of nicotine vapor in the first compartment of the cartridge and the vapor pressure of the acid in the second compartment of the cartridge are controlled and balanced proportionally to produce an efficient stoichiometric reaction between nicotine and acid. Advantageously, this can improve the efficiency of nicotine salt particle formation and the consistency of nicotine delivery to a user. Advantageously, this can also reduce the delivery of unreacted nicotine and unreacted acid to a user.

[00074] The cartridge comprises a heater cavity for receiving the electrical heater and the thermally conductive sleeve of the aerosol generating device. When the cartridge comprises two or more aerosol-forming substrates, such as a nicotine source and an acid source stored in a first compartment and a second compartment, the electric heater is preferably configured to heat the first compartment and the second compartment. . In such embodiments, the heater cavity is advantageously located between the first compartment and the second compartment. The first compartment and the second compartment are arranged on both sides of the heater cavity.

[00075] In preferred embodiments, the aerosol-forming substrate comprises a nicotine source and an acid source and the substrate compartment comprises a first compartment containing the nicotine source and a second compartment containing the acid source, wherein the first and second compartment are positioned on both sides of the heater cavity.

[00076] Advantageously, the heater cavity extends from the distal end of the cartridge at least halfway along the length of the cartridge. Advantageously, the heater cavity extends along the longitudinal axis of the cartridge.

[00077] The heater cavity may extend from the distal end of the cartridge to the proximal end of the cartridge. In such embodiments, the heater cavity has an open distal end and an open proximal end. The heater cavity may extend from the distal end to halfway along the length of the cartridge. In such embodiments, the heater cavity has an open distal end and a closed proximal end.

[00078] The heater cavity can be included along its length.

[00079] The heater cavity may be at least partially open along its length. This can make it easier to insert a heater into the heater cavity.

[00080] As further described and illustrated below, the cartridge preferably comprises a first compartment comprising the nicotine source and a second compartment comprising a lactic acid source. As used herein, the term "first compartment" is used to describe one or more chambers or containers within the cartridge that comprise the nicotine source. As used herein, the term "second compartment" is used to describe one or more chambers or containers within the cartridge comprising the acid source.

[00081] The first compartment may consist of one or more first chambers within the cartridge. The number and dimensions of the first chamber can be chosen to allow a desired amount of nicotine to be included in the cartridge. The second compartment may consist of one or more second chambers within the cartridge. The number and dimensions of the second chambers can be chosen to allow a desired amount of acid to be included in the cartridge.

[00082] The first compartment and the second compartment can touch each other. Alternatively, the first compartment and the second compartment may be spaced apart.

[00083] When in use, nicotine vapor is released from the nicotine source in the first compartment and acid is released from the acid source in the second compartment. Nicotine vapor reacts with acid vapor in the gas phase to form an aerosol, which is distributed to a user. Preferably, the aerosol generating system according to the present invention further comprises a reaction chamber downstream of the first compartment and the second compartment, configured to facilitate the reaction between the nicotine vapor and the acid vapor. The cartridge may include the reaction chamber. Alternatively, since the aerosol generating system comprises a nozzle portion, the nozzle portion may comprise the reaction chamber.

[00084] As described in more detail below, the first compartment and the second compartment can be arranged in series or parallel within the cartridge. Preferably, the first compartment and the second compartment are arranged in parallel.

[00085] As used herein, by "series" is meant that the first compartment and the second compartment are arranged within the cartridge so that, when in use, a flow of air drawn through the cartridge passes through one of the first compartment and the second compartment, then passing through the other between the first compartment and the second compartment. Nicotine vapor is released from the nicotine source in the first compartment into the air stream drawn through the cartridge and acid is released from the acid source in the second compartment into the air stream drawn through the cartridge. Nicotine vapor reacts with acid vapor in the gas phase to form an aerosol, which is distributed to a user.

[00086] In certain embodiments, the cartridge may comprise an air inlet, a first compartment comprising a nicotine source in communication with the air inlet, a second compartment comprising the acid source in communication with the first compartment; and an air outlet, wherein the air inlet and air outlet are in communication with each other and are configured so that air can pass from the cartridge through the air inlet, through the cartridge, and out of the cartridge through the outlet. of air.

[00087] As used herein with reference to the invention, the term "air inlet" is used to describe one or more openings through which air can be drawn into a component or portion of a component of the aerosol generating system. . As used herein with reference to the invention, the term "air vent" is used to describe one or more openings through which air can be drawn out of a component or portion of a component of the aerosol generating system.

[00088] In such embodiments, the first compartment and the second compartment are arranged in series from the air inlet to the air outlet within the cartridge. That is, the first compartment is downstream of the air inlet, the second compartment is downstream of the first compartment, and the air outlet is downstream of the second compartment. When in use, a flow of air is drawn into the housing through the air inlet, downstream through the first compartment and out of the cartridge through the air outlet.

[00089] In these embodiments, the cartridge may further comprise a third compartment in communication with the second compartment and the air outlet. When in use in these embodiments, a flow of air is drawn into the cartridge through the air inlet, downstream through the first compartment, the second compartment, and then the third compartment and out of the cartridge through the air outlet.

[00090] In these embodiments, the cartridge may further comprise a nozzle in communication with the second compartment or the third compartment, when present, and the air outlet. When in use in these embodiments, a stream of air is drawn into the cartridge through the air inlet, downstream through the first compartment, the second compartment, the third compartment, when present, and then through the nozzle and out of the cartridge. cartridge through the air outlet.

[00091] In other embodiments, the cartridge may comprise: an air inlet, a second compartment comprising an acid source in communication with the air inlet, a first compartment comprising the nicotine source in communication with the second compartment, and an outlet air inlet and air outlet are in communication with each other and are configured so that air can pass through the cartridge through the air inlet, through the cartridge, and out of the cartridge through the air outlet.

[00092] In such embodiments, the second compartment and the first compartment are arranged in series from the air inlet to the air outlet within the cartridge. That is, the second compartment is downstream of the air inlet, the first compartment is downstream of the second compartment, and the air outlet is downstream of the first compartment. When in use, a flow of air is drawn into the cartridge through the air inlet, downstream through the second compartment, then through the first compartment and out of the cartridge through the air outlet.

[00093] In these embodiments, the cartridge may further comprise a third compartment in communication with the first compartment and the air outlet. When in use in these embodiments, a flow of air is drawn into the cartridge through the air inlet, downstream through the second compartment, the first compartment, and then the third compartment, and out of the cartridge through the outlet. of air.

[00094] In these embodiments, the cartridge may further comprise a nozzle in communication with the first compartment or the third compartment, when present, and the air outlet. When in use in these embodiments, a stream of air is drawn into the cartridge through the air inlet, downstream through the second compartment, the first compartment, the third compartment, when present, and then through the nozzle and out of the cartridge. cartridge through the air outlet.

[00095] Since the first compartment and the second compartment are arranged in series within the cartridge, the second compartment is preferably downstream of the first compartment, so that, when in use, a flow of air drawn through the cartridge passes through from the first compartment and then passes through the second compartment.

[00096] Locating the second compartment comprising the acid source downstream of the first compartment comprising the nicotine source advantageously improves the consistency of nicotine delivery from the aerosol generating system. Without being bound by theory, it is believed that locating the acid source downstream of the nicotine source reduces or prevents the deposition of lactic acid vapor released from the acid source onto the nicotine source during use. This reduces the decline over time of nicotine delivery from the aerosol generating system. This can also reduce the risk of unwanted acid vapor delivery to a user.

[00097] As used herein, by "parallel", it is understood that the first compartment and the second compartment are arranged within the cartridge so that, when in use, a first stream of air drawn through the cartridge passes through the first compartment and a second stream of air drawn through the cartridge passes through the second compartment. Nicotine vapor is released from the nicotine source in the first compartment into the first air stream drawn through the cartridge and acid vapor is released from the acid source in the second compartment into the second air stream drawn through the cartridge . The nicotine vapor in the first air stream reacts with the acid vapor in the second air stream in the gas phase to form an aerosol, which is distributed to a user.

[00098] In certain embodiments, the cartridge comprises: an air inlet; a first compartment comprising a nicotine source in communication with the air inlet, a second compartment comprising an acid source in communication with the air inlet; and an air outlet, wherein the air inlet and air outlet are in communication with each other and are configured so that air can pass through the cartridge through the air inlet, through the cartridge, and out of the cartridge through the outlet. of air.

[00099] In such embodiments, the first compartment and the second compartment are arranged in parallel from the air inlet to the air outlet inside the cartridge. The first compartment and the second compartment are both located downstream of the air inlet and upstream of the air outlet. During use, a stream of air is drawn into the cartridge through the air inlet, a first portion of the air stream being drawn downstream through the first compartment and a second portion of the air stream being drawn downstream through the second compartment.

[000100] In these embodiments, the cartridge may further comprise a third compartment in communication with one or both of the first compartment and the second compartment and the air outlet. In these embodiments, the cartridge may further comprise a nozzle in communication with the first compartment and the second compartment or the third compartment, present and the air outlet.

[000101] In other embodiments, the cartridge comprises: a first air inlet; a second air intake; a first compartment comprising the nicotine source in communication with the first air inlet; a second compartment comprising the acid source in communication with the second air inlet; and an air outlet, wherein the first air inlet, the second air inlet and the air outlet are in communication with each other and are configured so that air can pass through the cartridge through the first air inlet, through the cartridge and out of the cartridge through the air outlet and so that air can pass through the cartridge through the first air inlet, through the cartridge and out of the cartridge through the air outlet.

[000102] In these embodiments, the first compartment and the second compartment are arranged in parallel within the cartridge. The first compartment is located downstream of the first air inlet and upstream of the air outlet and the second compartment is located downstream of the second air inlet and upstream of the air outlet. During use, the first air stream is drawn into the cartridge through the first air inlet and downstream through the first compartment and a second air stream is drawn into the cartridge through the second air inlet and downstream. downstream through the second compartment.

[000103] The first air outlet of the first cartridge compartment is located at the proximal end of the first cartridge compartment. The first air inlet of the first cartridge compartment is located upstream of the first air outlet of the first cartridge compartment. The second air outlet of the second cartridge compartment is located at the proximal end of the second cartridge compartment. The second air inlet of the second cartridge compartment is located upstream of the second air outlet of the second cartridge compartment.

[000104] In these embodiments, the cartridge may further comprise a third compartment in communication with one or both of the first compartment and the second compartment and the air outlet. In these embodiments, the cartridge may further comprise a nozzle in communication with the first compartment and the second compartment or the third compartment, present and the air outlet.

[000105] Since the cartridge comprises a third compartment, the third compartment may comprise one or more aerosol modifying agents. For example, the third compartment may comprise one or more sorbents, such as activated carbon, one or more flavoring agents, such as menthol, or a combination thereof.

[000106] Preferably, the first compartment is a first elongated compartment with a length L1 and a maximum cross-sectional area A1, the first compartment having a first air inlet and a first air outlet and containing a nicotine source comprising a first nicotine-loaded carrier material as described above.

[000107] Preferably the second compartment is a second elongated compartment with a length L2 and a maximum cross-sectional area A2, the second compartment having a second air inlet and a second air outlet and containing an acid source, where the first compartment and the second compartment are arranged parallel within the cartridge and wherein the ratio (L1)2:A1 is at least about 12:1 and wherein the ratio (L2)2:A2 is at least about 12:1 .

[000108] Advantageously, providing a first elongated compartment with a length L1 and a maximum cross-sectional area A1 and a second elongated compartment with a length L2 and a maximum cross-sectional area A2, in which ratio of (L1)2 to A1 and (L2)2 to A2 is at least about 12:1 facilitates uniform heating of the nicotine source in the first compartment from the acid source in the second compartment throughout the use of the cartridge. This may also facilitate the vaporization of nicotine from the nicotine source in the first compartment and the vaporization of acid from the acid source in the second compartment.

[000109] Preferably, the ratio of (L1)2 to A1 is between about 12:1 and about 400:1.

[000110] Preferably, the ratio of (L1)2 to A1 is at least about 15:1.

[000111] Preferably, the ratio of (L1)2 to A1 is between about 15:1 and about 200:1.

[000112] Preferably, the ratio of (L1)2 to A1 is at least about 20:1.

[000113] Preferably, the ratio of (L1)2 to a1 is between about 20:1 and about 100:1.

[000114] For example, the ratio of (L1)2 to A1 may be between about 25:1 and about 70:1 or between about 30:1 and about 70:1.

[000115] Preferably, the ratio of (L2)2 to A2 is between about 12:1 and about 400:1.

[000116] Preferably, the ratio of (L2)2 to A2 is at least about 15:1.

[000117] Preferably, the ratio of (L2)2 to A2 is between about 15:1 and about 200:1.

[000118] Preferably, the ratio of (L2)2 to A2 is at least about 20:1.

[000119] Preferably, the ratio of (L2)2 to A2 is between about 20:1 and about 100:1.

[000120] For example, the ratio of (L2)2 to A2 may be between about 25:1 and about 70:1 or between about 30:1 and about 70:1.

[000121] Providing the nicotine source and the acid source in separate compartments with separate air inlets and separate air outlets can advantageously facilitate control of the stoichiometry reaction between nicotine and acid.

[000122] The ratio between nicotine and acid necessary to carry out a reaction of adequate stoichiometry can be controlled and balanced by varying the volume of the first compartment in relation to the volume of the second compartment.

[000123] The number and dimensions of the first cartridge compartment can be chosen to allow a desired amount of nicotine to be included in the cartridge.

[000124] The shape and dimensions of the second cartridge compartment can be chosen to allow a desired amount of acid to be included in the cartridge.

[000125] The first compartment can have a length L1, a width W1 and a height H1 and the second compartment can have a length L2, a width W2 and a height H2. Advantageously, the ratio of L1 to W1 and L2 to W2 may be between about 2:1 and about 4:1, for example, between about 5:2 and about 3:1. Advantageously, the ratio of L1 to H1 and L2 to H2 may be at least about 6:1.

[000126] Advantageously, the ratio of L1 to H1 and L2 to H2 can be between about 6:1 and about 30:1. Advantageously, the ratio of L1 to H1 and L2 to H2 can be between about 8:1 and about 16:1.

[000127] Advantageously, the first cartridge compartment has a length L1 of between about 8 millimeters and about 40 millimeters, for example, between about 10 millimeters and about 20 millimeters. Advantageously, the first cartridge compartment has a width W1 of about 4 millimeters and about 6 millimeters. Advantageously, the first cartridge compartment has a height H1 of between about 0.5 millimeters and about 2.5 millimeters.

[000128] The first cartridge compartment may have a cross section of any suitable shape. For example, the cross-sectional shape of the first compartment may be circular, semicircular, elliptical, triangular, square, rectangular or trapezoidal.

[000129] Advantageously, the second cartridge compartment has a length L2 of between about 8 millimeters and about 40 millimeters, for example, between about 10 millimeters and about 20 millimeters. Advantageously, the second cartridge compartment has a W2 width of about 4 millimeters and about 6 millimeters. Advantageously, the second cartridge compartment has a height H2 of between about 0.5 millimeters and about 2.5 millimeters.

[000130] The second cartridge compartment may have any suitable transverse shape. For example, the cross-sectional shape of the second compartment may be circular, semicircular, elliptical, triangular, square, rectangular or trapezoidal.

[000131] The volume and dimensions of the first compartment and the second compartment of the cartridge may be the same or different.

[000132] Advantageously, the ratio of the length of the first L1 compartment to the length of the second L2 compartment is between about 2:1 and about 1:2, more advantageously between about 1.2:1 and about 1:1.2.

[000133] Advantageously, the ratio of the maximum cross-sectional area of the first compartment A1 to the maximum cross-sectional area of the first compartment A2 is between about 2:1 and about 1:2, more advantageously between about 1.2:1 and about 1:1.2.

[000134] Advantageously, the shape and dimensions of the first compartment and the second compartment are substantially the same. Providing a first compartment and a second compartment that have substantially the same shape and dimensions can advantageously simplify the manufacture of the cartridge.

[000135] The first air inlet of the first cartridge compartment and the second air inlet of the second cartridge compartment may each include one or more openings. For example, the first air inlet of the first cartridge compartment and the second air inlet of the second cartridge compartment may each comprise one, two, three, four, five, six or seven openings.

[000136] The first air inlet of the first cartridge compartment and the second air inlet of the second cartridge compartment may include the same or different numbers of openings.

[000137] Advantageously, the first air inlet of the first cartridge compartment and the second air inlet of the second cartridge compartment comprise a plurality of openings. For example, the first air inlet of the first cartridge compartment and the second air inlet of the second cartridge compartment may comprise two, three, four, five, six or seven openings each.

[000138] Providing a first compartment with a first air inlet comprising a plurality of openings and a second compartment with a second air inlet comprising a plurality of openings can advantageously result in a more homogeneous air flow within the first compartment and the second compartment, respectively. In use, this can improve nicotine entrainment in an airflow drawn through the first compartment and improve acid entrainment in an airflow drawn through the second compartment.

[000139] The ratio of nicotine to acid required to achieve adequate reaction stoichiometry can be controlled and balanced by varying the volumetric airflow through the first compartment of the cartridge in relation to the volumetric airflow through the second compartment of the cartridge. cartridge. The ratio of the volumetric airflow through the first compartment to the volumetric airflow through the second compartment can be controlled by varying one or more of the number, dimensions and location of openings forming the first air inlet of the first compartment. of the cartridge in relation to the number, dimensions and location of the openings forming the second air inlet of the second cartridge compartment.

[000140] In embodiments in which the acid source comprises lactic acid, advantageously the flow area of the second air inlet of the second cartridge compartment is greater than the flow area of the first air inlet of the first cartridge compartment.

[000141] As used herein with reference to the invention, the term "flow area" is used to describe the maximum cross-sectional area of an air inlet or air outlet through which air flows during use. In embodiments in which an air inlet or air outlet comprises a plurality of openings, the flow area of the air inlet or air outlet is the total flow area of the air inlet or air outlet and is equal to the sum of the flow areas of each of the plurality of openings forming the air inlet or air outlet. In embodiments in which the cross-sectional area of an air inlet or an air outlet varies in the direction of air flow, the flow area of the air inlet or air outlet is the minimum cross-sectional area in the direction of the air flow.

[000142] Increasing the flow area of the second air inlet of the second cartridge compartment relative to the flow area of the first air inlet of the first cartridge compartment advantageously increases the volumetric airflow through the second air inlet compared to volumetric flow through the first air inlet.

[000143] In embodiments in which the acid source comprises lactic acid, preferably the ratio of the flow area of the first air inlet of the first cartridge compartment to the flow area of the second air inlet of the second cartridge compartment is between approximately 3:4 and approximately 1:2. More preferably, the ratio of the flow area of the first air inlet of the first cartridge compartment to the flow area of the second air inlet of the second cartridge compartment is between approximately 2:3 and approximately 1:2.

[000144] The flow area of the second air inlet of the second cartridge compartment can be increased relative to the flow area of the first air inlet of the first cartridge compartment by increasing the size of one or more openings forming the second air inlet. air relative to the size of one or more openings forming the first air inlet and increasing the number of openings forming the second air inlet relative to the number of openings forming the first air inlet.

[000145] Advantageously, the flow area of the second air inlet of the second cartridge compartment is increased relative to the flow area of the first air inlet of the first cartridge compartment by increasing the number of openings forming the second air inlet in relation to the number of openings forming the first air intake.

[000146] Advantageously, the first air inlet of the first cartridge compartment comprises between 2 and 5 openings. Advantageously, the second air inlet of the second cartridge compartment comprises between 3 and 7 openings.

[000147] Advantageously, the flow area of the first air inlet of the first cartridge compartment is between about 0.1 square millimeters and about 1.6 square millimeters, more advantageously between about 0.2 square millimeters and about 0.8 square millimeters.

[000148] In embodiments in which the first air inlet of the first cartridge compartment comprises a plurality of openings, the openings may have different flow areas such that the flow area of the first air inlet of the first cartridge compartment is divided unevenly between the openings that form the first air intake.

[000149] In embodiments wherein the first air inlet of the first cartridge compartment comprises a plurality of openings, each of the openings may have the same flow area, such that the flow area of the first air inlet of the first compartment of the cartridge is divided equally between the openings that form the first air inlet. Providing a first compartment with a first air inlet comprising a plurality of openings having substantially the same flow area can advantageously simplify the manufacture of the cartridge.

[000150] The first air inlet of the first cartridge compartment may include one or more openings with any suitable cross-sectional shape. For example, the cross-sectional shape of each opening may be circular, elliptical, square, or rectangular. Advantageously, each opening has a substantially circular transverse shape. Advantageously, the diameter of each opening is between about 0.2 millimeters and about 0.6 millimeters.

[000151] In embodiments in which the acid source comprises lactic acid, advantageously the flow area of the second air inlet of the second cartridge compartment is between about 0.2 square millimeters and about 2.4 square millimeters, more advantageously between about 0.4 square millimeters and about 1.2 square millimeters.

[000152] In embodiments wherein the second air inlet of the second cartridge compartment comprises a plurality of openings, the openings may have different flow areas such that the total flow area of the second air inlet of the second cartridge compartment is divided unevenly between the openings that form the second air intake.

[000153] In embodiments wherein the second air inlet of the second cartridge compartment comprises a plurality of openings, each of the openings may have the same flow area, such that the total flow area of the second air inlet of the second cartridge compartment is divided equally between the openings that form the second air inlet. Providing a second compartment with a second air inlet comprising a plurality of openings with substantially the same flow area can advantageously simplify the manufacture of the cartridge.

[000154] The second air inlet of the second cartridge compartment may include one or more openings with any suitable cross-sectional shape. For example, the cross-sectional shape of each opening may be circular, elliptical, square, or rectangular. Advantageously, each opening has a substantially circular transverse shape. Advantageously, the diameter of each opening is between about 0.2 millimeters and about 0.6 millimeters.

[000155] Advantageously, the first compartment has a first longitudinal air inlet and the second compartment has a second longitudinal air inlet.

[000156] As used herein with reference to the invention, the term "longitudinal air inlet" is used to describe one or more openings through which air can be drawn in a longitudinal direction into a component or portion of a component of the cartridge .

[000157] Advantageously, before the first use of the cartridge, one or both of the first air inlet of the first compartment and the second air inlet of the second compartment may be sealed by one or more removable or frangible barriers. For example, one or both of the first air inlet of the first compartment and the second air inlet of the second compartment may be sealed by one or more removable or pierceable seals.

[000158] The one or more frangible or removable barriers can be formed from any suitable material. For example, the one or more removable or frangible barriers may be formed from a metal sheet or film.

[000159] The first air outlet of the first cartridge compartment and the second air outlet of the second cartridge compartment may each include one or more openings. For example, the first air outlet of the first cartridge compartment and the second air outlet of the second cartridge compartment may each comprise one, two, three, four, five, six or seven openings.

[000160] The first air outlet of the first cartridge compartment and the second air outlet of the second cartridge compartment may include the same or different numbers of openings.

[000161] Advantageously, the first air outlet of the first cartridge compartment and the second air outlet of the second cartridge compartment may each comprise a plurality of openings. For example, the first air outlet of the first cartridge compartment and the second air outlet of the second cartridge compartment may each comprise two, three, four, five, six or seven openings. Providing a first compartment with a first air outlet comprising a plurality of openings and a second compartment with a second air outlet comprising a plurality of openings can advantageously result in more homogeneous air flow within the first compartment and the second compartment, respectively. In use, this can improve nicotine entrainment in an airflow drawn through the first compartment and improve acid entrainment in an airflow drawn through the second compartment.

[000162] In embodiments in which the first air outlet of the first cartridge compartment comprises a plurality of openings, advantageously the first air outlet comprises between 2 and 5 openings. In embodiments in which the second air outlet of the second cartridge compartment comprises a plurality of openings, advantageously the second air outlet comprises between 3 and 7 openings.

[000163] Advantageously, the first air outlet of the first cartridge compartment of the cartridge assembly and the second air outlet of the second compartment of the cartridge assembly may each comprise a single opening. Providing a first compartment with a first air outlet comprising a single opening and a second compartment with a second air outlet comprising a single opening can advantageously simplify the manufacture of the cartridge.

[000164] The ratio of nicotine to acid required to achieve adequate reaction stoichiometry can be controlled and balanced by varying the volumetric airflow through the first compartment of the cartridge in relation to the volumetric airflow through the second compartment of the cartridge. cartridge. The ratio of volumetric airflow through the first compartment to the volumetric airflow through the second compartment may be controlled by varying one or more of the number, dimensions and location of openings forming the first air outlet of the first compartment. of the cartridge with respect to the number, dimensions and location of openings forming the second air outlet of the second cartridge compartment.

[000165] The flow area of the first air outlet of the first compartment may be the same as or different from the flow area of the second air outlet of the second cartridge compartment. The flow area of the second air outlet of the second cartridge compartment may be greater than the flow area of the first air outlet of the first cartridge compartment.

[000166] Increasing the flow area of the second air outlet of the second cartridge compartment relative to the flow area of the first air outlet of the first cartridge compartment can advantageously increase the volumetric air flow through the second outlet compared to the volumetric air flow through the first outlet.

[000167] In embodiments in which the acid source comprises lactic acid, the ratio of the flow area of the first air outlet of the first cartridge compartment to the flow area of the second air outlet of the second cartridge compartment is preferably between about 3:4 and about 1:2. More preferably, the ratio of the flow area of the first air outlet of the first cartridge compartment to the flow area of the second air outlet of the second cartridge compartment is between about 2:3 and about 1:2.

[000168] In embodiments in which the flow area of the second air outlet of the second cartridge compartment is greater than the flow area of the first air outlet of the first cartridge compartment, the flow area of the second air outlet of the second cartridge compartment may be increased relative to the flow area of the first air outlet of the first cartridge compartment by increasing the size of one or more openings forming the second air outlet relative to the size of one or more openings forming the first air outlet and by increasing the number of openings forming the second air outlet in relation to the number of openings forming the first air outlet.

[000169] Advantageously, the flow area of the second air outlet of the second cartridge compartment is increased relative to the flow area of the first air outlet of the first cartridge compartment by increasing the number of openings forming the second air outlet. in relation to the number of openings that form the first air outlet.

[000170] The first air inlet and the first air outlet of the first cartridge compartment may include the same or different numbers of openings. Advantageously, the first air inlet and the first air outlet of the first cartridge compartment comprise the same number of openings. Providing a first compartment with a first air inlet and a first air outlet comprising the same number of openings can advantageously simplify the manufacture of the cartridge.

[000171] The second air inlet and the second air outlet of the second cartridge compartment may include the same or different numbers of openings. Advantageously, the second air inlet and the second air outlet of the second cartridge compartment comprise the same number of openings. Providing a second compartment with a second air inlet and a second air outlet comprising the same number of openings can advantageously simplify the manufacture of the cartridge. Advantageously, the flow area of the first air outlet of the first cartridge compartment is between about 0.1 square millimeters and about 5 square millimeters.

[000172] In embodiments in which the first air outlet of the first cartridge compartment comprises a plurality of openings, the openings may have different flow areas, such that the flow area of the first air outlet of the first cartridge compartment is divided unevenly between the openings that form the first air outlet.

[000173] In embodiments in which the first air outlet of the first cartridge compartment comprises a plurality of openings, each of the openings may have the same flow area, such that the flow area of the first air outlet of the first compartment of the cartridge and divided equally between the openings that form the first air outlet. Providing a first compartment with a first air outlet comprising a plurality of openings with substantially the same flow area can advantageously simplify the manufacture of the cartridge.

[000174] The first air outlet of the first cartridge compartment may include one or more openings with any suitable cross-sectional shape. For example, the cross-sectional shape of each opening may be circular, elliptical, square, or rectangular. In embodiments wherein the first air outlet of the first cartridge compartment comprises a plurality of openings, advantageously each opening has a substantially circular transverse shape. In such embodiments, advantageously the diameter of each opening is between about 0.2 millimeters and about 0.6 millimeters.

[000175] The dimensions of one or more openings forming the first air inlet of the first cartridge compartment may be the same or different from the dimensions of one or more openings forming the first air outlet of the first cartridge compartment.

[000176] Advantageously, the dimensions of one or more openings forming the first air inlet of the first cartridge compartment may be substantially the same as the dimensions of one or more openings forming the first air outlet of the first cartridge compartment. Providing a first compartment with a first air inlet and a first air outlet comprising one or more openings of substantially the same dimensions can advantageously simplify the manufacture of the cartridge.

[000177] Advantageously, the dimensions of one or more openings forming the first air outlet of the first cartridge compartment may be larger than the dimensions of one or more openings forming the first air inlet of the first cartridge compartment. Increasing the dimensions of the openings forming the first air outlet of the first cartridge compartment relative to the dimensions of the openings forming the first air inlet of the first cartridge compartment may advantageously reduce the risk of the first air outlet of the first cartridge compartment cartridge is obstructed by, for example, dust.

[000178] Advantageously, the flow area of the second air outlet of the second cartridge compartment is between about 0.1 square millimeters and about 5 square millimeters.

[000179] In embodiments wherein the second air outlet of the second cartridge compartment comprises a plurality of openings, the openings may have different flow areas such that the total flow area of the second air outlet of the second cartridge compartment be divided unevenly between the openings that form the second air outlet.

[000180] In embodiments in which the second air outlet of the second cartridge compartment comprises a plurality of openings, each of the openings may have the same flow area, such that the total flow area of the second air outlet of the second cartridge compartment is divided equally between the openings that form the second air outlet. Providing a second compartment with a second air outlet comprising a plurality of openings with substantially the same flow area can advantageously simplify the manufacture of the cartridge.

[000181] The second air outlet of the second cartridge compartment may include one or more openings with any suitable cross-sectional shape. For example, the cross-sectional shape of each opening may be circular, elliptical, square, or rectangular. In embodiments wherein the second air outlet of the second cartridge compartment comprises a plurality of openings, advantageously each opening has a substantially circular transverse shape. In such embodiments, advantageously the diameter of each opening is between about 0.2 millimeters and about 0.6 millimeters.

[000182] The dimensions of one or more openings forming the second air inlet of the second cartridge compartment may be the same or different from the dimensions of one or more openings forming the second air outlet of the second cartridge compartment.

[000183] Advantageously, the dimensions of one or more openings forming the second air inlet of the second cartridge compartment may be substantially the same as the dimensions of one or more openings forming the second air outlet of the second cartridge compartment. Providing a second compartment with a second air inlet and a second air outlet comprising one or more openings of substantially the same dimensions can advantageously simplify the manufacture of the cartridge.

[000184] Advantageously, the dimensions of one or more openings forming the second air outlet of the second cartridge compartment may be larger than the dimensions of one or more openings forming the second air inlet of the second cartridge compartment. Increasing the dimensions of the openings forming the second air outlet of the second cartridge compartment relative to the dimensions of the openings forming the second air inlet of the second cartridge compartment may advantageously reduce the risk that the second air outlet of the second cartridge compartment is blocked by, for example, dust.

[000185] Advantageously, the first compartment has a first longitudinal air outlet and the second compartment has a second longitudinal air outlet.

[000186] As used herein with reference to the invention, the term "longitudinal air outlet" is used to describe one or more openings through which air can be drawn in a longitudinal direction from a component or portion of a component of the cartridge .

[000187] Advantageously, before the first use of the cartridge, one or both of the first air outlet of the first compartment and the second air outlet of the second compartment may be sealed by one or more removable or frangible barriers. For example, one or both of the first air outlet of the first compartment and the second air outlet of the second compartment may be sealed by one or more removable or pierceable seals.

[000188] The one or more frangible or removable barriers can be formed from any suitable material. For example, the one or more removable or frangible barriers may be formed from a metal sheet or film.

[000189] Advantageously, before the first use of the cartridge, the first air inlet and the first air outlet of the first cartridge compartment and the second air inlet and the second air outlet of the second cartridge compartment are sealed by one or more removable or frangible barriers.

[000190] The cartridge may further comprise a third compartment downstream of the first compartment and the second compartment and in fluid communication with the first air outlet of the first compartment and the second air outlet of the second compartment. The nicotine vapor in the first air stream can react with the acidic vapor in the second air stream in the third compartment to form an aerosol of nicotine salt particles.

[000191] In embodiments in which the cartridge further comprises a third compartment, the third compartment may comprise one or more aerosol modifying agents. For example, the third compartment may comprise one or more sorbents, one or more flavoring agents, one or more chimesthetic agents, or a combination thereof.

[000192] The first compartment and the second compartment can be arranged symmetrically with respect to each other within the cartridge.

[000193] Advantageously, the cartridge is an elongated cartridge. In embodiments in which the cartridge is an elongated cartridge and the substrate compartment comprises first and second compartments, the first compartment and the second cartridge compartment may be arranged symmetrically about the longitudinal axis of the cartridge.

[000194] The cartridge may have any suitable shape. For example, the cartridge may be substantially cylindrical. The cartridge may have any suitable cross-sectional shape. For example, the cross-sectional shape of the cartridge may be circular, semicircular, elliptical, triangular, square, rectangular or trapezoidal.

[000195] The cartridge can be of any suitable size.

[000196] For example, the nozzle may have a length of between about 5 millimeters and about 50 millimeters. Advantageously, the cartridge may have a length of between about 10 millimeters and about 20 millimeters.

[000197] For example, the cartridge may have a width of between about 4 millimeters and about 10 millimeters and a height of between about 4 millimeters and about 10 millimeters. Advantageously, the cartridge may have a width of about 6 millimeters and about 8 millimeters and a height of about 6 millimeters and about 8 millimeters.

[000198] Cartridges for use in aerosol generating systems according to the present invention can be formed by any suitable method. Suitable methods include, but are not limited to, inlaying, injection molding, blistering, blow molding and extrusion.

[000199] In preferred embodiments, the cartridge is substantially cylindrical and comprises a first compartment, a second compartment and, when present, a third compartment extending longitudinally between opposing substantially flat end faces of the cylindrical cartridge.

[000200] The cartridge can be designed to be disposed of once the nicotine in the first compartment and the acid in the second compartment run out. The cartridge may be designed to be refillable. In preferred embodiments, the cartridge is consumable and the aerosol generating device is reusable.

[000201] Advantageously, the cartridge comprises a body portion and one or more end caps.

[000202] The cartridge may include a body portion and a distal end cap.

[000203] The cartridge may include a body portion and a proximal end cap.

[000204] The cartridge may include a body portion, a distal end cap and a proximal end cap.

[000205] In embodiments wherein the cartridge comprises a distal end cap, one or more openings that form a first air inlet of a first compartment of the cartridge, and one or more openings that form a second air inlet of a second compartment of the cartridge. cartridge may be provided in the distal end cap.

[000206] In embodiments wherein the cartridge comprises a proximal end cap, one or more openings that form a first air outlet from a first compartment of the cartridge, and one or more openings that form a second air outlet from a second compartment of the cartridge. cartridge may be provided in the proximal end cap.

[000207] The cartridge can be formed from any suitable material or combination of materials. Suitable materials include, but are not limited to: aluminum, polyether ether ketone (PEEK), polyimides such as Kapton®, polyethylene terephthalate (PET), polyethylene (PE), high density polyethylene (HDPE), polypropylene (PP ), polystyrene (PS), fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyoxymethylene (POM), epoxy resins, polyurethane resins, vinyl resins, liquid crystal polymers (LCP), and modified LCPs, such as LCPs with graphite and glass fibers.

[000208] In embodiments in which the cartridge comprises a body portion and one or more end caps, the body portion and one or more end caps may be formed from the same or different materials. The cartridge may be formed from one or more materials that are nicotine resistant and acid resistant.

[000209] When the cartridge comprises two or more aerosol-forming substrates, such as a nicotine source and an acid source, stored in a first compartment and a second compartment, the first compartment of the cartridge can be coated with one or more nicotine-resistant materials and the second compartment of the cartridge may be coated with one or more acid-resistant materials.

[000210] Examples of suitable nicotine-resistant materials and acid-resistant materials include, but are not limited to, polyethylene (PE), polypropylene (PP), polystyrene (PS), fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), resins of epoxy, polyurethane resins, vinyl resins and their combinations.

[000211] The use of one or more nicotine-resistant materials to form the cartridge or coat the interior of a first compartment of the cartridge can advantageously improve the useful life of the cartridge. The use of one or more acid-resistant materials to form the cartridge or line the interior of a second cartridge compartment can advantageously improve the useful life of the cartridge.

[000212] The cartridge can be formed from one or more thermal conductive materials.

[000213] When the cartridge comprises one or more aerosol-forming substrates, such as a nicotine source and an acid source, stored in a first compartment and a second compartment, the first cartridge compartment and the second cartridge compartment can be coated with one or more thermally conductive materials. The use of one or more thermally conductive materials to form the cartridge or line the interior of the first compartment and the second compartment may increase heat transfer from the electric heater to the nicotine source and the acid source.

[000214] Suitable thermally conductive materials include, but are not limited to metals such as, for example, aluminum, chromium, copper, gold, iron, nickel and silver, alloys, such as bronze and steel and combinations thereof.

[000215] One or both ends of the cartridge may be sealed by one or more frangible barriers.

[000216] When the cartridge comprises one or more aerosol-forming substrates, such as a nicotine source and an acid source, stored in a first compartment and a second compartment, the first compartment comprising the nicotine source and the second compartment comprising the lactic acid source may be sealed by one or more frangible barriers.

[000217] The one or more frangible barriers can be formed from any suitable material. For example, the one or more frangible barriers may be formed from a metal foil or film. In such embodiments, the aerosol generating device further preferably comprises a piercing member configured to breach the one or more frangible barriers.

[000218] Alternatively or additionally, one or both ends of the cartridge may be sealed by one or more removable barriers, such as one or more removable seals. When the cartridge comprises one or more aerosol-forming substrates, such as a nicotine source and an acid source, stored in a first compartment and a second compartment, one or both of the first compartment comprising the nicotine source and the second compartment comprising the lactic acid source may be sealed by one or more removable barriers. For example, one or both of the first compartment comprising the nicotine source and the second compartment comprising the lactic acid source may be sealed by one or more removable barriers.

[000219] The one or more removable barriers can be formed from any suitable material. For example, the one or more removable barriers may be formed from a metal foil or film.

[000220] In preferred embodiments where the cartridge is substantially cylindrical, one or both opposing substantially flat end faces of the cartridge may be sealed by one or more frangible barriers.

[000221] The aerosol generating system may comprise a nozzle. The nozzle can form an aerosol-forming chamber. When the cartridge comprises one or more aerosol-forming substrates, such as a nicotine source and an acid source, stored in a first compartment and a second compartment, the nicotine vapor released from the nicotine source in the first compartment of the cartridge and the Acid vapor released from the acid source in the second compartment of the cartridge can react with each other in the gas phase in the mouthpiece to form an aerosol of nicotine salt particles.

[000222] The nozzle can be configured to engage with the cartridge.

[000223] In embodiments in which the mouthpiece is configured for engagement with the cartridge, the combination of the cartridge and mouthpiece can simulate the shape and dimensions of a combustible smoking article, such as a cigarette, a cigar, or a cigarillo. Advantageously, in such embodiments the combination of cartridge and mouthpiece can simulate the shape and dimensions of a cigarette.

[000224] The nozzle can be configured to engage with the housing of the aerosol generating device. The nozzle may be designed to be disposed of once the aerosol-forming substrate in the substrate compartment runs out.

[000225] The mouthpiece can be designed to be reusable. In embodiments where the nozzle is designed to be reusable, the nozzle may advantageously be configured to be removably attached to the cartridge or housing of the aerosol generating device.

[000226] The nozzle may comprise a filter. The filter may have low particle filtration efficiency or very low particle filtration efficiency. Alternatively, the nozzle may comprise a hollow tube.

[000227] As used herein with reference to the invention, the terms "proximal", "distal", "upstream" and "downstream" are used to describe the relative positions of the components or portions of the components, the cartridge, the aerosol generating device and aerosol generating system.

[000228] The aerosol generating system according to the present invention comprises a proximal end through which, when in use, an aerosol of nicotine salt particles exits the aerosol generating system for distribution to a user. The proximal end may also be referred to as the nozzle end. When in use, a user draws on the proximal end of the aerosol generating system to inhale an aerosol generated by the aerosol generating system. The aerosol generating system comprises a distal end opposite the proximal end.

[000229] When a user draws in the proximal end of the aerosol generating system, air is drawn into the aerosol generating system, passes through the cartridge and exits the aerosol generating system through the proximal end thereof. The components or portions of the components of the aerosol generating system can be described as being upstream or downstream of each other based on their relative positions between the proximal end and the distal end of the aerosol generating system.

[000230] As used herein with reference to the invention, the term "longitudinal" is used to describe the direction between the proximal end and the opposite distal end of the aerosol generating system, cartridge or aerosol generating device and the term " transverse" is used to describe the direction perpendicular to the longitudinal direction.

[000231] As used herein with reference to the present invention, by "length" is meant the maximum longitudinal dimension between the distal end and the proximal end of the components or portions of components of the aerosol generating system.

[000232] As used herein with reference to the invention, the terms "height" and "width" are used to describe the maximum transverse dimensions of the components or portions of the components, the cartridge or the aerosol generating system perpendicular to the longitudinal axis of the cartridge or the aerosol generating system. When the height and width of components or portions of components of the cartridge or aerosol generating system are not equal, the term "width" is used to refer to the greater of the two transverse dimensions perpendicular to the longitudinal axis of the cartridge or aerosol generating system of aerosol.

[000233] As used herein with reference to the invention, the term "elongated" is used to describe a component or portion of a cartridge component with a length greater than the width and height thereof.

[000234] In accordance with a second aspect of the present invention, there is provided an aerosol generating device for use with a cartridge comprising a cartridge body defining a substrate compartment and a heater cavity; and an aerosol-forming substrate positioned within the substrate compartment, the device comprising a housing defining a cavity of the device for receiving at least a portion of the cartridge body; an elongated electric heater located in the cavity of the device; and a thermally conductive sheath secured over the elongated electric heater such that the electric heater is substantially enclosed within the thermally conductive sheath along at least part of its length. The thermally conductive sheath and electrical heater are configured to extend into the heater cavity of the cartridge when the cartridge is received into the cavity of the device such that, in use, the substrate compartment of the cartridge is heated by the electrical heater through the sheath. thermally conductive.

[000235] According to a further aspect of the present invention, there is provided a thermally conductive sheath for use in an aerosol generating system according to the first aspect or an aerosol generating device according to the second aspect.

[000236] In accordance with a third aspect of the present invention, there is provided a kit for an aerosol generating system, the kit comprising one or more cartridges for an aerosol generating system and one or more thermally conductive sheaths, wherein each cartridge comprises a cartridge body defining a substrate compartment and a heater cavity and wherein each thermally conductive sheath is configured to extend into the heater cavity of one or more of the cartridges and, in use, to be secured over an elongated electrical heater of an aerosol generator, such that the electrical heater is included substantially within the thermally conductive sheath along at least a portion of its length and the substrate compartment of the cartridge is heated by the electrical heater through the thermally conductive sheath.

[000237] In accordance with a fourth aspect of the present invention, there is provided a method of adapting an aerosol generating device for use with a cartridge, comprising the steps of: providing a cartridge comprising a cartridge body defining a compartment of substrate and a heater cavity and an aerosol-forming substrate positioned within the substrate compartment; providing an aerosol generating device comprising a housing defining a device cavity for receiving at least a portion of the cartridge body; an elongated electric heater located in the cavity of the device; selection of a thermally conductive sheath based on the dimensions of the heater cavity and the dimensions of the electric heater; securing the thermally conductive sheath over the electric heater such that the electric heater is enclosed substantially within the thermally conductive sheath along at least part of its length; and inserting the cartridge into the cavity of the device so that the thermally conductive sheath and the electric heater extend into the heater cavity of the cartridge and so that the thermally conductive sheath is in contact with an outer surface of the electric heater and an inner surface from the heater cavity.

[000238] It should be evident that the characteristics described in relation to one aspect of the invention may also be applicable to other aspects of the invention. In particular, it should be clear that the characteristics described in relation to the system of the first aspect can equally be applied to the device of the second aspect, the kit of the third aspect or the method of the fourth aspect and vice versa.

[000239] Embodiments of the invention will be described below exclusively by way of example, with reference to the attached figures, in which:

[000240] Figure 1 shows an aerosol generating system according to the present invention;

[000241] Figure 2 shows a cartridge for use in the aerosol generating system of Figure 1;

[000242] Figure 3 schematically illustrates a longitudinal cross-section of the aerosol generating system of Figure 1 with the cartridge received in the aerosol generating device;

[000243] Figure 4 shows an enlarged view of a first embodiment of the sheath;

[000244] Figure 5 shows a partial sectional view of the aerosol generating system of Figure 1 with the first embodiment of the sheath positioned within the cartridge;

[000245] Figure 6 shows an enlarged view of a portion of a second embodiment of the sheath; It is

[000246] Figure 7 illustrates a partial profile of the sheath of Figure 6.

[000247] Figure 1 shows a schematic illustration of an aerosol generating system 10 according to the invention for generating an aerosol comprising nicotine lactate salt particles. The aerosol generating system 10 comprises an aerosol generating device 100, a cartridge assembly 200 and a nozzle 300.

[000248] Figure 2 shows schematic illustrations of a cartridge assembly 200 for use in the aerosol generating system of Figure 1. The cartridge 200 comprises an elongated body 202, a distal end cap 204 and a proximal end cap 206 and it has a length of around 15 millimeters, a width of around 7 millimeters and a height of around 5.2 millimeters. The body 202 has a length of about 13 millimeters, a width of about 7 millimeters and a height of about 5.2 millimeters. The distal end cap 204 and the proximal end cap 206 each have a length of about 2 millimeters, a width of about 7 millimeters, and a height of about 5.2 millimeters.

[000249] The cartridge 200 comprises a first elongated compartment 208 that extends from the proximal end of the body 202 to the distal end of the body 202. The first compartment 208 contains a nicotine source that comprises a first carrier material 210 impregnated with about 10 milligrams of nicotine and about 4 milligrams of menthol.

[000250] The cartridge 200 also comprises a second elongated compartment 212 that extends from the proximal end of the body 202 to the distal end of the body 202. The second compartment 212 contains a source of lactic acid comprising a second carrier material 214 impregnated with about of 20 milligrams of lactic acid.

[000251] The first compartment 208 and the second compartment 212 are arranged in parallel.

[000252] The cartridge 200 further comprises a heater cavity 216 for receiving an electrical heater from the aerosol generating device, which is configured to heat the first compartment 208 and the second compartment 212. The cavity 216 is located between the first compartment 208 and the second compartment 212 and extends from the proximal end of the body 202 to the distal end of the body 202. The cavity 216 has substantially a stadium-shaped transverse shape and has a width of about 6.3 millimeters and a height of about 1 millimeter.

[000253] The distal end of the lid 204 comprises a first air inlet 218 comprising a row of three spaced openings and a second air inlet 220 comprising a row of five separate spaced openings. Each of the openings forming the first air inlet 218 and the second air inlet 220 has a substantially circular cross-sectional shape and has a diameter of about 0.3 millimeters. The flow area of the first air inlet 218 is approximately 0.21 square millimeters and the flow area of the second air inlet 220 is approximately 0.35 square millimeters. The ratio of the flow area of the first air inlet 218 to the flow area of the second air inlet 220 is about 3:5. The distal end cap 204 further comprises a third inlet 222 located between the first air inlet 218 and the second air inlet 220. The third inlet 222 has a substantially transverse stadium shape and has a width of about 6.3 millimeters. and a height of about 1 millimeter.

[000254] The proximal end cap 206 comprises a first air outlet 224 comprising a row of three spaced openings and a second air outlet 226 comprising a row of five spaced openings. Each of the openings forming the first air outlet 224 and the second air outlet 226 have a substantially circular cross-sectional shape and have a diameter of about 0.3 millimeters. The flow area of the first air outlet 224 is about 0.21 square millimeters and the flow area of the second air outlet 226 is about 0.35 square millimeters. The ratio of the flow area of the first air outlet 224 to the flow area of the second air outlet 226 is about 3:5.

[000255] To form the cartridge 200, the proximal end cap 206 is inserted into the proximal end of the body 202 such that the first air outlet 224 is aligned with the first compartment 208 and the second air outlet 226 is aligned with the second compartment 212. The first carrier material 210 impregnated with nicotine and menthol is inserted into the first compartment 208 and the second carrier material 214 impregnated with lactic acid is inserted into the second compartment 212. The distal end cap 204 is then inserted into the distal end of the body 202 so that the first air inlet 218 is aligned with the first compartment 208, the second air inlet 220 is aligned with the second compartment 212, and the third inlet 222 is aligned with the heater cavity 216.

[000256] The first compartment 208 and the second compartment 212 have substantially the same shape and size. The first compartment 208 and the second compartment 212 have a substantially rectangular cross-section and have a length of about 11 millimeters, a width of about 4.3 millimeters, and a height of about 1 millimeter. The first carrier material 210 and the second carrier material 214 comprise a PET/PBT non-woven sheet and have substantially the same shape and size. The shape and size of the first carrier material 210 and the second carrier material 214 are similar to the shape and size of the first compartment 208 and the second compartment 212 of the cartridge 2 respectively.

[000257] The first air inlet 218 is in fluid communication with the first air outlet 224 so that a first air stream passes through the cartridge 200 through the first air inlet 218, through the first compartment 208 and out of the cartridge 200, through the first air outlet 224. The second air inlet 220 is in fluid communication with the second air outlet 226, so that a second air stream can pass through the cartridge 200, through the second air inlet 220 , through the second compartment 212 and out of the cartridge 2 through the second air outlet 226.

[000258] Prior to the first use of the cartridge 200, the first air inlet 218 and the second air inlet 220 may be sealed by a removable blade seal or a pierceable blade seal (not shown) applied to the outer face of the lid of distal end 204. Likewise, prior to the first use of the cartridge 200, the first air outlet 224 and the second air outlet 226 may be sealed by a removable blade seal or a pierceable blade seal (not shown). applied to the outer face of the proximal end cap 206.

[000259] Figure 3 schematically illustrates a longitudinal cross-section of the aerosol generating system 10 of Figure 1 with the cartridge 200 received in the aerosol generating device 100. As shown in Figure 3, the aerosol generating device 100 comprises a device housing 102 which defines a cavity of the device 104 for receiving the cartridge 200 and an upstream portion of the nozzle 300, which is coupled to the cartridge 200. The aerosol generating device 100 further comprises an elongated electrical heater 106 extending from a portion base portion 107, an electrical power supply 108, and a controller 110 for controlling a supply of electrical power from the electrical power source 108 to the electrical heater 106 via electrical contacts (not shown) on the base portion 107. The electrical heater 106 is positioned centrally in the device cavity 104 and extends from the base portion 107 along the main axis of the device cavity 104. The electrical heater 106 comprises an electrically insulating substrate and a resistive heating element positioned on the electrically insulating substrate. Positioned over the electric heater 106 is the thermally conductive sheath 112 which forms a protective covering for the electric heater 106 and acts as a thermal bridge between the electric heater 106 and the cartridge 200 during use. In an alternative embodiment (not shown), the distal end of the nozzle 300 may be configured to engage with the proximal end of the housing 102 of the aerosol generating device 100 instead of the cartridge 200.

[000260] In use, the controller 110 controls a supply of electrical energy from the electrical power supply 108 to the electric heater 106 to generate heat in the heating element which is then transferred to the cartridge 200 through the sheath 112 to heat the first compartment 208 and the second compartment 212 at an operating temperature of about 120 degrees Celsius. The thermally conductive sheath spreads heat from the electric heater across its outer surface to ensure more even heating of the cartridge compared to arrangements where no sheath is present. To bring the cartridge up to operating temperature as quickly as possible, a preheat profile is applied to heat the heating element to approximately 200 degrees Celsius for approximately 30 seconds. After preheating, the temperature of the heating element is reduced to a substantially constant temperature of about 140 degrees Celsius.

[000261] When a user draws on the proximal end of the nozzle 300, air is drawn through the aerosol generating system 10 through system airflow inlets that extend through the housing 102 of the aerosol generating device 100. The air is directed to the upstream end of the device cavity 104, where a first air stream is drawn through the first compartment 208 of the cartridge 200 and a second air stream is drawn through the second compartment 212 of the cartridge 200. According to the first flow of air is drawn through the first compartment 208, nicotine vapor is released from the first carrier material 210 into the first air stream. As the second air stream is drawn through the second compartment 212, lactic acid vapor is released from the second carrier material 214 into the second air stream. The nicotine vapor in the first air stream and the lactic acid vapor in the second air stream react with each other in the gas phase in mouthpiece 300 to form an aerosol of nicotine salt particles, which are delivered to the user through the tip. proximal nozzle 300.

[000262] Figure 4 shows the sheath 112 of the aerosol generating device 100 in more detail. The sheath 112 is formed from a flat metal sheet that is wider than the electric heater 106 and which has been bent into a U-shape along a fold line 113, so that the sheath 112 comprises two walls. sheath fittings 114. The sheath 112 is provided with a sheath fitting 116 at its distal end, by which the sheath 112 can be held in position over the electric heater 106. In this example, the sheath fitting 116 comprises two fitting portions. of the sheath 118, each provided at the distal end of one of the sheath walls 114 and configured so that the sheath fitting 116 is generally disk-shaped when the sheath walls 114 - and thus the sheath fitting portions 118 - are gathered. The fitting portions of the sheath 118 are made of a material with a high temperature resistance and preferably have low thermal conductivity, such as PEEK. In this example, the metal sheet from which the sheath 112 is formed is folded along a fold line 113 that is transverse to the longitudinal axis of the sheath 112 and is located at the proximal end of the sheath 112. In other examples, the line bend may have a different position or orientation. For example, sheet metal may be bent along a fold line that is parallel to the longitudinal axis of the sheath and extends along a side edge of the sheath. The bend line 113 provides a spring force to tilt the walls of the sheath 114 slightly away from each other at the distal end of the sheath 112. This can improve the ease with which the sheath 112 is positioned over the electric heater 106. The sheet metal from which the sheath 112 is made may be of any suitable thickness. In this example, the metal sheet has a sheet thickness of 0.27 mm. In other examples, the metal foil may have a different thickness depending on the dimensions of the electric heater and the cavity in the cartridge, along with the acceptable level of cartridge insertion and removal force for a given configuration.

[000263] Figure 5 shows a partial sectional view of the aerosol generating system 10 in which the sheath 112 is positioned over the electric heater and within the heater cavity 216 of the cartridge 200. To secure the sheath 112 within the device cavity 104, the sheath walls 114 are positioned on either side of the electric heater and compressed against spring force at the fold line 113, so that the electric heater is sandwiched between and covered by the sheath walls 114. The sheath 112 is then pushed toward the distal end of the device cavity 104 for press-fitting the sheath-fitting portions 118 against the inner diameter of a raised tab 109 extending around the base portion 107. In this manner, the sheath-fitting portions 107 sheath 118 are held firmly in the base portion 107 and the electric heater is clamped between the walls of the sheath 114. The cartridge 200 is then introduced into the cavity 104 together with the nozzle 300, so that the electric heater 106 and the sheath 112 extend into the heater cavity 216 of the cartridge 200. The sheath 112 protects the electric heater during insertion of the cartridge and is sized so that the walls of the sheath 114 are in direct contact with the inner surface of the heater cavity 216. Thus, The thermally conductive sheath 112 acts as a thermal bridge between the electric heater and the cartridge and adapts the shape of the electric heater to the heater cavity 216 of the cartridge 200.

[000264] Figure 6 illustrates an enlarged view of a portion of an alternative embodiment of the sheath 412. Unlike the smooth and flat profile of the sheath of the first embodiment, the sheath 412 is formed from a metal sheet with a wavy profile. This can be seen more clearly in Figure 7, which illustrates the profile of one of the sheath walls 414 of the sheath 412. As shown, the dimples form a plurality of ripple peaks 417 and troughs 419 on the outer surface of each of the walls 414 of the sheath 412. The dimples allow the walls of the sheath 414 to flex to conform to the inner surface of the cartridge heater cavity. This can improve the consistency of thermal contact between the electric heater and cartridge by compensating for manufacturing tolerances of the electric heater, sheath and cartridge. This can help ensure more consistent performance between different cartridges or different devices. Depending on their orientation, the corrugations can also increase the moment of inertia of the sheath relative to a flat sheet of the same sheet thickness. This increases the rigidity of the sheath and may reduce the risk of flexing of the electric heater and sheath during insertion of the cartridge into the device cavity. It can also reduce the amount of material required to manufacture a sheath of a certain stiffness or thickness. In the embodiment shown in Figure 6, the corrugations are arranged in a chevron pattern so that each corrugation extends in two different directions. By arranging the corrugations in such a way that they extend in at least two different directions, the rigidity of the sheath 412 can be maintained in all directions. This differs from an arrangement in which each corrugation extends in a single direction across the entire width or length of the hem. In such arrangements, the sheath will be more susceptible to bending if a bending moment is applied about an axis that is parallel to the direction of the curl.

[000265] The specific embodiments and examples described above illustrate, but do not limit the invention. It should be understood that other embodiments of the invention may be realized and that the specific embodiments and examples described herein are not exhaustive.

Claims (18)

1. Aerosol generating device (100) for use in an aerosol generating system (10), the aerosol generating device (100) comprising: a housing (102) defining a device cavity (104) for receiving at least a portion an aerosol generating article (200); and an elongated electric heater (106) located in the cavity of the device (104); characterized by the fact that the aerosol generating device (100) comprises a thermally conductive sheath (112, 412) secured over the elongated electric heater (106) such that the electric heater (106) is substantially enclosed within the thermally conductive sheath ( 112, 412) along at least part of the length of the elongated electric heater (106), the thermally conductive sheath (112, 412) having a thermal conductivity of at least as measured in accordance with ASTM C1114 - 00; wherein the thermally conductive sheath (112, 412) and the electrical heater (106) are configured to extend into the aerosol generating article (200) when the aerosol generating article (200) is received in the cavity of the device (104 ), so that, in use, the aerosol generating article (200) is heated by the electric heater (106) through the thermally conductive sheath (112, 412). 2. Aerosol generating device (100) according to claim 1, characterized in that the thermally conductive sheath (112, 412) is permanently fixed over the electric heater (106). 3. Aerosol generating device (100), according to claim 1, characterized by the fact that the thermally conductive sheath (112, 412) is removably fixed over the elongated electric heater (106). 4. Aerosol generating device (100) according to any one of claims 1 to 3, characterized in that the elongated electric heater (106) is substantially included within the thermally conductive sheath (112, 412) along substantially the entire length of the elongated electric heater (106). 5. Aerosol generating device (100), according to any one of claims 1 to 4, characterized by the fact that the thermally conductive sheath (112, 412) is thermally coupled to the electric heater (106) by means of one or more intermediate components. 6. Aerosol generating device (100) according to any one of claims 1 to 5, characterized in that the thermally conductive sheath (112, 412) is formed from a metal or alloy. 7. Aerosol generating device (100) according to any one of claims 1 to 6, characterized in that the thermally conductive sheath (112) is provided with a sheath fitting (116) whereby the thermally conductive sheath (112) is provided. conductor (112) is fixed over the electric heater (106). 8. Aerosol generating device (100) according to claim 7, characterized in that the sheath fitting (116) is made of PEEK. 9. Aerosol generating device (100) according to any one of claims 1 to 8, characterized in that the thermally conductive sheath (112) comprises a single sheet of thermally conductive material that has been flexed or bent into shape. 10. Aerosol generating device (100) according to claim 9, characterized in that the thermally conductive sheath (112) comprises a sheet of thermally conductive material that has been flexed or folded along a fold line (113 ), such that the sheath (112) comprises two opposing sheath walls (114), between which the elongated electric heater (106) is substantially enclosed along at least part of its length and an opening opposite the fold line . 11. Aerosol generating device (100) according to claim 10, characterized in that the sheet of thermally conductive material is elastic and has been flexed or bent so that the fold line (113) provides a spring force to angle the sheath walls (114) spaced apart in the opening. 12. Aerosol generating device (100) according to claim 10, characterized in that the fold line is parallel to a longitudinal axis of the thermally conductive sheath (112) and extends along a lateral edge of the sheath thermally conductive (112). 13. Aerosol generating device (100), according to any one of claims 1 to 12, characterized in that the thermally conductive sheath (412) comprises a corrugated sheet of thermally conductive material. 14. Aerosol generating device (100), according to claim 13, characterized by the fact that the corrugated sheet of thermally conductive material comprises a first set of corrugations extending along a first direction and a second set of corrugations extending along a second direction that is at an angle to the first direction. 15. Aerosol generating device (100), according to any one of claims 1 to 14, characterized in that the thermally conductive sheath (112, 412) has a thickness of 0.20 mm to 0.35 mm. 16. Aerosol generating device (100), according to any one of claims 1 to 14, characterized in that the thermally conductive sheath (112, 412) has a thickness of 0.22 mm to 0.30 mm. 17. Aerosol generating device (100), according to any one of claims 1 to 14, characterized in that the thermally conductive sheath (112, 412) has a thickness of 0.25 mm to 0.29 mm. 18. Aerosol generating device (100), according to any one of claims 1 to 14, characterized in that the thermally conductive sheath (112, 412) has a thickness of 0.27 mm.