EP4680054A1

EP4680054A1 - Aerosol provision system, consumable, and method

Info

Publication number: EP4680054A1
Application number: EP24713695.5A
Authority: EP
Inventors: Ugurhan Yilmaz
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-03-13
Filing date: 2024-03-12
Publication date: 2026-01-21
Also published as: WO2024189341A1; GB202303639D0; AR132106A1; TW202512949A; CN121240788A

Abstract

Described is an aerosol provision system for generating aerosol from an aerosol- generating material for inhalation, including a heater assembly comprising a substrate having a first surface on which a heater layer is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface. The distance from at least one side surface of a first region of an aerosol-generating material storage portion that shares a surface with one or more side walls of the aerosol-generating material storage portion to the centre of an exposed part of a second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol- generating material storage portion to the centre of the exposed part of the second surface of the heater assembly. Also described is a consumable and a method for manufacturing a component of aerosol provision system.

Description

AEROSOL PROVISION SYSTEM, CONSUMABLE, AND METHOD

Field

The present disclosure relates to electronic aerosol provision systems such as nicotine delivery systems (e.g. electronic cigarettes and the like).

Background

Electronic aerosol provision systems such as electronic cigarettes (e-cigarettes) generally contain a reservoir of a source liquid containing a formulation, typically including nicotine, from which an aerosol is generated, e.g. through heat vaporisation. An aerosol source for an aerosol provision system may thus comprise a heater having a heating element arranged to receive source liquid from the reservoir, for example through wicking I capillary action. While a user inhales on the device, electrical power is supplied to the heating element to vaporise source liquid in the vicinity of the heating element to generate an aerosol for inhalation by the user. Such devices are usually provided with one or more air inlet holes located away from a mouthpiece end of the system. When a user sucks on a mouthpiece connected to the mouthpiece end of the system, air is drawn in through the inlet holes and past the aerosol source. There is a flow path connecting between the aerosol source and an opening in the mouthpiece so that air drawn past the aerosol source continues along the flow path to the mouthpiece opening, carrying some of the aerosol from the aerosol source with it. The aerosol-carrying air exits the aerosol provision system through the mouthpiece opening for inhalation by the user.

Typically, such electronic aerosol provision systems are provided with heater assemblies suitable for heating the source liquid to form an aerosol. However, an example of such a heater assembly is a wick and coil heater assembly, which is formed of a coil of wire (typically nichrome NiCr 8020) wrapped or coiled around a wick (which typically comprises a bundle of collected fibres, such as cotton fibres, extending along the longitudinal axis of the coil of wire). Ends of the wick extend either side of the coil of wire and are inserted into the reservoir of source liquid.

However, such heater assemblies are not necessarily suited for all applications or all configurations of electronic aerosol provision systems. Such problems associated with these heater assemblies typically concern burning or charring of the wick material caused by the heater operating at too high a temperature, particularly when insufficient liquid is supplied to the heater assembly. In addition, the performance characteristics of these heater assemblies are generally not considered optimal and alternative solutions which are capable of providing more optimal aerosol delivery are desired. Various approaches are described which seek to help address some of these issues.

Summary

According to a first aspect of certain embodiments there is provided an aerosol provision system for generating aerosol from an aerosol-generating material for inhalation, wherein the aerosol provision system includes an aerosol-generating material storage portion for storing aerosol-generating material, the aerosol-generating material storage portion comprising one or more side walls, a base wall and a top wall opposite the base; and a heater assembly comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosolgenerating material to the heater layer for vaporisation, wherein when the heater assembly is mounted in the aerosol provision system, an exposed part of the second surface of the heater assembly is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension. The aerosol-generating material storage portion comprises a first region having a smaller distance between the base wall and the top wall than a second region of the aerosol-generating material storage portion, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater assembly and extending in a first direction from the second surface of the heater assembly, wherein the first direction is a direction from the first surface to the second surface of the heater assembly. The first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater assembly in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion. The distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly.

According to a second aspect of certain embodiments there is provided a consumable for an aerosol provision system for generating aerosol from an aerosol-generating material for inhalation, wherein the consumable includes an aerosol-generating material storage portion for storing aerosol-generating material, the aerosol-generating material storage portion comprising one or more side walls, a base wall and a top wall opposite the base; and a heater assembly comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater assembly is mounted in the aerosol provision system, an exposed part of the second surface of the heater assembly is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension. The aerosolgenerating material storage portion comprises a first region having a smaller distance between the base wall and the top wall than a second region of the aerosol-generating material storage portion, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater assembly and extending in a first direction from the second surface of the heater assembly, wherein the first direction is a direction from the first surface to the second surface of the heater assembly. The first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater assembly in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion. The distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly.

According to a third aspect of certain embodiments there is provided a method for manufacturing a component of aerosol provision system, wherein the method includes: providing an aerosol-generating material storage portion for storing aerosol-generating material, the aerosol-generating material storage portion comprising one or more side walls, a base wall and a top wall opposite the base; and providing a heater assembly comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater assembly is mounted in the aerosol provision system, an exposed part of the second surface of the heater assembly is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension. The aerosolgenerating material storage portion comprises a first region having a smaller distance between the base wall and the top wall than a second region of the aerosol-generating material storage portion, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater assembly and extending in a first direction from the second surface of the heater assembly, wherein the first direction is a direction from the first surface to the second surface of the heater assembly. The first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater assembly in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion. The distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly.

According to a fourth aspect of certain embodiments there is provided aerosol provision means for generating aerosol from an aerosol-generating material for inhalation, wherein the aerosol provision means including storage means for storing aerosol-generating material, the storage means comprising one or more side walls, a base wall and a top wall opposite the base; and heater means comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater means is mounted in the aerosol provision means, an exposed part of the second surface of the heater means is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension. The storage means comprises a first region having a smaller distance between the base wall and the top wall than a second region of the storage means, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater means and extending in a first direction from the second surface of the heater means, wherein the first direction is a direction from the first surface to the second surface of the heater means. The first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater means in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the storage means and at least one side surface that has an open surface with the second region of the storage means. The distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the storage means to the centre of the exposed part of the second surface of the heater means is greater than the distance from the at least one side surface that has an open surface with the second region of the storage means to the centre of the exposed part of the second surface of the heater means.

It will be appreciated that features and aspects of the invention described above in relation to the first and other aspects of the invention are equally applicable to, and may be combined with, embodiments of the invention according to other aspects of the invention as appropriate, and not just in the specific combinations described above.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of an aerosol provision system in accordance with aspects of the present disclosure;

Figure 2 is an exploded perspective view of an example cartomiser suitable for use in the aerosol provision system of Figure 1;

Figure 3 is a cross-sectional view of the cartomiser of Figure 2;

Figure 4 is a perspective view of a heater assembly, wherein the heater assembly comprises a substrate, an electrically resistive layer, and capillary tubes extending through the substrate and electrically resistive layer;

Figure 5 schematically shows a cross-section of the upper clamping unit and heater assembly looking along the longitudinal axis of the cartomiser of Figures 2 and 3;

Figure 6 schematically shows a representation of a plurality of regions of the cartomiser of Figures 2 and 3 to illustrate the distance to the centre of the heater assembly and the relative arrangement of the different regions;

Figure 7 is an exploded perspective view of a cartomiser suitable for use in the aerosol provision system of Figure 1 in accordance with aspects of the present disclosure;

Figure 8 is a cross-sectional view of the cartomiser of Figure 7; Figure 9 schematically shows a cross-section of the upper clamping unit and heater assembly looking along the longitudinal axis of the cartomiser of Figures 7 and 8;

Figure 10 schematically shows a representation of a plurality of regions of the cartomiser of Figures 7 and 8 to illustrate the distance to the centre of the heater assembly and the relative arrangement of the different regions;

Figure 11 is a perspective view of a heater assembly in accordance with an aspect of the present disclosure, wherein the heater assembly comprises a substrate, an electrically resistive layer, capillary tubes extending through the substrate and electrically resistive layer, and one or more distribution channels formed via interconnected pores in the substrate;

Figure 12 is a perspective view of a heater assembly in accordance with another aspect of the present disclosure, wherein the heater assembly comprises a substrate, an electrically resistive layer, capillary tubes extending through the substrate and electrically resistive layer, and one or more distribution channels formed via an engineering process in the substrate;

Figure 13 schematically shows a perspective view of a modification of the lower clamping unit of the cartomiser of Figures 7 and 8 employing the heater assembly of either of Figures 11 and 12, in which the longest side surfaces of the heater assembly are able to be exposed to the reservoir of the cartomiser; and

Figure 14 is a method in accordance with aspects of the present disclosure for forming a component of the aerosol provision system of Figure 1.

Detailed Description

Aspects and features of certain examples and embodiments are discussed I described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed I described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device, electronic cigarette or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement. Throughout the following description the term “e-cigarette” is sometimes used but this term may be used interchangeably with aerosol (vapour) provision system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosolgenerating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

In some embodiments, the or each aerosol-generating material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v..Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosolmodifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material. Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, and/or an aerosol-modifying agent.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

In accordance with the principles of the present disclosure, an aerosol provision system is provided which is configured such that the aerosol-generating material storage portion and heater assembly are configured such that the aerosol-generating material storage portion comprises a first region having a smaller distance between a base wall and a top wall than a second region of the aerosol-generating material storage portion. The first region defines a volume sharing a surface with an exposed part of a surface of the heater assembly. The first region further comprises a plurality of side surfaces, where at least one side surface shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosolgenerating material storage portion. The distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly. In this way, additional forces that act on the aerosol-generating material in the first region that are generated by the aerosol-generating material in the second region are able to be applied with a relatively greater magnitude at the centre of the exposed part of the second surface of the heater assembly owing to the relatively shorted distance. This can help improve the rate of replenishment of the heater assembly with aerosol-generating material.

According to another aspect, an aerosol provision system encompassing the heater assembly (such as in a cartomiser of the aerosol provision system) can be arranged such that the one or more distribution channels on the side surfaces of the heater assembly are provided in direct contact with the aerosol-generating material storage portion for storing the aerosol-generating material. In particular, the side surface with the shortest distance between the centre of the side surface to the centre of heater assembly is provided with the one or more distribution channels. In this way, distribution channels which typically have a much shorter distance to the centre to the heater assembly can be supplied with aerosolgenerating material to feed the capillary tubes (that subsequently feed the heater layer) to thereby enable a more rapid (and larger, i.e. , by mass) supply of aerosol-generating material to the heater layer. Moreover, because the distribution channels for feeding the capillary tubes can be provided on the surface that has the second largest surface area, a larger number of distribution channels may be provided thereby further enhancing the supply of aerosol-generating material to the heater layer. Therefore, it can be seen that providing the heater assembly with one or more distribution channels on the side surface of a substrate of the heater assembly and exposing this side surface to the aerosol-generating material storage portion may help improve the performance of the heater assembly, in terms of the ability to transport liquid aerosol-generating material to the heater layer.

Figure 1 schematically shows an aerosol provision system 1 in accordance with aspects of the present disclosure. The aerosol provision system 1 comprises an aerosol provision device 2 and a consumable 3, herein shown and referred to as a cartomiser 3. The aerosol provision device 2 and the cartomiser 3 together form the aerosol provision system 1.

The cartomiser 3 is configured to engage and disengage with the aerosol provision device 2. That is, the cartomiser 3 is releasably connected I connectable to the aerosol provision device 2. More specifically, the cartomiser 3 is configured to engage I disengage with the aerosol provision device 2 along the longitudinal axis L1. The cartomiser 3 and aerosol provision device 2 are provided with suitable interfaces to allow the cartomiser 3 and aerosol provision device 2 to engage I disengage from one another, e.g., a push fit interface, a screwthread interface, etc. The cartomiser 3 comprises a reservoir which stores an aerosol-generating material. Accordingly, the reservoir may also be referred to as an aerosol-generating material storage portion. In the following, the aerosol-generating material is a liquid aerosol-generating material. The liquid aerosol-generating material (herein sometimes referred to simply as liquid, source liquid or e-liquid) may be a conventional e-liquid which may or may not contain nicotine. However, it should be appreciated that other liquids and I or aerosol-generating materials may be used in accordance with the principles of the present disclosure. The cartomiser 3 is able to be removed from the aerosol provision device 2 when, for example, the cartomiser 3 requires refilling with liquid or replacement with another (full) cartomiser 3.

The aerosol provision device 2 comprises a power source (such as a rechargeable battery) and control electronics. As will be described below, the cartomiser 3 comprises an electrically powered heater assembly. When the cartomiser 3 is coupled to the aerosol provision device 2, the control electronics of the aerosol provision device 2 are configured to supply electrical power to the heater assembly of the cartomiser 3 to cause the heater assembly to generate an aerosol from the liquid aerosol-generating material supplied thereto. The control electronics may be provided with various components to facilitate I control the supply of power to the cartomiser 3. For example, the control electronics may be provided with an airflow sensor (not shown) configured to detect when a user of the aerosol provision system 1 inhales on the aerosol provision system and to supply power in response to such a detection and / or a push button (not shown) which is pressed by the user and to supply power in response to such a detection. Additional functions may be controlled by the control electronics depending on the configuration of the aerosol provision device 2 (for example, the control electronics may be configured to control I regulate recharging of the power source, or to facilitate wireless communication with another electronic device, such as a smartphone). The features and functions of the aerosol provision device 2 are not of primary significance in respect of the present disclosure.

Figures 2 and 3 show an example cartomiser 3 suitable for use in the aerosol provision system of Figure 1. Figure 2 schematically shows the cartomiser 3 in a perspective and exploded view (exploded along the longitudinal axis L1), while Figure 3 shows a cross- sectional view of the cartomiser 3. From the views of Figures 2 and 3, it may be seen that the cartomiser 3 is assembled from a stack of components: an outer housing 4, an upper clamping unit 5, a heater assembly 6, a lower support unit 7 and an end cap 8.

The cartomiser 3 has a top end 31 and a bottom end 32 which are spaced apart along the longitudinal axis L1 , which is the longitudinal axis of the cartomiser as well as being the longitudinal axis of the aerosol provision system 1. The top end 31 of the cartomiser 3 defines a mouthpiece 33 of the aerosol provision system 1 (around which a user may place their mouth and inhale). The mouthpiece 33 includes a mouthpiece orifice 41 which is provided at the top end 42 of outer housing 4 in the centre of a top face 43.

The outer housing 4 includes a circumferential side wall 44 which leads down from the top end 42 to a bottom end 45 of the outer housing 4 and which defines an internal reservoir 46 for holding the liquid aerosol-generating material. Prior to assembly of the cartomiser 3, the bottom end 45 of the outer housing is open, but upon assembly the bottom end 45 is closed by a plug formed by the upper clamping unit 5 and the lower support unit 7 which are stacked together with the heater assembly 6 positioned therebetween.

The upper clamping unit 5 is an intermediate component of the stack of components. The upper clamping unit 5 includes a foot 51 in the form of a block. The foot 51 includes a well 53 which descends from a flat top surface to a flat bottom surface of the foot 51. At the bottom surface, the well 53 is open. The bottom surface of the foot 51 includes an elongate recess sized to receive the heater assembly 6 (that is, the elongate recess has a similar size, i.e. , length, width and depth as the heater assembly 6). As will be described in more detail below, the heater assembly 6 extends across the opening of the well 531 foot 51, effectively sealing the opening of the well 531 foot 51. The foot 51 is designed to engage with the outer housing 4 (more specifically, such that the outer circumferential surface of the foot is pressed against an inner circumferential surface of the outer housing 4). The foot 51 may have a suitable shape and include suitable sealing components to reduce or prevent liquid from leaking between the outer surface of the foot 51 and the inner surface of the housing 4.

The lower support unit 7 is in the form of a block having a broadly flat top surface 71 and a flat bottom surface 72. A central air passage 73 extends upwardly from the bottom surface 72 toward the top surface 71. When the heater assembly 6 is positioned between the upper clamping unit 5 and the lower support unit 7, the central air passage 73 is provided in fluid communication with the heater assembly 6. On each side of the air passage 73, the block of the lower support unit 7 includes a through hole 74. In the example cartomiser 3 of Figures 2 and 3, a co-moulded contact pad 75 in the form of a pin is inserted into the through holes 74. More specifically, each contact pad 75 is press fit in its respective through hole 74. Each contact pad 75 provides an electrical connection path from the bottom surface 72 to a respective end portion of the heater assembly 6 when the heater assembly 6 is positioned between the top surface 71 of the lower support unit 7 and the recess of the bottom surface of the upper clamping unit 5.

Much like the upper clamping unit 5, the lower support unit 7 is designed to engage with the outer housing 4 (more specifically, such that the outer circumferential surface of the lower support unit 7 is pressed against an inner circumferential surface of the outer housing 4). The lower support unit 7 may have a suitable shape and include suitable sealing components to reduce or prevent liquid from leaking between the outer surface of the lower support unit 7 and the inner surface of the housing 4. The foot 51 of the upper clamping unit 5 and the lower support unit 7 (with its block-like form) combine together to form a plug which seals the bottom end of the reservoir 46.

As shown in Figures 2 and 3, the cartomiser 3 includes an end cap 8 at its bottom end. The end cap 8 is made of metal and serves to assist with retaining the cartomiser 3 in the aerosol provision device 2 when the cartomiser 3 is plugged in to the top end of the aerosol provision device 2, because, in this example, the aerosol provision device 2 is provided with magnets which are attracted to the metal of the end cap 8. The end cap 8 has a bottom wall 81 with a central opening (see Figure 3). The end cap 8 also has a circumferential side wall 83 which has two opposed cut-outs 84 which latch onto corresponding projections 49 on the outer surface of the bottom end of the side wall 44 of the outer housing 4, so that the end cap 8 has a snap-fit type connection onto the bottom end of the outer housing 4. When the end cap 8 has been fitted in position, it holds in position the lower support unit 7, the upper clamping unit 5 and the heater assembly 6 which is located between the lower support unit 7 and the upper clamping unit 5.

It would be possible to omit the end cap 8 (in order to reduce the component count) by arranging for the lower support unit 7 to form a snap-fit type connection with the bottom end of the side wall 44 of the outer housing 4. Additionally, the cartomiser 3 could be provided with indentations which engage with projections at the top end 21 of the main housing 2, so that a releasable connection is provided between the cartomiser and the main housing.

In any case, the cartomiser 3 is provided what may more generally be referred to as a device interface which is a part of the cartomiser 3 that interfaces with the main housing 2 (or aerosol-generating device). In the above example, the device interface may include the metal cap 8 including the bottom wall 81 and circumferential side wall 83 and I or the lower support unit 7 including the bottom surface 72. More generally, the device interface of the cartomiser 3 may encompass any part or parts of the cartomiser 3 that contact, abut, engage or otherwise couple to the main housing 2.

When the components of the cartomiser 3 have been assembled together, an overall air passage exists from the bottom end 32 to the top end 31 of the cartomiser 3. The overall air passage is formed initially by the air passage 73, which opens towards the surface of the heater assembly 6 (see Figures 2 and 3). The upper clamping unit 5 includes side channels 55 formed as part of the upper clamping unit 5 and extending from openings in the foot 51 that broadly align with the air passage 73 upwards from the foot 51 and curve inwards at the upper parts of the side channels 55 (as best seen in Figure 2). Correspondingly, air is permitted to flow from the air passage 73 along the side channels 55. It should be appreciated that the side channels 55 are surrounded by the reservoir 461 well 53 and as such form an air channel that is not in fluid connection with the reservoir 46 / well 53. In particular, the side channels 55 are provided abutting the longitudinal sides of the heater assembly 6. As such, air that is directed along the air passage 73 towards the heater assembly 6 bifurcates and flows either side of the heater assembly 6 along the air channels of the side channels 55. Additionally, an air tube 52 is provided which defines an air passage 58. The air tube 52 is arranged centrally in the cartomiser 3 (i.e. , coaxial with the longitudinal axis L1) and is arranged to couple between the side channels 55 and an air tube 47 which extends downwards from the mouthpiece orifice 41 in the top face 43 of the outer housing 4 (see Figure 3). The air tube 52 includes one or more side openings 52a which are arranged to fluidly couple to the side channels 55 (and more specifically, the air channels of the side channels 55). Therefore, air that exits from the side channels 55 is able to pass to the air tube 52 and along the air passage 58 via the side openings 52a, before exiting the air passage 58 to enter an air passage 48 provided in the air tube 47 (see Figure 3). Hence, it can be seen that an overall air passage extends from the air passage 73 which encompasses a region adjacent the heater assembly 6, to the side channels 55, to air passage 58, to air passage 48 and then to the mouthpiece orifice 41 when it subsequently is delivered to a user.

It should be appreciated that the various components forming the overall air passage are joined, fixed or abutted in such a way as to substantially prevent liquid aerosol-generating material (e.g., from the reservoir 46) passing into the air passage. Therefore, joins between components may be adhered, sealed or fixed in any suitable way (for example, through ultrasonic welding). Additionally, it should be appreciated that some of the abovementioned components may be integrally formed. For example, the air tube 52 may be integrally formed with the air tube 47. Alternatively, the air tube 52 may be integrally formed with the upper clamping unit 5.

With reference back to Figure 1, the top end 21 of the aerosol provision device 2 includes an air inlet hole 22 on each side of the aerosol provision device 2 (with one of the two air inlet holes 22 being visible in Figure 1). Air can enter the air inlet holes 22 and flow transversely inwards to the longitudinal axis L1 so as to enter the bottom end of the air passage 73 of the lower support unit 7 and to start to flow in the direction of the longitudinal axis L1 towards the mouthpiece 33. When the components of the cartomiser 3 have been assembled, the heater assembly 6 is arranged such that at least a surface thereof faces towards the well 53. Liquid aerosolgenerating material in the reservoir 46 is therefore able to pass to the surface of the heater assembly 6 through the well 53. Subsequently, in use, the heater assembly 6 vaporises the liquid aerosol-generating material supplied to the heater assembly 6 and the generated vapour is capable of being entrained in the airflow along the overall air passage (e.g., initially in the region of air passage 73 in proximity to the heater assembly 6) and delivered to the user through the mouthpiece orifice 41. It should be appreciated that the surface of the heater assembly 6 is provided in contact with the liquid aerosol-generating material in the reservoir 46 only in the event that the liquid aerosol-generating material is present in the wells 53. For example, if the cartomiser 3 is inverted during use (i.e., rotated 180° about an axis perpendicular to the longitudinal axis L1), then any air within the reservoir 46 will likely occupy the well 53 instead of liquid aerosol-generating material.

Turning now to the heater assembly 6, the heater assembly 6 is a microfluidic heater assembly. Figure 4 schematically illustrates the microfluidic heater assembly 6 in more detail, and in particular in a perspective view. Figure 4 shows certain elements of the heater assembly 6 in an exaggerated manner for the purposes of aiding understanding of the features of the heater assembly 6.

The microfluidic heater assembly 6 comprises a substrate 62 and an electrically resistive layer 64 disposed on a surface of the substrate 62.

The substrate 62 is formed from a non-conductive material, such as quartz (silicon dioxide); however, it should be appreciated that other suitable non-conductive materials may be used, such as ceramics, for example. In some implementations, the substrate 62 may be formed from a porous material. The porous substrate 62 may be formed from naturally porous materials, such as sponges, porous stones or ceramics etc., or via materials that are engineered to be porous, such as sintered metals or other materials. These materials, either formed naturally or engineered, have pores or hollow regions which are interconnected and define passages that follow a substantially random pathway through the material. In other implementations, the substrate 62 may be considered substantially impermeable. That is, the substrate 62 may take the form of an impermeable block of material. The way in which the substrate 62 is formed and the materials it is made therefrom is not of primary significance to the principles of the present disclosure.

The electrically resistive layer 64 is formed from any suitable electrically conductive material, for example a metal or a metal alloy such as titanium or nickel chromium. The electrically resistive layer 64 may be formed on the surface of the substrate 62 in any suitable way. For example, the electrically resistive layer 64 may be provided as a film that is adhered or otherwise bonded to the surface of the substrate 62. Alternatively, the electrically resistive layer 64 may be formed though a deposition technique, such as chemical or vapour deposition. The way in which the electrically resistive layer 64 is formed and the materials it is made therefrom is not of primary significance to the principles of the present disclosure.

In the described implementation, the heater assembly 6 is broadly planar and in the form of a rectangular cuboidal block, elongate in the direction of a longitudinal axis L2. The heater assembly 6 has the shape of a strip and has parallel sides. The heater assembly 6 has parallel upper and lower major (planar) surfaces (first surface 6a and second surface 6b) and parallel side surfaces (third surfaces 6c) and parallel end surfaces (fourth surfaces 6d). More particularly, the first and second surfaces 6a, 6b are defined by the width and length of the heater assembly 6, the third surfaces 6c are defined by the length and thickness of the heater assembly 6, and the fourth surfaces 6d are defined by the width and thickness of the heater assembly 6. The third and fourth surfaces 6c, 6d are side surfaces of the heater assembly 6 and extend between the first and second major planar surfaces 6a, 6b. The third and fourth surfaces 6c, 6d may more generally be defined as surfaces of the heater assembly 6 that share an edge with the first and second surfaces 6a, 6b.

The first surface 6a, one third surface 6c and one fourth surface 6d are shown in Figure 4. In the shown implementation of Figure 4, the length of the heater assembly 6 is 10 mm, its width is 1 mm, and its thickness is 0.12 mm (where the thickness of the substrate 62 is approximately 0.10 mm, and the thickness of the electrically resistive layer 64 is approximately 0.02 mm). The small size of the heater assembly 6 enables the overall size of the cartomiser 3 to be reduced and the overall mass of the components of the cartomiser to be reduced. However, it should be appreciated that in other implementations, the heater assembly 6 may have different dimensions and I or shapes depending upon the application at hand. For example, in some implementations, the heater assembly 6 may be a 3 x 3 mm chip.

More generally, the heater assembly 6 comprises a substrate 62 having a first major surface 6a on which the electrically resistive layer 64 is provided, and a second major surface 6b opposite the first major surface 6a. The second major surface 6b is defined by a width (first dimension) and a length (second dimension), where the length is greater than the width. That is to say, the second major surface 6b is elongated in the second dimension.

Along the longitudinal axis L2, the heater assembly 6 has a central portion 67 and first and second end portions 68, 69. In Figure 4, the length of the central portion 67 (relative to the lengths of the end portions 68, 69) has been exaggerated for reasons of visual clarity. When the heater assembly 6 is in situ in the cartomiser, the central portion 67 is positioned in the air passage 73. The central portion 67 extends across the top end of the air passage 73 of the lower support unit 7. The end portions 68, 69 are positioned between the lower support unit 7 and the upper clamping unit 5.

In the central portion 67 of the heater assembly 6, a plurality of capillary tubes 66 are provided. Only the openings of the capillary tubes 66 are shown in Figure 4 (and in an exaggerated way for clarity), but the capillary tubes 66 extend from one side of the heater assembly 6 to the other. More specifically, the capillary tubes extend from the side of the heater assembly 6 opposite the electrically resistive layer 64 (the second surface 6b not shown in Figure 4), through the substrate 62 toward the face of the substrate 62 on which the electrically resistive layer 64 is disposed, and then through the electrically resistive layer 64 (the first surface 6a).

The plurality of capillary tubes 66 extend substantially linearly through the heater assembly 6 (that is, the capillary tubes 66 follow substantially linear paths). By substantially, it is meant that the capillary tubes 66 follow pathways that are within 5 %, within 2 % or within 1 % of a straight line. This measure may be obtained in any suitable way, e.g., by comparison of the length of the distance from a first point to a second point along the extent of the capillary tube 66 and the corresponding distance that the central axis of the capillary tube 66 extends between the same two points. The capillary tubes 66 are formed in the heater assembly 66 via a manufacturing process. That is to say, the capillary tubes 66 do not naturally exist in the substrate material 62 or electrically resistive layer 64, but rather, the capillary tubes 66 are formed in the substrate material 62 and electrically resistive layer 64 through a suitable process. A suitable process for forming the capillary tubes 66, particularly when forming capillary tubes that substantially follow a linear path, is laser drilling. However, any other suitable technique may be employed in order to generate the capillary tubes 66.

The capillary tubes 66 are configured so as to transport liquid from one surface of the heater assembly 6 (i.e. , the second surface 6b) to the electrically resistive layer 64. The exact dimensions of the capillary tubes 66, and in particular the diameter, may be set in accordance with the liquid aerosol-generating material to be stored in the reservoir 46 of the cartomiser 3 and subsequently used with the heater assembly 6. For example, the properties of the liquid aerosol-generating material (e.g., viscosity) in the reservoir 46 of the cartomiser 3 may dictate the diameter of the capillary tubes 66 to ensure that a suitable flow of liquid is provided to the electrically resistive layer 64. However, in some implementations, the capillary tubes 66 may have a diameter on the order to tens of microns, e.g., between 10 pm to 250 pm, between 10 pm to 150 pm, or between 10 pm to 100 pm. However, it should be appreciated that capillary tubes 66 in other implementations may be set differently based on the properties of the liquid to be vaporised and / or a desired supply of liquid to the electrically resistive layer 64. Moreover, it should be appreciated that to achieve a desired level of flow to the electrically resistive layer 64, not only the diameter of the capillary tubes 66 but also the number I number per unit area of the capillary tubes 66 may also influence the supply of liquid to the electrically resistive layer 64.

In addition, it should be understood that when the substrate 62 is formed from a porous material, pathways formed by the interconnected pores may be intersected by the capillary tubes 66. In this way, liquid aerosol-generating material that is provided to the interconnected pores is capable of being supplied to the capillary tubes 66. This may encompass a lateral flow of liquid (i.e. , a flow of liquid along the longitudinal axis L2 of the heater assembly 6). The porous material may also act to retain liquid aerosol-generating material within the heater assembly 6, for example, in the event that the cartomiser 3 is inverted as described above. In this way, liquid aerosol-generating material may continue to be supplied to the capillary tubes 66 and the electrically resistive layer 64 even when the second surface 6b of the heater assembly 6 is no longer in direct contact with the liquid aerosol-generating material.

Whether the substrate is porous or not, in some implementations, a wicking material such as cotton or glass fibres, formed as a layer may be provided between the heater assembly 6 and the upper clamping unit 5, where the wicking material is arranged to be in contact with the wells 53. The wicking material may be capable of transporting the liquid aerosolgenerating material in the longitudinal direction of the wicking material I heater assembly 6 (that is, along the longitudinal axis L2 of the heater assembly 6). The wicking material may additionally, or alternatively, regulate the flow of liquid to the capillary tubes 66 and/or the second surface 6b of the heater assembly 6. The wicking material may additionally, or alternatively, act to retain liquid aerosol-generating material therein, so as to be able to continue to supply liquid aerosol-generating material to the capillary tubes 66 and the electrically resistive layer 64 even when the second surface 6b of the heater assembly 6 is no longer in direct contact with the liquid aerosol-generating material. In the event the wicking material is provided in conjunction with a porous substrate, the wicking material may act to complement the functions of the porous material as described above (to the extent these functions are present in a particular implementation of the heater assembly 6).

When the components of the cartomiser 3 are assembled, the heater assembly 6 is arranged such that the electrically resistive layer 64 faces towards the air passage 73 and the second major surface 6b faces towards the well 53 or reservoir 46. Accordingly, liquid aerosol-generating material is supplied to the capillary tubes 66 from the reservoir 46 and is transported to the electrically resistive layer 64 via the capillary tubes 66 for vaporisation. When the electrically resistive layer 64 is energised, e.g., an electrical current is applied thereto, liquid aerosol-generating material supplied to the electrically resistive layer 64 via the capillary tubes 66 is vaporised, and this vaporised liquid is subsequently entrained in the airflow.

The configuration of the cartomiser 3 is one in which the airflow path is arranged such that air passing along the air passage 73 is initially incident on the electrically resistive layer 64 (generally perpendicular to the plane of the electrically resistive layer 64) before being directed to the side channels 55 located on either (long) side of the heater assembly 6. In order to accommodate this airflow path, the cartomiser 3 has a certain structure which influences the shape or design of the reservoir 46.

Figure 5 schematically shows a cross-sectional view of the upper clamping unit 5 and heater assembly, broadly taken along the line labelled A in Figure 3 (that is, along a direction perpendicular to the longitudinal axis L1). Figure 5 is a cross-sectional view through upper clamping unit 5 looking along the longitudinal axis L1 towards the foot 51 of the upper clamping unit 5. The heater assembly 6 is shown partly visible with the non-visible part of the heater assembly 6 shown in phantom (dashed lines) in Figure 5. With reference to Figure 3, these phantom parts of the heater assembly 6 are positioned within the elongate recess of the foot 51 , and subsequently when viewed in Figure 5 are obstructed by upper clamping unit 5. The well 53 is also shown in Figure 5. The well 53 is shown (schematically) as narrowing down to the elongate recess into which the heater assembly 6 is provided. Additionally, for reference, the through holes 74, which comprises the co-moulded contact pad 75, are also shown in phantom in Figure 5.

Figure 5 also shows the side channels 55 and, in particular, shows the arrangement of the side channels 55 with respect to the position of the heater assembly 6. As has been described above, the side channels 55 are provided at a location along the longitudinal (the longest) sides of the heater assembly 6. The side channels 55 extend from the foot 51 and are arranged to curve inward to join the central air tube 52, as described above. Accordingly, with reference to Figure 3, one can define a region R or volume of the reservoir 46, represented in Figure 3 by a dashed line, which extends directly above the centre of the heater assembly 6. This region R of the reservoir 46 defines a volume which is, at least partly, bounded by side walls 55a of the side channels 55 and the lower part or base of the air tube 52 (see Figure 2 or 3). In this regard, the region R is capable of being replenished with liquid aerosol-generating material through the open sides of the region R (i.e., the left- and right-hand sides of the region R in Figure 3), and conversely is substantially prevented from being replenished through the sides that are bounded by the side walls 55a of the side channels 55 and the lower part of the air tube 52. During use of the heater assembly 6, liquid aerosol-generating material that is at the electrically resistive layer 64 or that is within the capillary tubes 66 (or porous substrate 62, if present) is able to be vaporised, as described above. When the rate of replenishment of the capillary tubes 66 of the heater assembly 6 is lower than the rate of vaporisation, this implies that the liquid aerosol-generating material in the capillary tubes 66 is used up (vaporised) faster than it can be replenished. As the amount of liquid aerosol-generating material in the capillary tubes 66 decreases, i.e. , the capillary tubes 66 start to run dry, the operational temperature of the electrically resistive layer 64 may increase. In some instances, for example when the rate of replenishment is sufficiently low and the duration of operation of the heater assembly is sufficiently high, the operational temperature of the electrically resistive layer 64 may increase to such an extent that the performance of the electrically resistive layer 64 is affected and, in some cases, damage may be caused to the electrically resistive layer 64, which may even prevent further use of the heater assembly 6.

The rate at which the capillary tubes 66 (or the porous substrate 62, if present) is replenished with liquid aerosol-generating material depends, in part, on the amount of aerosol-generating material that is provided above the second major surface 6b of the heater assembly 6 (or at least the exposed part of the second major surface 6b). Assuming the cartomiser 3 is held in a vertical position (e.g., as in Figure 3), liquid aerosol-generating material above heater assembly 6 acts to force the liquid aerosol-generating material towards the capillary tubes 66 (or porous substrate 62, if present) under its own weight. That is, the greater the mass of liquid aerosol-generating material above the heater assembly 6, the greater the force applied to the liquid aerosol-generating material closest to the heater assembly 6, and the greater the rate of replenishment. The region R directly above the heater assembly 6 is bounded (in the vertical direction) by the bottom wall of the air tube 58. Therefore, per unit area of the heater assembly 6 (in other words, a column extending in the vertical direction along axis L1 from a unit area in the plane of the heater assembly 6), the mass of aerosol-generating material directly above the heater assembly 6 in the region R is relatively lower than, for example, the mass of aerosol-generating material to the left or right of the region R (indicated by the region Ri to the left of region R and region R_r to the right of region R in Figure 3). Therefore, the rate of replenishment is expected to be lower for parts of the heater assembly 6 directly below the region R compared to parts of the heater assembly 6 to the left or right of the region R (e.g., as in region Ri or R_r).

It should be appreciated that the amount of force applied to a portion of liquid aerosolgenerating material may also be dependent on its proximity to other portions of liquid aerosol-generating material in the reservoir 46. Figure 6 is provided to schematically show the regions of the reservoir 46 in more detail to help explain this effect. It should be appreciated that the regions shown in Figure 6 are not to scale and are provided only for the purposes of explaining the foregoing effect. Figure 6 schematically shows the arrangement of regions R_h R_r and R of the reservoir 46 as described above. The height of region R is less than the height of regions Ri and R_r owing to the air tube 58 as explained above.

The portions of the region R which are closest to the left and right sides of the region R, that is regions Ri and R2 of Figure 6, may experience a slightly greater force than the portion of liquid aerosol-generating material in the centre of region R, that is region R_c of Figure 6. That is to say, although the mass of liquid aerosol-generating material for a given unit area of the heater assembly 6 in the region R is the same, the liquid aerosol-generating material in the regions to the left and right of region R, i.e. , regions Ri and R_r, may impart additional force to the portions of liquid aerosol-generating material in regions Ri and R2, respectively. This is thought to be due to the liquid trying to flow into the region R from the regions Ri and R_r. Overall, this means that the rate of replenishment may be slightly greater in the regions Ri and R2 of region R and subsequently slightly lower in the region Rc towards the centre of region R.

It is also noted that, in some implementations, the rate of vaporisation of the liquid aerosolgenerating material is not uniform across different parts of electrically resistive layer 641 the heater assembly 6. For example, different parts of the electrically resistive layer 64 may reach higher operational temperatures than other parts of the electrically resistive layer 64. These parts of the electrically resistive layer 64 where the temperature is relatively higher may be referred to as “hot-spots” of the electrically resistive layer 64. These “hot-spots” may be the result of one or more features of the heater assembly 6 and/or the cartomiser 3. For example, “hot-spots” may occur due to the application of an electric current to the electrically resistive layer 64, whereby variations in the flow of current across the electrically resistive layer 64 and/or variations in the resistance of the electrically resistive layer 64 may cause certain parts of the electrically resistive layer 64 to reach greater temperatures than others. Additionally, or alternatively, “hot-spots” may occur due to a cooling effect applied to the heater assembly 6 only being applied in certain parts or only having an effect in certain parts. Such cooling effects may be due to the direction and/or extent of coverage of an air flow towards or in the vicinity of the heater assembly 6 (e.g., along air passage 73), whereby air flow that impinges or otherwise passes by parts of the heater assembly may help cool those parts. Subsequently, the absence or reduced effectiveness of such cooling mechanism in a particular heater assembly 6 or configuration of cartomiser 3 can lead to the formation of “hot-spots”. As a result of the higher operational temperatures, liquid aerosolgenerating material may be observed to vaporise more quickly in these parts of the electrically resistive layer 64 / heater assembly 6, thus increasing the rate of vaporisation. In some implementations, these hot-spots have been observed at the centre of the central portion 67 of the heater assembly 6. (This central portion 67 may correspond with or lie below the central region R_c of the region R.)

It should also be appreciated that changes in one of the rate of replenishment or the rate of vaporisation may affect the other. For example, if the rate of replenishment drops in a region of the heater assembly 6, this may cause the rate of vaporisation to increase in that region owing to the reduction in any cooling effect the liquid aerosol-generating material in the capillary tubes 66 provides. Accordingly, the negative effects on the performance of the heater assembly 6 can be exacerbated in some implementations.

In some implementations, it has been observed that the centre of the heater assembly 6 (i.e., the centre part of the central portion 67 of the heater assembly 6, which may broadly correspond to the part of the heater assembly below the region Rc of Figure 6) can be prone to drying out and/or experiencing increased operational temperatures. As described above, this may lead to reduced performance and, in some cases, even damage to the heater assembly 6.

In addition, the region R is able to be replenished with liquid aerosol-generating material through the surfaces that are not bounded by the side walls 55a of the side channels 55 and the lower part of the air tube 52. These surfaces are the ones that are defined by the width of the second major surface 6b. For example, in the implementation of Figure 3, these are the surfaces that correspond to the width of heater assembly 6 and the distance between the heater assembly and the lower part of the air tube 52. With reference also to Figure 2, it can be seen that these side surfaces are relatively narrow and thus, in some implementations, this may reduce the rate of replenishment of the region R as the liquid aerosol-generating material is vaporised and drawn into the heater assembly 6 from the region R.

With reference back to Figure 5, it is thought that a contributing factor that reduces the rate or replenishment of the centre part of the central portion 67 of the heater assembly 6 with liquid aerosol-generating material is the distance from the centre of the heater assembly 6 to the mass of liquid aerosol-generating material in the regions R_r and Ri of the reservoir 46. As noted above, these regions R_r and Ri impart additional force to the regions Ri and R2 of the region R of the reservoir 46, as explained with reference to Figure 6. However, this additional force is either not impart or is imparted to a lower extent on the central region Rc of the region R of the reservoir 46. While Figure 6 shows three defined regions Ri, R2, Rc, it should be appreciated that the way in which the additional force acts may not be discretised as shown in Figure 6 but instead may vary as a continuous function with distance from the side surfaces of region R of the reservoir to the centre of region R. Figures 5 and 6 show a distance, di , which represents the shortest distance to the centre of the region R (corresponding broadly to the centre of the heater assembly 6) from the open side surfaces of the region R. The magnitude of the additional force imparted by the liquid aerosolgenerating material in the regions R_r and Ri of the reservoir 46 reduces along the distance di towards the centre of the heater assembly 6. This distance di is equal to half the width of the side channels 55.

Figures 7 and 8 show a cartomiser 3’ according to the principles of the present disclosure. The cartomiser 3’ is configured such that the distance from regions of the reservoir 46 which have a greater mass of aerosol-generating material per unit area (that is, the equivalent regions to R_r and Ri) are arranged such that the minimum distance between these regions and the centre of the heater assembly 6 is reduced. In this way, a greater proportion of the additional force is capable of being applied to the aerosol-generating material located in the centre region (that is, Rc) of the region R of the reservoir 46, thereby providing for a relatively greater rate of replenishment.

Figure 7 schematically shows the cartomiser 3’ in a perspective and exploded view (exploded along the longitudinal axis L1), while Figure 8 shows a cross-sectional view of the cartomiser 3’. Figures 7 and 8 broadly mirror the views of the cartomiser 3 in Figures 2 and 3 for the cartomiser 3. The cartomiser 3’ includes several features which are substantially the same as shown for the cartomiser 3, and these features are identified using the same reference signs. Only the differences will be explained herein for conciseness.

The cartomiser 3’ is similarly assembled from a stack of components: an outer housing 4, an upper clamping unit 5’, a heater assembly 6, a lower support unit 7’ and an end cap 8. The upper clamping unit 5’ and lower support unit 7’ are configured differently to their counterparts in cartomiser 3, as will be explained in more detail below. Otherwise, the components of the cartomiser 3’ are substantially as described above in respect of cartomiser 3.

The upper clamping unit 5’ of the cartomiser 3’ is similarly an intermediate component of the stack of components and is provided for broadly similar reasons as the upper clamping unit 5 of cartomiser 3. The upper clamping unit 5’ includes a foot 5T in the form of a block which includes a well 53’ that is open at the bottom surface, similarly to the upper clamping unit 5 of cartomiser 3. The upper clamping unit 5’ also includes side channels 55’ that are similarly formed as part of the upper clamping unit 5’ and extend from openings in the foot 5T that broadly align with the air passage 73’ in the lower support unit 7’ (described in more detail below). The side channels 55’ similarly extend upwards from the foot 5T and curve inwards at the upper parts of the side channels 55’ towards the longitudinal axis L1 (as best seen in Figure 7). However, the side channels 55’ are arranged in an alternative manner compared to their counterparts in cartomiser 3. In particular, the side channels 55’ are arranged at either end of the upper clamping unit 5’. In the arrangement of Figures 7 and 8, the side channels 55’ extend from the longitudinal ends of the foot 5T. As should be appreciated with reference to Figure 7, the side channels 55’ are provided at positions corresponding to either end of the heater assembly 6. That is, the side channels 55’ are not provided at positions corresponding to the longitudinal sides of the heater assembly 6, but are instead provided at positions corresponding to the parallel end surfaces of the heater assembly 6.

The lower support unit 7’ is also similarly provided in the form of a block having a broadly flat top surface and a flat bottom surface 72’. An air passage 73’ extends upwardly from the bottom surface 72’ toward the top surface. In a similar manner, when the heater assembly 6 is positioned between the upper clamping unit 5’ and the lower support unit 7’, the air passage 73’ is provided in fluid communication with the heater assembly 6. However, as seen in Figures 7 and 8, the air passage 73’ also extends in the longitudinal direction of the lower support unit 73’. For instance, the air passage 73’ comprises a trench or recess portion which extends along the longitudinal axis of the lower support unit 7’. As should be appreciated, the air passage 73’ is provided such that it fluidly connects to the side channels 55’ of the upper clamping unit 5’ that are provided at the ends of the upper clamping unit 5’. As should be understood from Figures 7 and 8, air that enters through the opening in the bottom surface 72’ of the lower support unit 7’ is able to pass along the air channel 73’ in the vicinity of the heater assembly 6 (and more particularly, the electrically resistive layer 64 of the heater assembly 6, and subsequently bifurcates and flows in a direction around the parallel ends of the heater assembly 6 to the side channels 55’. The side channels 55’ similarly connect to the air tube 52, such that air is able to flow from the side channels 55’ along the air passage 58 via the side openings 52a.

As with the lower support unit 7 of Figures 2 and 3, the lower support unit 7’ includes through holes 74. However, owing to the different arrangement of the air channel 73’, the lower support unit 7’ includes two protruding supports 74a which protrude from a base of the lower support unit 7’ to the top surface of the lower support unit 7’. In effect, the protruding supports 74a of the lower support unit 7’ of Figures 7 and 8 can be considered the remaining portions of the lower support unit 7 of Figures 2 and 3 if one were to carve or remove a section of the lower support unit 7 to enlarge the air channel 73. The protruding supports 74a each include a through hole 74 which may similarly be provided with a co-moulded contact pad 75 in the form of a pin inserted (e.g., press fit) into the through holes 74. The top surface of the protruding supports 74a act to support the heater assembly 6 such that the heater assembly 6 is sandwiched between the upper clamping unit 5’ and the lower support unit 7’. Additionally, the contact pads 75 of the protruding supports 74a similarly provide an electrical contact to the heater assembly 6 (e.g., via a power supply that is able to be coupled to the opposite ends of the contact pads 75).

Hence, an overall air passage extends from the air passage 73’ which encompasses a region adjacent the heater assembly 6, to the side channels 55’, to air passage 58, to air passage 48 and then to the mouthpiece orifice 41 when it subsequently is delivered to a user. As air flows through the air channel 73’ it is able to pass around the protruding supports 74a as it passes towards the side channels 55’ provide at either end of the upper clamping unit 5’.

As in the case of the implementation described in Figures 2 and 3, it should be appreciated that the various components forming the overall air passage are joined, fixed or abutted in such a way as to substantially prevent liquid aerosol-generating material (e.g., from the reservoir 46) passing into the air passage. Therefore, joins between components may be adhered, sealed or fixed in any suitable way (for example, through ultrasonic welding). Additionally, it should be appreciated that some of the abovementioned components may be integrally formed. For example, the air tube 52 may be integrally formed with the upper clamping unit 5’. Additionally, it should also be appreciated that the protruding supports 74a may be omitted and instead the exposed electrical contact pad 75 may protrude upwards to the top surface of the lower support unit 7’, although the protruding supports 74a may provide additional protection from aerosol for the contact pads 75.

With reference to Figure 8, a similar region R or volume of the reservoir 46 can be defined for the reservoir 46 of cartomiser 3’. The region R, represented in Figure 8 by a dashed line, extends directly above the centre of the heater assembly 6 and defines a volume which is, at least partly, bounded by side walls 55a’ of the side channels 55 and the lower part or base of the air tube 52 (see Figure 8). The region R is capable of being replenished with liquid aerosol-generating material through the open sides of the region R. In cartomiser 3’, this can be considered the front and back sides of the region R. In this regard, the front side is considered to be the side of region R which is in a plane parallel with the plane of Figure 8 but provided in front of the plane of Figure 8, while the back side is considered to be the side of region R which is in a plane parallel with the plane of Figure 8 but provided behind the plane of Figure 8. Conversely, the region R is substantially prevented from being replenished through the left and right hand sides of the region R as shown in Figure 8 (i.e. , those sides that are bounded by the side walls 55a’ of the side channels 55’) as well as the top side that is bounded by the lower part of the air tube 52. Figure 9 will be understood from Figure 5 and schematically shows a cross-sectional view of the upper clamping unit 5’ and heater assembly 6, broadly taken along the line labelled B in Figure 8 (that is, along a direction perpendicular to the longitudinal axis L1). Figure 9 is a cross-sectional view through upper clamping unit 5’ looking along the longitudinal axis L1 towards the foot 5T of the upper clamping unit 5’. The heater assembly 6 is shown partly visible with the non-visible part of the heater assembly 6 shown in phantom (dashed lines) in Figure 9. With reference to Figure 8, these phantom parts of the heater assembly 6 are positioned within the elongate recess of the foot 5T, and subsequently when viewed in Figure 9 are obstructed by upper clamping unit 5’. The well 53’ is also shown in Figure 9. The well 53’ is shown (schematically) as narrowing down to the elongate recess into which the heater assembly 6 is provided. Additionally, for reference, the through holes 74, which comprises the co-moulded contact pad 75, are also shown in phantom in Figure 9.

Figure 9 also shows the side channels 55’ and, in particular, shows the arrangement of the side channels 55’ with respect to the position of the heater assembly 6. As has been described above, the side channels 55’ are provided at a location at the parallel end (the shortest) sides of the heater assembly 6.

Figure 10 is similar to Figure 6 and schematically shows the regions of the reservoir 46 of cartomiser 3’ in more detail. It should be appreciated that the regions shown in Figure 10 are not to scale and are provided only for the purposes of explaining the foregoing effect. Figure 10 schematically shows the arrangement of regions R_f, R_b and R of the reservoir 46 as described above. The height of region R is less than the height of regions R_f and R_b owing to the presence of the air tube 58 as explained above. The regions Rf and R_b are the regions of the reservoir 46 that are in front of or behind the region R, as described above.

Figures 9 and 10 show a distance d, which represents the shortest distance to the centre of the region R (broadly corresponding to the centre of the heater assembly 6) from the open side surfaces of region R. The distance d is equal to half the width of the heater assembly 6. As such, and by visual inspection of Figures 5 and 9 with Figures 9 and 10, it can be seen that in cartomiser 3’ the distance d is much smaller than the distance di in cartomiser 3 of Figure 3 to 5. As noted above, any additional force generated by the liquid aerosolgenerating material in the regions R_r or Ri in cartomiser 3 or Rf and R_b in cartomiser 3’ acts on the liquid aerosol-generating material in the region R of the reservoir 46; however, the magnitude of this additional force at locations within the region R varies with the distance from the open side surface of the region R towards the centre of the region R. Owing to the way in which the heater assembly 6 is oriented with respect to the regions of the reservoir 46 in cartomisers 3 and 3’, the distance di in cartomiser 3 is greater than the distance d in cartomiser 3’ and this means that the magnitude of the additional force generated by regions Rf and R_b is generally greater at the centre of region R in cartomiser 3’ than the additional force generated by regions Ri and R_r at the centre of region R in cartomiser 3. Consequently, the rate of replenishment at the centre of the heater assembly 6 in cartomiser 3’ is generally greater than the rate of replenishment at the centre of the heater assembly 6 in cartomiser 3, owing to the relatively greater additional force that is generated by the regions of the reservoir 46 adjacent the region R that is bounded (at least in part) by the side walls 55a/55a’ and the lower part of the air tube 52 in cartomiser 3’.

Accordingly, because the rate of replenishment is thought to generally be relatively greater at the centre of the heater assembly 6 of cartomiser 3’ than in cartomiser 3, the operating temperature of the heater assembly 6 of cartomiser 3’ in the centre of central portion 67 may be more easily maintained at an acceptable operating temperature, thereby preventing or reducing instances where parts of the heater assembly 6 are dried out and/or damage to the heater assembly 6 and the electrically resistive layer 64 in particular.

It should be understood that the relatively greater force provided by the abovementioned configuration of cartomiser 3’ may provide benefits to the rate of replenishment at the centre of the heater assembly 6 in the event that the side channels 55 of cartomiser 3 have a width (i.e., the dimension in the direction of the axis L2 of the heater assembly) that is greater than twice the width of the heater assembly 6.

Hence, described above is a cartomiser having a reservoir 46 that comprises one or more side walls (e.g., circumferential side wall 44, outer walls of air tube 52, outer walls of side channels 55’), a base wall (e.g., provided by the upper clamping unit 5’) and a top wall (e.g., top end 42 and the lower part of air tube 52). The reservoir comprises a first region R having a smaller distance between the upper clamping unit 5’ and the lower part of the air tube 52 than at least a second region of the reservoir (e.g., regions Rf and R_b). The region R defines a volume sharing a surface with a surface of the heater assembly 6, and more particularly, an exposed surface of the heater assembly 6 (that is, the second major surface 6b). The region R also extends in a first direction from the surface of the heater assembly 6, wherein the first direction is a direction from the first major surface 6a to the second major surface 6b of the heater assembly 6. In other words, the region R extends substantially in a direction that is normal to the second major surface 6b of the heater assembly 6.

The region R comprises a plurality of side surfaces that are defined by the height (or more generally, the extent of the region R from the second major surface 6b of the heater assembly 6 in the first direction to the lower part of the air tube 52). The region R comprises at least one side surface that shares a surface with the side walls of the reservoir 46 and at least one side surface that has an open surface that is in fluid communication with the second regions R_f and R_b of the reservoir 46. In the example described in Figures 7 to 10, the region R comprises two side surfaces that share a surface with the side walls of the reservoir 46 (namely the walls 55a’ of side channels 55), and two side surfaces that are open and in fluid communication with the remaining regions Rf and R_b of the reservoir 46. The distance from the at least one side surface of the region R that shares a surface with the one or more side walls of the reservoir 46 to the centre of the second major surface 52b of the heater assembly 6 is greater than the distance from the at least one side surface that has an open surface with the remaining regions of the reservoir 46 to the centre of the second major surface 6b of the heater assembly 6.

Accordingly, by configuring the cartomiser 3’ such that the distance between the side surfaces of the region R that are in communication with the remaining regions of the reservoir R and the centre of the exposed surface of the heater assembly 6 is less than the corresponding distance from the side surfaces that share a surface with the walls of the reservoir 46, the forces acting at the centre of the region R (and correspondingly at the centre of the second major surface 52b of the heater assembly 6) can be maximised. In this way, the rate of replenishment of liquid aerosol-generating material at the centre region of the heater assembly 6 can be improved and therefore can reduce or prevent dry-out conditions, over-heating of the heater assembly 6 and/or damage to the heater assembly 6.

It should be appreciated that in the example of Figures 7 to 10, the heater assembly 6 is shown with at least part of the second major surface 6b that is not exposed to the reservoir 46 / well 53. For example, with reference to Figure 9, the end portions 68, 69 of the heater assembly 6 are arranged to be between the upper clamping unit 5’ and the lower support unit 7’, and therefore are generally not in fluid communication with the reservoir 46. In this regard, the relevant part of the heater assembly 6 is the exposed part of the second major surface 6b. That is to say, it is not the fact that the heater assembly 6 perse is elongated, but the fact that the exposed part of the second major surface 6b is elongated in one direction. By providing a second surface that is elongated in at least one direction, the principles of the present disclosure may be applied; namely, arranging the cartomiser 3, 3’ such that the distance from the at least one side surface of the region R that shares a surface with the one or more side walls of the reservoir R to the centre of the second major surface 6b of the heater assembly 6 is greater than the distance from the at least one side surface of the region R that has an open surface with the second region of the reservoir 46 to the centre of the second surface of the heater assembly 6. For example, the principles of the present disclosure may be applicable to implementations where the heater assembly 6 is formed so that the second surface 6b is square, but where a part of the surface 6b is covered when the cartomiser is assembled. The distance from the at least one side surface of the region R that shares a surface with the one or more side walls of the reservoir 46 to the centre of the second major surface 6b of the heater assembly 6 is greater than half the shorter dimension of the exposed second surface 6b of the heater assembly 6. In the example implementation of Figures 7 to 10, this corresponds to the width of the heater assembly 6, but again it should be appreciated that the heater assembly 6 itself may be wider than shown but a part of the heater assembly (or the second major surface 6b thereof) may not be exposed to the reservoir 46.

In respect of the expression, distance from the at least one side surface of the region R to the centre of the second major surface 6b of the heater assembly 6, it should be appreciated that this distance may be measured at any vertical elevation (i.e. , in the direction normal to the second major surface 6b of the heater assembly 6) as desired. The distance to the centre of the exposed part of the second major surface 6b of the heater assembly 6 can be measured relative to an axis passing through the centre of the heater assembly 6. In this way, the distance can be measured on a plane that is parallel to the plane of the second major surface of the heater assembly 6.

It has also been described above that the regions of the reservoir 46 other than region R are arranged so as to be prevented from supplying liquid aerosol-generating material through the at least one side surface of the region R that shares a surface with the one or more side walls of the reservoir 46. That is to say, in defining the region R, the region R includes surfaces which correspond to the side walls of the reservoir 46. Accordingly, the other regions are provided in fluid communication with the region R only through the at least one side surface that has an open surface with the other regions of the reservoir 46.

In some implementations, the region R may not necessarily be defined by a rectangular cuboid, and instead may be defined by any other corresponding shape depending on the arrangement of the cartomiser 3, 3’. Regardless, the principles of the present disclosure still apply. For surfaces of the region R that may be defined by some curvature, the distance to be selected may be suitably chosen - for example to correspond to the minimum distance if the surface is curved in a convex manner (i.e., curves towards the heater assembly) or to the maximum distance if the surface is curved in a concave manner (i.e., curves away from the heater assembly).

The cartomiser 3, 3’ described above is generally arranged so that the reservoir is II- shaped. That is to say, e.g., with reference to Figures 3 to 10, the reservoir 46 has a II- shaped section which comprises a base and arms. For example, with reference to Figure 6 or 10 the regions R_r, Ri, Rf and Rb correspond to the arms of the U-shaped section, while the regions R correspond to the base of the U-shaped section. It should be appreciated that the U-shaped section need not define the entire reservoir 46. For example, the arms may correspond only to a part of the reservoir 46, with the arms in fluid communication with other regions of the reservoir 46.

The cartomisers 3, 3’ described above further comprise an air flow path. As described, a part of the air flow path, and in particular the lower part of air tube 52, is arranged to abut the top surface of the region R. The air flow path, e.g., the air tube 52, extends upwards from the top surface of the region R and coaxially with the central longitudinal axis L1 of the cartomiser 3, 3’. The presence of the centrally provided air tube 52 may therefore be considered as providing the U-shaped section of the reservoir 46, with the central air tube 52 having the regions R_r, Ri, Rf and Rb respectively arranged either side of the central air tube 52.

Moreover, a part of the air flow path is arranged adjacent to the first dimension (i.e., the length) of the second major surface 6b of the heater assembly 6. As described above, air is able to pass around the heater assembly 6 via the side channels 55’.

In accordance with a further aspect of the present disclosure, the side surfaces 6c of the heater assembly 6 are configured so as to be exposed to the liquid aerosol-generating material of the reservoir 46.

Figure 11 shows a first implementation of a heater assembly 6 whereby the heater assembly 6 comprises a substrate 62 formed from or comprising a porous material. As above, the porous substrate 62 may be formed from naturally porous materials, such as sponges, porous stones or ceramics etc., or via materials that are engineered to be porous, such as sintered metals or other materials. These materials, either formed naturally or engineered, have pores or hollow regions which are interconnected and define passages that follow a substantially random path through the material. By way of a concrete example, in Figure 11 , the substrate 62 is formed from sintered quartz (silicon dioxide). The interconnected pores or voids of the porous substrate 62 provide one or more distribution channels (shown representatively by reference sign 62a in Figure 11). More particularly, the interconnected pores or voids of the porous substrate 62 provide one or more naturally-formed distribution channels 62a in that these distribution channels 62a are either naturally occurring (e.g., in a porous ceramic) or occur naturally as a result of forming the substrate (e.g., a sintered quartz). The one or more distribution channels 62a extend from the surface of the substrate 62 (e.g., the second surface 6b, third surface 6c or fourth surface 6d) through the substrate 62 following a substantially random path. By virtue of the presence of the capillary tubes 66 formed in the porous substrate 62 (e.g., via machining or drilling), at least some of the random paths provided by the interconnected pores or voids intersect the capillary tubes 66. Accordingly, any liquid aerosol-generating material within the interconnected pores or voids that is able to travel along a path that intersects a capillary tube 66 is capable of being supplied to the capillary tube 66, and subsequently to the electrically resistive layer 64 via the capillary tube 66. Hence, the naturally-formed distribution channels 6a are capable of supplying liquid-aerosol generating material to the capillary tubes 66, thereby aiding the wicking performance of the capillary tubes 66 and the heater assembly 6.

Figure 12 shows a second implementation of a heater assembly 6 whereby the heater assembly 6 comprises a substrate 62 formed from a material that is substantially impermeable or impermeable. Unlike the implementation of Figure 11, the substantially impermeable substrate 62 is formed from a material that does not permit liquids (particularly liquid aerosol-generating material) to flow through it. It should be appreciated this relates only to the material from which the substrate 62 is made from. For instance, the presence of the capillary tubes 66 allow for liquid aerosol-generating material to flow from one side of the substrate 62 to the other, but in the context of the material from which the substrate 62 is formed, liquid aerosol-generating material is not permitted to flow into or through the material itself. Any suitable material may be used to provide the impermeable substrate 62; for example, bulk quartz (silicon dioxide) may be used.

In the implementation of Figure 12, the substrate 62 is provided with one or more distribution channels 62b. In this implementation, the distribution channels 62b are artificially-formed (or engineered) distribution channels. That is, the distribution channels 62b are formed by performing an engineering process, such as drilling, machining, etching etc. to form the distribution channels 62b. In some implementations, the distribution channels 62b may be formed through the same process as forming the capillary tubes 66; for example, via laser drilling. As seen in Figure 12, the distribution channels 62b extend from an opening in the side surface (in particular, the longitudinal side surface 6c) into the substrate 62. The distribution channels may pass all the way through the width of the substrate 62, or may only pass partway through the width of the substrate 62. In either case, the distribution channels 62b are formed such that they intercept at least one capillary tube 66. That is, much like in the implementation of Figure 11 , any liquid aerosol-generating material within the distribution channels 62b (for example, that enters via the opening on the third surface 6c of the heater assembly 6) is able to travel along a path that intersects a capillary tube 66, and is therefore capable of being supplied to the capillary tube 66, and subsequently to the electrically resistive layer 64 via the capillary tube 66. Hence, the artificially-formed (engineered) distribution channels 62b are capable of supplying liquid-aerosol generating material to the capillary tubes 66, thereby aiding the wicking performance of the capillary tubes 66 and the heater assembly 6. In the example of Figure 12, however, the distribution channels 62b are formed extending along a predetermined path as opposed to a more random path that is provided by the interconnected pores or voids.

It should be appreciated, however, that a combination of the approaches described in the first and second implementations of Figures 11 and 12 respectively may also be provided. That is, in some implementations, the porous substrate 62 of the implementation of Figure 11 may be provided with the artificially-formed distribution channels 62b of the implementation of Figure 12. In such implementations, at least some of the random paths provided by the interconnected pores or voids may additionally or alternatively intersect the artificially-formed distribution channels 62b, and thereby be capable of supplying liquid aerosol-generating material to the capillary tubes 66.

Regardless of the way in which the distribution channels 62a, 62b are provided, the distribution channels 62a, 62b are configured such that they permit the flow of liquid aerosolgenerating material along the distribution channels 62a, 62b. For example, the average pore size and/or properties of the substrate 62 may be selected so as to encourage liquid along the random paths formed by the interconnected pores. Alternatively, the size and shape (e.g., cross-section) of the distribution channels 62b may be chosen to so as to encourage liquid along the predetermined paths formed by the distribution channel 62b. It should be appreciated, however, that the properties of the liquid aerosol-generating material that the heater assembly 6 is to be used with may dictate the actual sizes, dimensions, etc. of the distribution channels 62a, 62b.

In accordance with the principles of the present disclosure, one or more distribution channels 62a, 62b, are provided extending from the third outer surface 6c of the heater assembly 6. As should be appreciated, the third outer surface 6c of the heater assembly 6 corresponds to the longest side surfaces of the heater assembly 6 and, moreover, in the arrangement of the cartomiser 3’, correspond to the surfaces of the heater assembly that are adjacent the regions Rf and Rb of the reservoir 46. The one or more distribution channels 62a, 62b, extend from the third outer surface 6c of the heater assembly 6 at least to a position within the substrate 62, whereby liquid aerosol-generating material is capable of being supplied to the capillary tubes 66 via the one or more distribution channels 62a, 62b.

In particular, the one or more distribution channels 62a, 62b are provided with inlets or openings that are present on the third outer surface 6c of the heater assembly 6, whereby the distance from the centre of the third outer surface 6c to the centre of the heater assembly 6 is the shortest distance between the centre of any other side surface (e.g., the fourth outer surface 6d) of the heater assembly 6 to the centre of the heater assembly 6. As should be appreciated, when providing the distribution channels 62a and 62b, distribution channels 62a, 62b that are provided extending from the third surface 6c of the heater assembly 6 extend a shorter distance to the centre or central portion 67 of the heater assembly 6 (i.e. , where the capillary tubes 66 are provided) than distribution channels 62a, 62b provided extending from the fourth surface 6d of the heater assembly 6. Accordingly, and broadly speaking, distribution channels 62a, 62b that are provided extending from the third surface 6c may enable liquid aerosol-generating material to be more rapidly provided to the capillary tubes 66, and hence to the centre of the central portion 67 of the heater assembly 6, by virtue of the fact that the one or more distribution channels extend a shorter distance to the capillary tubes 66.

Figure 13 shows a perspective view of a heater assembly 6 located in a recessed portion of the lower clamping unit 7’. Certain other features of the cartomiser 3’ are not shown for clarity. Broadly speaking, the heater assembly 6, upper clamping unit 5’ and lower support unit 7’ are configured as described in respect of Figures 7 through 10, with the exception that the heater assembly 6 is provided in a recessed portion of the lower support unit 7’ rather than the recessed portion of the upper clamping unit 5’ for reasons of visual clarity. It should be appreciated, however, that the foregoing may equally apply to arrangements where the upper clamping unit 5’ includes the recessed portion.

Figure 13 shows in more detail the arrangement of the heater assembly 6 with respect to the lower support unit 7’. In particular, the heater assembly 6 is located in the elongate recess as described above, but it should also be noted that the elongate recess is wider than the heater assembly 6, forming troughs 76 arranged either side of the heater assembly 6. As such, the reservoir 46 and/or the well 53 formed in the upper clamping unit 5’ are provided in fluid communication with the longest side surfaces 6c of the heater assembly 6 via the troughs 76. More particularly, it can be seen that the third outer surface 6c of the heater assembly 6 is left exposed and is in direct fluid communication with the well 53 via the troughs 76..Accordingly, it should be appreciated that liquid-aerosol generating material from the reservoir 46 is capable of penetrating the heater assembly 6 via the second surface 6b of the heater assembly 6, via either the capillary tubes 66 and/or interconnected pores or voids if the substrate 62 is formed from a porous material, and via the third surface 6c of the heater assembly 6 via either the distribution channels 62a and/or 62b.

Configuring the heater assembly 6 such that any side surface 6c,) is exposed to the reservoir 46 allows for the possibility of more liquid aerosol-generating material penetrating the heater assembly 6 (through the exposed surface(s)), thereby leading to increased wetting of the heater assembly 6. Further, configuring the heater assembly 6 such that it is the third surface 6c that is exposed to the reservoir 46 (e.g., as opposed to the fourth surface 6d) allows for the possibility for more rapid liquid uptake I wetting of the heater assembly 6 due to the relatively shorter distances the liquid aerosol-generating material has to travel to reach the centre of the heater assembly 6. Additionally, because the third surface 6c is by definition generally larger than the fourth surface 6d of the heater assembly 6, there is a greater surface area that is exposed to the reservoir 46 and therefore a greater surface area through which liquid is able to penetrate the heater assembly 6.

When utilised in combination with the arrangement of the heater assembly 6 of cartomiser 3’ of Figures 7 to 10, it can be seen that liquid aerosol-generating material is capable of being supplied more readily I quickly to the centre of the heater assembly 6. Not only does the shorter distance from the at least one side surface that has an open surface with the remaining regions of the reservoir 46 to the centre of the second major surface 6b of the heater assembly 6 mean that a greater force is applied to the liquid aerosol-generating material located above the centre part of the central portion 67 of the heater assembly and therefore a relatively increased rate of replenishment is provided, but by exposing the side surfaces of the heater assembly 6 that have the shortest distance from a centre of the side surfaces to the centre of the heater assembly 6, a further route for the liquid aerosolgenerating material to travel to the centre part of the heater assembly 6 is provided, which may help to further improve the rate of replenishment.

Hence, configuring the heater assembly 6 such that one or more distribution channels 62a, 62b are provided extending from the third outer surface 6c of the heater assembly 6 (where the third outer surface is a side surface of the heater assembly sharing an edge with at least one of the first outer surface 6a and the second outer surface 6b and wherein the third outer surface 6c is defined as the surface where the distance from the centre of the third outer surface 6c to the centre of the heater assembly 6 is the shortest distance between the centre of any other side surface of the heater assembly 6 to the centre of the heater assembly 6) enables a potential improvement in the ability of the heater assembly 6 to take up (absorb) liquid, otherwise known as wetting or replenishment. Not only may wetting being improved in respect of the amount of liquid the heater assembly 6 is able to absorb and subsequently transfer to the electrically resistive layer 64, but also the rate of wetting can be improved (that is, the time taken to transition from a dry heater assembly 6 to a wet heater assembly 6 can be reduced). It should be understood that improvements in wicking and wetting may also lead to improvements in the aerosol that is subsequently generated using the heater assembly 6; for example, the volume of aerosol generated or the consistency at which aerosol is generated. In accordance with the examples defined above, the heater assembly 6 is provided as a structure having a rectangular cuboid shape. The first outer surface 6a and the second outer surface 6b are the surfaces of the rectangular cuboid having the largest surface area (i.e., the largest faces of the heater assembly 6). With the heater assembly 6 having a rectangular cuboid shape, the third outer surface 6c is (one or both of) the two surfaces having the second largest surface area. Accordingly, the fourth outer surface 6d is (one or both of) the two surfaces having the smallest surface area. In this regard, it should be understood that surface area in this context refers to the area defined by the perimeter of the respective surfaces (as opposed to the surface area which may encompass ridges, grooves or pores or the like).

However, it should be understood that the present disclosure is not limited to heater assemblies having a rectangular cuboid shape. The heater assembly may take any suitable three-dimensional shape comprising at least first, second and side outer surfaces. In such implementations, the advantages of the present disclosure may still be realised when the third outer surface comprises one or more distribution channels and is exposed to the reservoir (where the distance from the centre of the third outer surface to the centre of the heater assembly is the shortest distance between the centre of any other side surface of the heater assembly to the centre of the heater assembly).

Furthermore, it should also be understood that the heater assembly may comprise one or more distribution channels on surfaces other than the third outer surface. For example, the heater assembly 6 may also include one or more distribution channels extending from the fourth surface 6d, in addition to those channels extending from the third surface 6c.

Broadly speaking, in accordance with the present disclosure, the one or more distribution channels 62a, 62b extend in a direction from an opening in the third outer surface 6c towards the longitudinal axis L2 of the heater assembly 6. This, in part, is due to the fact that the third outer surface 6c runs parallel to the longitudinal axis L2 in the example of the rectangular cuboid shaped heater assembly. However, even if the heater assembly is not rectangular cuboid shaped, side surfaces that run substantially parallel to the longitudinal axis (as opposed to substantially perpendicular) are likely to offer a shorter distance to the electrically resistive layer 64. Moreover, in some implementations, the one or more distribution channels 62a, 62b extend in a direction perpendicular to the longitudinal axis L2 of the heater assembly. In some implementations, the one or more distribution channels 62a, 62b extend in a direction substantially towards the centre of the heater assembly 6. This may be along a two-dimensional plane relative to the heater assembly (in other words, for a three dimensional structure, the centre lies on an axis that passes through each of the two- dimensional planes). Alternatively, the centre may be a point centre in the centre of the heater assembly. As noted above, the one or more distribution channels 62b may be formed through an engineering process (such as drilling or machining). In such cases, the one or more distribution channels 62b follow a predetermined path formed in the substrate via the engineering process. In some implementations, the one or more distribution channels 62b follow a (substantially) linear path. This may particularly be the case where the one or more distribution channels 62b are formed via an engineering process, e.g., by drilling into a bulk material, simply due to the physical limitations of the engineering process. However, even when the one or more distribution channels 62b are formed via an engineering process, it may be possible to form the channels in a non-linear manner. For example, the distribution channels may be formed by etching a pattern into the surfaces of two substrates (or two halves of a substrate) and subsequently joining or abutting the two substrates together whereby the etched patterns on the surfaces of the substrates are aligned to form the distribution channel. In this way, more complex patterns, and subsequently distribution channels 62b that may not necessarily follow a linear path, are achievable.

Additionally, or alternatively, the one or more distribution channels 62a may follow a random path formed in the substrate 62 via a series of interconnected pores (for example, when the substrate 62 is formed form a porous material). In some implementations, the porous substrate 62 may be treated or otherwise modified to remove or enhance some of the interconnected voids (forming the distribution channels). For example, the fourth surface 6d of the heater assembly may be sealed, for example by applying a coating or the like, on the fourth surface 6d to seal pores close to the surface 6d.

It should be appreciated that the configuration of the cartomiser 3, 3’ accommodating the heater assembly 6 are provided as example configurations of such a cartomiser 3, 3’. The principles of the present disclosure apply equally to other configurations of the cartomiser 3 (for example, comprising similar or different components to those as shown in Figures 1 to 10). That is, the cartomiser 3, 3’ and the relative position of the heater assembly 6 in the cartomiser 3 is not significant to the principles of the present disclosure. Broadly speaking, a cartomiser is likely to comprise a top end (having the mouthpiece orifice 41) and a bottom end. In the examples shown above, the heater assembly 6 is arranged to be below the reservoir 46, substantially horizontal to the longitudinal axis of the cartomiser 3, 3’, and arranged in an airflow path that initially impinges on the surface of the heater assembly 6 (the electrically resistive layer 64) before proceeding perpendicularly to longitudinal axis of the heater assembly 6 and up to the side channels 55. However, this need not be case, and in other implementations the cartomiser 3, 3’ may be configured differently depending on the particular design and application at hand. For example, the heater assembly 6 may be arranged such that airflow is substantially perpendicular to the longitudinal axis of the heater assembly, e.g., along the exposed surface of the electrically resistive layer 64. For example, an air passage may be provided to one side of the upper clamping unit 5. Air may enter the cartomiser 3, 3’ by a suitable inlet and flow along the longitudinal surface of the heater assembly 6 (and along the electrically resistive layer 64) before passing in a substantially vertical direction through an air tube positioned at one end of the upper clamping unit 5 (e.g., the end opposite the air inlet). The outer housing 4 and mouthpiece orifice 41 may be suitably configured. Hence, although the heater assembly 6 has been described in the specific context of the example cartomiser 3, 3’ of Figures 1 to 10, the principles described herein can be applied to different heater assemblies for use in different cartomisers 3.

In the example shown in Figure 2 or 7, the contact pads 75 directly contact the electrically resistive layer 64 of the heater assembly 6. However, the cartomiser 3, 3’ may be provided with any suitable arrangement that facilitates the electrical contact between the aerosol provision device 2 and the heater assembly 6. For example, in some implementations, electrical wiring or other electrically conductive elements may extend between the electrically resistive layer 64 and the contact pads 75 of the cartomiser 3, 3’. This may particularly be the case when the heater assembly 6 has its largest dimension (e.g., its length) less than a minimum distance between the contact pads 75. The distance between the contact pads 75 may be dictated by the electrical contacts on the aerosol provision device 2.

It should also be appreciated that while the above has described a cartomiser 3, 3’ which includes the heater assembly 6, in some implementations the heater assembly 6 may be provided in the aerosol provision device 2 itself. For example, the aerosol provision device 2 may comprise the heater assembly 6 and a removable cartridge (containing a reservoir of liquid aerosol-generating material). The heater assembly 6 is provided in fluid contact with the liquid in the cartridge (e.g., via a suitable wicking element or via another fluid transport mechanism). Alternatively, the aerosol provision device 2 may include an integrated liquid storage area in addition to the heater assembly 6 which may be refillable with liquid. More broadly, the aerosol provision system (which encompasses a separable aerosol provision device and cartomiser / cartridge or an integrated aerosol provision device and cartridge) includes the heater assembly.

Additionally, the above has described a heater assembly 6 in which an electrically resistive layer 64 is provided on a surface of the respective substrate. In the aerosol provision system 1 of Figure 2 or 7, electrical power is supplied to the electrically resistive layer 64 via the contact pads 75. Accordingly, an electrical current is able to flow through the electrically resistive layer 64 from one end to the other to cause heating of the electrically resistive layer 64. However, it should be understood that electrical power for the purposes of causing the electrically resistive layer 64 to heat may be provided via an alternative means, and in particular, via induction. In such implementations, the aerosol provision system 1 is provided with a coil (known as a drive coil) to which an alternating electrical current is applied. This subsequently generates an alternating magnetic field. When the electrically resistive layer 64 is exposed to the alternating magnetic field (and it is of sufficient strength), the alternating magnetic field causes electrical current (Eddy currents) to be generated in the electrically resistive layer 64. These currents can cause Joule heating of the electrically resistive layer 64 owing to the electrical resistance of this layer 64. Depending on the material which the electrically resistive layer 64 is formed, heating may additionally be generated through magnetic hysteresis (if the material is ferro- or ferrimagnetic). More generally, the electrically resistive layer 64 is an example of a heater layer of the heater assembly 6 which is configured to generate heat when supplied with energy (e.g., electrical energy), which, for example, may be provided through direct contact or via induction. Additional ways of causing the heater layer to generate heat are also considered within the principles of the present disclosure.

Moreover, it should be understood that in some implementations, an additional layer or layers, e.g., serving as a protective layer, may be disposed on top of the electrically resistive layer 64. In such implementations, the capillary tubes 66 still extend to an opening on the electrically resistive layer 64 but may additionally extend through the additional layer(s). More broadly, the capillary tubes 66 extend through the heater assembly 6 to an opening at a surface of a side of the heater assembly 6 comprising the electrically resistive layer 64, which includes an opening in the electrically resistive layer 64 itself as well as an opening in any additional layer(s) positioned above the electrically resistive layer 64.

Figure 14 depicts an example method for manufacturing a component for an aerosol provision system 1. The component may be a cartomiser 3’ or it may be a component that is incorporated in an aerosol provision system as described above.

The method begins at step S1 by providing a reservoir 46. As noted above, the reservoir 46 may be formed, at least in part, by the outer circumferential wall 44 of the outer housing 4 of the cartomiser 3’. At step S1, the reservoir 46 may be incomplete (that is, the reservoir 46 may not be completed until the upper clamping unit 5’ and the lower support unit 7’ are assembled together). As noted above, the reservoir 46 may take any shape, including having a U-shaped section.

The method proceeds to step S2 by providing a heater assembly 6. The heater assembly 6 may be formed in a number of steps. For example, step S2 may include firstly forming a substrate 62. The way in which the substrate 62 is formed is not significant to the principles of the present disclosure. For example, the substrate 62 may be cut from a portion of cultured quartz or formed via a sintering process by sintering quartz powders I fibres, for example. Step S2 may then include providing the electrically resistive layer 64 provided on a surface of the substrate 62. The way in which the electrically resistive layer 64 is formed on the surface of the substrate 62 is not significant to the principles of the present disclosure. For example, the electrically resistive layer 64 may be a sheet of metal (e.g., titanium) adhered, welded, or the like to the substrate 62. Alternatively, the electrically resistive layer 64 may be formed through a vapour or chemical deposition technique using the substrate 62 as a base. Alternatively, the electrically resistive layer 64 may be provided before the substrate; for instance, a further alternative is to grow or culture the substrate 62 using the electrically resistive layer 64 as a base. Step S2, further includes providing one or more capillary tubes 66 in the substrate 621 electrically resistive layer 64. As noted above, the capillary tubes 66 extend from a surface (surface 6b) of the substrate 621 heater assembly 6, through the electrically resistive layer 64 provided on the first surface of the substrate 62. That is, the capillary tubes 66 extend all the way through the heater assembly 6. The capillary tubes 66 may be formed by laser drilling, as noted above, or any other suitable technique. The capillary tubes 66 may be formed in the substrate 62 prior to applying the electrically resistive layer 64. In some implementations, the one or more distribution channels 62a, 62b may be provided as part of step S2. The distribution channels 62a, 62b may be formed prior to, or after, application of the electrically resistive layer 64. Additionally, the capillary tubes 66 may be formed in such a way as to align with the one or more distribution channels 62a, 62b formed in the substrate 62 (this may particularly be the case where the one or more distribution channels 6b are engineered), such that the capillary tubes 66 are essentially in fluid communication with the one or more distribution channels 62a, 62b as described above.

Once the heater assembly 6 has been provided, the component for the aerosol provision system is assembled at step S3.

Step S3 includes assembling the various elements of the component for the aerosol provision system. For example, as described above, this may include stacking the outer housing 4, upper clamping unit 5’, heater assembly 6, lower support unit 7’ and optional end cap 8.

In forming or assembling the component, the component is configured to have the characteristics as described above. Namely, the reservoir 46 is arranged to have a first region R having a smaller distance between the base wall and the top wall of the reservoir 46 than a second region of the reservoir 46. The first region R defines a volume sharing a surface with an exposed part of the second surface 6b of the heater assembly 6 and extending in a first direction from the second surface 6b of the heater assembly 6. The first direction is a direction from the first surface 6a to the second surface 6b of the heater assembly 6. The first region R further comprises a plurality of side surfaces defined by the extent of the first region R from the second surface 6b of the heater assembly 6 in the first direction. The first region R comprises at least one side surface that shares a surface with the one or more side walls of the reservoir 46 and at least one side surface that has an open surface with the second region of the reservoir 46. The distance from the at least one side surface of the first region R that shares a surface with the one or more side walls of the reservoir 46 to the centre of the exposed part of the second surface 6b of the heater assembly 6 is greater than the distance from the at least one side surface that has an open surface with the second region of the reservoir 46 to the centre of the exposed part of the second surface of the heater assembly 6.

Broadly, it should be understood that the method of Figure 14 is an example method only, and adaptations to the steps or ordering of the steps of this method are contemplated within this disclosure, for example, as described above.

Thus, there has been described an aerosol provision system for generating aerosol from an aerosol-generating material for inhalation, wherein the aerosol provision system includes an aerosol-generating material storage portion for storing aerosol-generating material, the aerosol-generating material storage portion comprising one or more side walls, a base wall and a top wall opposite the base; and a heater assembly comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater assembly is mounted in the aerosol provision system, an exposed part of the second surface of the heater assembly is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension. The aerosol-generating material storage portion comprises a first region having a smaller distance between the base wall and the top wall than a second region of the aerosolgenerating material storage portion, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater assembly and extending in a first direction from the second surface of the heater assembly, wherein the first direction is a direction from the first surface to the second surface of the heater assembly. The first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater assembly in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion. The distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosolgenerating material storage portion to the centre of the exposed part of the second surface of the heater assembly. Also described is a consumable and a method for manufacturing a component of aerosol provision system.

While the above described embodiments have in some respects focussed on some specific example aerosol provision systems, it will be appreciated the same principles can be applied for aerosol provision systems using other technologies. That is to say, the specific manner in which various aspects of the aerosol provision system function are not directly relevant to the principles underlying the examples described herein.

In order to address various issues and advance the art, this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and to teach the claimed invention(s). It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claims. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein, and it will thus be appreciated that features of the dependent claims may be combined with features of the independent claims in combinations other than those explicitly set out in the claims. The disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. An aerosol provision system for generating aerosol from an aerosol-generating material for inhalation, wherein the aerosol provision system comprises: an aerosol-generating material storage portion for storing aerosol-generating material, the aerosol-generating material storage portion comprising one or more side walls, a base wall and a top wall opposite the base; and a heater assembly comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater assembly is mounted in the aerosol provision system, an exposed part of the second surface of the heater assembly is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension, wherein the aerosol-generating material storage portion comprises a first region having a smaller distance between the base wall and the top wall than a second region of the aerosol-generating material storage portion, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater assembly and extending in a first direction from the second surface of the heater assembly, wherein the first direction is a direction from the first surface to the second surface of the heater assembly, wherein the first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater assembly in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion, and wherein the distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly.

2. The aerosol provision system of claim 1, wherein the distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than half the first dimension of the exposed second surface of the heater assembly.

3. The aerosol provision system of claim 2, wherein the first dimension corresponds to the width of the heater assembly.

4. The aerosol provision system of any of the preceding claims, wherein the second region of the aerosol-generating material storage portion is arranged so as to be prevented from supplying aerosol-generating material through the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion.

5. The aerosol provision system of any of the preceding claims, wherein the second region is provided in fluid communication with the first region only through the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion.

6. The aerosol provision system of any of the preceding claims, wherein the aerosolgenerating material storage portion is arranged so as to have a U-shaped section comprising a base and arms, wherein the base of the U-shape section includes the first region and the arms of the U-shaped section include the second region.

7. The aerosol provision system of any of the preceding claims, wherein the aerosol provision system further comprises an air flow path, and wherein a part of the air flow path is arranged to abut the top surface of the first region of the aerosol-generating material storage portion.

8. The aerosol provision system of claim 7, wherein a part of the air flow path is arranged adjacent to the second dimension of the second surface of the heater assembly and configured such that air is able to pass around the heater assembly.

9. The aerosol provision system of any of the preceding claims, wherein the heater assembly defines a rectangular cuboid, wherein the first surface and the second surface are the surfaces of the rectangular cuboid having the largest surface area.

10. The aerosol provision system of any of the preceding claims, wherein the first region further comprises a wicking element arranged to contact at least a part of the second surface of the heater assembly, the wicking element arranged to guide aerosol-generating material in the first region to the one or more capillary tubes of the heater assembly.

11. The aerosol provision system of any of the preceding claims, wherein the aerosol provision system comprises an aerosol provision device and a consumable, wherein the consumable and the aerosol provision device are configured to releasably engage with one another, wherein the consumable comprises the aerosol-generating material storage portion and, optionally, the heater assembly.

12. The aerosol provision system of any of the preceding claims, wherein the heater assembly comprises a third surface, the third surface sharing an edge with the second surface, wherein the edge has an extent equal to the second dimension, wherein the second region is configured to supply aerosol-generating material to the third surface.

13. The aerosol provision system of claim 12, wherein the distance from the centre of the third surface to the centre of the heater assembly is the shortest distance between the centre of any other side surface of the heater assembly to the centre of the heater assembly.

14. The aerosol provision system of claim 12 or 13, wherein the heater assembly defines a rectangular cuboid, wherein the first surface and the second surface are the surfaces of the rectangular cuboid having the largest surface area, and wherein the third surface is either one or both of the two surfaces having the second largest surface area.

15. The aerosol provision system of any of claims 12 to 13, wherein the heater assembly further comprises one or more distribution channels extending from the third surface in a direction towards the one or more capillary tubes, the one or more distribution channels arranged to provide aerosol-generating material to the one or more capillary tubes.

16. The aerosol provision system of claim 15, wherein the one or more distribution channels extend in a direction from an opening in the third surface towards the longitudinal axis of the heater assembly.

17. The aerosol provision system of claim 15 or 16, wherein the one or more distribution channels extend in a direction perpendicular to the longitudinal axis of the heater assembly.

18. The aerosol provision system of any of claims 15 to 17, wherein the one or more distribution channels extend in a direction substantially towards the centre of the heater assembly.

19. The aerosol provision system of any of claims 15 to 18, wherein the one or more distribution channels follow a predetermined path formed in the substrate via an engineering process.

20. The aerosol provision system of any of claims 15 to 19, wherein the one or more distribution channels follow a substantially linear path.

21. The aerosol provision system of any of claims 15 to 18, wherein the one or more distribution channels follow a random path formed in the substrate via a series of interconnected pores.

22. A consumable for an aerosol provision system for generating aerosol from an aerosol-generating material for inhalation, wherein the consumable comprises: an aerosol-generating material storage portion for storing aerosol-generating material, the aerosol-generating material storage portion comprising one or more side walls, a base wall and a top wall opposite the base; and a heater assembly comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater assembly is mounted in the aerosol provision system, an exposed part of the second surface of the heater assembly is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension, wherein the aerosol-generating material storage portion comprises a first region having a smaller distance between the base wall and the top wall than a second region of the aerosol-generating material storage portion, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater assembly and extending in a first direction from the second surface of the heater assembly, wherein the first direction is a direction from the first surface to the second surface of the heater assembly, wherein the first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater assembly in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion, and wherein the distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly.

23. A method for manufacturing a component of aerosol provision system, wherein the method comprises: providing an aerosol-generating material storage portion for storing aerosolgenerating material, the aerosol-generating material storage portion comprising one or more side walls, a base wall and a top wall opposite the base; and providing a heater assembly comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater assembly is mounted in the aerosol provision system, an exposed part of the second surface of the heater assembly is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension, wherein the aerosol-generating material storage portion comprises a first region having a smaller distance between the base wall and the top wall than a second region of the aerosol-generating material storage portion, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater assembly and extending in a first direction from the second surface of the heater assembly, wherein the first direction is a direction from the first surface to the second surface of the heater assembly, wherein the first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater assembly in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the aerosol-generating material storage portion and at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion, and wherein the distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly is greater than the distance from the at least one side surface that has an open surface with the second region of the aerosol-generating material storage portion to the centre of the exposed part of the second surface of the heater assembly.

24. An aerosol provision means for generating aerosol from an aerosol-generating material for inhalation, wherein the aerosol provision means comprises: storage means for storing aerosol-generating material, the storage means comprising one or more side walls, a base wall and a top wall opposite the base; and heater means comprising a substrate having a first surface on which a heater layer configured to generate heat when supplied with energy is provided, a second surface opposite the first surface, and one or more capillary tubes extending from the second surface through the heater layer provided on the first surface, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, wherein when the heater means is mounted in the aerosol provision means, an exposed part of the second surface of the heater means is defined by a first dimension and a second dimension, where the second dimension is greater than the first dimension, wherein the storage means comprises a first region having a smaller distance between the base wall and the top wall than a second region of the storage means, the first region defining a volume sharing a surface with the exposed part of the second surface of the heater means and extending in a first direction from the second surface of the heater means, wherein the first direction is a direction from the first surface to the second surface of the heater means, wherein the first region comprises a plurality of side surfaces defined by the extent of the first region from the second surface of the heater means in the first direction, wherein the first region comprises at least one side surface that shares a surface with the one or more side walls of the storage means and at least one side surface that has an open surface with the second region of the storage means, and wherein the distance from the at least one side surface of the first region that shares a surface with the one or more side walls of the storage means to the centre of the exposed part of the second surface of the heater means is greater than the distance from the at least one side surface that has an open surface with the second region of the storage means to the centre of the exposed part of the second surface of the heater means.