JP2023027393A - Cartridge for aerosol generation system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cartridge for use in an aerosol generation system.

SOLUTION: The cartridge includes a liquid storage portion including a housing (24) for holding a liquid aerosol forming base substance, the liquid storage portion including at least two portions in fluid communication with each other. A first portion (32) of the liquid storage portion includes a heater assembly (46), a first capillary material (36) provided in contact with the heater assembly, and a second capillary material (38) in contact with the first capillary material and spaced from the heater assembly by the first capillary material. A second portion (34) of the liquid storage portion includes a container (e.g., a tank) for holding the liquid aerosol forming base substance and supplies a liquid to the second capillary material.

SELECTED DRAWING: Figure 2

COPYRIGHT: (C)2023,JPO&INPIT

Description

The present invention relates to aerosol generation systems. In particular, the present invention relates to hand-held aerosol generating systems, such as electrically operated smoking systems. Aspects of the present invention relate to cartridges for aerosol generating systems, particularly electrically actuated smoking systems.

One type of aerosol generating system is an electrically operated smoking system. Hand-held, electrically operated smoking systems are known that include a device portion that includes a battery and control electronics, a cartridge portion that includes a supply of aerosol-forming substrates, and an electrically operated vaporizer. A cartridge with both a supply of aerosol-forming substrate and a vaporizer is sometimes referred to as a "cartomizer." Vaporizers generally include a heater wire coil wound around an elongated wick that is immersed in a liquid aerosol-forming substrate. A capillary material immersed in the aerosol-forming substrate supplies the liquid to the wick. The cartridge portion generally includes not only a supply of aerosol-forming substrates and an electrically operated vaporizer, but also a mouthpiece which, in use, is sucked by the user to draw the aerosol into the mouth.

In some types of electrically operated aerosol generators, a reservoir of aerosol-forming liquid is provided within a tank. When used in an aerosol generating system, liquid is transported by capillary action from the tank to the wick of the coil wick heater assembly where the liquid is vaporized. When the user puffs on the mouthpiece, airflow flows through the heater assembly and the generated aerosol is inhaled by the user.

A problem with such tank devices is that the system will stop generating aerosol if the device is held at an angle where the liquid aerosol-generating substrate in the tank does not contact the capillary system. Moreover, these systems may be prone to leaks, for example, if liquid from the tank floods the core or leaks through the airflow path.

In other systems, the liquid storage portion of the cartridge is filled with capillary media. A liquid aerosol-generating substrate is retained within the capillary material and delivered to the wick. In such a system, the retention angle and leakage risk issues mentioned above may be reduced. However, some residual liquid remains in the capillary material after use, leading to waste. Furthermore, smoke delivery in such systems can be inconsistent due to reduced saturation of the capillary medium during use, which does not allow for a consistently high quality smoking experience.

It would be desirable to have a cartridge that avoids one or more of the above mentioned or other disadvantages, e.g., avoids wasting the aerosol-generating substrate liquid, while at the same time aerosol-generating the aerosol-generating system in which the cartridge is used. is preferably maintained or improved.

According to a first aspect of the invention there is provided a cartridge for use in an aerosol generating system, e.g. an electrically operated aerosol generating system, comprising a liquid reservoir for holding a liquid aerosol forming substrate. there is The liquid storage portion includes at least two portions in fluid communication with each other. A first portion of the liquid storage portion is in contact with the heater assembly and a first capillary material provided in contact with the heater assembly; and a second capillary material spaced apart by the capillary material. A second portion of the liquid storage portion preferably comprises a container for holding a liquid aerosol-forming substrate and is arranged to supply the liquid to the second capillary material. A second portion of the liquid storage portion may comprise a substantially empty tank suitable for holding a liquid aerosol-forming substrate.

The capillary material is preferably designed to be capable of holding sufficient liquid substrate for several puffs. Since the capillary material is positioned in contact with the heater, the heater is provided independent of the holding angle of the aerosol-generating liquid with sufficient aerosol-generating liquid. The remaining internal volume of the liquid storage portion contains no capillary material and represents an empty tank for storing the aerosol-generating liquid. Under normal handling conditions, the aerosol-generating medium, particularly the aerosol-generating smoking device, is moved between smoke ducts and the capillary material regularly contacts and reabsorbs new aerosol-generating liquid.

Because less capillary material is used, the amount of residual liquid remaining in the capillary material after use of the cartridge is less than in conventional cartridges in which the entire liquid storage portion is filled with capillary material. Moreover, in performance tests, the TPM (Total Particulate Matter) yield of aerosol-generating smoking devices equipped with cartridges of the present invention is, in many instances, at least as high as the performance of aerosol-generating smoking devices equipped with cartridges currently available. shown to be comparable.

The liquid capacity of the capillary material is preferably such that it can hold sufficient liquid for 30-40 puffs or more. A 3 second puff may contain about 1 mg to 4 mg of liquid, such as 3 mg to 4 mg of liquid. The capacity of the capillary material is preferably between about 30 mg and about 160 mg, preferably 90 mg to about 160 mg or more, or more preferably 100 mg to 150 mg, eg 130 mg. If there are two layers that make up the capillary material, the volumes of the first and second layers are such that about 10-20 weight percent of the liquid volume is within the first layer. For example, if the capillary material has a capacity of 30 puffs, the first layer can have a capacity of about 5 puffs and the second layer can have a capacity of about 25 puffs.

Without being bound by any particular theory, it is believed that a capillary material with a dose of several puffs (eg, 30 or more puffs) reduces the risk of leakage from the device. If the capillary material is too small, it is believed that upon smoking, liquid may be drawn directly through the capillary material and heater without being vaporized from the reservoir, leading to leakage. Also, having a capacity of 90 mg or more allows multiple puffs to be removed from the device even when the liquid in the reservoir is not in direct contact with the capillary material.

The heater assembly can be substantially planar and can comprise a conductive filament and does not require any winding of the heater wire around the capillary core.

The conductive filaments can lie in a single plane. A planar heater assembly is easy to handle during manufacturing and provides a robust construction.

The conductive filaments can define gaps between the filaments, and the width of the gaps can be between 10 μm and 100 μm. The filaments may induce capillary action within the gap such that the liquid to be vaporized in use is drawn into the gap, increasing the contact area between the heater assembly and the liquid.

The conductive filaments may form a mesh size of 160-600 mesh US (±10%) (ie, 160-600 filaments per inch (±10%)). The width of the gap is preferably 75 μm to 25 μm. The area ratio of the openings of the mesh, which is the ratio of the area of the gaps to the total area of the mesh, is preferably 25 to 56%. The mesh may be formed using different types of woven or lattice constructions. Alternatively, the conductive filaments consist of a series of filaments arranged parallel to each other.

The diameter of the conductive filaments can be 10 μm to 100 μm, preferably 8 μm to 50 μm, more preferably 8 μm to 39 μm. The filaments may have a round cross-section or may have a flat cross-section. Heater filaments may be formed by etching a sheet of material (such as foil). This can be particularly advantageous when the heater assembly includes a series of parallel filaments. If the heater assembly includes a mesh or woven fabric of filaments, the filaments may be formed individually and braided together.

As described in relation to the first aspect, the heater assembly includes at least one filament made from a first material and at least one filament made from a second material different from the first material. a filament;

The heater assembly may comprise an electrically insulated substrate on which a filament is supported, the filament extending across an opening formed in the substrate. The electrically insulating substrate can comprise any suitable material, but preferably is a material that can withstand high temperatures (greater than 300 degrees Celsius) and rapid temperature changes. One example of a suitable material is a polyimide film such as Kapton®.

The heater assembly can include conductive contacts in contact with the plurality of filaments. A conductive contact may be provided between the housing of the liquid storage portion and the electrically insulating substrate. A conductive contact may be provided between the filament and the electrically insulating substrate. An opening may be formed in the insulating layer and the cartridge may include two conductive contacts located on opposite sides of the opening from each other.

The capillary material is preferably a material that actively transports liquid from one end of the material to the other. The capillary material is advantageously oriented within the housing to carry the liquid to the heater assembly.

The second capillary material may comprise a fibrous structure, where the fibers are generally oriented in the direction of travel in the liquid to the heater. The first capillary material can have fibers that are less oriented. For example, the first capillary material can have the structure of felt.

Capillary material may have a fibrous or spongy structure. Preferably, the capillary material comprises a bundle of capillaries. For example, capillary material may include a plurality of fibers or threads, or other microscopic tubes. The fibers or threads can be generally aligned to move the liquid to the heater. Alternatively, the capillary material may comprise a sponge-like or foam-like material. The structure of the capillary material forms a large number of small holes or tubes through which liquid can move by capillary action. The capillary material may comprise any suitable material or combination of materials. Examples of suitable materials include spongy or foam materials, ceramic- or graphite-based materials in the form of fibers or sintered powders, foamed metal or plastic materials, e.g. spun or extruded fibers ( fibrous materials made of cellulose acetate, polyester, or bonded polyolefins, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics, etc.). The capillary material may have any suitable capillary and porosity for use with different liquid physical properties. Liquids have physical properties, including but not limited to viscosity, surface tension, density, thermal conductivity, boiling point and vapor pressure, that allow them to move through capillary devices by capillary action.

The capillary material can be in contact with a heater, eg, a conductive filament. The capillary material can extend into the interstices between the filaments. The heater assembly may draw the liquid aerosol-forming substrate into the gap by capillary action. The capillary material can contact the conductive filament substantially the entire length of the opening.

The housing may contain two or more different capillary materials, where the first capillary material in contact with the heater element has a higher pyrolysis temperature and is in contact with the first capillary material, A second capillary material not in contact with the heater element has a lower pyrolysis temperature. The first capillary material effectively acts as a spacer separating the heater element from the second capillary material so that the second capillary material is not exposed to temperatures above its thermal decomposition temperature. As used herein, "thermal decomposition temperature" means the temperature at which a material begins to decompose and lose mass by producing gaseous by-products. The second capillary material can advantageously occupy a larger volume than the first capillary material, but can also hold more aerosol-forming substrate than the first capillary material. The second capillary material may have better wicking performance than the first capillary material. The second capillary material can be less expensive than the first capillary material. The second capillary material can be polypropylene.

The first capillary material is selected from the group of Kevlar felt, ceramic paper, ceramic felt, carbon felt, cellulose acetate, cannabis felt, PET/PBT sheets, cotton pads, porous ceramic discs or porous metal discs. can be done.

Preferred materials include Kevlar felt, ceramic paper, ceramic felt, porous ceramic discs or porous metal discs. The first capillary material may comprise fiberglass paper or felt. Preferably, the first capillary material is substantially free of organics.

Preferably, the porosity of the first capillary material is less than the porosity of the second capillary material. The pore size of the first capillary material is preferably smaller than the porosity of the second capillary material. Pore size can be measured, for example, as the average pore size over an area of capillary material. It can be seen that in this way the aerosol-generating substrate moves to the heater more efficiently. In a broad aspect of the invention, a cartridge is provided comprising a heater and a capillary material in contact with the heater for supplying an aerosol-generating substrate to the heater, wherein the capillary material adjacent the heater The porosity or pore size of the region is smaller than the porosity or pore size of the region of the capillary material remote from the heater. Thus, a single material can be used, eg, with a gradient of pore sizes in one or more of its dimensions.

The first capillary material may have a fiber size/pore size of 0.1-50 μm, preferably 0.5-10 μm, most preferably about 4 μm. The first capillary material has a density of less than 2 g/ml, preferably about 0.5 g/ml.

The second capillary material is selected from the group of polypropylene (PP), polyethylene (PE), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), rolled nonwoven material or rolled felt. It can be a retentive material (HRM). Preferably, the second capillary material comprises a polymeric material. Materials can include coatings, for example, to reduce hydrophobicity.

The second capillary material may have a fiber size/pore size of 1-100 μm, preferably 15-40 μm, most preferably about 25 μm. The second capillary material has a density of less than 1 g/ml, preferably 0.1-0.3 g/ml.

The first capillary material may separate the heater assembly from the second capillary material by a distance of at least 0.8 mm (at least 1.5 mm), yet provides a sufficient temperature drop across the first capillary material. Therefore, it is preferably 0.8 mm to 2 mm.

The first and second capillary materials can also be made of the same material and can be distinguished from each other only by exhibiting different porosities or different capillary action. For example, the first capillary material has its pore size or porosity reduced and its capillary action increased compared to a second capillary material which may be used in an uncompressed or at least less compressed state. can be compressed as

In one preferred embodiment, the first and second materials are manufactured from a single continuous element of the same base material. The material has a gradient of pore size or porosity in a direction toward the heater element or opening such that the pore size or porosity decreases, e.g., continuously decreases, toward the heater element within the capillary material. More preferably, it is processed to be oriented.

The at least first capillary material is preferably compressed after insertion into the first portion of the housing of the liquid storage portion such that its effective pore size or porosity is reduced. For example, a single continuous element may have the shape of a truncated cone, where the diameter of the circular base of the truncated cone is greater than the inner diameter of the cylindrical housing of the liquid storage portion, while The diameter of the conical truncated tip corresponds substantially to the inner diameter of the cylindrical housing of the liquid storage portion. After insertion, the capillary material at the base of the cone of capillary material is compressed more than in the region of the truncated tip. The more compressed material represents the first capillary material and the less compressed material represents the second capillary material. Those skilled in the art will readily appreciate that the resulting gradient of compression will depend on the relative geometries chosen for the capillary element and the housing of the liquid storage portion.

In a particularly preferred embodiment, the capillary element has a regular cylindrical shape with a circular cross-section and a predetermined diameter. The inner surface of the housing includes a tapered portion at the open end such that the capillary material is compressed by the tapered portion after inserting the capillary material into the housing. The inner surface of the housing preferably has a conical shape such that the inner diameter continuously increases from the open end to the closed end of the cartridge.

The first capillary material and the second capillary material may comprise different regions of the same capillary material element. Compression of the capillary material when entrained within the housing may be such that the pore size or porosity of the capillary material decreases or decreases continuously toward the heater assembly.

In further embodiments, the first and second capillary materials are also formed from a single continuous piece of the same material. The capillary material may be a rectangular web of capillary material having a thickness of less than 50%, but preferably about 25% of the inner diameter of the cylindrical housing of the cartridge. The width of the web of capillary material corresponds to the peripheral circumference of the housing. The web of capillary material can have any length desired, and is preferably about half the length of the cartridge housing. A web of capillary material is rolled to form a cylindrical shape. The winding compresses the central portion of the web to a greater degree than the outer portions of the web such that a pore size or porosity gradient is obtained in the radial direction of the wound web of capillary material. An air channel is formed in the center of the wound capillary material. A tubular fluid permeable heater element is provided within the air channel such that it is in direct contact with the inner surface of the capillary material around which the heater is wound. As the capillary material is rolled, the portion of the material closer to the central axis of the cylinder is compressed more than the material located radially outwardly of the capillary material. Thus, again a pore size gradient is obtained, but here the pore size of the capillary material decreases continuously in the direction of the heater element within the capillary material. The capillary material is in fluid communication with the liquid reservoir, where the liquid reservoir is provided within a portion of the housing not occupied by the capillary material. A partition is provided within the housing so that the liquid substrate does not communicate directly with the air flow channel.

The web of capillary material can also comprise multiple layers of capillary material such that the liquid retention properties of the capillary material can be designed in any desired manner most suitable for a given aerosol generating system.

In certain preferred embodiments, the heater element is wound together with the capillary material so that in only one manufacturing step a unitary capillary material containing the radial gradient and the heating element is obtained.

The liquid storage portion is located on a first side of the conductive filament and the airflow channel extends from the opposite side of the conductive filament such that the flow of air past the conductive filament is entrained in the vaporized liquid aerosol-forming substrate. It can be located in the liquid storage portion.

Preferably, the aerosol-generating system includes a housing. The housing is preferably elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composites containing one or more of these materials, or materials such as polypropylene, polyetheretherketone (PEEK) and polyethylene for food or pharmaceutical applications. Suitable thermoplastics are mentioned. Preferably, the material is lightweight and non-brittle. Materials may include PET, PBT or PPS.

Preferably, the aerosol generation system is portable. Aerosol-generating systems can have sizes comparable to conventional cigars and cigarettes. The overall length of the smoking system may be approximately 30 mm to approximately 150 mm. The outer diameter of the smoking system can be approximately 5 mm to approximately 30 mm.

Aerosol-forming substrates are substrates capable of releasing volatile compounds capable of forming an aerosol. Volatile compounds can be released by heating the aerosol-forming substrate.

Aerosol-forming substrates may include plant-derived materials. Aerosol-forming substrates may include tobacco. The aerosol-forming substrate can comprise a tobacco-containing material that includes volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise non-tobacco-containing materials. The aerosol-forming substrate can comprise homogenized plant-derived material. The aerosol-forming substrate may comprise homogenized tobacco material. The aerosol-forming substrate may comprise at least one aerosol-forming agent. The aerosol-forming substrate may contain other additives and ingredients such as flavorants.

Preferably, the liquid storage portion includes an opening and the heater assembly extends across the opening in the housing. A heater assembly may comprise an electrically insulating substrate on which a heater element is supported. The electrically insulating substrate can comprise any suitable material, but preferably is a material that can withstand high temperatures (greater than 300 degrees Celsius) and rapid temperature changes. One example of a suitable material is a polyimide film such as Kapton®. The electrically insulating substrate can have an opening formed therein and the heater element extends across the opening. The heater assembly may comprise electrical contacts connected to the conductive filaments.

According to a second aspect of the invention, a cartridge for use in an aerosol generating system, such as an electrically operated aerosol generating system, comprising a liquid storage portion comprising a housing for holding a liquid aerosol-forming substrate. is provided, wherein the liquid storage portion includes at least two portions in fluid communication with each other. A first portion of the liquid storage portion contacts the first capillary material and is spaced from the opening by the first capillary material with a first capillary material provided near the opening of the housing. and two capillary materials. A second portion of the liquid storage portion may be substantially empty and suitable for holding a liquid aerosol-forming substrate.

The cartridge preferably further includes a fluid permeable heater assembly extending across the housing opening.

In an embodiment of the invention, the first portion of the liquid storage portion occupies less than 50% of the volume of the liquid storage portion, preferably 10% to 30%, preferably 15% to 25%. More preferably, it is most preferably about 20%.

The capillary material extends across the entire cross-section of the first portion of the liquid storage portion such that the liquid aerosol-generating substrate cannot flow directly into the opening of the heater assembly or cartridge.

According to a further aspect of the invention there is provided an aerosol generating system comprising a cartridge according to the invention.

The system may further comprise an electrical circuit connected to the heater assembly and the power supply, the electrical circuit monitoring the electrical resistance of the heater assembly or of one or more filaments of the heater assembly to or configured to control the power supply to the heater assembly depending on the electrical resistance of one or more filaments.

The electrical circuit may comprise a microprocessor, but it may also be a programmable microprocessor. The electrical circuit may comprise further electronic components. An electrical circuit may be configured to regulate the power supply to the heater assembly. Power can be supplied to the heater assembly continuously after system activation, or intermittently, such as with each inhalation. Power may be supplied to the heater assembly in the form of current pulses.

Advantageously, the system comprises a power supply within the body of the housing. Alternatively, the power source can be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity to allow storage of sufficient energy for one or more smoking experiences. For example, the power source has sufficient capacity to allow continuous generation of aerosol for a period of about 6 minutes, or a multiple of 6 minutes, corresponding to the typical time it takes to smoke a single conventional cigarette. can have In another example, the power supply may have sufficient capacity to allow for a predetermined number of puffs or discontinuous activation of the heater assembly.

Preferably, the aerosol-generating system includes a housing. The housing is preferably elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composites containing one or more of these materials, or materials such as polypropylene, polyetheretherketone (PEEK) and polyethylene for food or pharmaceutical applications. Suitable thermoplastics are mentioned. Preferably, the material is lightweight and non-brittle.

Preferably, the aerosol generation system is portable. Aerosol-generating systems can have sizes comparable to conventional cigars and cigarettes. The overall length of the smoking system may be approximately 30 mm to approximately 150 mm. The outer diameter of the smoking system can be approximately 5 mm to approximately 30 mm.

Aerosol-forming substrates are substrates capable of releasing volatile compounds capable of forming an aerosol. Volatile compounds can be released by heating the aerosol-forming substrate.

Aerosol-forming substrates may include plant-derived materials. Aerosol-forming substrates may include tobacco. The aerosol-forming substrate can comprise a tobacco-containing material that includes volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise non-tobacco-containing materials. The aerosol-forming substrate can comprise homogenized plant-derived material. The aerosol-forming substrate may comprise homogenized tobacco material. The aerosol-forming substrate may comprise at least one aerosol-forming agent. The aerosol-forming substrate may contain other additives and ingredients such as flavorants.

The system preferably includes a mouthpiece, wherein the cartridge is inserted into the system with the opening of the cartridge facing away from the mouthpiece.

In another preferred embodiment, the cartridge is inserted into the system with the cartridge opening facing the mouthpiece. Depending on usage, one of these cartridge orientations may provide superior performance compared to the other.

According to a further aspect of the invention, a liquid storage portion including a housing for holding a liquid aerosol-forming substrate, the liquid storage portion including a heater assembly and provided in contact with the heater assembly. A cartridge is provided for use in an aerosol generating system comprising a capillary material and wherein the average porosity or pore size of a region of the capillary material adjacent to the heater assembly is spaced apart from the heater assembly. smaller than the average porosity or pore size of the region of capillary material. A portion of the capillary material in this region can be compressed to reduce its porosity or pore size. The liquid storage portion includes at least two portions in fluid communication with each other, a first portion of the liquid storage portion comprising a capillary material, and a container for holding a liquid aerosol-forming substrate, and a liquid through the capillary material. and a second portion of the liquid storage portion that supplies regions of greater porosity or pore size.

The present invention also provides a liquid storage portion including a housing having first and second parts, a heater assembly, and a first capillary material in direct contact with the heater assembly. disposing a first capillary material within a first portion of the housing of the liquid storage portion as provided in the first capillary material, the second capillary material being in contact with the first capillary material and and disposing a second capillary material within the first portion of the housing of the liquid storage portion so as to be spaced apart from the heater assembly by the material. It relates to a method of manufacturing a cartridge. A second portion of the liquid storage portion is substantially empty and suitable for holding a liquid aerosol-forming substrate.

The first capillary material is preferably compressed during or prior to insertion into the housing so that its pore size or porosity is reduced compared to the pore size or porosity in the relaxed state. .

One aspect of the present invention comprises the steps of providing a liquid storage portion including a housing, providing a heater assembly, and applying a capillary material to the liquid storage such that the capillary material is provided in direct contact with the heater assembly. and placing within a housing of the portion, wherein the method reduces the porosity or pore size of the portion of capillary material. compressing a portion of the capillary material during or prior to placement of the housing so as to

The present invention also provides an aerosol generating system, described herein as being an electrically actuated smoking system.

The term "substantially planar" filament arrangement is preferably used to mean a filament arrangement that is substantially in the form of a two-dimensional topological manifold. Accordingly, the substantially planar filament arrangement extends two-dimensionally along a surface that is substantially greater than the third dimension. In particular, the dimension of the two-dimensional substantially planar filament arrangement within the surface is at least five times greater than the third dimension perpendicular to the surface. An example of a substantially planar filament arrangement is a structure between two substantially parallel surfaces, wherein the distance between the two surfaces is substantially less than the extension within the surfaces. . In some embodiments, the substantially planar filament arrangement is planar. In other embodiments, the substantially planar filament arrangement is curved along one or more dimensions, eg, forming a dome shape or bridge shape.

The term "filament" is preferably used to mean an electrical path disposed between two electrical contacts. The filaments may optionally branch off into several pathways or filaments each, or may merge from several electrical pathways into one pathway. Filaments can have round, square, flat or any other cross-sectional shape. The filaments can be arranged linearly or curvilinearly.

The term "filament arrangement" is preferably used to mean the arrangement of one, or preferably a plurality of filaments. A filament arrangement can be, for example, a series of filaments arranged parallel to each other. Preferably the filaments are capable of forming a mesh. The mesh can be woven or non-woven.

It will be appreciated that, where appropriate, features of one aspect of the invention may be provided in conjunction with another aspect of the invention, in any suitable combination.

The invention will be further described, by way of example only, with reference to the following accompanying drawings, in which: FIG.

FIG. 1a is a schematic diagram of a system incorporating a cartridge, according to an embodiment of the present invention. FIG. 1b is a schematic diagram of a system incorporating a cartridge, according to an embodiment of the present invention. FIG. 1c is a schematic diagram of a system incorporating a cartridge, according to an embodiment of the present invention; Figure Id is a schematic diagram of a system incorporating a cartridge, according to an embodiment of the present invention. FIG. 2 shows a cartridge with porous media according to a first aspect of the invention. FIG. 3 shows an exploded view of a cartridge similar to that shown in FIG. FIG. 4 shows a cartridge with a single porous medium compressed by the shape of the porous material after insertion into the housing. FIG. 5 shows a cartridge with a single porous medium compressed by the shape of the inner surface of the housing after insertion into the housing. FIG. 6 shows capillary material wound into a cylindrical shape and provided with a central tubular heater.

1a-1d are schematic diagrams of aerosol generation systems including cartridges according to embodiments of the present invention. FIG. 1a is a schematic illustration of an aerosol generating device 10 and a separate cartridge 20, collectively forming an aerosol generating system. In this example, the aerosol generating system is an electrically operated smoking system.

Cartridge 20 includes an aerosol-forming substrate and is configured to be received within recess 18 within the device. Cartridge 20 should be replaceable by the user when the aerosol-forming substrate provided within the cartridge is exhausted. FIG. 1a shows the cartridge 20 just prior to its insertion into the device, the arrow 1 in FIG. 1a indicating the direction of insertion of the cartridge.

The aerosol generator 10 is portable and has a size comparable to that of a conventional cigar or cigarette. Device 10 includes body 11 and mouthpiece portion 12 . Body 11 includes battery 14 (such as a lithium iron phosphate battery), control electronics 16 and recess 18 . The mouthpiece portion 12 is connected to the body 11 by a hinged connection 21 and is movable between an open position shown in FIGS. 1a-1c and a closed position shown in FIG. 1d. Mouthpiece portion 12 is placed in an open position to allow insertion and removal of cartridge 20, and in a closed position when the system is used for aerosol generation, as described below. The mouthpiece portion includes multiple air inlets 13 and outlets 15 . In use, the user inhales or inhales through the outlet, drawing air from the air inlet 13 through the mouthpiece portion to the outlet 15, where it then enters the user's mouth or lungs. An internal baffle 17 is provided to force the flow of air through the mouthpiece portion 12 and past the cartridge, as described below.

Recess 18 has a circular cross-section and is sized to receive housing 24 of cartridge 20 . Electrical connectors 19 are provided on the sides of recess 18 for providing electrical connections between control electronics 16 and battery 14 and corresponding electrical contacts on cartridge 20 .

FIG. 1b shows the system of FIG. 1a with a cartridge inserted into recess 118 and cover 26 removed. In this position, the electrical connector rests against electrical contacts on the cartridge, as described below.

Figure Ic shows the system of Figure Ib with the cover 26 completely removed and the mouthpiece portion 12 moved to the closed position.

Figure Id shows the system of Figure Ic with the mouthpiece portion 12 in the closed position. Mouthpiece portion 12 is held in the closed position by a clasp mechanism. Mouthpiece portion 12 in the closed position keeps the cartridge in electrical contact with electrical connector 19 so that good electrical connection is maintained in use regardless of system orientation. Mouthpiece portion 12 may include an annular resilient element that engages a surface of the cartridge and is compressed between the rigid mouthpiece housing element and the cartridge when mouthpiece portion 12 is in the closed position. This maintains a good electrical connection regardless of manufacturing tolerances.

Of course, other mechanisms for maintaining good electrical connection between the cartridge and the device may alternatively or additionally be employed. For example, housing 24 of cartridge 20 may be provided with grooves or threads (not shown) that engage corresponding threads or grooves (not shown) formed in the wall of recess 18 . Threaded engagement between the cartridge and the device can be used to ensure correct rotational alignment as well as retention of the cartridge within the recess and good electrical connection. The threaded connection may extend no more than half a turn of the cartridge, or it may extend a few turns. Alternatively or additionally, electrical connector 19 may be biased to contact contacts on the cartridge.

Those skilled in the art can conceive of other cartridge designs incorporating capillary material arrangements according to the present disclosure. For example, the cartridge may include a mouthpiece portion, may include multiple heater assemblies, and may have any desired shape. Moreover, capillary assemblies according to the present disclosure can be used in other types of systems previously described, including humidifiers, air fresheners, and other aerosol generating systems.

The exemplary embodiments described above are illustrative but not limiting. Other embodiments consistent with the above-described exemplary embodiments will now be apparent to those of ordinary skill in the art in light of the exemplary embodiments discussed above.

The cartridge shown in FIG. 2 includes a polypropylene housing 24 with a two-part liquid reservoir. A first component 32 of the liquid storage portion includes a first capillary material 36 and a second capillary material 38 . A second component 34 of the liquid storage portion is an empty tank that can be filled or partially filled with a liquid aerosol-generating substrate.

A ceramic substrate 42 is provided at the upper end of the cartridge. Substrate 24 defines an opening 44 and has electrical contacts (not shown) on the opposite side thereof. A heater element 46 is connected to the electrical contacts of the substrate 32 and extends over an opening 44 defined by the substrate.

Both the first capillary material 36 and the second capillary material 38 hold a liquid aerosol-forming substrate. The first capillary material 16 in direct contact with the heater element 46 has a higher thermal decomposition temperature (at least 160° C. or higher, such as about 250° C.) than the second capillary material 38 . The first capillary material 36 effectively acts as a spacer separating the heater element 46 from the second capillary material 38 so that the second capillary material 38 is not exposed to temperatures above its thermal decomposition temperature. . The thermal gradient across first capillary material 36 is such that second capillary material 38 is exposed to temperatures below its thermal decomposition temperature. The second capillary material 38 can be selected to have better wicking properties than the first capillary material 36, can hold more liquid per unit volume than the first capillary material 36, and can hold more liquid than the first capillary material 36. It may be less expensive than the material 36. In this example, the first capillary material 36 is a refractory element such as fiberglass or an element containing fiberglass, and the second capillary material 38 is a high density polyethylene (HDPE), or polyethylene terephthalate (PET), or the like. is a polymer.

3 is an exploded view of a cartridge similar to the cartridge of FIG. 2; FIG. The cartridge includes a generally circular cylindrical housing 24 that includes a first part 32 and a second part 34 . A first part of housing 24 includes first and second capillary materials 36, 38 that are immersed in a liquid aerosol-forming substrate. In this example, the aerosol-forming substrate comprises 39 weight percent glycerin, 39 weight percent propylene glycol, 20 weight percent water and flavor, and 2 weight percent nicotine. A capillary material herein is a material that actively transports liquid from one end to the other and can be made from any suitable material. In this example, the capillary material is formed from polyester.

Housing 24 has an open end to which the heater assembly is secured. The heater assembly includes a base 42 having an opening 44 formed therein, a pair of electrical contacts 48 secured to the base 42 and separated from each other by a gap 40, and extending over and through the opening 44. and a resistive heater element 46 secured to an electrical contact 48 on the opposite side.

The heater assembly is covered by removable cover 26 . Cover 26 comprises a liquid impermeable plastic sheet that is adhered to the heater assembly but can be easily peeled off. Tabs are provided on the sides of the cover to allow the user to grip the cover for removal. Although gluing is described as a method of securing the impermeable plastic sheet to the heater assembly, other methods familiar to those skilled in the art, including heat sealing and ultrasonic welding, are used so long as the cover can be easily removed by the consumer. It will be apparent to those skilled in the art that the method of can also be used.

FIG. 4 shows an embodiment in which the housing 24 has the shape of a regular cylinder with a circular cross-section. The first and second capillary materials are manufactured from the same material and are integrally molded as a single continuous piece of capillary material 60 having the shape of a truncated cone. The diameter of the truncated tip of the cone corresponds to the inner diameter of the cylindrical housing. The diameter of the base of the cone is twice as large as the inner diameter of the cylindrical housing. The capillary material 60 is inserted tip first into the cylindrical housing 24 until the surface of the base of the cone is flush with the front surface of the cylindrical housing. After insertion, the capillary material 40 is compressed, and due to the relative shapes of the capillary material and the cylindrical housing, the compression of the capillary material 60 increases towards the end face of the cylindrical housing. At the same time, the pore size or porosity of the capillary material near the end face of the housing is smaller than the pore size or porosity of the capillary material located in the center of the cylindrical housing. Or the porosity decreases. The open end of the cylindrical housing on the right side of Figure 4 is provided closed so that the interior of the cylindrical housing forms a tank reservoir for holding the liquid aerosol-generating substrate. At the other end, the heater assembly illustrated in FIGS. 2 and 3 can be provided.

FIG. 5 shows an alternative embodiment with similar effects to the embodiment illustrated in FIG. In this case, the inner surface of the housing is provided with a conical shape with an inner taper towards one end of the housing 24 . Here, the inner diameter of housing 24 on the left side of FIG. 5 is half the inner diameter of housing 24 on the right side. Again, the first and second capillary materials are manufactured from the same material and are integrally molded as a single continuous piece of capillary material 60 . A piece of capillary material 60 has a regular cylindrical shape with a circular cross-section. The diameter of the cylindrical piece of capillary material 60 corresponds to the inner diameter of housing 24 on the right in FIG. Capillary material 60 is inserted into housing 24 until the end face of capillary material 60 is flush with the smaller diameter front face of the cylindrical housing, ie, the left end face of housing 24 . Again, after insertion, the capillary material 60 is compressed, and due to the relative shapes of the capillary material and the cylindrical housing, the compression of the capillary material 60 increases towards the left end face of the cylindrical housing 24 . At the same time, the pores of the capillaries are such that the pore size or porosity of the capillary material 60 near the end faces of the housing is smaller than the pore size or porosity of the capillary material 60 located in the center of the cylindrical housing. Decrease in size or porosity. Again, the open end of the cylindrical housing on the right side of Figure 5 is provided closed such that the interior of the cylindrical housing forms a tank reservoir for holding the liquid aerosol-generating substrate. ing. The other end of the housing can be provided with the heater assembly illustrated in FIGS.

A further embodiment is illustrated in FIG. 6 whereby only a capillary material 50 is shown for use with a cylindrical housing. Again, the first and second capillary materials are formed from a single continuous piece of the same material 50. FIG. The capillary material is a web of rectangular pieces of capillary material having a thickness of about 25% of the inner diameter of the cylindrical housing of the cartridge. The width of the web of capillary material corresponds to the peripheral circumference of the housing. The length of the web of capillary material is about half the length of the cartridge housing. A web of capillary material is rolled to form a cylindrical shape. An air channel 52 is formed in the center of the wound capillary material. A tubular fluid permeable heater element 54 is provided within the air channel 52 so as to be in direct contact with the inner surface 56 of the capillary material 50 on which the heater is wound. As the capillary material is rolled, the material portion 50a closer to the central axis of the cylinder is compressed more than the material of the portion 50b located radially outward of the capillary material. Thus, again a pore size or porosity gradient is obtained, but here the pore size or porosity of the capillary material 50 continuously decreases in the direction of the heater element 54 within the capillary material. The capillary material is in fluid communication with a liquid reservoir (not shown), where the liquid reservoir is provided within a portion of the housing not occupied by the capillary material. A partition is provided within the housing so that the liquid substrate does not communicate directly with the air flow channel 52 .

It is understood that different methods and configurations are possible to obtain capillary materials with different pore sizes or porosities in different regions. In each instance, a region of smaller pore size or porosity is located at one end of the capillary material. Thus, regions of smaller pore size or porosity are located in the heater. Thus, the pore size or porosity gradient enhances capillary action in the material for drawing the aerosol-generating substrate liquid to the heater.

1. A cartridge for use in an aerosol generating system, comprising:
a liquid storage portion,
a housing for holding a liquid aerosol-forming substrate, said liquid reservoir portion having at least two portions in fluid communication with each other, a first portion of said liquid reservoir portion comprising:
- a heater assembly;
- a first capillary material provided in contact with the heater assembly;
- a second capillary material in contact with said first capillary material and spaced from said heater assembly by said first capillary material;
A cartridge, wherein a second portion of said liquid storage portion includes a container for holding a liquid aerosol-forming substrate and supplying said liquid to said second capillary material.
2. The cartridge of Claim 1, wherein the liquid storage portion includes an opening and the heater assembly extends across the opening in the housing.
3. A cartridge for use in an aerosol generating system, comprising:
a liquid storage portion,
a housing for holding a liquid aerosol-forming substrate, said housing having an opening;
said liquid storage portion comprising at least two portions in fluid communication with each other, a first portion of said liquid storage portion comprising:
- a first capillary material provided near the opening of the housing;
- a second capillary material in fluid contact with said first capillary material and spaced from said opening by said first capillary material;
A cartridge, wherein a second portion of said liquid storage portion includes a container for holding a liquid aerosol-forming substrate and supplying said liquid to said second capillary material.
4. 4. The cartridge of Claim 3, further comprising a fluid permeable heater assembly extending across said opening in said housing.
5. 5. The cartridge of any of claims 1-4, wherein the average pore size or porosity of the first capillary material is less than the average pore size or porosity of the second capillary material.
6. A cartridge according to any of claims 1-5, wherein said first capillary material has a fiber or pore size of 0.1-50 μm, preferably 0.5-10 μm, most preferably about 4 μm.
7. 7. A cartridge according to any one of 1 to 6, wherein said first capillary material has a density of less than 2 g/ml, preferably about 0.5 g/ml.
8. A cartridge according to any of claims 1-7, wherein said second capillary material has a fiber or pore size of 1-100 μm, preferably 15-40 μm, most preferably about 25 μm.
9. Cartridge according to 7 or 8, wherein said second capillary material has a density of less than 1 g/ml, preferably between 0.1 and 0.3 g/ml.
10. 10. The cartridge of any of claims 1-9, wherein the first capillary material or the second capillary material is compressed within the housing such that its effective pore size is reduced.
11. 11. A cartridge according to any one of 1 to 10, wherein said first capillary material and said second capillary material comprise different regions of the same capillary material element.
12. 12. Any of 1 to 11, wherein the compression of the capillary material when disposed within the housing is such that the pore size or porosity of the capillary material continuously decreases toward the heater assembly. Cartridge described in.
13. 13. A cartridge according to any one of claims 1 to 12, wherein said first and said second capillary material are formed as a unitary element from a continuous piece of material, thereby increasing the cross-section at one end of said element. .
14. 14. A cartridge according to any one of the preceding claims, wherein the inner surface of said housing is in the shape of a regular cylinder with a circular cross-section and said piece of capillary material is conical.
15. The capillary material has the shape of a regular cylinder with a circular cross-section, and the inner surface of the housing includes a tapered portion at an open end, the tapered portion after insertion of the capillary material into the housing. 15. A cartridge according to any one of 1 to 14, which is compressed by.
16. A cartridge for use in an aerosol generating system, comprising:
a liquid storage portion,
a housing for holding a liquid aerosol-forming substrate, the liquid storage portion comprising:
- a heater assembly;
- a capillary material provided in contact with the heater assembly, wherein the average porosity or pore size of a region of the capillary material adjacent to the heater assembly is spaced apart from the heater assembly; A cartridge that is smaller than the average porosity or pore size of the area of the cartridge.
17. 17. The cartridge of claim 16, wherein a portion of said capillary material in said region is compressed to reduce its porosity or pore size.
18. said liquid storage portion comprising at least two portions in fluid communication with each other;
said first portion of said liquid storage portion comprising said capillary material and said second portion of said liquid storage portion comprising a container for holding a liquid aerosol-forming substrate; 18. A cartridge according to 16 or 17 which feeds areas of higher porosity or pore size of the material.
19. A method of manufacturing a cartridge for use in an aerosol generating system comprising:
- providing a liquid storage part comprising a housing having a first part and a second part;
- providing a heater assembly;
- placing a first capillary material within said first portion of said housing of said liquid storage portion such that said first capillary material is in direct contact with said heater assembly;
- said second capillary material is in contact with said first capillary material and is spaced from said heater assembly by said first capillary material; and disposing within said first portion of
A method according to claim 1, wherein said second portion of said liquid storage portion is substantially empty and suitable for holding an aerosol-forming substrate in liquid form.
20. 20. A portion of the capillary material is compressed during or prior to insertion into the housing such that the porosity or pore size of the portion of the capillary material is reduced. the method of.
21. A method of manufacturing a cartridge for use in an aerosol generating system comprising:
- providing a liquid storage part comprising a housing;
- providing a heater assembly;
- positioning a capillary material within the housing of the liquid storage portion such that the capillary material is in direct contact with the heater assembly;
wherein the method comprises compressing a portion of the capillary material during or prior to placement of the housing such that the porosity or pore size of the portion of the capillary material is reduced. .
22. 18. An aerosol generating system comprising the cartridge according to any one of 1 to 17.
23. 23. The aerosol generating system of Claim 22, further comprising a mouthpiece, wherein the cartridge is inserted into the system with the opening of the cartridge facing away from or toward the mouthpiece.
24. 24. An aerosol generating system according to 22 or 23, wherein said system is an electrically actuated smoking system.

Claims (13)

A cartridge for use in an aerosol generating system, comprising:
a liquid storage portion,
a housing for holding a liquid aerosol-forming substrate, said housing having an opening;
said liquid storage portion comprising at least two portions in fluid communication with each other, a first portion of said liquid storage portion comprising:
- a first capillary material provided near the opening of the housing;
- a second capillary material in fluid contact with said first capillary material and spaced from said opening by said first capillary material, said average pore size or void of said first capillary material; is less than the average pore size or porosity of the second capillary material;
a second portion of the liquid storage portion comprising a container for holding a liquid aerosol-forming substrate and supplying the liquid to the second capillary material;
A cartridge further comprising a fluid permeable heater assembly extending across said opening in said housing. 2. The cartridge of claim 1, wherein said first capillary material has a fiber or pore size of 0.1-50 μm. A cartridge according to any preceding claim, wherein said first capillary material has a density of less than 2 g/ml. A cartridge according to any preceding claim, wherein said second capillary material has a fiber or pore size of 1-100 µm. 5. A cartridge according to claim 3 or 4, wherein said second capillary material has a density of less than 1 g/ml. A cartridge according to any preceding claim, wherein the first capillary material or the second capillary material is compressed within the housing such that its effective pore size is reduced. A cartridge according to any preceding claim, wherein said first capillary material and said second capillary material comprise different regions of the same capillary material element. Claims 1-7, wherein the compression of the capillary material when positioned within the housing is such that the pore size or porosity of the capillary material continuously decreases toward the heater assembly. The cartridge according to any one of . 9. Any one of claims 1 to 8, wherein said first and said second capillary material are formed as a unitary element from a continuous piece of material, thereby increasing the cross-section at one end of said element. cartridge described in . 10. The cartridge of claim 9, wherein the interior surface of said housing is in the shape of a regular cylinder with a circular cross-section and said piece of capillary material is conical. The capillary material has the shape of a regular cylinder with a circular cross-section, and the inner surface of the housing includes a tapered portion at an open end, the tapered portion after insertion of the capillary material into the housing. 11. The cartridge of claim 10, wherein the cartridge is compressed by A method of manufacturing a cartridge for use in an aerosol generating system comprising:
- providing a liquid storage part comprising a housing having a first part and a second part, said housing having an opening;
- disposing a first capillary material within said first portion of said housing of said liquid storage portion such that said first capillary material is provided near said opening of said housing;
- placing a second capillary material in the housing of the liquid storage portion such that the second capillary material is in contact with the first capillary material and is spaced from the opening by the first capillary material; disposing within the first portion, wherein the average pore size or porosity of the first capillary material is smaller than the average pore size or porosity of the second capillary material; ,
- positioning a fluid permeable heater assembly extending across the opening of the housing;
A method according to claim 1, wherein said second portion of said liquid storage portion is substantially empty and suitable for holding an aerosol-forming substrate in liquid form. An aerosol generating system comprising the cartridge according to any one of claims 1-11.

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