RU2844462C1 - Aerosol-generating system and cartridge for aerosol-generating system with sealed liquid reservoir - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: invention relates to an aerosol-generating system and a cartridge for an aerosol-generating system. Cartridge (10) comprises housing (36) comprising sealed liquid reservoir (44), heater assembly (14) inside the housing, wherein heater assembly comprises heating element (12) and piercing element (34). Heater assembly is movable relative to the housing from a first position, in which the piercing element is outside the sealed liquid reservoir, to a second position, in which piercing element penetrates into liquid reservoir. Heater assembly includes a sealing surface that forms a liquid-impermeable seal with the housing or liquid reservoir when the assembled heater is in the second position.

EFFECT: possibility to isolate liquid from other system components during storage and transportation.

14 cl, 21 dwg

Description

The present invention relates to an aerosol generating system and a cartridge for the aerosol generating system. In particular, the present invention relates to an aerosol generating system having a cartridge for the aerosol generating system that generates an aerosol by spraying a liquid substrate that forms the aerosol.

Aerosol generating systems that vaporize a liquid aerosol-forming substrate to generate an aerosol are well known. An electronic cigarette is an example of a system of this type. The use of a liquid substrate has the advantage of allowing a large amount of aerosol to be generated from a relatively compact source of aerosol-forming substrate. For aerosols for inhalation by a user, it is also desirable for the generated aerosol to contain water and aerosol-forming substances that are in a liquid phase at temperatures suitable for inhalation by the user.

The liquid is typically stored in a liquid storage container or reservoir. The reservoir may be refillable or may be part of a disposable cartridge. During use, the liquid must be able to leave the reservoir to form an aerosol that can be delivered to the user. However, leakage of liquid from the reservoir prior to use is undesirable both because the amount of liquid available to form the aerosol is reduced and because the leaked liquid may damage or interfere with the operation of other components of the cartridge or system. It is also undesirable for contaminants to be able to enter the reservoir prior to use because they may affect the quality of the aerosol produced by the system. Additionally, it may be desirable to prevent contact of the aerosol-forming liquid substrate with the skin of users if the aerosol-forming liquid substrate contains substances that are irritating or harmful to the skin at the concentrations in which they are contained in the aerosol-forming liquid substrate.

Typically, the liquid substrate that produces the aerosol is contained in a cartridge, and the entire cartridge is sealed in a secondary packaging prior to use. This protects the liquid from contaminants during shipping and transport, and protects the end user from contact with the liquid prior to use. However, this solution does not prevent liquid from leaking from the reservoir into other parts of the cartridge or system prior to use. Since aerosol-generating systems typically include electrical components that may not function properly when in contact with liquid, this is undesirable. Requiring the user to remove the sealed secondary packaging prior to use is also inconvenient for users.

Publication WO 2013159245 A1 discloses an electronic cigarette that comprises a separate cartridge unit and an evaporator unit. The cartridge unit has a cartridge tube containing liquid, with a seal that seals the liquid inside the cartridge tube. The evaporator unit has a piercing element and a heater, wherein the front side of the evaporator unit can move into interaction with the cartridge unit, causing the piercing element to pierce the seal in preparation for use of the electronic cigarette.

It would be desirable to provide a system and cartridge that allows the fluid to be isolated from other system components during storage and transport and keeps the fluid in its original state until use, but which is also more convenient for end users.

According to the present invention, a cartridge for an aerosol generating system is provided. The cartridge may comprise a housing comprising a sealed liquid reservoir. The cartridge may comprise a heater assembly inside the housing. The heater assembly may comprise a heating element and a piercing element. The heater assembly may be configured to move relative to the housing from a first position, in which the piercing element is outside the sealed liquid reservoir, to a second position, in which the piercing element penetrates the liquid reservoir. The heater assembly may comprise a sealing surface that forms a liquid-tight seal with the housing or the liquid reservoir when the heater assembly is in the second position.

This arrangement allows the liquid substrate that forms the aerosol to be isolated from other components of the cartridge until use. It also means that secondary packaging for the cartridge is not required. The liquid reservoir is opened by moving the heater assembly relative to the cartridge housing. This allows the reservoir to be opened by moving a relatively small component of the cartridge. In the second position, in which the piercing element penetrates the liquid reservoir and thus opens the reservoir, the liquid in the liquid reservoir may be able to flow or be transferred to the heating element of the heater assembly. The heater assembly may be configured to vaporize the liquid on or near the heating element. The cartridge may be advantageously configured to retain the liquid within the cartridge housing when the heater assembly is in the second position. The cartridge may be configured to allow the vapor generated by the heating element to exit the cartridge when the heater assembly is in the second position.

The cartridge may be configured so that the heater assembly moves from a first position to a second position as part of a normal process of connecting the cartridge to another component of the aerosol generating system prior to use. The heater assembly may comprise an engagement surface facing away from the reservoir and accessible from the outside of the cartridge. The engagement surface may be pressed against a contact surface on the other component of the aerosol generating system to move the heater assembly from the first position to the second position.

This arrangement also allows the heater assembly to be located close to another component of the aerosol generating system, which typically contains a power source for the heating element, during use. This simplifies the supply of power to the heating element in both embodiments in which the power is supplied as an electric current through electrical connections and in embodiments in which the power is supplied by electromagnetic induction.

A sealing surface that forms a liquid-tight seal with the housing or the liquid reservoir when the heater assembly is in the second position ensures that unwanted liquid leakage from the housing is prevented during use. In the context of this document, a "liquid-tight" seal means a seal that substantially prevents liquid from passing and thus prevents liquid leakage. The sealing surface may advantageously form a liquid-tight seal with the housing when the heater assembly is in the second position. The housing may advantageously be rigid and liquid-tight. The sealing surface may form a liquid-tight seal with the liquid reservoir when the heater assembly is in the second position. The liquid reservoir may be formed at least partially by the cartridge housing.

The liquid reservoir may be formed at least partially by a pierceable element. The pierceable element may comprise a sealing foil. In the second position, the piercing element may penetrate the sealing foil. The pierceable element may be a multilayer foil. The pierceable element may comprise an elastomeric membrane. The pierceable element may comprise an elastic plug. The pierceable element may form a liquid-impermeable seal around the pierceable element.

The pierceable element may form a liquid-tight seal with the rest of the liquid reservoir body until the cartridge is used until the heater assembly is moved to the second position. The pierceable element may form a hermetic seal with the rest of the liquid reservoir body until the cartridge is used until the heater assembly is moved to the second position. The hermetic seal may ensure that the liquid aerosol-forming substrate inside the reservoir remains in its original state until use.

The heater assembly can be moved relative to the housing from the first position to the second position. The heater assembly can be moved relative to the housing from the first position to the second position in any suitable way. In some embodiments, the heater assembly can slide relative to the housing. The heater assembly can slide relative to the housing in a direction parallel to the longitudinal axis of the system. The heater assembly can slide relative to the housing in a direction parallel to the direction in which the cartridge and the component in the form of a power source are connected together. In some embodiments, the heater assembly can be configured to rotate relative to the housing.

The piercing element may be hollow. Liquid from the liquid reservoir may flow through the piercing element when the heater assembly is in the second position.

The heater assembly may contain a plurality of piercing elements. The heater assembly may contain two, three, four or more piercing elements.

The heater assembly may comprise a heater holder. The heater holder may comprise a piercing element or piercing elements. The heater holder may support the heating element.

The heater holder is configured to withstand temperatures to which the heating element is heated to heat the aerosol-forming substrate.

The heater holder may be formed from any suitable materials that can withstand the temperatures to which the heating element is heated to heat the substrate that forms the aerosol. Preferably, the heater holder comprises a heat-insulating material. Advantageously, forming the heater holder from a heat-insulating material can minimize heat transfer from the heating element to the heater holder. Preferably, the heater holder comprises an electrically insulating material. The heater holder may be formed from a durable material. The heater holder may be formed from a liquid-impermeable material. The heater holder may be formed from a moldable plastic material, such as polypropylene (PP) or polyethylene terephthalate (PET). The heater holder may be a single molded component that contains a piercing element or piercing elements.

In some embodiments, the heater holder is tubular. The tubular heater holder may form an internal passage or a central opening. In some embodiments, the heater assembly extends into the internal passage of the heater holder. In some preferred embodiments, the heating element extends into the internal passage of the heater holder. The heating element may extend through the internal passage of the heater holder. The heating element may be supported by the heater holder to cover the central opening. When the heating element extends through the internal passage of the heater holder, the heating element may comprise a first attachment region on the first side of the heating element in contact with the heater holder and a second attachment region on the second side of the heating element opposite to the first side in contact with the heater holder. Advantageously, the arrangement of the heating element for contact with the heater holder from opposite sides may allow the heater holder to securely fix the heating element in the cartridge.

The internal passage of the heater holder may extend substantially along the longitudinal axis. In some embodiments, the heating element is substantially flat, and the heating element extends parallel to the longitudinal axis. In some embodiments, the heating element is substantially flat, and the heating element extends perpendicular to the longitudinal axis.

In some embodiments, the internal passage of the heater holder may form part of the air passage of the cartridge. In these embodiments, the heating region of the heating element may be located in the internal passage of the heater holder.

In some embodiments, the inner passage of the heater holder may form a wall of the cartridge fluid reservoir when the heater assembly is in the second position. In these embodiments, at least one region of the heating element attachment may extend into the inner passage of the heater holder.

The tubular heater holder may comprise at least one side wall. The tubular heater holder may have an open end, so that the internal passage of the heater holder is open at least at one end. At least one side wall of the tubular heater holder may form an opening between the ends of the tubular heater holder. At least one area of fastening of the heating element may extend into the opening of the tubular heater holder. In some embodiments, when the heating element comprises a plurality of fastening areas, at least one side wall of the tubular heater holder forms a plurality of openings between the ends of the tubular heater holder. In these embodiments, each area of fastening of the heating element may extend into one of the plurality of openings of at least one side wall of the tubular heater holder.

The heater holder may comprise a piercing element or piercing elements in the form of a single molded component.

The heater assembly may comprise a gasket. The sealing surface may be provided by the gasket. The gasket may be mounted on the heater holder. The gasket may comprise a plurality of sealing ribs, wherein each rib forms part of the sealing surface and provides a seal with the outer housing. The gasket may comprise an elastomeric material. The ribs may comprise an elastomeric material. The gasket may be compressed between the cartridge housing and the heater holder when the heater assembly is in the second position.

The sealing surface can form a liquid-tight seal with the housing when the heater assembly is in the first position. This prevents unwanted liquid from entering the cartridge before use.

The heater assembly may further comprise a wick element. The wick element may be in fluid communication with the heating element. The wick element may be in fluid communication with the liquid reservoir when the heater assembly is in the second position. The wick element may be configured to transfer the aerosol-forming substrate from the liquid reservoir to the heating element. In particular, the wick element may be configured to transfer the aerosol-forming substrate from the liquid reservoir through the main surface of the heating element. The heating element may be attached to the wick element. The heating element may be a component part of the wick element. The heating element may comprise at least a portion of the wick material.

Providing a wick element improves the wetting of the heating element and thus increases the aerosol generation of the system. This allows the heating element to be made from materials that do not provide good wicking or wetting properties on their own. The wick element can be formed, for example, from cotton, viscose or fiberglass.

In some embodiments, the heating assembly comprises a plurality of heating elements. When the heater assembly comprises a plurality of heating elements and a wick element, each heating element may be arranged in fluid communication with the wick element. In some embodiments, the heater assembly comprises a plurality of heating elements and a plurality of wick elements.

In some preferred embodiments, the heater assembly comprises a first heating element and a second heating element, wherein the second heating element is located at a distance from the first heating element. The wick element may be located in the space between the first heating element and the second heating element. In some particularly preferred embodiments, the first heating element, the second heating element and the wick element are substantially flat, and the first heating element is located on the first side of the flat wick element, the second heating element is located on the second side of the flat wick element, opposite the first side.

Preferably, the heater assembly is located substantially outside the liquid tank. In particular, said or each heating element of the heater assembly may be located substantially outside the liquid tank. In particular, preferably, at least a portion of the main surfaces of said or each heating element is not in direct contact with the liquid tank in the first position or in the second position. Preferably, at least a portion of each of the two opposite main surfaces of the heater assembly is in direct contact with the air in the air flow passage in the system.

In some embodiments, the cartridge comprises a retaining material for containing a liquid substrate that forms an aerosol. The retaining material may be located in the liquid reservoir or between the liquid reservoir and the heating element. The retaining material may be a foam material, a sponge material, or a set of fibers. The retaining material may be formed from a polymer or a copolymer. In one embodiment, the retaining material is a spun polymer. The retaining material may be formed from any of the materials described above as suitable for the wick element.

When the aerosol generating system comprises a wick element and a retaining material, the wick element and the retaining material may be formed from the same material or from different materials. The retaining material may be in fluid communication with the heating element. The retaining material may be in contact with the heating element. The retaining material may be in fluid contact with the wick element of the heater assembly. The retaining material may be in contact with the wick element of the heater assembly.

The cartridge may contain an aerosol-forming substrate. In the context of this document, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds may be released by heating the aerosol-forming substrate. Preferably, the liquid reservoir contains a liquid aerosol-forming substrate.

The aerosol-forming substrate may be liquid at room temperature. The aerosol-forming substrate may contain both liquid and solid components. The liquid aerosol-forming substrate may contain nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may contain a material of plant origin. The liquid aerosol-forming substrate may contain tobacco. The liquid aerosol-forming substrate may contain a tobacco-containing material containing volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may contain homogenized tobacco material. The liquid aerosol-forming substrate may contain a material that does not contain tobacco. The liquid aerosol-forming substrate may contain homogenized material of plant origin.

The liquid aerosol-forming substrate may comprise one or more aerosol forming agents. The aerosol forming agent is any suitable known compound or mixture of compounds that, when used, promotes the formation of a dense and stable aerosol and is substantially resistant to thermal degradation at the operating temperature of the system. Examples of suitable aerosol forming agents include glycerol and propylene glycol. Suitable aerosol forming agents are well known in the art and include, but are not limited to: polyhydric alcohols such as triethylene glycol, 1,3-butanediol and glycerol; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The liquid aerosol-forming substrate may comprise water, solvents, ethanol, plant extracts and natural or artificial flavors.

The liquid aerosol-forming substrate may comprise nicotine and at least one aerosol-forming agent. The aerosol-forming agent may be glycerin or propylene glycol. The aerosol-forming agent may comprise both glycerin and propylene glycol. The nicotine concentration in the liquid aerosol-forming substrate may be from about 0.5% to about 10%, such as about 2%.

The assembled heater may comprise a current-collecting element, which is designed with the possibility of induction heating. The said or each heating element may be a current-collecting element.

In the context of this document, "current collecting element" means an element that is designed to be heated when an alternating magnetic field penetrates it. The current collecting element is usually designed to be heated by at least one of Joule heating due to inducing eddy currents in the current collecting element and hysteresis losses.

The use of induction heating can be particularly advantageous in a system in which the liquid container is opened immediately prior to use. The element that is heated in an induction heating system, namely the susceptor, does not require conductive electrical connections to other components of the system, such as the control circuit and power supply.

The current-receiving element of the current-receiving unit may comprise a heating region and at least one fastening region. The heating region is a region of the current-receiving element that is designed with the possibility of heating to a temperature necessary for evaporation of the substrate forming the aerosol when a suitable alternating magnetic field penetrates it.

The heating region may comprise a first material, which is a magnetic material capable of heating when an alternating magnetic field penetrates it. The term "magnetic material" is used herein to describe a material capable of interacting with a magnetic field, including both paramagnetic and ferromagnetic materials. The first material may be any suitable magnetic material capable of heating when an alternating magnetic field penetrates it. In some preferred embodiments, the first material comprises ferritic stainless steel. Suitable ferritic stainless steels include stainless steels of the AISI 400 series, such as stainless steels of the AISI 409, 410, 420 and 430 type.

In some preferred embodiments, the heating region consists of a first material. However, in other embodiments, the heating region comprises the first material and one or more other materials. When the heating region comprises the first material and one or more other materials, the heating region may comprise any suitable proportion of the first material. For example, the heating region may comprise at least 10% by weight of the first material, or at least 20% by weight of the first material, or at least 30% by weight of the first material, or at least 40% by weight of the first material, or at least 50% by weight of the first material, or at least 60% by weight of the first material, or at least 70% by weight of the first material, or at least 80% by weight of the first material, or at least 90% by weight of the first material.

At least one region of fastening of the current-receiving element may be a region of the current-receiving element which is configured to contact the heater holder. At least one region of fastening may be in contact with the heater holder. In the context of this document, the term "contact" means both direct contact and indirect contact. The heating region may be configured to heat up to a substantially higher temperature than the fastening region in the presence of an alternating magnetic field. This may be due to differences in the material between the heating region and the fastening region, differences in the geometry between the heating region and the fastening region, or differences in both the material and the geometry.

Preferably, at least one fastening region is in direct contact with the heater holder. In the context of this document, the term "direct contact" means contact between two components without any intermediate material, so that the surfaces of the two components are in contact with each other.

At least one fastening area may be in indirect contact with the heater holder. In the context of this document, the term "indirect contact" is used to denote contact between two components by means of one or more intermediate materials located between the two components in such a way that the surfaces of the two components do not come into contact with each other. For example, at least one fastening area is in indirect contact with the current collecting element when an adhesive layer is provided between the surface of at least one fastening area and the surface of the heater holder.

At least one fastening region may comprise a second material. The second material may be a non-magnetic material. The term "non-magnetic material" is used herein to describe a material that does not interact with a magnetic field and is not capable of heating when an alternating magnetic field penetrates it. The second material may be any suitable non-magnetic material. In some embodiments, the second material is a non-magnetic metal. For example, the second material may be a non-magnetic austenitic stainless steel. Suitable austenitic stainless steels include AISI 300 series stainless steels, such as AISI stainless steels of types 304, 309 and 316.

The heater holder may be in contact with the second material in at least one region of fastening of the current-receiving element. The heater holder may contact the current-receiving element only on the second material. Advantageously, providing contact between the heater holder and the current-receiving element on the second material may help to minimize heat transfer from the current-receiving element to the heater holder.

In some embodiments, the second material is non-metallic. For example, the second material may be a ceramic material.

In some embodiments, the second material is an electrically conductive material. As used herein, the term "electrically conductive" material means a material having a volume resistivity at 20 degrees Celsius (°C) of less than about 1×10-5 ohm-meters (Ohm-m), typically from about 1×10-5 ohm-meters (Ohm-m) to about 1×10-9 ohm-meters (Ohm-m). Suitable electrically conductive materials include metals, alloys, electrically conductive ceramics, and electrically conductive polymers. Suitable electrically conductive materials may include gold and platinum.

In some embodiments, the second material is an electrically insulating material. Advantageously, the electrically insulating second material can help minimize heat transfer from the current-receiving element to the heater holder. In the context of this document, the term "electrically insulating" material means a material having a volume resistivity at 20 degrees Celsius (°C) greater than about 1×106 ohm-meters (Ohm-m), typically from about 1×109 ohm-meters (Ohm-m) to about 1×1021 ohm-meters (Ohm-m). Suitable electrically insulating materials include glass, plastics, and some ceramic materials.

In some embodiments, the second material is a thermally insulating material. The advantageously thermally insulating second material can help minimize heat transfer from the current-receiving element to the heater holder. As used herein, the term "thermally insulating" refers to a material having a bulk thermal conductivity of less than about 5 watts per meter-kelvin (mW/(m-K)) at a temperature of 23°C and a relative humidity of 50%, as measured using the modified transient plane source (MTPS) method.

In some embodiments, the second material is a thermally conductive material. As used herein, the term "thermally conductive" refers to a material having a bulk thermal conductivity of at least about 10 watts per meter-kelvin (mW/(m-K)) at a temperature of 23°C and a relative humidity of 50%, as measured using the modified transient plane source (MTPS) method.

In some embodiments, the second material may be a hydrophilic material. In some embodiments, the second material may be an oleophilic material. Advantageously, providing a hydrophilic second material or an oleophilic second material may promote transport of the aerosol-forming substrate through the current collecting element.

In some embodiments, the second material comprises a cellulosic material. For example, the second material may comprise viscose.

In some preferred embodiments, at least one fastening region comprises the second material. However, in other embodiments, at least one fastening region comprises the second material and one or more other materials. When at least one fastening region comprises the second material and one or more other materials, the at least one fastening region may comprise any suitable proportion of the second material. For example, at least one fastening region of the current collecting element may comprise: at least 10 percent by weight of the second material, or at least 20 percent by weight of the second material, or at least 30 percent by weight of the second material, or at least 40 percent by weight of the second material, or at least 50 percent by weight of the second material, or at least 60 percent by weight of the second material, or at least 70 percent by weight of the second material, or at least 80 percent by weight of the second material, or at least 90 percent by weight of the second material.

At least one fastening region may contain the first material. However, at least one fastening region contains a smaller proportion of the first material than the heating region. The proportion by weight of the first material in the heating region may be greater than the proportion by weight of the first material in at least one fastening region. For example: the heating region of the current-receiving element may contain at least 90 percent by weight of the first material, and at least one area of fastening of the current-receiving element may contain less than 10 percent by weight of the first material, or the heating region of the current-receiving element may contain at least 80 percent by weight of the first material, and at least one area of fastening of the current-receiving element may contain less than 20 percent by weight of the first material, or the heating region of the current-receiving element may contain at least 70 percent by weight of the first material, and at least one area of fastening of the current-receiving element may contain less than 30 percent by weight of the first material, or the heating region of the current-receiving element may contain at least 60 percent by weight of the first material, and at least one area of fastening of the current-receiving element may contain less than 40 percent by weight of the first material, or the heating region of the current-receiving element may contain at least 50 percent by weight of the first material, and at least one area of fastening of the current-receiving element may contain less 50 percent by weight of the first material.

At least one fastening region may comprise: 90 percent or less by weight of the first material, or 80 percent or less by weight of the first material, or 70 percent or less by weight of the first material, or 60 percent or less by weight of the first material, or 50 percent or less by weight of the first material, or 40 percent or less by weight of the first material, or 30 percent or less by weight of the first material, or 20 percent or less by weight of the first material, or 10 percent or less by weight of the first material.

At least one fastening region may comprise: at least 10 percent by weight of the second material and less than 90 percent by weight of the first material, or at least 20 percent by weight of the second material and less than 80 percent by weight of the first material, or at least 30 percent by weight of the second material and less than 70 percent by weight of the first material, or at least 40 percent by weight of the second material and less than 60 percent by weight of the first material, or at least 50 percent by weight of the second material and less than 50 percent by weight of the first material, or at least 60 percent by weight of the second material and less than 40 percent by weight of the first material, or at least 70 percent by weight of the second material and less than 30 percent by weight of the first material, or at least 80 percent by weight of the second material and less than 20 percent by weight of the first material, or at least 90 percent by weight of the second material and less than 10 percent by weight of the first material.

The heating region may contain a second material. For example, the heating region may contain: 90 or less percent by weight of the second material, or 80 or less percent by weight of the second material, or 70 or less percent by weight of the second material, or 60 or less percent by weight of the second material, or 50 or less percent by weight of the second material, or 40 or less percent by weight of the second material, or 30 or less percent by weight of the second material, or 20 or less percent by weight of the second material, or 10 or less percent by weight of the second material.

The heating region may contain: at least 10 percent by weight of the first material and less than 90 percent by weight of the second material, or at least 20 percent by weight of the first material and less than 80 percent by weight of the second material, or at least 30 percent by weight of the first material and less than 70 percent by weight of the second material, or at least 40 percent by weight of the first material and less than 60 percent by weight of the second material, or at least 50 percent by weight of the first material and less than 50 percent by weight of the second material, or at least 60 percent by weight of the first material and less than 40 percent by weight of the second material, or at least 70 percent by weight of the first material and less than 30 percent by weight of the second material, or at least 80 percent by weight of the first material and less than 20 percent by weight of the second material, or at least 90 percent by weight of the first material and less than 10 percent by weight of the second material.

The heating region may comprise any suitable proportion of the current-receiving element. For example, the heating region may comprise at least 90 percent of the surface area of the current-receiving element, at least 80 percent of the surface area of the current-receiving element, or at least 70 percent of the surface area of the current-receiving element. The heating region may have any suitable size and shape for heating the aerosol-forming substrate at the required rate for generating the desired amount of inhalable aerosol.

At least one fastening region may comprise any suitable proportion of the current-receiving element. Typically, at least one fastening region comprises a smaller proportion of the current-receiving element than the heating region. For example, at least one fastening region may comprise 10 percent or less of the surface area of the current-receiving element, or 20 percent or less of the surface area of the current-receiving element, or 30 percent or less of the surface area of the current-receiving element. At least one fastening region may have any suitable size and shape to ensure a strong connection between the current-receiving element and the heater holder.

In some embodiments, at least one fastening region is located adjacent to the periphery of the heating region, wherein the heating region has a length and a width, and at least one fastening region has a length and a width. It is preferable that the length of at least one fastening region is less than the length of the heating region. In some embodiments, the length of at least one fastening region is no more than half the length of the heating region. In some embodiments, the length of at least one fastening region is no more than a quarter of the length of the heating region. It is preferable that the width of at least one fastening region is less than the width of the heating region. In some embodiments, the width of at least one fastening region is no more than half the width of the heating region. In some embodiments, the width of at least one fastening region is no more than a quarter of the width of the heating region.

In some embodiments, at least one fastening region is secured to the heater holder. At least one fastening region may be secured to the heater holder by means of adhesive.

At least one area of fastening of the current-receiving element may be located in any suitable position relative to the heating area of the current-receiving element. In some preferred embodiments, at least one area of fastening of the current-receiving element is located on the periphery of the current-receiving element. For example, at least one area of fastening may be located on one side of the current-receiving element.

In some preferred embodiments, at least one fastening region comprises a plurality of fastening regions. The current-receiving element may comprise any suitable number of fastening regions. For example, the current-receiving element may comprise one, two, three, four, five or six fastening regions. Advantageously, providing the current-receiving element with a plurality of fastening regions may allow the heater holder to provide more reliable support for the current-receiving element compared to a current-receiving element having one fastening region.

In some embodiments, the plurality of attachment regions may include a first attachment region and a second attachment region, wherein the first attachment region is located on one side of the current-receiving element, and the second attachment region is located on the same side of the current-receiving element as the first attachment region. In some of these embodiments, the first attachment region is located on the first end of the current-receiving element, and the second attachment region is located on the second end of the current-receiving element, opposite the first end.

In some embodiments, the plurality of fastening regions include a first fastening region and a second fastening region, wherein the first fastening region is located on the first side of the current-receiving element, and the second fastening region is located on the second side of the current-receiving element, opposite to the first side. In some of these embodiments, the heating region has a length, and the first fastening region and the second fastening region are located in the same position along the length of the heating region. In some of these embodiments, the first fastening region and the second fastening region are located at one end of the current-receiving element. In some of these embodiments, the heating region has a length, and the first fastening region and the second fastening region are located in the center along the length of the heating region. In some of these embodiments, the heating region has a length, and the first fastening region and the second fastening region are located in different positions along the length of the heating region. In some of these embodiments, the first fastening region is located at the first end of the current-receiving element, and the second fastening region is located at the second end of the current-receiving element, opposite to the first end.

In some preferred embodiments, the plurality of fastening regions include a first fastening region and a second fastening region, wherein the second fastening region is located opposite the first fastening region.

In some preferred embodiments, the plurality of attachment regions include: a first pair of attachment regions located at the first end of the current-receiving element on opposite sides of the current-receiving element; and a second pair of attachment regions located at the second end of the current-receiving element on opposite sides of the current-receiving element, wherein the second end of the current-receiving element is located opposite the first end.

In some embodiments, the plurality of attachment regions includes a plurality of pairs of attachment regions, each pair of attachment regions includes a first attachment region located on the first side of the current-receiving element and a second attachment region located on the second side of the current-receiving element, wherein the second side of the current-receiving element is opposite the first side of the current-receiving element.

In some embodiments, the plurality of fastening regions includes a plurality of pairs of fastening regions, each pair of fastening regions includes a first fastening region and a second fastening region, wherein the second fastening region is located opposite the first fastening region.

The thickness of the current collector element is preferably 2-10 times greater than the depth of the surface layer of the current collector material at the operating frequency of the system. When using several layers of the current collector, a thickness greater than the depth of the surface layer minimizes the interaction between the different layers of the current collector. The fact that the layers of the current collector are less than 10 times greater than the depth of the surface layer ensures that there is no excessive mass of current collector material for heating. Preferably, the current collector assembly or heating element assembly has a thickness of no more than 2 millimeters. This allows the heating element or heating elements to be placed inside and to cover a small channel for the air flow.

The or each heating element may be a heating element with resistive heating. The heater assembly may comprise a plurality of electrical connectors connected to the or each heating element and configured to be connected to a power source in another component of the aerosol generating system. The electrical connector may comprise a connection surface accessible from the outside of the cartridge. The connection surface may be part of the engagement surface.

The heating element with resistive heating may comprise a fastening region and a heating region, as described above with respect to the current-collecting element, wherein in use the heating region is heated to a higher temperature than the fastening region. The heating region may comprise materials different from the materials of the fastening region. The heating region may have a geometry different from the geometry of the fastening region. The heating region may be located between two electrical connectors.

The or each heating element may take any suitable form. The heating element may comprise, for example, a mesh, a flat spiral coil, fibers or fabric. In some embodiments, the heating element may comprise a sheet or strip.

Preferably, the heater assembly is configured to hold only a small volume of liquid aerosol-forming substrate, sufficient for one puff by the user. This is advantageous because it allows a small volume of liquid to be evaporated quickly with minimal heat loss to other system components or to the liquid aerosol-forming substrate that does not evaporate. Preferably, the heater assembly can hold between 2 milliliters and 10 milliliters of liquid aerosol-forming substrate.

At least a portion of the heating element may be fluid-permeable. In some embodiments, the heating element is fluid-permeable. In the context of this document, a "fluid-permeable" element means an element that allows a liquid or gas to penetrate through it. The heating element may have a plurality of openings formed therein to allow a fluid to penetrate through it. In particular, the heating element may allow an aerosol-forming substrate, either in a gaseous phase or in both a gaseous and a liquid phase, to penetrate through it.

In some preferred embodiments, the or each heating element may comprise a mesh. The heating element may comprise a matrix of threads forming a mesh. In the context of this document, the term "mesh" includes grids and matrices of threads between which spaces exist. The term "mesh" also includes woven and non-woven materials.

The filaments may form spaces between the filaments, and the spaces may be between 10 micrometers and 100 micrometers wide. Preferably, the filaments cause capillary action in the spaces so that, in use, the source liquid is drawn into the spaces, increasing the contact area between the heating element and the liquid.

The yarns may form a mesh of 160 to 600 US mesh (+/- 10%) (i.e., 160 to 600 threads per inch (+/- 10%)). The width of the spaces may be 35 micrometers to 140 micrometers or 25 micrometers to 75 micrometers. For example, the width of the spaces may be 40 micrometers or 63 micrometers. The percentage of open area of the mesh, which is the ratio of the area of the spaces to the total area of the mesh, is preferably 25% to 56%. The mesh may be formed using various types of woven or lattice structures. Alternatively, the yarns consist of a matrix of yarns arranged parallel to each other.

The threads may be formed by etching a sheet material such as foil. This may be particularly advantageous if the heating unit comprises a matrix of parallel threads. If the heating element comprises a mesh or woven material of threads, the threads may be produced individually and knitted together.

Preferably, the mesh is sintered. Advantageously, sintering the mesh creates electrical connections between the threads running in different directions. In particular, if the mesh comprises one or more woven and non-woven materials, it is advantageous that the mesh is sintered to create electrical connections between the overlapping threads.

The mesh may also be characterized by its ability to retain liquid, as is well known in the art.

The mesh threads may have a diameter of 8 micrometers to 100 micrometers, 30 micrometers to 100 micrometers, 8 micrometers to 50 micrometers, or 8 micrometers to 39 micrometers. The mesh threads may have a diameter of 50 micrometers.

The threads of the mesh may have any suitable cross-section. For example, the threads may have a circular cross-section or may have a flattened cross-section.

Advantageously, in embodiments in which the heating element is a current-collecting element, the grid may have a relative permeability of 1 to 40,000. When it is desired to ensure that eddy currents are used for most of the heating, a material with a lower permeability may be used, and when hysteresis effects are desired, a material with a higher permeability may be used. Preferably, the material has a relative permeability of 500 to 40,000. This can ensure efficient heating of the current-collecting element.

When the heating element comprises a grid, the heating region may comprise threads of the first material. In some embodiments, the heating region may comprise threads of the first material and threads of the second material. The heating region may comprise threads of the first material in the first direction and threads of the second material in the second direction, different from the first direction.

When the heating element comprises a grid, at least one fastening region may comprise threads of a second material. In some embodiments, at least one fastening region may comprise threads of a first material and threads of a second material. At least one fastening region may comprise threads of a first material in a first direction and threads of a second material in a second direction different from the first direction.

When the heating element contains a mesh, the mesh may be woven. The woven mesh contains threads in the weft direction and threads in the warp direction.

When the heating element comprises a woven mesh, at least one fastening region may comprise threads of the second material in the weft direction. The heater holder may be in contact with the heating element in at least one fastening region on the threads running in the weft direction. The heater holder may be in contact with the heating element in at least one fastening region only on the threads running in the weft direction and not in contact with the threads running in the warp direction. Advantageously, the formation of threads running in the weft direction from the second material in at least one fastening region may reduce heat transfer from the heating element to the heater holder compared to a heating element having threads in the weft direction formed from the first material in at least one fastening region.

Advantageously, the cartridge comprises a channel for air flow through the cartridge, passing from the air inlet past the heating element to the air outlet when the heater assembly is in the second position. The air outlet may be located in the mouthpiece portion of the outer housing. The channel for air flow may pass through the heater assembly. In particular, the channel for air flow may pass through the heater holder.

A part of the heater assembly, and in particular the heating element, may be located inside the air flow passage. The heating area of the heating element may be located inside the air flow passage. The aerosol-forming substrate evaporated by the heating element may be discharged into the air flow passage. The steam may condense to form an aerosol in the air flow passage. The aerosol may be discharged from the aerosol-generating system through an air outlet. The air outlet may be provided at the mouthpiece end of the aerosol-generating system, through which the generated aerosol may be drawn in by the user.

The heating element or heating elements, or the current collecting unit, may have a first surface parallel to the first plane, and a second surface parallel to the first plane, opposite the first surface, wherein at least a part of both the first and second surfaces is in direct contact with the air in the air flow passage. Preferably, the air flow passage runs parallel to the first plane near the heating element or heating elements.

The first side of the heating element may face the mouthpiece end, and the second side of the heating element may face the connecting end. However, the heating element is preferably flat and extends in a plane that is substantially parallel to the longitudinal axis of the cartridge, passing between the mouthpiece end and the connecting end. When the flat heating element extends in a plane that is substantially parallel to the longitudinal axis of the cartridge, the first and second sides of the heating element face opposite sides of the system.

The liquid reservoir may surround a portion of the air flow passage. The air flow passage may extend through the liquid reservoir. For example, the liquid reservoir may have an annular cross-section defining an internal passage, and the air flow passage may extend through the internal passage of the liquid reservoir.

When the heater holder is a tubular heater holder, the internal passage of the tubular heater holder may form part of a closed air flow passage. The closed air flow passage may extend from an air inlet at the connecting end of the cartridge, through the internal passage of the tubular heater holder, through the internal passage of the liquid reservoir to an air outlet in the opening at the mouthpiece end.

In some embodiments, at least a portion of the air flow passage is formed between the heater holder and the outer housing of the cartridge. At least a portion of the air flow passage may be formed between the liquid reservoir and the outer housing of the cartridge. In some embodiments, the closed air flow passage may extend from the air inlet through the passage between the heater holder and the outer housing, through the passage between the liquid reservoir and the outer housing to the air outlet.

The present invention also provides an aerosol generating system comprising a cartridge as described above and a reusable device which is configured to be connected or engaged with the cartridge, wherein the reusable device may comprise a power source for supplying power to the heating element. The cartridge is one component of the aerosol generating system, and the reusable device is another component of the aerosol generating system. The aerosol generating system may consist of a cartridge and a reusable device.

The reusable device may comprise a housing. The housing may be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials comprising one or more of such materials, or thermoplastic materials suitable for applications in the food or pharmaceutical industries, such as polypropylene, polyetheretherketone (PEEK) and polyethylene. The material is preferably lightweight and non-brittle.

The aerosol generating system may be designed so that the heater assembly moves from the first position to the second position due to the connection of the cartridge with the reusable device. The reusable device may comprise a contact surface that engages with the engagement surface on the heating unit when the cartridge is connected to the reusable device to bring the heater assembly to the second position, wherein the engagement surface on the heating unit faces away from the reservoir.

In embodiments using resistive heating, the contact surface may include electrical contacts configured to engage with corresponding electrical connectors on the cartridge. Electrical power may be supplied to the heating element through the electrical contacts and electrical contacts when the cartridge and the reusable device are engaged with each other.

The housing of the reusable device may form a cavity for accommodating at least a portion of the cartridge. The reusable device may comprise one or more air inlets. The one or more air inlets may provide for the suction of ambient air into the cavity.

The reusable device may have a connecting end configured to connect the reusable device to the cartridge. The connecting end may comprise a cavity for accommodating at least a portion of the cartridge.

The reusable device may have a distal end opposite the connecting end. The distal end may comprise an electrical connector configured to connect the aerosol-generating device to an electrical connector of an external power source for charging the power source of the aerosol-generating device.

In embodiments configured for induction heating, the reusable part comprises one or more induction coils configured to generate an alternating magnetic flux through the heating element. One or more induction coils may be located outside the cavity. The cavity may be open at the connecting end. The contact surface may be at the far end of the cavity. At least one of the induction coils may be a flat induction coil, and the current-collecting element may be flat and located parallel to the flat induction coil when the reusable device is engaged with the cartridge.

The cartridge body may comprise an outer body. The outer body may be formed from a durable material. The outer body may be formed from a liquid-impermeable material. The outer body may be formed from a moldable plastic material, such as polypropylene (PP) or polyethylene terephthalate (PET). The outer body may be formed from the same material as the heater holder, or may be formed from another material.

The heater assembly may be located in an outer housing. The heater holder may be located in the outer housing. In some embodiments, the heater holder may be made as a single unit with the outer housing.

The outer housing may form part of the liquid reservoir. The outer housing may form the liquid reservoir. The outer housing and the liquid reservoir may be formed as a single unit. Alternatively, the liquid reservoir may be formed separately from the outer housing and located in the outer housing.

Advantageously, providing the cartridge with a heater holder that connects the heating element to the housing can separate the heating element from the outer housing, so that the outer housing does not need to be designed to withstand the temperatures to which the heating element is heated to heat the substrate that forms the aerosol. This can allow the cartridge to be manufactured from less durable and less expensive materials.

The aerosol generating system may be a hand-held aerosol generating system configured to allow the user to draw on a mouthpiece to draw the aerosol through an opening at the mouthpiece end. The aerosol generating system may be of a size comparable to a traditional cigar or cigarette. The aerosol generating system may have a total length of about 30 millimeters to about 150 millimeters. The aerosol generating system may have an outer diameter of about 5 millimeters to about 30 millimeters.

The aerosol generating system may be configured to deliver nicotine or cannabinoids to the user. The aerosol generating system may be an electric smoking device.

The aerosol generating system may comprise a control circuit. The control circuit may be located in a reusable device. The control circuit may comprise a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, or an application-specific integrated circuit (ASIC) or other electronic circuit capable of providing control. The control circuit may be configured to supply power to at least one induction coil or to the heating element continuously after activation of the device, or may be configured to supply power intermittently, for example, from puff to puff. Power may be supplied to the heating unit in the form of electric current pulses, for example, by means of pulse width modulation (PWM). The control circuit may comprise a DC to AC converter, which may comprise a class D or class E power amplifier. The control circuit may comprise additional electronic components. For example, in some embodiments, the control circuit may comprise any of: sensors, switches, display elements.

The aerosol generating system may comprise a power source. The power source may be contained in a reusable device. The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium-cobalt, lithium-iron phosphate, lithium-titanate or lithium-polymer battery. The battery may be a nickel-metal hydride battery or a nickel-cadmium battery. The power source may be another type of charge storage device, such as a capacitor. The power source may be rechargeable and be capable of performing multiple charge and discharge cycles. The power source may have a capacity that allows storing a sufficient amount of energy for one or more sessions of a user of the aerosol generating system; For example, the power source may have a capacity sufficient to continuously generate aerosol for approximately six minutes, which corresponds to the typical time required to smoke a regular cigarette, or for a period of multiples of six minutes. In another example, the power source may have a capacity sufficient to enable a given number of puffs or individual activations of the spray unit.

The present invention further provides an aerosol generating system comprising: a housing comprising a sealed liquid reservoir; a heater assembly inside the outer housing, wherein the heater assembly comprises a heating element and a piercing element, and wherein the heater assembly is configured to move relative to the outer housing from a first position in which the piercing element is removed from the sealed liquid reservoir to a second position in which the piercing element penetrates the liquid reservoir; and a power source for supplying power to the heating element.

In this aspect, the heater assembly may be provided in a reusable portion of the system rather than in a replaceable cartridge. The sealed fluid reservoir may be provided as a replaceable component separate from other system components, such as the heater assembly.

The system may comprise any one or more of the features of the cartridge and the system described above. For example, the aerosol generating system may comprise one or more induction coils configured to generate an alternating magnetic flux through the heating element. At least one of the induction coils may be a flat induction coil, and the current collecting element may be flat and located parallel to the flat induction coil. The sealed liquid reservoir may be a separate and replaceable component of the system.

The present invention further provides a cartridge for an aerosol generating device comprising: a housing comprising a sealed liquid reservoir; a heater assembly inside the housing, wherein the heater assembly comprises a current-collecting element configured to be heated when an alternating magnetic field penetrates into it, and a piercing element, and wherein the heater assembly is configured to be movable relative to the sealed liquid reservoir from a first position, in which the piercing element is removed from the sealed liquid reservoir, to a second position, in which the piercing element penetrates into the liquid reservoir. In this cartridge, one or both of the heater assembly and the liquid reservoir can move relative to the housing to move from the first position to the second position.

The cartridge may comprise any one or more of the cartridge features described above. For example, the heater assembly may comprise a transport material for transporting liquid to the heating surface of the current collector when the heater assembly is in the second position.

It should be understood that any features described herein with respect to one embodiment of a cartridge or aerosol-generating device may also be applicable to other embodiments of cartridges and aerosol-generating devices according to the present invention. A feature described with respect to one embodiment may be equally applicable to another embodiment according to the present invention. It should also be understood that the aerosol-generating system according to the present invention may be provided in an aerosol-generating device without a cartridge. Accordingly, any of the features described herein with respect to a cartridge may be equally applicable to an aerosol-generating device.

The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more of the features of these examples can be combined with any one or more features of another example, embodiment or aspect described herein.

EX1. Cartridge for an aerosol generating system, containing:

a housing containing a sealed reservoir for liquid;

a heater assembly within a housing, wherein the heater assembly comprises a heating element and a piercing element, and wherein the heater assembly is configured to move relative to the housing from a first position in which the piercing element is located outside the sealed liquid reservoir to a second position in which the piercing element penetrates the liquid reservoir, wherein the heater assembly comprises a sealing surface that forms a liquid-tight seal with the housing or liquid reservoir when the heater assembly is in the second position.

EX2. A cartridge according to example EX1, wherein the sealing surface forms a liquid-tight seal with the housing when the heater assembly is in the first position.

EX3. A cartridge according to example EX1 or EX2, wherein the cartridge is configured such that the heater assembly is movable from the first position to the second position as part of the normal process of connecting the cartridge to another component of the aerosol generating system prior to use.

EX4. A cartridge according to any of the previous examples, wherein the heater assembly comprises an engagement surface facing away from the reservoir and accessible from the outside of the cartridge.

EX5. A cartridge according to any of the previous examples, wherein the heater assembly is configured to move from a first position to a second position along a first longitudinal axis.

EX6. A cartridge according to any of the previous examples, wherein the heater assembly is configured to slide relative to the housing when moving from the first position to the second position.

EX7. A cartridge according to any of the previous examples, wherein the heater assembly is configured to rotate relative to the housing when moving from the first position to the second position.

EX8. A cartridge according to any of the previous examples, configured such that pressure on the engagement surface along the first longitudinal axis moves the heater assembly from the first position to the second position.

EX9. A cartridge according to any of the previous examples, having a mouthpiece end adapted to be placed in the mouth of a user, and a connecting end opposite the mouthpiece end, wherein the heater assembly in a first position is located at the connecting end and moves closer to the mouthpiece end to reach a second position.

EX10. A cartridge according to any of the preceding examples, wherein the heating element is substantially flat.

EX11. A cartridge according to any of the previous examples, comprising a plurality of heating elements.

EX12. A cartridge according to example EX11, wherein each heating element is substantially flat and arranged parallel to each other.

EX13. A cartridge according to any of the previous examples, wherein the heater assembly comprises a wick material for transferring liquid to the heating surface of the or each heating element.

EX14. A cartridge according to any of the previous examples, wherein the heating element comprises a current-collecting element that is capable of induction heating.

EX15. A cartridge according to any of the preceding examples, comprising a wick element that is attached to or integral with the heating element.

EX16. A cartridge according to any of the preceding examples, wherein the piercing element is hollow.

EX17. A cartridge according to any of the previous examples, comprising a plurality of piercing elements.

EX18. A cartridge according to any of the preceding examples, wherein the heater assembly comprises a gasket, and wherein the sealing surface is provided by the gasket.

EX19. A cartridge according to example EX18, wherein the gasket comprises a plurality of sealing ribs, each rib providing a seal with the outer housing.

EX20. A cartridge according to any of the previous examples, wherein the sealing surface forms a liquid-tight seal with the housing when the heater assembly is in the first position.

EX21. A cartridge according to any of the previous examples, wherein the heater assembly comprises a plurality of heating elements.

EX22. A cartridge according to any of the previous examples, comprising a passage for air flow through the cartridge, extending from the air inlet past the heating element to the air outlet when the heater assembly is in the second position.

EX23. A cartridge according to the example EX22, where the air outlet is located in the mouthpiece part of the outer body.

EX24. A cartridge according to example EX22 or EX23, wherein the liquid reservoir surrounds part of the air flow channel.

EX25. A cartridge according to example EX22, EX23 or EX24, wherein at least part of the heating element is located in the air flow channel.

EX26. A cartridge according to any one of examples EX22-EX25, wherein the heater assembly comprises an engagement surface facing away from the reservoir and accessible from the outside of the cartridge, and wherein an air flow channel passes through the engagement surface.

EX27. A cartridge according to any of the preceding examples, wherein the liquid reservoir comprises a sealing foil, and wherein in the second position the piercing element penetrates the sealing foil.

EX28. A cartridge according to any of the previous examples, wherein the heater assembly comprises a heater holder, wherein the heater holder comprises a piercing element or piercing elements, wherein the heater holder supports the heating element.

EX29. A cartridge according to example EX28, wherein the heater holder containing the piercing element or piercing elements is a single molded component.

EX30. A cartridge according to example EX28 or EX29, wherein the heater holder comprises a central opening, and the heating element is supported by the heater holder to enclose or pass into the central opening.

EX31. Cartridge according to the example EX30, where the air flow channel passes through the central hole.

EX32. Cartridge according to example EX30, where the liquid channel passes through the central hole.

EX33. A cartridge according to example EX30, EX31 or EX32, where the central hole runs along the longitudinal axis of the cartridge.

EX34. A cartridge according to any of the previous examples, wherein the liquid reservoir has an annular cross-section.

EX35. An aerosol generating system comprising a cartridge according to any of the previous examples and a reusable device configured to be connected to the cartridge, wherein the reusable device comprises a power source for supplying power to the heating element.

EX36. An aerosol generating system according to example EX35, wherein the system is designed so that the heater assembly moves from a first position to a second position due to the connection of the cartridge to the reusable device.

EX37. An aerosol generating system according to example EX36, wherein the reusable device comprises a contact surface that engages with an engagement surface on the heating unit when the cartridge is connected to the reusable device to drive the heater assembly into a second position, wherein the engagement surface on the heating unit faces away from the reservoir.

EX38. An aerosol generating system according to example EX35, EX36 or EX37, comprising a mechanical engagement mechanism between the cartridge and the reusable device, such as a snap-fit mechanism, a screw-fit mechanism or a push-fit mechanism.

EX39. An aerosol generating system according to any of the examples Ex35-Ex38, wherein the reusable part comprises one or more induction coils configured to generate an alternating magnetic flux through the heating element.

EX40. An aerosol generating system according to example EX39, wherein at least one of the induction coils is a flat induction coil and the current collecting element is flat and located parallel to the flat induction coil.

EX41. An aerosol generating system according to any of the examples Ex35-Ex40, wherein the reusable device comprises a cavity configured to accommodate at least a portion of a cartridge, including a heater assembly.

EX42. An aerosol generating system according to example EX41, wherein the reusable device comprises one or more induction coils arranged around the cavity.

EX43. An aerosol generating system according to example EX41 or EX42, wherein the reusable device comprises one or more induction coils located within the cavity.

EX44. An aerosol generating system comprising:

a housing containing a sealed reservoir for liquid;

a heater assembly inside the outer housing, wherein the heater assembly comprises a heating element and a piercing element, and wherein the heater assembly is configured to move relative to the outer housing from a first position in which the piercing element is removed from the sealed liquid reservoir to a second position in which the piercing element penetrates the liquid reservoir; and a power source for supplying power to the heating element.

EX45. An aerosol generating system according to example EX44, comprising one or more induction coils configured to generate an alternating magnetic flux through a heating element.

EX46. An aerosol generating system according to example EX45, wherein at least one of the induction coils is a flat induction coil and the current collecting element is flat and located parallel to the flat induction coil.

EX47. An aerosol generating system according to any of the examples EX44-EX46, wherein the sealed liquid reservoir is a separate replaceable component of the system.

EX48. A cartridge for an aerosol generating device comprising: a housing comprising a sealed liquid reservoir; a heater assembly inside the housing, wherein the heater assembly comprises a current-collecting element configured to be heated when an alternating magnetic field penetrates it, and a piercing element, and wherein the heater assembly is configured to be movable relative to the sealed liquid reservoir from a first position in which the piercing element is removed from the sealed liquid reservoir to a second position in which the piercing element penetrates the liquid reservoir.

EX49. A cartridge according to example EX48, wherein the heater assembly comprises a transport material for transporting liquid to the heating surface of the current collector when the heater assembly is in the second position.

EX50. A cartridge according to example EX48 or EX49, wherein the current collecting element is substantially flat.

EX51. A cartridge according to any of the examples EX48-EX50, wherein the heater assembly is tubular and forms an internal passage, and wherein the current-collecting element extends into the internal passage.

EX52. A cartridge according to example EX51, where the current-collecting element passes through an internal passage.

EX53. A cartridge according to any of the examples EX48-EX52, wherein the internal passage extends substantially along the longitudinal axis, and wherein the current collecting element is substantially flat and extends parallel to the longitudinal axis.

EX54. A cartridge according to any of the examples EX48-EX52, wherein the internal passage extends substantially along the longitudinal axis, and wherein the current collecting element is substantially flat and extends perpendicular to the longitudinal axis.

EX55. A cartridge according to any of the examples EX48-EX54, wherein the cartridge has a mouthpiece end adapted to be placed in the user's mouth and a connecting end opposite the mouthpiece end, wherein the heater assembly in the first position is located at the connecting end.

The examples will be further described below with reference to the drawings, in which:

Fig. 1a is a schematic illustration of an aerosol generating system according to one example of the present invention;

Fig. 1b shows a schematic representation of the aerosol generating system of Fig. 1a, rotated 90 degrees relative to the central longitudinal axis of the aerosol generating system;

Fig. 2a shows a schematic representation of a cartridge for the aerosol generating system of Figs. 1a and 1b;

Fig. 2b shows a schematic representation of the cartridge according to Fig. 2a, rotated 90 degrees relative to the central longitudinal axis of the cartridge;

Fig. 2c shows a schematic representation of the cartridge of Fig. 2a, wherein the cartridge is in the use configuration;

Fig. 3a shows a side view of the current collecting unit of the cartridge according to Figs. 1a and 1b;

Fig. 3b shows a perspective view of the current collecting unit according to Fig. 3a;

Fig. 3c shows a top view of the current collecting unit according to Fig. 3a;

Fig. 4a is a perspective view of an assembled heater according to one example of the present invention;

Fig. 4b shows a cross-section of the heater assembly according to Fig. 3b;

Fig. 5a is a partial view of a cartridge containing a heater assembly as shown in Fig. 3a in a first position prior to use;

Fig. 5b is a partial view of the cartridge containing the heater assembly as shown in Fig. 3a in a second position ready for use;

Fig. 6a shows a schematic illustration of a cartridge for an aerosol generating system according to another example of the present invention, wherein the cartridge is in a storage configuration;

Fig. 6b shows a schematic representation of the cartridge of Fig. 6a, wherein the cartridge is in the use configuration;

Fig. 7a shows a schematic representation of an aerosol generating system according to a second example of the present invention, wherein the aerosol generating system comprises a cartridge according to Fig. 6a and 6b, placed in an aerosol generating device;

Fig. 7b shows a schematic representation of the aerosol generating system of Fig. 7a, rotated 90 degrees relative to the central longitudinal axis of the aerosol generating system;

Fig. 8a shows a schematic representation of an aerosol generating system according to another example of the present invention;

Fig. 8b shows a schematic representation of the aerosol generating system of Fig. 8a, rotated 90 degrees relative to the central longitudinal axis of the aerosol generating system;

Fig. 9a shows a schematic representation of a cartridge for the aerosol generating system of Figs. 8a and 8b;

Fig. 9b shows a schematic representation of the cartridge of Fig. 9a, rotated 90 degrees relative to the central longitudinal axis of the cartridge; and

Fig. 9c shows a schematic representation of the cartridge of Fig. 9a, wherein the cartridge is in the use configuration.

Fig. 1a shows a schematic representation of an aerosol generating system according to one example of the present invention. Fig. 1b shows a schematic representation of the aerosol generating system of Fig. 1a rotated 90 degrees relative to the central longitudinal axis of the aerosol generating system. The system comprises a cartridge 10 and a device 60 which are connected together to form an aerosol generating system. The aerosol generating system is portable and has a size comparable to the size of a traditional cigar or cigarette.

The cartridge 10 is shown separately in Fig. 2a, 2b and 2c. Fig. 2a shows the cartridge with the heater assembly in the first position before use. Fig. 2b shows the cartridge rotated 90 degrees relative to the central longitudinal axis of the cartridge. Fig. 2c shows the cartridge in the use configuration, wherein the heater assembly has been moved to the second position.

The cartridge 10 comprises a heater assembly comprising a current collecting unit mounted in a heater holder. The current collecting unit 12 is shown in more detail in Fig. 3a, 3b and 3c. The current collecting unit 12 is flat and thin, and its thickness dimension is substantially smaller than its length dimension and its width dimension. The current collecting unit 12 has the shape of a cross and comprises three layers: a first current collecting element 16, a second current collecting element 18 and a wick element 20 located between the first and second current collecting elements 16, 18. Each of the first current collecting element 16, the second current collecting element 18 and the wick element 20 usually has the shape of a cross, and each element has the same length and width dimensions. The first and second current-collecting elements 16, 18 are essentially identical and comprise a sintered mesh formed by ferritic stainless steel threads and austenitic stainless steel threads, which is described in more detail below. The wick element 20 comprises a porous body of viscose threads. The wick element 20 is designed to supply liquid from the outer open surfaces of the wick element 20 to the first and second current-collecting elements 16, 18.

Each of the first and second current-receiving elements 16, 18 comprises a pair of fastening regions 22 and a heating region 24. The heating region 24 is a substantially rectangular region located in the center of the current-receiving elements 16, 18. The pair of fastening regions 22 are also substantially rectangular regions located on the periphery of the heating region 24, on opposite sides of the heating region 24. In this embodiment, the fastening regions 22 are located in the same central position along the length of the heating region 24.

Each of the pair of fastening regions 22 has a smaller surface area than the heating region 24. The length l _m of each of the fastening regions 22 is less than the length l _h of the heating region 24, and the width w _m of each of the fastening regions 22 is less than the width w _h of the heating region 2 4. In this embodiment, the heating region 24 has a length l _h of approximately 6.50 millimeters and a width w _h of approximately 3.50 millimeters, and each of the fastening regions 22 has a length l _m of approximately 2.50 millimeters and a width w _m of approximately 1.15 millimeters. Thus, each of the first and second current collecting elements 16, 18 has a total maximum length of approximately 6.50 millimeters and a total maximum width of approximately 5.80 millimeters.

The heating region 24 is configured to heat up when an alternating magnetic field penetrates into it to evaporate the substrate forming the aerosol. The pair of fastening regions 22 is configured to contact the heater holder 14, so that the heater holder 14 can support the current-collecting unit 12 in position in the cartridge 10. The pair of fastening regions 22 is configured to minimize heat transfer from the current-collecting unit 12 to the heater holder 14.

Each of the first and second current-collecting elements 16, 18 comprises a grid having threads extending in the first direction and threads extending in the second direction, which is substantially perpendicular to the first direction. The heating region 24 comprises threads of stainless steel AISI 410, ferritic stainless steel, extending both in the first and second directions. The pair of fastening regions 22 comprises threads of stainless steel AISI 410 extending in the first direction and threads of stainless steel AISI 316, austenitic stainless steel, extending in the second direction. Accordingly, the heating region 24 consists of a magnetic material, and the pair of fastening regions 22 consists partly of a magnetic material and partly of a non-magnetic material. The weight fraction of stainless steel AISI 410 in the heating region 24 is greater than the weight fraction of AISI 410 in each of the pair of fastening regions 22.

Providing the first and second current-receiving elements 16, 18 with fastening regions 22 having a reduced cross-section compared to the heating region 24 and at least partially including fastening regions 22 made of a non-magnetic material helps to reduce the heating of the fastening regions 22 when an alternating magnetic field penetrates into the current-receiving elements. Such a configuration also helps to reduce the heat transfer from the current-receiving unit 12 to the heater holder 14.

It should be understood that in other embodiments, the heating region 24 and the pair of fastening regions 22 may be made of other combinations of magnetic and non-magnetic materials. For example, in some embodiments, the heating region 24 comprises threads of AISI 410 stainless steel, a ferritic stainless steel, extending in a first direction, and threads of AISI 316 stainless steel, an austenitic stainless steel, extending in second directions. In these embodiments, the pair of fastening regions 22 may comprise threads of AISI 316 stainless steel extending in both the first and second directions. Accordingly, in these embodiments, the heating region 24 consists partly of a magnetic material and partly of a non-magnetic material, and the pair of fastening regions 22 consists of a non-magnetic material.

The heater holder 14 comprises a tubular body made of a moldable plastic material, such as polypropylene. The tubular body of the heater holder 14 comprises a side wall forming an internal passage 2 6 with open ends. A pair of openings 2 8 pass through the side wall on opposite sides of the tubular heater holder 14. The openings 28 are located centrally along the length of the heater holder 14.

The current-collecting unit 12 is located inside the internal passage 26 of the tubular heater holder 14 and extends in a plane parallel to the central longitudinal axis of the heater holder 14. The heating region 24 of the first and second current-collecting elements 16, 18 is completely located inside the internal passage 26 of the heater holder 14, and each of the fastening regions 22 passes through one of the openings 28 in the side wall of the heater holder 14. The openings 28 in the side wall of the heater holder 14 have a size capable of accommodating the current-collecting unit 12 with a friction fit, so that the current-collecting unit is secured in the heater holder 14. The friction fit between the current collecting unit 12 and the heater holder 14 results in the fastening areas 22 directly contacting the heater holder 14 in the openings 28. The current collecting unit 12 and the heater holder 14 are fastened together in such a way that movement of the heater holder 14 also moves the current collecting unit 12.

It should be understood that the current collecting unit 12 and the heater holder 14 may be secured together by other means. For example, in some embodiments, the current collecting unit 12 is secured to the heater holder 14 by means of adhesive in the attachment regions 22 of the current collecting unit 12, so that the attachment regions 22 indirectly come into contact with the heater holder 14.

The heater holder 14 comprises a base 30 which partially closes one end of the internal passage 26. The base 30 comprises a plurality of air inlet openings 32 which allow air to be drawn into the internal passage 26 through the partially closed end.

The heater holder 14 further comprises a pair of piercing elements 34 extending from the outer surface of the side wall to the open end of the heater holder 14 opposite the end partially closed by the base 30. The openings 28 in the side wall of the heater holder 14 are located between the piercing elements 34 along the circumference of the side wall in such a way that the piercing elements 34 are offset from the openings 28 along the circumference of the side wall of the tubular heater holder by approximately 90 degrees. Each of the piercing elements 34 comprises a hollow pin facing in the direction of the open end of the heater holder 14.

The cartridge 10 further comprises an outer housing 36 made of a moldable plastic material, such as polypropylene. The outer housing 36 typically forms a hollow cylinder that defines an internal space in which the current-collecting unit 12 and the heater holder 14 are located.

The outer housing 36 forms the first part of the cartridge 10, and the current collecting unit 12 and the heater holder 14 form the second part of the cartridge 10. The second part of the cartridge can be designed to slide relative to the first part of the cartridge between a storage configuration, as shown in Fig. 2a and 2b, and a use configuration, as shown in Fig. 2c.

The cartridge 10 has a mouthpiece end and a connecting end opposite to the mouthpiece end. The outer housing 36 forms an opening 38 at the mouthpiece end of the cartridge 10. The connecting end is designed to connect the cartridge 10 to the aerosol generating device, as described in detail below. The current collecting unit 12 and the heater holder 14 are located in the direction of the connecting end of the cartridge 10. The outer width of the outer housing 36 is greater at the mouthpiece end of the cartridge 10 than at the connecting end connected to the projection 37. This allows the connecting end of the cartridge to be placed in the cavity of the aerosol generating device, wherein the projection 37 fixes the cartridge in the correct position in the device. This also allows the mouthpiece end of the cartridge 10 to remain outside the aerosol generating device, wherein the mouthpiece end corresponds to the external shape of the aerosol generating device.

The liquid reservoir 44 is formed in the cartridge for containing the liquid substrate 42 that forms the aerosol. The liquid reservoir 44 is located in the direction of the mouthpiece end of the outer body 36 and comprises an annular space formed by the outer body 36. The annular space has an internal passage 48 that extends between the opening 38 at the mouthpiece end and the open end of the internal passage 26 of the heater holder 14. The annular space 46, into which the liquid enters from the reservoir after puncturing the reservoir, is located in the direction of the connecting end of the outer body 36 and is formed between the internal surface of the outer body 36 and the external surface of the heater holder 14. The base 20 of the tubular holder 14 of the heater is provided with an annular ribbed elastomer gasket 50, which passes between the outer surface of the tubular current collector 14 and the inner surface of the outer housing 36. The gasket 50 provides a liquid-tight seal between the holder 14 of the heater and the outer housing 36, ensuring that the second part 4 6 of the reservoir 40 for liquid is capable of containing the liquid substrate 42, forming an aerosol.

The base 30 comprises an engagement surface that engages with the contact surfaces on the projections 63 in the cavity 64 of the reusable aerosol generating device when the cartridge is engaged with the device.

The liquid reservoir 44 is fluidly isolated by an aluminum foil seal 52 which is pierceable by the piercing elements 34 of the heater holder, allowing the aerosol-forming liquid substrate 42 to flow into the space 46 and to the heater assembly, as described in more detail below.

The air passage through the cartridge 10 is formed by the internal passage 26 of the heater holder 14 and the internal passage 48 through the first part 44 of the reservoir 40 for liquid. The air passage passes from the air inlet openings 32 in the base 30 of the heater holder 14 through the internal passage 26 of the heater holder 14 and through the internal passage 48 of the first part 44 of the reservoir 40 for liquid to the opening 38 at the mouthpiece end. The air passage allows air to be drawn through the cartridge 10 from the connecting end to the mouthpiece end.

In the storage configuration, as shown in Fig. 2a and 2b, the base 30 of the heater holder 14 extends beyond the outer housing 36, and the piercing elements 34 of the heater holder 14 are at a distance from the seal 52 in the direction of the connecting end of the cartridge 10. In this configuration, the liquid substrate 42 forming an aerosol is held in the liquid reservoir 44 and is isolated from the space 46 by the seal 52. Accordingly, in the storage configuration, the susceptor unit 12 is isolated from the aerosol forming substrate 42. Advantageously, sealing the liquid substrate 42 forming an aerosol in the reservoir 44 can completely prevent the liquid substrate 42 forming an aerosol from leaking from the cartridge 10 when the cartridge is in the storage configuration.

In the configuration of use as shown in Fig. 2c, the heater holder 14 and the current collecting unit 12 are pushed into the outer housing 36 in the direction of the mouthpiece end. As the heater holder 14 is pushed in the direction of the mouthpiece end of the outer housing 36 by engaging with the projections 63, the gasket 50 in the base 30 of the heater holder 14 slides along the inner surface of the outer housing 36, maintaining a liquid-tight seal between the inner surface of the outer housing 36 and the outer surface of the body of the tubular heater holder as the base of the heater holder 14 is placed in the outer housing. As the piercing elements 34 of the heater holder 14 move toward the mouth end, the piercing elements 34 contact and pierce the seal 52, providing fluid communication between the liquid reservoir 44 and the space 46. The aerosol-forming liquid substrate 42 in the liquid reservoir 44 is released into the space 46, and the susceptor assembly 12 is exposed to the aerosol-forming liquid substrate 42. In the configuration of use, the region 22 of fastening of the first and second current-receiving elements 16, 18 and the corresponding parts of the wick element 20, which extend into the space 46, are capable of drawing the liquid substrate 42, forming the aerosol, from the space 46 into the region 24 of heating of the first and second current-receiving elements 16, 18. As a result, in the configuration of use, the cartridge 10 is ready for use for generating the aerosol by heating the substrate 42, forming the aerosol.

The aerosol generating device 60 comprises a generally cylindrical body 62 comprising a connecting end and a distal end opposite the connecting end. A cavity 64 for accommodating the connecting end of the cartridge is located at the connecting end of the device 60, and an air inlet 65 is provided in the outer body 62 at the base of the cavity 64 to ensure that ambient air is drawn into the cavity 64 at the base.

The device 60 additionally comprises an induction heating device placed in the housing 62. The induction heating device comprises a pair of induction coils 66, 68, a control circuit 70 and a power source 72. The power source 72 comprises a rechargeable nickel-cadmium battery, which is configured to be recharged through an electrical connector (not shown) at the far end of the device. The control circuit 70 is connected to the power source 72, as well as to the first and second induction coils 66, 68, so that the control circuit 70 controls the supply of power to the induction coils 66, 68. The control circuit 70 is configured to supply alternating current to the first and second induction coils 66, 68.

The pair of induction coils includes a first induction coil 66 and a second induction coil 68. The first induction coil 66 is located on the first side of the cavity 64, and the second induction coil 68 is located on the second side of the cavity 64 opposite the first induction coil 66. Each of the induction coils 66, 68 is substantially identical and contains a flat coil with a rectangular cross-section, made of wire with a rectangular cross-section. Each of the induction coils 66, 68 extends substantially in a plane, wherein the first coil 66 extends in the first plane, and the second coil 68 extends in the second plane. The first and second planes are substantially parallel to each other and extend substantially parallel to the central longitudinal axis of the cavity 64 at the connecting end of the device 60. When the cartridge 10 is placed in the cavity 64, the current collecting unit 12 is located between the first and second induction coils 66, 68, and the plane of the current collecting unit 12 is located substantially parallel to the first and second planes.

Flux concentrators 69 are provided around each of the induction coils to hold and concentrate the magnetic field within the cavity. Flux concentrators 69 may be made of a magnetic material such as iron.

Each of the first and second induction coils 66, 68 is designed in such a way that when alternating current is supplied to the induction coils 66, 68, the induction coil generates an alternating magnetic field in the cavity 64. The alternating magnetic field generated by each of the induction coils 66, 68 is directed substantially perpendicular to the plane of the current-receiving unit 12 and the current-receiving elements 16, 18.

The induction heating device is also designed in such a way that the second induction coil 68 generates an alternating magnetic field in the cavity 64, which is equal and opposite to the alternating magnetic field generated in the cavity 64 by the first induction coil 66. In this embodiment, the first and second induction coils 66, 68 are connected together in series and are substantially identical, but wound in opposite directions. In this configuration, the first and second induction coils 66, 68 generate alternating magnetic fields in the cavity 64 with substantially the same magnitudes, but in substantially opposite directions.

Fig. 4a is a perspective view of the heater holder 14 and the current collecting unit 12. Fig. 4b is a cross-sectional view of Fig. 4a rotated 90 degrees. The heater holder is a molded plastic component and is typically tubular. The heater holder comprises solid hollow piercing elements 34 on opposite sides of the tubular heater holder. The central opening of the heater holder forms part of the air flow passage through the cartridge. The current collecting unit 12 is typically located parallel to the axis of the air flow passage. It can be seen that when the piercing elements 34 penetrate the foil seal of the liquid reservoir, liquid can flow through the hollow piercing elements into the space 4 6 and from there is drawn into the ends of the current collecting unit.

Fig. 5a is a perspective view of the heater holder and current collecting unit of Figs. 4a and 4b inside the cartridge in the first position prior to use. Fig. 5b is a view of the cartridge of Fig. 5b with the heater assembly pushed into the second position.

In Fig. 5a, the base 30 projects from the outer housing 36. The piercing elements 34 have not penetrated the sealing element 52 made of foil, and the liquid is retained in the reservoir 44.

In Fig. 5b, the base 30 is pushed into the outer housing 36 so that the piercing element 34 is pushed through the sealing element made of foil. The liquid in the reservoir then flows into the space 4 6 and comes into contact with the current-collecting unit 12.

It can be seen that this arrangement provides a convenient way to open the liquid reservoir immediately before using the system. The user is not required to perform any additional actions to open the reservoir before attaching the cartridge to the reusable component of the device.

It should be understood that the sealing element 52, described above as comprising a foil, may be in the form of a plug or partition that provides a seal around the piercing elements when the sealing element is pierced. This may provide an alternative design in which the gasket 50 is not required.

Fig. 6a and 6b show schematic illustrations of a cartridge 10 for an aerosol generating device according to another embodiment of the present invention. The cartridge 10 shown in Fig. 6a is substantially similar to the cartridge 10 shown in Fig. 2a, 2b and 2c, and like features are designated by like reference numerals.

The cartridge 10 comprises two current collecting units 12 mounted in the heater holder 14. Each current collecting unit 12 is flat and thin and has the shape of the letter "C". Each current collecting unit 12 has the same three-layer configuration as the current collecting unit 12 shown in Fig. 3a-3c, with a wick element located between the first and second current collecting elements (not shown). Each current collecting element has a rectangular heating area and two fastening areas located on one side of the heating area at opposite ends of the heating area.

The heater holder 14 comprises a tubular body comprising a side wall forming an internal passage 26 with open ends. Two pairs of openings 28 pass through the side wall, wherein each pair of openings 28 has one opening located on one side of the heater holder 14 and another opening located on the opposite side of the heater holder 14.

In this embodiment, each of the two current-collecting units 12 is located substantially outside the internal passage 26 of the tubular heater holder 14 and extends in a plane parallel to the central longitudinal axis of the heater holder 14. The heating region of each current-collecting element is located completely outside the internal passage 26, and each of the fastening regions extends through one of the openings 28 in the side wall of the heater holder.

The heater holder comprises a base 30 that partially closes one end of the internal passage 26. In this embodiment, the base 30 forms a liquid-tight seal with the internal passage 26 such that the internal passage is configured to contain liquid. The base 30 comprises a plurality of air inlets 32; however, the air inlets 32 are located outside the internal passage 26.

The heater holder 14 additionally comprises a pair of piercing elements 34 extending from the inner surface of the side wall into the inner passage 26 in the direction of the central longitudinal axis of the heater holder 14.

The cartridge 10 further comprises an outer housing 36, which typically forms a hollow cylinder, forming an internal space in which the current-collecting unit 12 and the heater holder 14 are placed. The outer housing 36 forms the first part of the cartridge 10, and the current-collecting unit 12 and the heater holder 14 form the second part of the cartridge 10. The second part of the cartridge is designed to slide relative to the first part of the cartridge between a storage configuration, as shown in Fig. 6a, and a use configuration, as shown in Fig. 6b.

The cartridge 10 has a mouthpiece end forming an opening 38 at the mouthpiece end and a connecting end configured to connect the cartridge 10 to an aerosol generating device. The current collecting unit 12 and the heater holder 14 are located in the direction of the connecting end of the cartridge 10. The outer width of the outer body 36 is greater at the mouthpiece end of the cartridge 10 than at the connecting end connected to the projection 37.

The liquid reservoir 40 is formed in the cartridge for containing the liquid substrate 42 that forms the aerosol. The liquid reservoir 44 is located in the direction of the mouthpiece end of the outer housing 36 and comprises a cylindrical space formed by the inner wall of the outer housing 36. The space 46 is located in the direction of the connecting end of the outer housing 36 and comprises a cylindrical space formed by the internal passage 26 of the heater holder 14.

The liquid reservoir 44 and the space 46 are fluidly isolated from each other by means of a seal 52 made of aluminum foil, which is designed with the possibility of being pierced by the piercing elements 34 of the heater holder, which allows the liquid substrate 42 forming the aerosol to flow between the first and second parts 44, 46 of the liquid reservoir.

The first passage 48 is formed between the outer surface of the inner wall forming the reservoir 44 for liquid and the inner surface of the outer wall of the outer housing 36. The first passage 48 extends between the opening 38 at the mouthpiece end and the heater holder 14. The second passage 49 is formed between the inner surface of the outer wall of the outer housing 36 and the outer surface of the heater holder 14. The base 30 of the tubular heater holder 14 is provided with an annular ribbed elastomer gasket 50, which extends between the outer surface of the tubular current collector 14 and the inner surface of the outer wall of the outer housing 36. The gasket 50 provides an airtight seal between the heater holder 14 and the outer housing 36.

The air passage through the cartridge 10 is formed by the first and second passages 48, 49. The air passage extends from the air inlet openings 32 in the base 30 of the heater holder 14 through the second passage 49 and through the first passage 48 to the opening 38 at the mouthpiece end. The air passage allows air to be drawn through the cartridge 10 from the connecting end to the mouthpiece end.

In the storage configuration as shown in Fig. 6a, the base 30 of the heater holder 14 extends beyond the outer housing 36, and the piercing elements 34 of the heater holder 14 are at a distance from the seal 52 in the direction of the connecting end of the cartridge 10. In this configuration, the liquid substrate 42 forming the aerosol is retained in the liquid reservoir 44 and is isolated from the space 4 6 by the seal 52.

In the configuration of use as shown in Fig. 6b, the heater holder 14 and the current collecting unit 12 are pushed into the outer housing 36 in the direction of the mouthpiece end. As the heater holder 14 is pushed in the direction of the mouthpiece end of the outer housing 36, the gasket 50 in the base 30 of the heater holder 14 slides along the inner surface of the outer housing 36, maintaining an airtight seal between the inner surface of the outer housing 36 and the outer surface of the body of the tubular heater holder as the base of the heater holder 14 is placed in the outer housing. As the piercing elements 34 of the heater holder 14 move toward the mouth end, the piercing elements 34 come into contact and pierce the seal 52, providing fluid communication between the liquid reservoir 44 and the space 46. The liquid substrate 42 forming an aerosol in the liquid reservoir 44 is released into the space 44, and the susceptor unit 12 is opened for the liquid substrate 42 forming an aerosol. In the configuration of using the region 22 of fastening the susceptor elements and the corresponding parts of the wick element that extend into the second part 46 of the liquid reservoir 40, are capable of drawing the liquid substrate 42 forming an aerosol from the space 46 into the heating regions 24 of the susceptor elements.

Fig. 7a and 7b show an aerosol generating system comprising a cartridge 10 of Fig. 6a and 6b in a use configuration placed in an aerosol generating device 60. Fig. 7b shows the aerosol generating system of Fig. 7a rotated 90 degrees relative to the longitudinal axis of the system. The aerosol generating device 60 is substantially similar to the aerosol generating device 60 shown in Fig. 1a and 1b, and like features are designated by like reference numerals.

The aerosol generating device 60 comprises a generally cylindrical body 62 comprising a connecting end and a distal end opposite the connecting end. A cavity 64 for receiving the connecting end of the cartridge is located at the connecting end of the device 60, and an air inlet 65 is provided in the outer body at the base of the cavity 64 to ensure that ambient air is drawn into the cavity 64 in the base. The cavity comprises a projection 63 at the base of the cavity, which provides a contact surface against which the engagement surface on the base of the cartridge is pressed when the cartridge is inserted into the cavity. This brings the heater assembly to the second position.

The device 60 further comprises an induction heating device arranged in a housing 62. The induction heating device comprises two pairs of induction coils, a control circuit 70 and a power source 72. In Fig. 7b, only one pair of induction coils 90, 91 is visible. The power source 72 comprises a rechargeable nickel-cadmium battery which is configured to be recharged via an electrical connector (not shown) at the far end of the device. The control circuit 70 is connected to the power source 72 and to the induction coil 90 in such a way that the control circuit 70 controls the supply of power to the induction coil 90. The control circuit 70 is configured to supply alternating current to the induction coil 90.

The induction coils comprise a pair of opposite flat induction coils located around each current-receiving unit 12 when the cartridge 10 is placed in the cavity 64. The induction coils have a size and shape corresponding to the size and shape of the heating areas of the current-receiving elements.

The induction coils 90, 91 are designed in such a way that when alternating current is supplied to the induction coils, the induction coils generate opposite alternating magnetic fields on opposite sides of the current-receiving units 12. The alternating magnetic fields generated by the induction coils are directed substantially perpendicular to the plane of the current-receiving units 12 and the current-receiving elements. Alternatively, a single spiral coil located around the cavity can be used instead.

During operation, when the user draws on the opening 38 at the mouth end of the cartridge 10, ambient air is drawn into the base of the cavity 64 through the air inlet 65 and into the cartridge 10 through the air inlet openings 32 in the base 30 of the cartridge 10, as shown by the arrows in Fig. 7a. The ambient air passes through the cartridge 10 from the base 30 to the opening 38 at the mouth end through the air passage and over the current collecting assemblies 12.

The control circuit 70 controls the supply of electric power from the power source 72 to the induction coils 90, 91 when the system is activated. The control circuit 72 may comprise an air flow sensor (not shown), and the control circuit 72 may supply electric power to the induction coil 66 when the air flow sensor detects puffs made by the user from the cartridge 10.

When the system is activated, alternating current is established in the induction coils 90, 91, which generates alternating magnetic fields in the cavity 64, penetrating into the current-receiving unit 12, causing heating of the heating areas of the current-receiving elements. The liquid substrate forming the aerosol in the space 46 is drawn into the current-receiving units 12 through the wick elements to the heating areas of the current-receiving elements. The liquid substrate forming the aerosol is heated in the heating areas of the current-receiving elements, and volatile compounds from the heated substrate forming the aerosol are released into the air passage of the cartridge 10 and cool with the formation of an aerosol. The aerosol is entrained by the air drawn through the air passage of the cartridge 10, and is drawn out of the cartridge 10 through the opening 38 at the mouthpiece end for inhalation by the user.

In Fig. 8a and 8b an aerosol generating system according to another embodiment is shown, in which resistive heating is used instead of induction heating. In Fig. 8b the aerosol generating system of Fig. 8a is shown rotated 90 degrees with respect to the longitudinal axis of the system. The aerosol generating device 100 is similar to the aerosol generating device 60 shown in Fig. 1a and 1b, and like features are designated by like reference numerals. However, instead of induction coils, a pair of electrical contacts 110 are provided in the cavity 64. The electrical contacts 110 also provide a contact surface that drives the heater assembly of the cartridge to the second position, as described below with reference to Fig. 9c. The electrical contacts supply electrical power to the cartridge 120 from the power source 72 under the control of the control circuit 70.

The cartridge 120 according to the embodiment of Fig. 8a and 8b is shown separately in Fig. 9a, 9b and 9c. Fig. 9a shows the cartridge with the heater assembly in the first position before use. Fig. 9b shows the cartridge rotated by 90 degrees relative to the central longitudinal axis of the cartridge. Fig. 9c shows the cartridge in the use configuration, where the heater assembly is moved to the second position.

The cartridge 120 of Fig. 9a, 9b and 9c is identical to the cartridge 10 of Fig. 2a, 2b and 2c, except that instead of the current collecting unit with induction heating, a heating element 112 with resistive heating is provided in the heater holder. The heating element 112 comprises a stainless steel mesh and a wick element. A pair of electrical connectors 113 are provided, one on each side of the heating element and passing through the base 30 for providing a connection with electrical contacts 110 in the device 100. In all other respects, and especially with respect to the means for penetrating into the liquid reservoir, the cartridge is the same as the cartridge 10 shown in Fig. 2a, 2b and 2c. As the cartridge is inserted into the cavity of the device 100, the electrical connectors 113 engage with the contacts 100. As the cartridge body is pushed further in the distal direction, the heater assembly is pushed into a second position inside the cartridge body, as shown in Fig. 9c. In this position, penetration into the fluid reservoir occurs, and the fluid is transferred to the heating element. The electrical connectors 113 are in contact with the electrical contacts 110, and an electrical current can be supplied to the heating element under the control of the control circuit.

Claims (16)

1. A cartridge for an aerosol generating system, comprising: a housing containing a sealed reservoir for liquid; a heater assembly inside a housing, wherein the heater assembly comprises a heating element and a piercing element, wherein the heater assembly is configured to move relative to the housing from a first position in which the piercing element is located outside the sealed liquid reservoir to a second position in which the piercing element penetrates the liquid reservoir, wherein the heater assembly comprises a sealing surface that forms a liquid-tight seal with the housing or liquid reservoir when the heater assembly is in the second position, wherein the heating element comprises a current-collecting element configured to provide induction heating. 2. The cartridge of claim 1, wherein the heater assembly comprises a wick material for transferring liquid to the heating surface of the heating element. 3. The cartridge of claim 2, wherein the heating element comprises at least a portion of the second wick material. 4. A cartridge according to any of the preceding claims, wherein the piercing element is hollow. 5. A cartridge according to any of the preceding claims, wherein the heater assembly comprises a gasket, and the sealing surface is provided by said gasket. 6. The cartridge of claim 5, wherein the gasket comprises a plurality of sealing ribs, each rib providing a seal with the outer housing. 7. A cartridge according to any one of the preceding claims, wherein the heater assembly comprises an engagement surface facing away from the reservoir and accessible from the outside of the cartridge. 8. A cartridge according to any of the preceding claims, comprising a mouthpiece end adapted to be placed in the mouth of a user, and a connecting end opposite the mouthpiece end, wherein the heater assembly in a first position is located at the connecting end and moves closer to the mouthpiece end to reach a second position. 9. A cartridge according to any one of the preceding claims, wherein the liquid reservoir comprises a sealing foil, and wherein in the second position the piercing element penetrates the sealing foil. 10. A cartridge according to any one of the preceding claims, comprising a passage for air flow through the cartridge, extending from the air inlet past the heating element to the air outlet when the heater assembly is in the second position. 11. The cartridge of claim 10, wherein the liquid reservoir surrounds a portion of the air flow channel. 12. An aerosol generating system comprising a cartridge according to any of the preceding claims and a reusable device configured to be connected to the cartridge, wherein the reusable device comprises a power source for supplying power to the heating element. 13. The aerosol generating system of claim 12, wherein the reusable device comprises a contact surface that engages with an engagement surface on the heating assembly when the cartridge is connected to the reusable device to drive the heater assembly into a second position, such that the heater assembly moves from the first position to the second position due to the connection of the cartridge to the reusable device, and the engagement surface on the heating assembly faces away from the reservoir. 14. An aerosol generating system according to claim 12 or 13, wherein the reusable portion comprises one or more induction coils configured to generate an alternating magnetic flux through the heating element.