RU2847578C1 - Aerosol generator with arched chamber, cartridge for aerosol-generating system comprising aerosol generator with arched chamber, and aerosol-generating system comprising aerosol generator with arched chamber - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: aerosol generator is configured to generate an aerosol from an aerosol-forming substrate, wherein the aerosol generator comprises a non-thermal element, an aerosol-generating unit configured to convert the aerosol-forming substrate into an aerosol; at least one air inlet; at least one air outlet; and chamber between at least one air inlet hole and at least one air outlet hole. Aerosol-generating element is located in the chamber and is configured to discharge the aerosol-converted aerosol-forming substrate into the chamber. Aerosol generator further comprises an air flow path extending through the chamber between the air inlet and at least one air outlet through a non-thermal element, an aerosol-generating element, and a sidewall surrounding the aerosol-generating element. Side wall has curved surface forming chamber curved surface, and at least one air inlet opening passes through the side wall and is configured to direct air into the chamber in a direction tangential to the curved surface of the chamber.

EFFECT: invention provides an aerosol generator that reduces the likelihood of aerosol droplets settling on the surfaces of the generator before delivering the aerosol to the consumer.

15 cl, 10 dwg

Description

The present invention relates to an aerosol generator, an aerosol generating system containing the aerosol generator, and a cartridge containing the aerosol generator.

Aerosol-generating systems comprising aerosol generators configured to generate an aerosol from an aerosol-forming substrate are commonly known in the art. Such aerosol-generating systems often generate a respirable aerosol for inhalation by a user. Some known aerosol generators use heat to vaporize the aerosol-forming substrate, whereby the vaporized aerosol-forming substrate cools to form an aerosol. Other aerosol generators use non-thermal methods to convert a liquid aerosol-forming substrate into an aerosol. For example, some known non-thermal aerosol generators use a vibrating mesh to convert a liquid aerosol-forming substrate into an aerosol, and some known non-thermal aerosol generators use surface acoustic waves to convert a liquid aerosol-forming substrate into an aerosol.

It has been found that after an aerosol is generated by an aerosol generator, aerosol droplets can come into contact with the surfaces of the aerosol generator and deposit on the surfaces, preventing the deposited aerosol droplets from being delivered to the user. In particular, it has been found that aerosol droplet deposition on aerosol generator surfaces is a particular problem in non-thermal aerosol generators, in which the aerosolized liquid aerosol-forming substrate can tend to consist of larger droplets than the vapor generated by heated aerosol-forming substrates. Larger aerosol droplets have a greater tendency to deposit on the surfaces of the aerosol generator before being delivered to the user. Similarly, non-thermal aerosol generators can be configured to generate aerosol droplets without any air flowing through or along the non-thermal aerosol generator. The lack of air flow during aerosol droplet generation can result in aerosol droplet deposition on the surfaces of the aerosol generator.

It would be desirable to provide an aerosol generator that reduces the likelihood of aerosol droplets settling on the generator surfaces before delivery of the aerosol to the consumer.

According to the present invention, an aerosol generator is provided, configured to generate an aerosol from an aerosol-forming substrate. The aerosol generator may comprise an aerosol-generating element configured to convert the aerosol-forming substrate into an aerosol. The aerosol generator may comprise at least one air inlet and at least one air outlet. The aerosol generator may comprise a chamber between at least one air inlet and at least one air outlet. The aerosol-generating element may be located in the chamber and configured to discharge the aerosolized aerosol-forming substrate into the chamber. The aerosol generator may further comprise an air flow path passing through the chamber between at least one air inlet and at least one air outlet, via the aerosol-generating element.

According to a preferred embodiment of the present invention, an aerosol generator is provided, configured to generate an aerosol from an aerosol-forming substrate. The aerosol generator may comprise an aerosol-generating element configured to convert the aerosol-forming substrate into an aerosol. The aerosol generator may further comprise at least one air inlet and at least one air outlet. The aerosol generator may further comprise a chamber between the at least one air inlet and at least one air outlet. The aerosol-generating element may be located in the chamber and configured to discharge the aerosolized aerosol-forming substrate into the chamber. The aerosol generator may further comprise an air flow path passing through the chamber between the air inlet and at least one air outlet, through the aerosol-generating element. The aerosol generator may further comprise a side wall surrounding the aerosol-generating element. The side wall may have a curved surface that forms a curved chamber surface. At least one air inlet may extend through the side wall. The at least one air inlet may be configured to direct air into the chamber in a direction tangential to the curved chamber surface.

It has been found that providing an aerosol generator with a curved surface and directing air into the chamber in a direction tangential to the curved surface can advantageously reduce the deposition of aerosol droplets and particles on the aerosol generator surfaces. Reducing the deposition of aerosol droplets on the aerosol generator surfaces can improve the stability of aerosol delivery to the user. This can also reduce unwanted liquid accumulation on the aerosol generator surfaces. Reducing unwanted liquid accumulation on the aerosol generator surfaces can reduce leakage from the aerosol generator.

Providing an aerosol generator with a curved surface and directing air into the chamber in a direction tangential to the curved surface can cause air entering the chamber through at least one air inlet to follow the curved surface of the chamber, forming a pocket of air circulating along the periphery of the chamber. The inventors have found that such a pocket of air circulating along the periphery of the chamber can be used to envelop the aerosol generated by the aerosol-generating element and direct the generated aerosol away from the chamber surfaces. By directing the generated aerosol away from the chamber surfaces, the amount of aerosol deposited on the chamber surfaces can be significantly reduced.

In particularly preferred embodiments, the aerosol-generating element is a non-thermal aerosol-generating element. It has been found that providing an aerosol generator with a curved surface and directing air into the chamber in a direction tangential to the curved surface can be particularly effective in reducing the deposition of the generated aerosol on the surfaces of the aerosol generator for aerosol generators with non-thermal aerosol-generating elements. This is because the aerosol droplets generated by non-thermal aerosol-generating elements can tend to be larger than those generated by thermal aerosol-generating elements, and larger aerosol droplets have a greater tendency to deposit on the surfaces of the aerosol generator. Similarly, non-thermal aerosol generators can be configured to generate aerosol droplets without any air flowing through or along the non-thermal aerosol generator. Lack of air flow when generating aerosol droplets can also result in aerosol droplets settling on the surfaces of the aerosol generator.

According to another preferred embodiment of the present invention, an aerosol generator is provided, configured to generate an aerosol from an aerosol-forming substrate. The aerosol generator may comprise a flat aerosol-generating element configured to convert an aerosol-forming substrate into an aerosol. The flat aerosol-generating element may extend substantially in a plane. The aerosol generator may further comprise at least one air inlet and at least one air outlet. The aerosol generator may further comprise a chamber between the at least one air inlet and at least one air outlet. The flat aerosol-generating element may be located in the chamber and configured to discharge the aerosolized aerosol-forming substrate into the chamber. The aerosol generator may further comprise an air flow path passing through the chamber between the air inlet and at least one air outlet, through the flat aerosol-generating element. The aerosol generator may further comprise a side wall surrounding the aerosol-generating element. The side wall may have a surface that forms the surface of a chamber. At least one air inlet may extend through the side wall. The at least one air inlet may be configured to direct air into the chamber in a direction away from the plane of the flat aerosol-generating element. The at least one air inlet may be configured to direct air in a direction between the plane of the flat aerosol-generating element and at least one air outlet.

It has been found that directing the air flow into the chamber away from the flat aerosol-generating element and toward the opening can improve aerosol generation from the aerosol-generating element. Advantageously, air flow in the chamber away from the flat aerosol-generating element can promote the removal of aerosol generated from the aerosol-generating element from the aerosol-generating element and can reduce the backflow of aerosol to the aerosol-generating element. It has been found that the backflow of aerosol generated from the aerosol-generating element to the aerosol-generating element can disrupt aerosol generation, leading to one or more of the following: a reduced aerosol generation rate and the generation of an aerosol with other less desirable characteristics.

According to another preferred embodiment of the present invention, an aerosol generator is also provided, configured to generate an aerosol from an aerosol-forming substrate. The aerosol generator may comprise a flat aerosol-generating element configured to convert the aerosol-forming substrate into an aerosol. The aerosol generator may further comprise a flat auxiliary element mated with the aerosol-generating element. The aerosol generator may further comprise at least one air inlet opening passing through the flat auxiliary element. The flat aerosol-generating element and the flat auxiliary element may extend substantially in the same plane. The at least one air inlet opening may be configured to direct air in a direction away from the plane.

As mentioned above, it was found that directing airflow into the chamber away from the flat aerosol-generating element can improve aerosol generation from the aerosol-generating element. Preferential airflow away from the flat aerosol-generating element can facilitate the removal of aerosol generated from the aerosol-generating element from the aerosol-generating element and can reduce the backflow of aerosol to the aerosol-generating element.

In preferred embodiments comprising a chamber between at least one air inlet and at least one air outlet, the at least one air inlet and the chamber may be configured to direct air for rotation or circulation along the periphery of the chamber. Preferably, the at least one air inlet is configured to direct air along the periphery of the chamber. The at least one air inlet may be positioned to direct air tangentially into the chamber.

In some embodiments, the chamber extends along a central longitudinal axis. In these embodiments, the chamber may be substantially symmetrical about the central longitudinal axis. At least one air inlet may be configured to direct air into the chamber in a direction that does not intersect the central longitudinal axis of the chamber. At least one air inlet may be configured to direct air into the chamber in a direction around the central longitudinal axis of the chamber.

Preferably directing air into the chamber in a direction that causes air to rotate along the periphery of the chamber, around the axis of rotation, can reduce the deposition of aerosol droplets on the surfaces of the chamber.

In some preferred embodiments, the aerosol generator comprises a side wall surrounding the aerosol-generating element and having a surface that forms the surface of the chamber. At least one air inlet may extend through the side wall. In some embodiments, the side wall surface is curved and forms the curved surface of the chamber.

At least one air inlet may be configured to direct air into the chamber in a direction tangential to the curved surface of the chamber. At least one air inlet may be configured to direct air into the chamber in a direction inclined from the tangent to the curved surface at an angle in the range of: from 0 degrees to 90 degrees; or from 0 degrees to 80 degrees; or from 0 degrees to 70 degrees; or from 0 degrees to 60 degrees; or from 0 degrees to 50 degrees; or from 0 degrees to 40 degrees; or from 0 degrees to 30 degrees; or from 0 degrees to 20 degrees; or from 0 degrees to 100 degrees. In some embodiments, the chamber extends along the central longitudinal axis, and at least one air inlet and the surface of the chamber are configured to direct air around the central longitudinal axis of the chamber. In some embodiments, at least one air inlet may be configured to direct air into the chamber in a direction between a tangent of the curved surface and the central longitudinal axis of the chamber.

The chamber may comprise a mouthpiece end. At least one air outlet may be located at or near the mouthpiece end. The chamber may comprise an aerosol-generating end. An aerosol-generating element may be located at or near the aerosol-generating end. At least one air inlet may be located near the aerosol-generating end. The aerosol-generating end may be opposite the mouthpiece end.

The aerosol-generating element may form the surface of the chamber. The aerosol-generating element may form a surface at the end of the aerosol-generating chamber.

In embodiments comprising a side wall forming the surface of the chamber, at least one air inlet may extend through the side wall at the aerosol-generating end of the chamber. The side wall may surround an aerosol-generating element. The side wall may extend between the mouthpiece end and the aerosol-generating end. The side wall may extend between the aerosol-generating element at the aerosol-generating end and at least one air outlet at the mouthpiece end. The at least one air inlet may extend through the side wall.

The camera can be of any suitable shape and size.

In some embodiments, the sidewall surface forms a constricted chamber. For example, the chamber width at the mouthpiece end may be smaller than the chamber width at the aerosol-generating end. This can be achieved by an aerosol generator in which the width of the aerosol-generating element is greater than the width of the mouthpiece end opening. In some embodiments in which the aerosol-generating element is provided with an airflow during aerosol droplet generation, the provision of a constricted chamber can be advantageously used to enhance aerosol generation.

In some embodiments in which the sidewall surface forms a tapered chamber, the chamber's tapering may be constant from the aerosol-generating end to the mouthpiece end. In other words, the angle of tapering of the sidewall surface relative to the central longitudinal axis of the chamber may be constant from the aerosol-generating end to the mouthpiece end. In other words, the sidewall surface extends straight in one direction, between the aerosol-generating end and the mouthpiece end. The tapered sidewall may form a conical chamber surface. The sidewall may form a circular conical chamber surface. The sidewall may form an elliptically conical chamber surface.

In some embodiments in which the sidewall surface forms a tapered chamber, the chamber's tapering may vary from the aerosol-generating end to the mouthpiece end. In other words, the angle of the sidewall surface's tapering relative to the chamber's central longitudinal axis may vary from the aerosol-generating end to the mouthpiece end. Advantageously, varying the chamber's tapering from the aerosol-generating end to the mouthpiece end may further reduce the deposition of aerosol droplets on the chamber surfaces.

In some embodiments, the chamber constriction or the angle of constriction of the sidewall surface may increase from the aerosol-generating end to the mouthpiece end. In other words, the sidewall may form a concave chamber surface. In these embodiments, the sidewall may form a domed chamber surface.

In some embodiments, the chamber constriction or the angle of constriction of the sidewall surface may decrease from the aerosol-generating end to the mouthpiece end. In these embodiments, the sidewall may form a convex chamber surface. In these embodiments, the sidewall may form a horn-shaped chamber surface.

In some embodiments, the sidewall surface forms a cylindrical chamber. The chamber width at the mouthpiece end may be the same as the chamber width at the aerosol-generating end. The sidewall surface may form a circular cylindrical chamber surface. The sidewall surface may form an elliptical cylindrical chamber surface.

In some embodiments, at least one air guide may be provided on the surface of the chamber. The at least one air guide may direct air flow in the chamber along the periphery of the chamber. The at least one air guide may direct air flow in the chamber along the circumference of the chamber. The at least one air guide may direct air flow in the chamber toward at least one air outlet. The at least one air guide may direct air flow in the chamber away from the aerosol-generating element. Providing one or more air guides on the surface of the chamber may improve air rotation along the periphery of the chamber, around the axis of rotation, and further reduce the deposition of aerosol droplets on the surfaces of the chamber.

The aerosol-generating element may take any suitable form depending on the desired type of aerosol-generating element. The aerosol-generating element may comprise, for example, a mesh, a flat spiral coil, fibers, or fabric. In some embodiments, the aerosol-generating element may comprise a sheet or strip.

In some embodiments, the aerosol-generating element is a thermal aerosol-generating element. As used herein, the term "thermal aerosol-generating element" describes an aerosol-generating element that is configured to generate an aerosol from an aerosol-forming substrate by heating. The thermal aerosol-generating element may be a resistive heater. The thermal aerosol-generating element may be a susceptor that is capable of being heated by the penetration of an alternating magnetic field. The thermal aerosol-generating element may be an aerosol-forming substrate configured to be heated by absorbing energy from an electromagnetic field applied to the substrate.

The aerosol-generating thermal element may be an internal heater. The internal heater is configured to heat the aerosol-generating substrate from within the aerosol-generating substrate. The aerosol-generating thermal element may be configured to penetrate the aerosol-generating substrate. For example, the aerosol-generating thermal element may be in the form of a plate or rod configured to penetrate the aerosol-generating substrate.

The aerosol-generating thermal element may be an external heater. The external heater is configured to heat the aerosol-generating substrate from the outer surface of the aerosol-generating substrate.

The thermal element that generates the aerosol may be in the form of a coil or a mesh.

In some preferred embodiments, the aerosol-generating element is a non-thermal aerosol-generating element. As used herein, the term "non-thermal aerosol-generating element" describes an aerosol-generating element that is configured to generate an aerosol from an aerosol-forming substrate by means other than heating.

The aerosol generating element may be any suitable type of non-thermal aerosol generating element.

In some embodiments, the non-thermal aerosol-generating element is a mesh. The mesh aerosol-generating element may have a plurality of gaps, passages, or nozzles. The plurality of gaps, passages, or nozzles may have a tapered shape along their length. The plurality of gaps, passages, or nozzles may have a conical shape along their length.

In some preferred embodiments, the aerosol-generating mesh element may be a vibrating mesh element that is configured to oscillate. The aerosol-generating mesh element may be configured to convert an aerosol-forming substrate into an aerosol upon oscillation of the vibrating mesh element. The liquid aerosol-forming substrate may pass through nozzles of the vibrating mesh element upon oscillation of the vibrating mesh element. The liquid aerosol-forming substrate may be converted into an aerosol as it passes through nozzles of the vibrating mesh element upon oscillation of the vibrating mesh element.

In these embodiments, the aerosol generator may further comprise an actuator coupled to the aerosol-generating mesh element. The actuator may be configured to impart vibrations to the aerosol-generating mesh element.

The actuator may be any type of actuator for inducing vibrations in the aerosol-generating mesh element. The actuator may be a piezoelectric transducer.

A piezoelectric transducer can provide an actuator that is small, lightweight, and easy to operate for use in a portable aerosol generating system.

The piezoelectric transducer may comprise a single-crystal material. The piezoelectric transducer may comprise quartz. The piezoelectric transducer may comprise ceramics. The ceramics may comprise barium titanate (BaTiOs). The ceramics may comprise lead zirconate titanate (PZT). The ceramics may comprise alloying materials such as Ni, Bi, La, Nd, or Nb ions. The piezoelectric transducer may be polarized. The piezoelectric transducer may be non-polarized. The piezoelectric transducer may further comprise both polarized and non-polarized piezoelectric materials.

The actuator may be located at any suitable location relative to the aerosol-generating mesh element. The actuator may be positioned to transmit vibrations to the aerosol-generating mesh element on the inlet side or the outlet side of the aerosol-generating mesh element. The actuator may be positioned to transmit vibrations to the aerosol-generating mesh element on the inlet side. The actuator may be positioned to transmit vibrations to the aerosol-generating mesh element on the outlet side. The actuator may be in direct contact with the aerosol-generating mesh element. The actuator may be attached to the aerosol-generating mesh element. The actuator may be attached to the aerosol-generating mesh element by pressure. The actuator may be connected to the aerosol-generating mesh element. A transmission link may be provided between the actuator and the aerosol generating mesh element to transmit vibrations from the actuator to the element subject to vibration.

The actuator may comprise at least one actuator. The at least one actuator may be of any suitable shape. The at least one actuator may be substantially circular or elliptical. The at least one actuator may be substantially triangular, square, or of any regular or irregular shape. The at least one actuator may be annular. The at least one actuator may substantially surround the aerosol-generating mesh element.

At least one actuator may be planar. The at least one planar actuator may extend substantially in a plane. Preferably, in embodiments in which the aerosol-generating mesh element is planar, the at least one actuator is planar. In embodiments in which the aerosol-generating mesh element is planar and the at least one actuator is planar, the at least one actuator extends substantially in the same plane as the aerosol-generating mesh element.

In some particularly preferred embodiments, the aerosol-generating mesh element is flat, extending in a plane and having a circular cross-section, and at least one actuator is flat, extending substantially in the same plane as the aerosol-generating mesh element and surrounding the aerosol-generating mesh element.

The actuator can be configured to impart vibrations to the vibrating element at a predetermined frequency. The predetermined frequency can range from approximately 20 kHz to approximately 1500 kHz, or from approximately 50 kHz to approximately 1000 kHz, or from approximately 100 kHz to approximately 500 kHz. This can ensure the desired aerosol production rate and droplet size for a pleasant user experience.

In some preferred embodiments, in which the non-thermal aerosol-generating element is a mesh aerosol-generating element, the mesh aerosol-generating element may not be configured to vibrate. In these embodiments, the mesh aerosol-generating element may be located in an oscillating chamber. The oscillating chamber may comprise a cavity configured to contain a liquid aerosol-forming substrate to be converted into an aerosol. The oscillating chamber may further comprise a liquid inlet for providing the liquid to be converted into an aerosol into the cavity. The oscillating chamber may further comprise an elastically deformable element and an actuator arranged to impart oscillations to the elastically deformable element. The oscillation of the elastically deformable element by the actuator may change the pressure within the cavity. The oscillation of the elastically deformable element can change the pressure of the liquid contained in the cavity, causing the liquid inside the cavity to pass through the aerosol-generating mesh element and turn into an aerosol.

The actuator may be a piezoelectric transducer as described above.

The actuator may be configured to impart vibrations to the elastically deformable element at any suitable frequency. For example, the actuator may be configured to impart vibrations to the elastically deformable element at a frequency of approximately 0.05 MHz to approximately 10.0 MHz, approximately 0.1 MHz to approximately 5.0 MHz, approximately 0.2 MHz to approximately 4.5 MHz, approximately 0.3 MHz to approximately 3 MHz, approximately 0.4 MHz to approximately 2.5 MHz, or approximately 0.5 MHz to approximately 2 MHz. The actuator may be configured to impart vibrations to the elastically deformable element at a frequency to achieve resonance of the oscillatory system.

In some embodiments, the non-thermal aerosol-generating element may be part of a surface acoustic wave (SAW) atomizer. A SAW atomizer utilizes surface acoustic waves to atomize a liquid substrate, forming an aerosol. The term "surface acoustic wave" is used herein to include Rayleigh waves, Lamb waves, and Love waves.

A surfactant atomizer contains a substrate containing an active surface. An aerosol-generating element can form a substrate containing an active surface.

The SAW atomizer may further comprise at least one transducer located on the active surface of the substrate for generating surface acoustic waves on the active surface of the substrate.

In use, power can be supplied to a SAW atomizer, which drives at least one transducer to generate surface acoustic waves (Rayleigh waves) that propagate along the active surface. The energy of the surface acoustic waves can be transferred to an aerosol-forming liquid substrate, which is supplied to the spray region of the active surface. The energy supplied to the aerosol-forming liquid substrate results in the formation of aerosol droplets from the aerosol-forming liquid substrate, converting the aerosol-forming liquid substrate into an aerosol in the aerosolization region. The surface acoustic waves transmitted into the liquid destabilize the droplets on the exposed surface of the liquid, causing the droplet surface to disintegrate and form a suspension of aerosol droplets.

Well-known SAW sensor chips can be used as SAW atomizers. SAW sensor chips typically contain at least one interdigitated (or interdigitated) transducer containing electrodes positioned on a piezoelectric substrate, for example, printed on the substrate. An alternating current (AC) voltage applied to individual "pins" of the transducer electrodes causes mechanical deformation of the piezoelectric substrate due to alternating regions of tensile strength and relative compression in the piezoelectric substrate created between the pins. Because the pins on the same side of the transducer are at the same level of compression or tension, the space between them (known as the transducer pitch) corresponds to the wavelength of the mechanical wave. The generated waves typically have nanometer-sized amplitudes and propagate along the surface of the piezoelectric substrate at frequencies in the megahertz range.

At least one transducer of the SAW atomizer may be an interdigital transducer comprising electrodes arranged on a piezoelectric substrate. The transducer may comprise a reflector to improve the directivity of the generated surface acoustic waves. The transducer may be configured to generate parallel waves, for example, using an array of straight electrodes arranged in parallel. The transducer may be configured to exert a focusing effect on the generated waves. For example, the transducer may be provided with electrodes having parallel but curved shapes to focus the generated wave onto a small area. Preferably, the transducer comprises a reflector and has a focusing effect.

The SAW atomizer can be configured to generate surface acoustic waves at a predetermined frequency. The predetermined frequency can be approximately 20 MHz or higher, for example, from approximately 20 MHz to approximately 100 MHz, or from approximately 20 MHz to approximately 80 MHz. This can ensure the desired aerosol production rate and droplet size for a pleasant user experience.

In some embodiments, the non-thermal aerosol generating element comprises one or more of the following: a falling jet, a rotating disk, a spray nozzle, a flow focusing/blurring device, and an impingement atomizer.

In some preferred embodiments, the aerosol-generating element is a flat aerosol-generating element. The flat aerosol-generating element extends substantially in a plane. The flat element may extend in a plane.

The flat aerosol generating element may be positioned in any suitable manner within the aerosol generator chamber.

In some embodiments, the chamber extends along the central longitudinal axis, and the plane of the flat aerosol generating element is parallel to the central longitudinal axis of the chamber.

In some preferred embodiments, the chamber extends along the central longitudinal axis, and the plane of the flat aerosol-generating element is perpendicular to the central longitudinal axis of the chamber. In some embodiments, in which the chamber comprises a mouthpiece end and at least one air outlet is located at the mouthpiece end, the flat aerosol-generating element is positioned such that the main surface of the aerosol-generating element, through which the aerosol is generated, faces the mouthpiece end.

In some embodiments, at least one air inlet is positioned to direct air in a direction parallel to the plane of the flat aerosol generating element.

In some preferred embodiments, at least one air inlet may be arranged to direct air into the chamber in a direction away from the plane of the flat aerosol generating element. At least one air inlet is arranged to direct air in a direction inclined from the plane of the flat aerosol generating element at an angle in the range of: from 0 degrees to 90 degrees; or from 5 degrees to 85 degrees; or from 10 degrees to 80 degrees; or from 15 degrees to 75 degrees; or from 20 degrees to 70 degrees; or from 25 degrees to 65 degrees; or from 30 degrees to 60 degrees; or from 65 degrees to 85 degrees; or from 70 degrees to 80 degrees.

At least one air inlet may be arranged to direct air in a direction between the plane of the flat aerosol generating element and at least one air outlet.

The aerosol-generating element may be thin. In other words, the aerosol-generating element may have a thickness dimension that is substantially smaller than the width and length dimensions of the aerosol-generating element.

At least a portion of the aerosol-generating element may be fluid-permeable. In some embodiments, the aerosol-generating element is fluid-permeable. As used herein, a "fluid-permeable" element means an element that allows liquid or gas to pass through it. The aerosol-generating element may have a plurality of openings formed therein to allow fluid to pass through it. In particular, the aerosol-generating element may allow an aerosol-forming substrate, either in the gas phase or in both the gas and liquid phases, to pass through it.

In some preferred embodiments, the aerosol-generating element may comprise a mesh. The aerosol-generating element may comprise an array of threads forming a mesh. As used herein, the term "mesh" encompasses grids and arrays of threads with spaces between them. The term "mesh" also includes woven and non-woven materials.

The threads can form gaps between them, and these gaps can be between 10 micrometers and 100 micrometers wide. Preferably, the threads create capillary action in the gaps, so that during use, the source liquid is drawn into the gaps, increasing the contact area between the aerosol-generating element and the liquid.

The yarns may form a mesh with a mesh size of 160 to 600 U.S. standard mesh (+/- 10%) (i.e., 160 to 600 threads per inch (+/- 10%)). The interspace width may range from 35 micrometers to 140 micrometers or from 25 micrometers to 75 micrometers. For example, the interspace width may be 40 micrometers or 63 micrometers. The open mesh area percentage, which is the ratio of the interspace area to the total mesh area, is preferably between 25 and 56%. The mesh may be formed using various types of woven or lattice structures. Alternatively, the yarns may consist of an array of yarns arranged parallel to each other.

The filaments can be formed by etching a sheet material such as foil. This can be particularly advantageous if the heater assembly contains an array of parallel filaments. If the heating element contains a mesh or woven fabric made of filaments, the filaments can be produced individually and knitted together.

Preferably, the mesh is sintered. The strands of the mesh can be sintered together. Sintering the mesh advantageously creates electrical connections between the strands running in different directions. In particular, when the mesh comprises one or more woven and nonwoven materials, it is advantageous for the mesh to be sintered to create electrical connections between the overlapping strands.

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

The mesh threads can 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 can have a diameter of 50 micrometers.

The mesh threads can have any suitable cross-section. For example, the threads can have a round cross-section or a flattened cross-section.

Preferably, the aerosol generator comprises at least one air inlet. The at least one air inlet can be configured to direct air into the chamber of the aerosol generator. When the aerosol generator comprises a side wall defining the surface of the chamber, the at least one air inlet can extend through the side wall.

At least one air inlet may have any suitable cross-sectional shape. For example, at least one air inlet may have one of: a circular cross-section; an elliptical cross-section; a square cross-section; a rectangular cross-section; and a triangular cross-section. At least one air inlet may have a polygonal cross-section.

At least one air inlet may have a total cross-sectional area in the range of: from 0.5 square millimeters to 30 square millimeters; or from 2 square millimeters to 25 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 15 square millimeters. Such a total cross-sectional area may allow at least one air inlet to direct an air flow at a desired velocity into the chamber.

At least one air inlet may comprise a plurality of air inlets. The at least one air inlet may comprise any suitable number of air inlets. For example, the at least one air inlet may comprise two, three, four, five, six, seven, eight, or nine air inlets. The at least one air inlet may comprise any suitable number of air inlets to provide a desired air flow rate into the chamber. The plurality of air inlets may have a total cross-sectional area in the range of: from 2 square millimeters to 30 square millimeters; or from 2 square millimeters to 25 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 15 square millimeters.

A plurality of air inlet openings may be arranged at a distance around the circumference of the aerosol generating element.

In some embodiments in which the chamber extends along the central longitudinal axis, a plurality of air inlets are located at different positions along the central longitudinal axis of the chamber. In some embodiments in which the chamber extends along the central longitudinal axis, a plurality of air inlets are located at the same position along the central longitudinal axis of the chamber.

In some preferred embodiments, all air inlets have the same cross-sectional shape. In some preferred embodiments, all air inlets have the same cross-sectional area. The air inlets may have different cross-sectional shapes. The air inlets may have different cross-sectional areas.

In some preferred embodiments, at least one air inlet comprises two air inlets, a first air inlet and a second air inlet. The first air inlet may be configured to direct air into the chamber in a first direction, and the second air inlet may be configured to direct air into the chamber in a second direction different from the first direction. The first air inlet may be configured to direct air into the chamber in the first direction, and the second air inlet may be configured to direct air into the chamber in a second direction opposite to the first direction. The first air inlet may be located on a first side of the chamber, and the second air inlet may be located on a second side of the chamber opposite to the first side.

In some embodiments in which the chamber extends along the central longitudinal axis, the first air inlet and the second air inlet are located at the same position along the longitudinal axis. In some embodiments in which the chamber extends along the central longitudinal axis, the first air inlet is located at a first position along the longitudinal axis, and the second air inlet is located at a second position along the longitudinal axis, different from the first position.

At least one air inlet may be formed by an air passage. The air passage may have a length and a cross-sectional area. The air passage, forming at least one air inlet, may extend between the outer surface of the aerosol generator and the surface forming the chamber.

An air passage defining at least one air inlet may have a cross-section on a surface defining the chamber. The air passage defining at least one air inlet may have a length. The length of the air passage may be greater than the cross-sectional dimensions of the air inlet on the surface of the chamber. For example, when the air passage has a circular cross-section on the surface of the chamber, the length of the air passage may be greater than the cross-sectional diameter of the passage on the surface of the chamber. Advantageously, configuring the air passage defining the air inlet such that the length of the passage is greater than the cross-section of the passage can improve the directionality of air flowing through the air passage into the chamber.

When at least one air inlet comprises a plurality of air inlets, each air inlet may be formed by a different air passage. The aerosol generator may comprise a plurality of air passages.

In some preferred embodiments, at least one air inlet is configured to direct air into the chamber in a direction away from the aerosol generating element.

Preferably, at least one air inlet is configured to direct air into the chamber in a direction that does not intersect with the aerosol-generating element. At least one air inlet may be configured to direct air into the chamber in a direction at least partially toward at least one air outlet. In some embodiments, in which the chamber comprises a mouthpiece end and at least one air outlet is located at the mouthpiece end, at least one air inlet may be configured to direct air into the chamber in a direction at least partially toward the mouthpiece end.

In embodiments in which the chamber extends along the central longitudinal axis, at least one air inlet may be arranged to direct air into the chamber in a direction that is not perpendicular to the central longitudinal axis. At least one air inlet may be arranged to direct air into the chamber in a direction that is inclined from the central longitudinal axis at an angle in the range of: from 1 degree to 89 degrees; or from 5 degrees to 85 degrees; or from 10 degrees to 80 degrees; or from 15 degrees to 75 degrees; or from 20 degrees to 70 degrees; or from 25 degrees to 65 degrees; or from 30 degrees to 60 degrees.

Preferably, the aerosol generator comprises at least one air outlet. The at least one air outlet can be configured to direct air from the chamber of the aerosol generator. When the aerosol generator comprises a chamber having a mouthpiece end, the at least one air outlet can be located at the mouthpiece end of the chamber.

The at least one air outlet may have any suitable cross-sectional shape. For example, the at least one air outlet may have one of: a circular cross-section; an elliptical cross-section; a square cross-section; a rectangular cross-section; and a triangular cross-section. The at least one air outlet may have a polygonal cross-section.

The at least one air outlet may have a total cross-sectional area in the range of: from 2 square millimeters to 30 square millimeters; or from 2 square millimeters to 25 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 15 square millimeters. Such a total cross-sectional area may allow the at least one air outlet to direct air flow at a desired velocity from the chamber.

At least one air outlet may comprise a plurality of air outlets. The at least one air outlet may comprise any suitable number of air outlets. For example, the at least one air outlet may comprise two, three, four, five, six, seven, eight or nine air outlets. The at least one air outlet may comprise any suitable number of air outlets to provide a desired air flow rate from the chamber. The plurality of air outlets may have a total cross-sectional area in the range: from 0.5 square millimeters to 30 square millimeters; or from 2 square millimeters to 25 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 20 square millimeters; or from 5 square millimeters to 15 square millimeters.

The aerosol generator may comprise a chamber between at least one air inlet and at least one air outlet. The aerosol generator may further comprise an air flow path extending through the chamber between the at least one air inlet and at least one air outlet. The air flow path may extend through the chamber between the at least one air inlet and at least one air outlet through the aerosol-generating element.

In some preferred embodiments, the aerosol generator comprises an auxiliary element coupled to the aerosol generating element.

The aerosol generator may further comprise at least one air inlet extending through the auxiliary element. The at least one air inlet may have any suitable cross-sectional shape. For example, the at least one air inlet may have a circular, elliptical, square, rectangular, or triangular cross-sectional shape. The at least one air inlet may have a polygonal cross-sectional shape. The at least one air inlet may form a slit through the auxiliary element.

At least one air inlet may comprise a plurality of air inlets. The plurality of air inlets may comprise any suitable number of air inlets. For example, the plurality of air inlets may comprise two, three, four, five, six, seven, eight, or nine air inlets. The plurality of air inlets may be spaced circumferentially around the auxiliary element. Preferably, the auxiliary element surrounds the aerosol-generating element, and the plurality of air inlets are spaced circumferentially around the auxiliary element. In some embodiments, the plurality of air inlets have different cross-sectional shapes. In some embodiments, the plurality of air inlets have identical cross-sectional shapes. In some embodiments, the plurality of air inlets have different cross-sectional areas. In some embodiments, the plurality of air inlets have identical cross-sectional areas.

In some particularly preferred embodiments, the aerosol generator comprises a flat aerosol-generating element and a flat auxiliary element mating with the flat aerosol-generating element. In these particularly preferred embodiments, the flat aerosol-generating element and the flat auxiliary element may extend substantially in the same plane.

In these particularly preferred embodiments, the at least one air inlet may be configured to direct air in a direction away from the plane. Preferably, the at least one air inlet is configured to direct air in a direction perpendicular to the plane. The at least one air inlet may pass through the flat auxiliary element in a direction perpendicular to the plane. The at least one air inlet may be configured to direct air in a direction between the plane and a direction perpendicular to the plane. The at least one air inlet may pass through the flat auxiliary element in a direction between the plane and a direction perpendicular to the plane. The at least one air inlet may be configured to direct air in a direction inclined to the plane at an angle in the range of: from 1 degree to 89 degrees; or from 5 degrees to 85 degrees; or from 10 degrees to 80 degrees; or from 15 degrees to 75 degrees; or from 20 degrees to 70 degrees; or from 25 degrees to 65 degrees; or from 30 degrees to 60 degrees; or from 65 degrees to 85 degrees; or from 70 degrees to 80 degrees.

The auxiliary element may surround the aerosol-generating element. The flat auxiliary element may surround the flat aerosol-generating element.

The auxiliary element may comprise a support element. When the aerosol generator comprises a sidewall, the support element may mate the aerosol-generating element with the sidewall. When the aerosol generator forms part of an aerosol-generating device or cartridge, the support element may mate the aerosol-generating element with the housing of the aerosol-generating device or cartridge. At least one air inlet may extend through the support element.

Preferably, the support element comprises a thermally insulating material. Advantageously, forming the support element from a thermally insulating material can minimize heat transfer from the aerosol-generating element to the support element. Preferably, the aerosol-generating element comprises an electrically insulating material. The support element can be formed from a durable material. The support element can be formed from a liquid-impermeable material. The support element can be formed from a moldable plastic material, such as polypropylene (PP) or polyethylene terephthalate (PET).

The support element may have any suitable shape and size. The support element may be a flat support element. If the aerosol-generating element is flat, the flat support element may extend in the same plane as the flat aerosol-generating element. The support element may surround the aerosol-generating element.

When the aerosol-generating element comprises a mesh element, the auxiliary element may comprise an actuator. The actuator may be coupled to the aerosol-generating mesh element. The actuator may be configured to impart vibrations to the aerosol-generating mesh element. Preferably, the actuator is a piezoelectric transducer. At least one air inlet may extend through the actuator.

Preferably, the aerosol-generating mesh element is flat, and the actuator is flat, wherein the actuator extends in the same plane as the aerosol-generating mesh element. The actuator may surround the aerosol-generating mesh element.

The auxiliary element may comprise a support element and an actuator. The actuator may be coupled with the aerosol-generating element. The support element may be coupled with the actuator. The actuator may surround the aerosol-generating element. The support element may surround the actuator. The support element may surround both the actuator and the aerosol-generating element.

In some preferred embodiments, at least one air inlet extends through the support element. In some embodiments, the at least one air inlet comprises a plurality of air inlets, at least one of the plurality of air inlets extends through the support element, and at least one of the plurality of air inlets extends through the actuator.

In some preferred embodiments, the auxiliary element is a flat element comprising a flat actuator and a flat support element. In these preferred embodiments, the aerosol-generating element may be flat, and the flat auxiliary element may extend in the same plane as the flat aerosol-generating element. The aerosol-generating element may have a substantially circular cross-section, the actuator may form a ring surrounding the aerosol-generating element, and the support element may form a ring surrounding the actuator.

According to the present invention, an aerosol-generating system is provided. The aerosol-generating system comprises an aerosol generator as described above. The aerosol-generating system may further comprise a reservoir for holding a liquid aerosol-forming substrate. The aerosol-generating system may further comprise a liquid supply element configured to supply liquid from the reservoir to the aerosol-generating element.

The aerosol-generating system may be a portable aerosol-generating system configured to allow the user to draw on a mouthpiece to draw the aerosol through the opening of the mouthpiece end. The aerosol-generating system may be sized similar to a traditional cigar or cigarette. The aerosol-generating system may have an overall length of approximately 30 mm to approximately 150 mm. The aerosol-generating system may have an outer diameter of approximately 5 mm to approximately 30 mm.

The reservoir is configured to hold an aerosol-forming substrate. Specifically, the reservoir is configured to hold a liquid aerosol-forming substrate. The reservoir may have any suitable shape and size, depending on the requirements of the aerosol-generating system.

An aerosol-generating system may contain an aerosol-forming substrate. For the purposes 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 aerosol generating system contains a liquid substrate that forms the aerosol.

The aerosol-forming substrate may be liquid at room temperature and atmospheric pressure. 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 plant-based material. 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 non-tobacco-containing material. The liquid substrate that forms the aerosol may contain homogenized material of plant origin.

The liquid aerosol-forming substrate may contain one or more aerosol formers. The aerosol former 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 formers include glycerin and propylene glycol. Suitable aerosol formers are well known in the art and include, but are not limited to: polyhydric alcohols such as triethylene glycol, 1,3-butanediol, and glycerin; 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 contain water, solvents, ethanol, plant extracts, and natural or artificial flavors.

The liquid aerosol-forming substrate may contain 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 liquid supply element is arranged to supply a liquid aerosol-forming substrate to the aerosol-generating element. Preferably, the liquid supply element is arranged to supply the liquid aerosol-forming substrate from the reservoir to the aerosol-generating element.

The fluid delivery element may be in fluid communication with the aerosol-generating element. The fluid delivery element may be in fluid communication with the reservoir. The fluid delivery element may be configured to transfer the aerosol-forming substrate from the reservoir to the current-collecting element.

The liquid delivery element may comprise a capillary material. A capillary material is a material capable of transporting liquid from one end of the material to the other by capillary action. The capillary material may have a fibrous or spongy structure. The capillary material preferably comprises a capillary bundle. For example, the capillary material may comprise a plurality of fibers or filaments, or other tubes with narrow channels. The fibers or filaments may be generally aligned to transport the liquid aerosol-forming substrate to the aerosol-generating element. In some embodiments, the capillary material may comprise a sponge-like or foam-like material. The structure of the capillary material may form a plurality of small openings or tubes through which the liquid aerosol-forming substrate may be transported by capillary action. When the aerosol-generating element comprises gaps or openings, the capillary material may extend into the gaps or openings in the current-collecting element. An aerosol-generating element can draw a liquid aerosol-forming substrate into interstices or openings by capillary action. If the aerosol-generating element forms part of a surfactant atomizer and the aerosol-generating element contains a substrate with an active surface, the liquid supply element can be positioned to deliver liquid to the spray area of the active surface. The liquid supply element can include a pump.

In some embodiments, the reservoir contains a retaining material for retaining the liquid aerosol-forming substrate. The retaining material may be a foam, a sponge, or a fiber composite. The retaining material may be formed from a polymer or copolymer. In some embodiments, the retaining material is a spun polymer. The retaining material may be formed from any of the materials described above as suitable for the liquid delivery element.

If the aerosol-generating system comprises a fluid delivery element and a retaining material, the fluid delivery 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 aerosol-generating element. The retaining material may contact the aerosol-generating element. The retaining material may be in fluid communication with the fluid delivery element. The retaining material may contact the fluid delivery element.

The aerosol-generating system may further comprise a power supply unit. The power supply unit may be coupled to the aerosol generator to supply power to the aerosol generator. The power supply unit may be coupled to the aerosol-generating element to supply power to the aerosol generator.

The power supply may be a direct current power supply. The power supply 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 supply may be another form of electrical charge storage device, such as a capacitor. The power supply may be rechargeable and capable of undergoing multiple charge and discharge cycles. The power supply may have a capacity that allows for the storage of sufficient energy for one or more sessions of a user of the aerosol-generating system; for example, the power supply may have a capacity sufficient to ensure continuous aerosol generation for a period of approximately six minutes, which corresponds to the typical time spent smoking a conventional cigarette, or for a period of multiples of six minutes. In another example, the power supply may have sufficient capacity to enable a specified number of puffs or individual activations of the atomizer assembly.

The power supply may be configured to store and supply energy other than electrical energy. The power supply may be configured to store and supply mechanical energy. The mechanical energy may be provided or generated by the user.

The aerosol generating system may further comprise a control circuit.

The control circuit may include a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, an application-specific integrated circuit (ASIC), or other electronic circuit capable of providing control.

The control circuit may be coupled to a power supply unit. The control circuit may be coupled to an aerosol generator. The control circuit may be configured to control the supply of power from the power supply unit to the aerosol generator. In some embodiments, the control circuit is configured to control the supply of power from the power supply unit to the aerosol generating element of the aerosol generator. In some embodiments, in which the aerosol generator comprises an actuator, the control circuit may be configured to supply power to the actuator. In some embodiments, in which the aerosol generator comprises a converter, the control circuit may be configured to supply power to the converter. In some embodiments, in which the aerosol generator comprises a liquid supply element, the control circuit may be configured to supply power to the liquid supply element. The control circuit may be configured to supply power to a pump contained in the liquid supply element. The control circuit may be configured to synchronize two or more components of the aerosol generating system. In some embodiments, the control circuit is configured to synchronize the aerosol generating element and the liquid supply element.

The control circuit may be configured to continuously supply power to the aerosol generator after activation of the device, or it may be configured to supply power intermittently, for example, puff-to-puff. Power may be supplied to the aerosol generator in the form of pulses of electrical current, for example, via pulse-width modulation (PWM).

When the aerosol generator comprises a mesh oscillated by an actuator, the control circuit can be configured to control the actuator to impart vibrations to the vibrating element at a predetermined frequency. The predetermined frequency can be from approximately 20 kHz to approximately 1500 kHz, or from approximately 50 kHz to approximately 1000 kHz, or from approximately 100 kHz to approximately 500 kHz. This can ensure the desired aerosol production rate and the desired droplet size for a pleasant user experience.

When the aerosol generator comprises an oscillating chamber, the control circuit can be configured to control the actuator to excite vibrations in the vibrating element at a predetermined frequency. The predetermined frequency can be from approximately 20 kHz to approximately 1500 kHz, or from approximately 50 kHz to approximately 1000 kHz, or from approximately 100 kHz to approximately 500 kHz. This can ensure the desired aerosol production rate and the desired droplet size for a pleasant user experience.

When the aerosol generator comprises a surface acoustic wave (SAW) atomizer, the control circuit can be configured to control the SAW atomizer to generate surface acoustic waves at a predetermined frequency. The predetermined frequency can be approximately 20 MHz or higher, for example, from approximately 20 MHz to approximately 100 MHz, or from approximately 20 MHz to approximately 80 MHz. This can ensure the desired aerosol production rate and droplet size for a pleasant user experience.

When the aerosol-generating element is a current-receiving element, the aerosol-generating device may comprise an induction heating unit. The induction heating unit may comprise at least one induction coil. In these embodiments, a power supply unit may be coupled to at least one induction coil for supplying power to at least one induction coil. At least one induction coil may be coupled to a control circuit. The control circuit may be configured to supply an alternating current to at least one induction coil for generating an alternating magnetic field. The current-receiving element may be positioned so that an alternating magnetic field from at least one induction coil penetrates it, thereby heating the current-receiving element by the alternating magnetic field. The control circuit may be configured to continuously supply power to the induction coil after activation of the device or may be configured to supply power intermittently, for example, from puff to puff. Power can be supplied to the induction coil in the form of pulses of electric current, for example by pulse width modulation (PWM).

The control circuit may comprise a DC-to-AC converter, which may include a Class D or Class E power amplifier. The control circuit may also comprise additional electronic components. For example, in some embodiments, the control circuit may comprise any of the following: sensors, switches, and display elements.

An aerosol-generating system may comprise an aerosol-generating device and a cartridge configured to interface with the aerosol-generating device. The cartridge may comprise an aerosol generator. The cartridge may further comprise a reservoir for holding a liquid aerosol-generating substrate. The cartridge may further comprise a liquid supply element. The aerosol-generating device may comprise a power supply and a control circuit.

The aerosol-generating 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 containing one or more of these materials, or thermoplastic materials suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. The material is preferably lightweight and non-fragile.

The housing of the aerosol-generating device may define a cavity for housing the cartridge. The aerosol-generating device may contain one or more air inlets. The one or more air inlets may draw ambient air into the cavity.

The aerosol-generating device may have a connecting end configured to mate the aerosol-generating device with a cartridge. The connecting end may comprise a cavity for accommodating the cartridge.

The aerosol-generating 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 supply for charging the aerosol-generating device's power supply.

According to the present invention, a cartridge for an aerosol-generating system is provided. The cartridge may comprise an aerosol generator, as described herein. The cartridge may further comprise a reservoir for holding a liquid aerosol-generating substrate. The cartridge may be disposable. The cartridge may further comprise a liquid supply element configured to supply liquid from the reservoir to the aerosol-generating element.

In some embodiments, the aerosol generator is integral with the cartridge. In other embodiments, the aerosol generator is separate from the cartridge and located within the cartridge.

The cartridge may contain a housing. The housing may be made of a durable material. The housing may be made of a liquid-impermeable material. The housing may be made of a moldable plastic material such as polypropylene (PP) or polyethylene terephthalate (PET).

An aerosol generator may be located in a housing. The aerosol generator may be mated with the housing. In some embodiments, the cartridge housing may form one or more walls of the aerosol generator. At least one air inlet of the aerosol generator may extend through the cartridge housing. At least one air outlet may extend through the cartridge housing.

The housing may define a portion of the reservoir. The housing may define the reservoir. The housing and reservoir may be formed as a single unit. Alternatively, the reservoir may be formed separately from the outer housing and located within the outer housing.

The cartridge may have a mouthpiece end through which the generated aerosol can be drawn by the user. The cartridge may have a connecting end configured to connect the cartridge to an aerosol-generating device.

When the aerosol generator comprises a substantially flat aerosol-generating element, the first side of the aerosol-generating element may face the mouthpiece end of the cartridge, and the second side of the aerosol-generating element may face the connecting end. In some embodiments, the flat aerosol-generating element 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 aerosol-generating element extends in a plane that is substantially parallel to the longitudinal axis of the cartridge, the first and second sides of the aerosol-generating element face opposite sides of the cartridge, rather than the mouthpiece end and the connecting end of the cartridge.

The cartridge may define at least one air inlet of the aerosol generator. The at least one air inlet may be located at or around the connecting end of the cartridge. The cartridge may define a mouthpiece opening. At least one air outlet of the aerosol generator may be the mouthpiece opening of the cartridge. The user may be able to draw the aerosol generated from the cartridge through the mouthpiece opening. The cartridge may define a closed airflow passage from the air inlet of the aerosol generator to the mouthpiece opening. The closed airflow passage may extend from the air inlet past the aerosol-generating element to the mouthpiece opening.

A closed airflow passage may extend through the tank. For example, the tank may have an annular cross-section defining an internal channel, and the airflow passage may extend through the internal passage of the tank.

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

Accordingly, any of the features described in this document 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 features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

EX1. An aerosol generator configured to generate an aerosol from an aerosol-forming substrate, wherein the aerosol generator comprises:

an aerosol generating element configured to convert an aerosol-forming substrate into an aerosol;

at least one air inlet;

at least one air outlet;

a chamber between the air inlet and at least one air outlet, wherein the aerosol generating element is located in the chamber and is configured to release the aerosolized aerosol-forming substrate into the chamber; and

an air flow path passing through the chamber between the air inlet and at least one air outlet, through the aerosol generating element.

EX2. Aerosol Generator

according to example EX1, in which at least one air inlet is configured to direct air around the periphery of the chamber.

EX3. An aerosol generator according to EX1 or EX2, wherein at least one air inlet is arranged to direct air tangentially into the chamber.

EX4. An aerosol generator according to any of the examples EX1, EX2 or EX3, wherein the chamber extends along the central longitudinal axis.

EX5. An aerosol generator according to example EX4, wherein the chamber is substantially symmetrical about the central longitudinal axis.

EX6. An aerosol generator according to examples EX4 or EX5, in which at least one air inlet is configured to direct air into the chamber in a direction that does not intersect with the central longitudinal axis of the chamber.

EX7. An aerosol generator according to any of examples EX4, EX5 or EX6, in which at least one air inlet is configured to direct air into the chamber in a direction around the central longitudinal axis of the chamber.

EX8. An aerosol generator according to example EX1, wherein the aerosol generator comprises a side wall surrounding the aerosol generating element and having a surface that forms the surface of the chamber.

EX9. An aerosol generator according to example EX8, wherein at least one air inlet extends through a side wall.

EX10. An aerosol generator according to EX8 or EX9, wherein the side wall surface is a curved surface and forms a curved chamber surface.

EX11. An aerosol generator according to example EX10, in which at least one air inlet is configured to direct air into the chamber in a direction tangential to the curved surface of the chamber.

EX12. An aerosol generator according to example EX10, in which at least one air inlet is configured to direct air into the chamber in a direction inclined from a tangent to the curved surface at an angle in the range:

from 0 degrees to 80 degrees; or

from 0 degrees to 70 degrees; or

from 0 degrees to 60 degrees; or

from 0 degrees to 50 degrees; or

from 0 degrees to 40 degrees; or

from 0 degrees to 30 degrees; or

from 0 degrees to 20 degrees; or

from 0 degrees to 10 degrees.

EX13. An aerosol generator according to any of the examples EX8-EX12, in which the chamber extends along the central longitudinal axis, and at least one air inlet and the surface of the chamber are configured to direct air around the central longitudinal axis of the chamber.

EX14. An aerosol generator according to any of the examples EX8-EX13, wherein the surface of the side wall forms a narrowed chamber.

EX15. An aerosol generator according to examples EX8-EX14, wherein the chamber comprises a mouthpiece end and an aerosol generating end opposite the mouthpiece end, wherein at least one air outlet is located at the mouthpiece end, and wherein the width of the chamber at the mouthpiece end is less than the width of the chamber at the aerosol generating end.

EX16. An aerosol generator according to example EX15, wherein the aerosol generating element is located at the aerosol generating end of the chamber.

EX17. An aerosol generator according to any of the examples EX8-EX16, wherein the side wall forms a circular conical surface of the chamber.

EX18. An aerosol generator according to any of the examples EX8-EX16, wherein the side wall forms an elliptically conical chamber surface.

EX19. An aerosol generator according to any one of the examples EX8-EX13, wherein the surface of the side wall forms a circular cylindrical surface of the chamber.

EX20. An aerosol generator according to any of the examples EX8-EX13, wherein the surface of the side wall forms an elliptically cylindrical chamber surface.

EX21. An aerosol generator according to any one of examples EX1 to EX20, wherein the aerosol generating element is a non-thermal aerosol generating element.

EX22. An aerosol generator according to example EX21, wherein the non-thermal aerosol generating element comprises a mesh element having a plurality of nozzles.

EX23. An aerosol generator according to example EX22, wherein the aerosol-generating mesh element is configured to convert an aerosol-forming substrate into an aerosol when the aerosol-forming substrate passes through nozzles during oscillation of the vibrating mesh element.

EX24. The aerosol generator according to example EX23 further comprises an actuator coupled to the mesh and configured to impart vibrations to the mesh element generating the aerosol.

EX25. An aerosol generator according to example EX22, wherein the aerosol generator comprises an oscillating chamber having:

a cavity containing a liquid to be converted into an aerosol;

a liquid inlet for providing the liquid to be sprayed into the cavity;

an elastically deformable element; an aerosol-generating mesh element; and

an actuator arranged so as to impart vibrations to the elastically deformable element, and

wherein the oscillation of the elastically deformable element by the actuator changes the pressure inside the cavity to push the liquid contained in the cavity out of the cavity through the nozzles of the mesh element generating the aerosol.

EX26. An aerosol generator according to examples EX24 or EX25, in which the actuator is a piezoelectric transducer.

EX27. An aerosol generator according to example EX21, wherein the aerosol generating element is part of a surface acoustic wave (SAW) atomizer.

EX28. An aerosol generator according to example EX27, wherein the surfactant atomizer comprises:

a substrate containing an active surface; and

at least one transducer located on the active surface of the substrate for generating surface acoustic waves on the active surface of the substrate,

In this case, the aerosol-generating element forms a substrate.

EX29. An aerosol generator according to any of the examples EX1-EX28, in which at least one air inlet is configured to direct air into the chamber in a direction away from the aerosol generating element.

EX30. An aerosol generator according to any of the examples EX1-EX29, in which at least one air inlet is configured to direct air into the chamber in a direction that does not intersect with the aerosol generating element.

EX31. An aerosol generator according to any of the examples EX1-EX30, in which at least one air inlet is configured to direct air into the chamber in a direction at least partially toward at least one air outlet.

EX32. An aerosol generator according to any one of the examples EX1-EX31, wherein the chamber comprises a mouthpiece end and an aerosol generating end opposite the mouthpiece end, wherein at least one air outlet is located at the mouthpiece end, and wherein the aerosol generating element is located at the aerosol generating end.

EX33. An aerosol generator according to example EX32, in which at least one air inlet is located near the aerosol generating end of the chamber.

EX34. An aerosol generator according to examples EX32 or EX33, further comprising a side wall that surrounds the aerosol generating element and extends between the aerosol generating element at the aerosol generating end and at least one air outlet at the mouthpiece end.

EX35. An aerosol generator according to example EX34, wherein at least one air inlet extends through a side wall.

EX36. An aerosol generator according to any of the examples EX32-EX35, in which at least one air inlet is configured to direct air into the chamber in a direction towards the mouthpiece end of the chamber.

EX37. An aerosol generator according to any one of examples EX1-EX36, wherein the aerosol generating element forms at least part of the surface of the chamber.

EX38. An aerosol generator according to any one of examples EX1-EX37, wherein the chamber extends along the central longitudinal axis, and wherein at least one air inlet is arranged to direct air into the chamber in a direction that is not perpendicular to the central longitudinal axis.

EX39. An aerosol generator according to any one of examples EX1-EX37, wherein the chamber extends along the central longitudinal axis, and wherein at least one air inlet is arranged to direct air into the chamber in a direction that is inclined from the central longitudinal axis at an angle in the range:

from 1 degree to 89 degrees; or

from 5 degrees to 85 degrees; or

from 10 degrees to 80 degrees; or

from 15 degrees to 75 degrees; or

from 20 degrees to 70 degrees; or

from 25 degrees to 65 degrees; or

from 30 degrees to 60 degrees.

EX40. An aerosol generator according to any of examples EX1 to EX39, wherein the aerosol generating element is a flat aerosol generating element.

EX41. An aerosol generator according to example EX40, wherein the flat aerosol generating element extends substantially in a plane.

EX42. An aerosol generator according to example EX41, in which the chamber extends along the central longitudinal axis, and wherein the plane of the flat aerosol generating element is perpendicular to the central longitudinal axis of the chamber.

EX43. An aerosol generator according to examples EX41 or EX42, in which at least one air inlet is arranged to direct air into the chamber in a direction away from the plane of the flat aerosol generating element.

EX44. An aerosol generator according to any of the examples EX41-EX43, in which at least one air inlet is arranged to direct air in a direction between the plane of the flat aerosol-generating element and at least one air outlet.

EX45. An aerosol generator according to any of the examples EX41-EX44, in which at least one air inlet is arranged to direct air in a direction inclined from the plane of the flat aerosol generating element at an angle in the range:

from 1 degree to 89 degrees; or

from 5 degrees to 85 degrees; or

from 10 degrees to 80 degrees; or

from 15 degrees to 75 degrees; or

from 20 degrees to 70 degrees; or

from 25 degrees to 65 degrees; or

from 30 degrees to 60 degrees; or

from 65 degrees to 85 degrees; or

from 70 degrees to 80 degrees.

EX46. An aerosol generator according to examples EX41 or EX42, in which at least one air inlet is arranged to direct air in a direction parallel to the plane of the flat aerosol generating element.

EX47. An aerosol generator according to any one of examples EX1 to EX46, wherein at least one air inlet has one of:

circular cross-section;

elliptical cross-section;

square cross-section;

rectangular cross-section; or

triangular cross-section.

EX48. An aerosol generator according to any of the examples EX1-EX47, wherein at least one air inlet has a polygonal cross-section.

EX49. An aerosol generator according to any one of the examples EX1-EX48, wherein at least one air inlet has a total cross-sectional area in the range:

from 2 square millimeters to 30 square millimeters; or

from 2 square millimeters to 25 square millimeters; or

from 5 square millimeters to 20 square millimeters; or

from 5 square millimeters to 20 square millimeters; or

from 5 square millimeters to 15 square millimeters.

EX50. An aerosol generator according to any one of the examples EX1-EX49, wherein at least one air inlet comprises two air inlets, a first air inlet and a second air inlet.

EX51. An aerosol generator according to example EX50, in which the first air inlet is configured to direct air into the chamber in a first direction, and wherein the second air inlet is configured to direct air into the chamber in a second direction different from the first direction.

EX52. An aerosol generator according to examples EX50 or EX51, in which the first air inlet is configured to direct air into the chamber in a first direction, and wherein the second air inlet is configured to direct air into the chamber in a second direction opposite to the first direction.

EX53. An aerosol generator according to any of the examples EX50-EX52, in which the first air inlet is located on the first side of the chamber, and the second air inlet is located on the second side of the chamber, opposite the first air inlet.

EX54. An aerosol generator according to any of examples EX50-EX53, wherein the chamber extends along the central longitudinal axis, and wherein the first air inlet and the second air inlet are located in the same position along the longitudinal axis.

EX55. An aerosol generator according to any of the examples EX50-EX53, in which the chamber extends along the central longitudinal axis, and wherein the first air inlet is located in a first position along the longitudinal axis, and the second air inlet is located in a second position along the longitudinal axis, different from the first position.

EX56. An aerosol generator according to any one of examples EX1-EX49, wherein at least one air inlet comprises a plurality of air inlets.

EX57. An aerosol generator according to example 56, wherein a plurality of air inlet openings are spaced apart around the circumference of the aerosol generating element.

EX58. An aerosol generator according to examples EX56 or EX57, wherein the chamber extends along the central longitudinal axis, and wherein a plurality of air inlet openings are arranged at different positions along the central longitudinal axis of the chamber.

EX59. An aerosol generator according to examples EX56 or EX57, wherein the chamber extends along the central longitudinal axis, and wherein a plurality of air inlet openings are arranged in the same position along the central longitudinal axis of the chamber.

EX60. An aerosol generator according to any of examples 50-59, wherein all air inlets have the same cross-sectional shape.

EX61. An aerosol generator according to any of examples 50-60, wherein the air inlet openings have the same cross-sectional area.

EX62. An aerosol generator according to any one of examples 50-59, wherein the air inlet openings have different cross-sectional shapes.

EX63. An aerosol generator according to any one of examples 50-59, wherein the air inlet openings have different cross-sectional areas.

EX64. An aerosol generator according to any one of the examples EX1 to EX63, wherein the total cross-sectional area of the air inlet openings is in the range:

from 2 square millimeters to 30 square millimeters; or

from 2 square millimeters to 25 square millimeters; or

from 5 square millimeters to 20 square millimeters; or

from 5 square millimeters to 20 square millimeters; or

from 5 square millimeters to 15 square millimeters.

EX65. An aerosol generator according to any of the examples EX1-EX64, wherein at least one air inlet is formed by an air passage.

EX66. An aerosol generator according to example EX65, wherein an air passage defining at least one air inlet extends between the outer surface of the aerosol generator and the surface defining the chamber.

EX67. An aerosol generator according to examples EX65 or EX66, wherein the air passage defining at least one air inlet has a length and a cross-section on the surface defining the chamber, and wherein the length of the air passage is greater than the dimensions of the cross-section of the air inlet on the surface of the chamber.

EX68. An aerosol generating system comprising:

a reservoir for holding a liquid substrate that forms an aerosol;

an aerosol generator according to any one of examples EX1 to EX67; and

a liquid supply element configured to supply liquid from the reservoir to the aerosol generating element.

EX69. An aerosol generating system according to example EX68, further comprising:

a power supply unit coupled to the aerosol generator for supplying power to the aerosol generator; and

a control circuit configured to control the supply of power from the power supply to the aerosol generator.

EX70. An aerosol generating system according to example EX69, further comprising:

a cartridge comprising a reservoir, an aerosol generator and a liquid delivery element; and

a device configured to accommodate a cartridge, wherein the device comprises a power supply and a control circuit.

EX71. A cartridge for an aerosol generating system, the cartridge comprising:

a reservoir for holding a liquid substrate that forms an aerosol;

an aerosol generator according to any one of examples EX1 to EX67; and

a liquid supply element configured to supply liquid from the reservoir to the aerosol generating element.

EX72. An aerosol generator configured to generate an aerosol from an aerosol-forming substrate, wherein the aerosol generator comprises:

a flat aerosol generating element configured to convert an aerosol-forming substrate into an aerosol;

a flat auxiliary element coupled with the aerosol generating element; and

at least one air inlet opening passing through the flat auxiliary element,

wherein the flat aerosol generating element and the flat auxiliary element extend substantially in the same plane, and wherein at least one air inlet is configured to direct air in a direction away from the plane.

EX73. An aerosol generator according to example EX72, wherein the flat auxiliary element surrounds the flat aerosol generating element.

EX74. An aerosol generator according to examples EX72 or EX73, wherein the aerosol generating element comprises a mesh element having a plurality of nozzles.

EX75. An aerosol generator according to example EX74, in which the flat auxiliary element comprises a flat actuator element configured to impart vibrations to the mesh element generating the aerosol.

EX76. An aerosol generator according to example EX74, in which the flat auxiliary element comprises a flat support element and a flat actuator, wherein the flat actuator is coupled with an aerosol-generating mesh element and is configured to impart vibrations to the aerosol-generating mesh element.

EX77. An aerosol generator according to example EX76, in which at least one air inlet passes through a flat support element.

EX78. An aerosol generator according to examples EX76 or EX77, wherein a flat actuator surrounds an aerosol-generating mesh element and a flat support element surrounds the flat actuator element.

EX79. An aerosol generator according to any of the examples EX75-EX78, wherein at least one air inlet passes through a flat actuator.

EX80. An aerosol generator according to any of the examples EX75-EX79, wherein the flat actuator is a piezoelectric transducer.

EX81. An aerosol generator according to any of the examples EX72-EX80, wherein at least one air inlet forms a slot through the flat auxiliary element.

EX82. An aerosol generator according to any of the examples EX72-EX81, wherein at least one air inlet has one of a circular, elliptical, square, rectangular or triangular cross-section.

EX83. An aerosol generator according to any of the examples EX72-EX81, wherein at least one air inlet has a polygonal cross-section.

EX84. An aerosol generator according to any of the examples EX72-EX83, in which at least one air inlet is configured to direct air in a direction perpendicular to the plane.

EX85. An aerosol generator according to any of the examples EX72-EX83, in which at least one air inlet is configured to direct air in a direction between a plane and a direction perpendicular to the plane.

EX86. An aerosol generator according to any of the examples EX72-EX83, in which at least one air inlet is configured to direct air in a direction inclined to the plane at an angle in the range:

from 1 degree to 89 degrees; or

from 5 degrees to 85 degrees; or

from 10 degrees to 80 degrees; or

from 15 degrees to 75 degrees; or

from 20 degrees to 70 degrees; or

from 25 degrees to 65 degrees; or

from 30 degrees to 60 degrees; or

from 65 degrees to 85 degrees; or

from 70 degrees to 80 degrees.

EX87. An aerosol generator according to any of the examples EX72-EX836, wherein at least one air inlet comprises a plurality of air inlets.

EX88. An aerosol generator according to example EX87, in which a plurality of air inlet openings are located at a distance along the circumference of the auxiliary element.

EX89. An aerosol generator according to any of the examples EX87-EX88, wherein the plurality of air inlet openings have different cross-sectional shapes.

EX90. An aerosol generator according to any of the examples EX87-EX89, wherein the plurality of air inlet openings have different cross-sectional areas.

EX91. An aerosol generator according to examples EX87 or EX88, in which the plurality of air inlet openings have identical cross-sections.

EX92. An aerosol generating system comprising:

a reservoir for holding a liquid substrate that forms an aerosol;

an aerosol generator according to any of examples EX72-EX91; and

a liquid supply element configured to supply liquid from the reservoir to the aerosol generating element.

EX93. An aerosol generating system according to example EX92, further comprising:

a power supply unit coupled to the aerosol generator for supplying power to the aerosol generator; and

a control circuit configured to control the supply of power from the power supply to the aerosol generator.

EX94. An aerosol generating system according to example EX93, further comprising:

a cartridge comprising a reservoir, an aerosol generator and a liquid delivery element; and

a device configured to accommodate a cartridge, wherein the device comprises a power supply and a control circuit.

EX95. A cartridge for an aerosol generating system, the cartridge containing:

a reservoir for holding a liquid substrate that forms an aerosol;

an aerosol generator according to any of examples EX72-EX91; and

a liquid supply element configured to supply liquid from the reservoir to the aerosol generating element.

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

Fig. 1 is a schematic illustration of an aerosol generator according to one embodiment of the present invention;

Fig. 2a shows a cross-section along line A-A through the chamber of the aerosol generator according to Fig. 1;

Fig. 2b shows a cross-section along line A-A through the chamber of an aerosol generator according to another embodiment of the present invention;

Fig. 3a-3d show cross-sections along line A-A through chambers of aerosol generators according to other embodiments in accordance with the present invention;

Fig. 4a is a schematic illustration of an aerosol generator according to another embodiment of the present invention;

Fig. 4b is a schematic illustration of an aerosol generator according to another embodiment of the present invention;

Fig. 5a is a schematic illustration of an aerosol generator according to another embodiment of the present invention;

Fig. 5b is a schematic illustration of an aerosol generator according to another embodiment of the present invention;

Fig. 6a-6c are top views of aerosol generating elements coupled with auxiliary elements according to embodiments of the present invention;

Fig. 7 is a schematic illustration of an aerosol generating system according to an embodiment of the present invention, wherein the aerosol generating system comprises a cartridge having an aerosol generator of Fig. 1 and an aerosol generating device coupled to the cartridge;

Fig. 8 shows an oscillating chamber containing an aerosol generating element according to one embodiment of the present invention;

Fig. 9a-9b are schematic illustrations of embodiments of surface acoustic wave (SAW) atomizers according to one embodiment of the present invention;

Fig. 10a is a schematic illustration of an aerosol generator according to another embodiment of the present invention; and

Fig. 10b is a schematic illustration of an aerosol generator according to another embodiment of the present invention.

Fig. 1 is a schematic illustration of an aerosol generator 1 according to one embodiment of the present invention.

The aerosol generator 1 comprises a non-thermal aerosol-generating element 2, configured to convert an aerosol-forming substrate into an aerosol by methods other than heating. In this embodiment, the aerosol-generating element 2 is a mesh element having passages through which a liquid aerosol-forming substrate can pass and is converted into an aerosol by oscillating the mesh element. An actuator (not shown) in the form of a piezoelectric transducer is coupled to the mesh aerosol-generating element and is configured to impart vibrations to the aerosol-generating element to convert the liquid aerosol-forming substrate into an aerosol in contact with the aerosol-generating element.

The aerosol generator 1 further comprises a pair of air inlets 4 located on opposite sides of the aerosol generator and an air outlet 6. A chamber 8 is formed between the pair of air inlets 4 and the air outlet 6. An aerosol generating element 2 is located in the chamber 8 and is configured to release an aerosolized aerosol-forming substrate into the chamber 8. An air flow path passes through the chamber between the air inlets 4 and at least one air outlet 6, via the aerosol generating element 2. The air flow path is indicated by the dotted arrows shown in Fig. 1.

The chamber 8 has a mouthpiece end and an aerosol generating end opposite the mouthpiece end. An air outlet 6 is located at the mouthpiece end of the chamber 8. An aerosol generating element 2 is located at the aerosol generating end of the chamber 8. The main surface of the aerosol generating element forms the aerosol generating end of the chamber 8. A side wall 10 surrounds the aerosol generating element 2, and the inner surface of the side wall 10 forms the sides of the chamber 8, between the mouthpiece end and the aerosol generating end. Air inlets 4 pass through the side wall 10 and are located near the aerosol generating end, in immediate proximity to the aerosol generating element 2.

The side wall 10 has a curved inner surface that forms a curved surface of the chamber 8. In this embodiment, the inner surface of the side wall 10 defines a substantially circular cross-sectional shape, giving the cavity 8 a substantially circular cross-sectional shape along its length, as shown in Fig. 2a, which is a cross-sectional view through the aerosol generator 1 along the line A-A. The side wall 10 also tapers from the end for generating the aerosol to the mouthpiece end, so that the inner surface of the side wall 10 forms a substantially circular conical chamber 8. The chamber 8 extends along the central longitudinal axis and is substantially rotationally symmetrical with respect to the central longitudinal axis, which is shown in Fig. 1a by the dashed line B-B.

The aerosol-generating element 2 is a flat element extending substantially in a plane. In this embodiment, the plane of the aerosol-generating element 2 is substantially perpendicular to the central longitudinal axis of the chamber 8. The aerosol-generating element 2 is centered along the central longitudinal axis of the chamber 8, and the main surface of the aerosol-generating element 2 faces the air outlet 6. The aerosol-generating element 2 is thin, with a thickness that is substantially less than its diameter, and has a generally circular shape.

As shown in Fig. 2a, the air inlet openings 4 are arranged in such a way as to direct air into the chamber 8 from opposite sides of the chamber 8. Each of the air inlet openings 4 passes through the side wall 10 in a direction tangential with respect to the curved inner surface of the side wall 10. Thus, the air inlet openings 4 are oriented in such a way as to direct air into the chamber 8 tangentially to the curved inner surface of the side wall 10. In other words, the air inlet openings 4 direct air into the chamber along the curved inner surface of the side wall 10. The orientation of the air inlet openings 4 and the curved surface of the side wall 10 result in the air entering the chamber 8 through the air inlet openings 4 circulating along the periphery of the chamber 8, as shown by the dotted arrow in Fig. 2a. Circulating air along the periphery of the chamber directs the aerosolized aerosol-forming substrate from the aerosol-generating element 2 away from the side wall 10, which reduces the deposition of the aerosolized aerosol-forming substrate on the side wall 10 and increases the proportion of the aerosolized aerosol-forming substrate that exits the chamber through the air outlet 6 at the mouth end of the chamber 8.

Fig. 2b is a cross-sectional view through an aerosol generator according to another embodiment of the present invention. The aerosol generator of Fig. 2b is similar to the aerosol generator 1 of Figs. 1 and 2a, and like reference numerals are used to designate like elements. The aerosol generator shown in Fig. 2b differs from the aerosol generator 1 of Figs. 1 and 2a in that the aerosol generator has four air inlet openings 4 located at an equal distance around the circumference of the side wall 10.

Fig. 3a-d illustrate cross-sectional views through aerosol generators according to other embodiments of the present invention.

Fig. 3a and 3b show aerosol generators that are essentially similar to the aerosol generators shown in Fig. 2a and 2b, respectively. The aerosol generators shown in Fig. 3a and 3b differ from the aerosol generators shown in Fig. 2a and 2b in that the air inlet openings extend into the chamber 8. The air inlet openings of the aerosol generators shown in Fig. 3a and 3b contain air passages that have a length. Increasing the length of the air passages improves the directionality of the air entering the chamber.

Fig. 3c and 3d illustrate aerosol generators that are substantially similar to the aerosol generators illustrated in Fig. 2a and 2b, respectively. The aerosol generators illustrated in Fig. 3c and 3d differ from the aerosol generators illustrated in Fig. 2a and 2b in that the inner surface of the side wall 10 defines a substantially elliptical cross-sectional shape, providing the cavity 8 with a substantially elliptical cross-sectional shape along its length. In these embodiments, the inner surface of the side wall 10 forms a substantially elliptically conical chamber 8.

Fig. 4a and 4b show schematic illustrations of aerosol generators 1 according to other embodiments of the present invention. The aerosol generators of Fig. 4a and 4b are similar to the aerosol generator 1 of Fig. 1 and 2a, and like reference numerals are used to designate like elements.

The aerosol generator 1 shown in Fig. 4a differs from the aerosol generator 1 shown in Figs. 1 and 2a in that the aerosol generating element 2 is surrounded by an auxiliary element 12. A plurality of air inlet openings 14 pass through the auxiliary element 12 and are located at an equal distance along the circumference of the auxiliary element 12. In this embodiment, the auxiliary element 12 is a support element that mates the aerosol generating element 2 with the side wall 10 of the aerosol generator 1. The plurality of air inlet openings 14 passing through the auxiliary element 12 are configured to direct air into the chamber 8 away from the plane of the aerosol generating element 2. In this embodiment, a plurality of air inlet openings 14 are oriented to direct air into the chamber 8 in a direction substantially parallel to the central longitudinal axis of the chamber, toward the mouthpiece end of the chamber and the air outlet opening 6. The side wall 10 also comprises additional air inlet openings 16 located under the aerosol-generating element 2 to allow ambient air to be drawn into the aerosol generator 1 through the side wall and subsequently into the chamber 8 through the air inlet openings 14 in the auxiliary element 12.

The aerosol generator 1 shown in Fig. 4b is essentially the same as the aerosol generator 1 shown in Fig. 4a, except that the side wall 10 of the aerosol generator 1 shown in Fig. 4b does not taper and maintains a constant diameter along the length of the aerosol generator. Accordingly, the inner surface of the side wall 10 of the aerosol generator 1 shown in Fig. 4b forms a circular, cylindrical chamber 8.

Fig. 5a and 5b show schematic illustrations of aerosol generators 1 according to other embodiments of the present invention. The aerosol generators of Fig. 5a and 5b are similar to the aerosol generator 1 of Fig. 4a, and like reference numerals are used to designate like elements.

The aerosol generator 1 shown in Fig. 5a differs from the aerosol generator 1 shown in Fig. 4a in that the chamber 8 tapers inward at an increasing degree or angle from the aerosol generating end to the mouthpiece end, so that the inner surface of the side wall 10 forms a substantially dome-shaped chamber 8, which is narrower at the mouthpiece end than at the aerosol generating end. The increasing angle of taper of the side wall 10 relative to the central longitudinal axis of the chamber 8 results in the inner surface of the side wall 10 forming a concave surface of the dome-shaped chamber 8.

The aerosol generator 1 shown in Fig. 5b differs from the aerosol generator 1 shown in Fig. 4a in that the chamber 8 tapers inward at a decreasing degree or angle from the aerosol generating end to the mouthpiece end, so that the inner surface of the side wall 10 forms a chamber 8 substantially in the shape of a horn, which is narrower at the mouthpiece end than at the aerosol generating end. The decreasing angle of taper of the side wall 10 relative to the central longitudinal axis of the chamber 8 results in the inner surface of the side wall 10 forming a convex surface of the chamber 8 in the shape of a horn.

Fig. 6a-6c depict a top view of aerosol generating elements 2 associated with auxiliary elements 12, according to embodiments of the present invention. In each of these embodiments, the aerosol generating elements 2 are flat mesh elements that are capable of oscillating to convert a liquid aerosol-forming substrate into an aerosol.

Fig. 6a shows a circular mesh element 2 generating an aerosol surrounded by an auxiliary element 12. Both the mesh element 2 generating an aerosol and the auxiliary element 12 are flat and extend in the same plane. In this embodiment, the auxiliary element 12 is a piezoelectric transducer, which is arranged to impart vibrations to the mesh element 12 generating an aerosol. The piezoelectric transducer comprises a plurality of air inlet openings 14 arranged at an equal distance around the circumference of the piezoelectric transducer. The air inlet openings have a circular cross-section and are configured to direct air away from the plane of the aerosol generating element 2 and the auxiliary element 12.

Fig. 6b shows a circular mesh element 2 generating an aerosol surrounded by an auxiliary element 12, substantially similar to that shown in Fig. 6a. The auxiliary element 12 shown in Fig. 6b differs from that shown in Fig. 6a in that the plurality of air inlet openings 14 are rectangular slits passing through the auxiliary element 12.

Figure c shows a circular mesh element 2 generating an aerosol surrounded by an auxiliary element 12. Both the mesh element 2 generating an aerosol and the auxiliary element 12 are flat and extend in the same plane. In this embodiment, the auxiliary element 12 comprises a piezoelectric transducer 12a, which is arranged so as to impart vibrations to the mesh element 12 generating an aerosol, and a support element 12b. The piezoelectric transducer 12a is coupled with the element 2 generating an aerosol and surrounds the element 2 generating an aerosol. The support element 12b is coupled with the piezoelectric transducer 12a and surrounds

piezoelectric transducer 12a. Support element 12b comprises a plurality of air inlet openings 14, located at equal distances around the circumference of support element 12b. Air inlet openings 14 have a circular cross-section and are configured to direct air away from the plane of aerosol-generating element 2 and auxiliary element 12.

Fig. 7 is a schematic illustration of an aerosol generating system 20 according to the present invention. The aerosol generating system 20 comprises an aerosol generating device 22 and a cartridge 24 coupled to the aerosol generating device 22.

Cartridge 24 comprises an aerosol generator 1, which is substantially similar to the aerosol generator 1 shown in Figs. 1 and 2a, and like references are used to designate like elements. Cartridge 24 further comprises a housing 26, a liquid reservoir 28 holding a liquid substrate that forms an aerosol, and a liquid supply element 29 fluidly connecting the liquid reservoir 28 to the aerosol generator 1.

The aerosol generator 1 is formed as a single unit with the housing 26 of the cartridge 24 in such a way that the side wall 10 of the aerosol generator is formed by the housing 26 of the cartridge 24. The air inlet openings 4 pass through the housing 26 of the cartridge, so that ambient air can be drawn into the chamber through the housing 26 of the cartridge through the air inlet openings 4. The air outlet opening 6 of the mouthpiece end of the chamber 8 forms the opening of the mouthpiece end of the cartridge 24, through which the aerosol is delivered to the user. The air flow path is formed between the air inlet openings 4 and the opening 6 of the mouthpiece end through the aerosol generating element 2.

The liquid transfer element 29 is formed from a main part made of a wick material, one end of which is placed in the reservoir 28, and the other end of which is in contact with the aerosol-generating element 2, the aerosol-generating element 2. The liquid transfer element 29 is configured to deliver a liquid aerosol-forming substrate from the reservoir 28 to the aerosol-generating element 2.

The aerosol generating element 2 is a flat mesh element that is capable of oscillating to convert a liquid aerosol-forming substrate delivered to the aerosol generating element 2 from the reservoir 28 into an aerosol. An actuator in the form of a piezoelectric transducer (not shown) is coupled with the aerosol generating element 2 to impart oscillations to the aerosol generating element. Electrical contacts (not shown) are provided from the actuator to the connecting end of the cartridge 24 to supply electrical energy to the actuator from the aerosol generating device 22 when the cartridge 24 is coupled with the aerosol generating device 22.

The aerosol generating device 22 comprises a housing 30 defining a cavity at the connecting end for coupling the aerosol generating device 22 with a cartridge 24. The aerosol generating device further comprises a power supply unit 32 and a control circuit 34 housed within the housing 30. The power supply unit 32 is a rechargeable lithium-ion battery. Electrical contacts (not shown) are provided in the cavity of the device 22 for coupling the power supply unit 32 and the control circuit 34 with the cartridge 24 when the cartridge is placed in the cavity. The control circuit 34 is configured to control the supply of power from the power supply unit 32 to the cartridge 24.

In use, when the cartridge 24 is placed in the cavity of the device 22, the aerosol generating system 20 can be activated either by the user, who takes a puff on the mouthpiece end of the cartridge, and a sensor (not shown) in the device 22 detecting the puff, or by the user pressing a button. When the aerosol generating system is activated, the control circuit 34 supplies power from the power supply unit 32 to the actuator of the aerosol generator 1 in the cartridge 22. The actuator imparts vibrations to the aerosol generating element 2, which converts into an aerosol the liquid substrate forming the aerosol, delivered to the aerosol generating element 2 from the reservoir 28 by means of the liquid transfer element 29.

When the user draws on the mouthpiece end of the cartridge 24, ambient air is drawn into the chamber 8 through the air inlet openings 4 along the air flow path. The ambient air in the chamber 8 is directed along the periphery of the chamber 8 by the air inlet openings 4 and the curved surface of the side wall 10. The aerosolized aerosol-forming substrate is obtained in the chamber 8 by the aerosol-generating element 2 and forms an aerosol that is drawn toward the opening 6 of the mouthpiece end of the cartridge. The ambient air circulating along the periphery of the chamber directs the generated aerosol away from the surfaces of the chamber 8, preventing the generated aerosol droplets from settling on the surfaces of the cartridge. The aerosol is drawn from the chamber 8 through the opening of the mouthpiece end and delivered to the user for inhalation.

Fig. 8 shows a perspective cross-sectional view of a flat mesh element 2 generating an aerosol, forming part of an oscillating chamber 50. Such an oscillating chamber can be located at the end for generating an aerosol of the chamber 8 of the aerosol generator 1 according to embodiments of the present invention. Accordingly, Fig. 8 shows an alternative non-thermal element 2 generating an aerosol, which can be used in an aerosol generator according to the present invention. The mesh element 2 is located inside a housing 52 of the mesh element. The oscillating chamber 50 also contains an elastically deformable element 54 and an actuator 56, located so as to impart oscillations to the elastically deformable element 54. The actuator 56 is a piezoelectric transducer.

The oscillating chamber 50 also comprises a pre-load element 58 arranged to compress the actuator 56 between the pre-load element 58 and the elastically deformable element 54. The pre-load element 58, the actuator 56 and the elastically deformable element 54 are arranged inside the housing 60 of the actuator. The housing 60 of the actuator is attached to the housing 52 of the mesh element to form a cavity 62 between the mesh element 2 and the elastically deformable element 54. The housing 60 of the actuator forms an inlet opening 64 for liquid to ensure the supply of liquid to be converted into an aerosol into the cavity 62.

The elastically deformable element 54 extends radially outward from the mesh element 2 over the housing 52 of the mesh element to the housing 60 of the actuator. The region of the cavity 62 between the mesh element 2 and the elastically deformable element 54 is substantially circular and cylindrical. The housing 52 of the mesh element contains a raised region 63 along the circumference of the mesh element 2, thus the gap between the housing 52 of the mesh element and the elastically deformable element 54 narrows around the circumference of the mesh element 2. The narrow gap between the raised region 63 of the housing 52 of the mesh element and the elastically deformable element 54 limits the flow of liquid into the region of the cavity 62 directly between the mesh element 2 and the elastically deformable element 54 and from it, which contributes to the generation of high liquid pressure in this region. The outer region of the cavity 62, extending radially outward from the raised region 63 of the housing 52 of the mesh element, extends partially into the housing 60 of the actuator to provide a region of the cavity 62 that is capable of holding a small volume of liquid outside the region directly between the mesh element 2 and the elastically deformable element 54. This outer region of the cavity 62 provides for the supply of a reserve supply of liquid to the region between the mesh element 2 and the elastically deformable element 54 as the liquid is consumed from this region during operation. An inlet hole 64 for liquid is provided in the housing 60 of the actuator to supply liquid to the outer region of the cavity 62. The inlet hole 64 for liquid is located with an offset from the region of the cavity 62 between the mesh element 2 and the elastically deformable element 54. This arrangement of the inlet hole for liquid can reduce the likelihood of liquid being pushed out of the cavity through the inlet hole for liquid when exposed to vibrations from the elastically deformable element. This may also reduce the likelihood of air being drawn directly into this area from the liquid inlet 64.

During use, a liquid to be converted into an aerosol is supplied to the cavity 62 through the liquid inlet 64. The actuator 56 oscillates the elastically deformable element 54, pushing at least a portion of the liquid inside the cavity 62 through the channels 15 and the nozzles 18 of the mesh element 2. The liquid pushed through the nozzles 18 of the mesh element 2 forms droplets. The momentum of the force of the liquid pushed through the nozzles 18 to form droplets carries the droplets away from the mesh element 2. Consequently, during use, the oscillating chamber 50 generates an aerosol containing liquid droplets pushed through the mesh element 2.

Fig. 9a and 9b show schematic illustrations of surface acoustic wave (SAW) atomizers. Such SAW atomizers can be located at the aerosol-generating end of the chamber 8 of the aerosol generator 1 according to embodiments of the present invention. Accordingly, Fig. 9a and 9b show alternative non-thermal aerosol-generating elements 2 that can be used in the aerosol generator according to the present invention.

Fig. 9a shows a surfactant atomizer having an aerosol-generating element 2 in the form of a piezoelectric substrate with an active surface. In this embodiment, one interdigital transducer 70 is located on a section of the side surface of the piezoelectric substrate 2. The transducer 70 is a direct transducer containing a series of straight alternating electrodes 72 arranged in parallel (direct transducer). The spray region 74 on the active surface of the piezoelectric substrate 2 is indicated by a dotted line and is located near the transducer 70, but on the opposite section of the side surface of the piezoelectric substrate 2.

Fig. 9b shows a surfactant atomizer having an aerosol-generating element 2 in the form of a piezoelectric substrate with an active surface. In this embodiment, one interdigital transducer 70 is located on a section of the lateral surface of the piezoelectric substrate 2. The transducer 70 is a focusing transducer comprising a series of curved and tapering alternating electrodes 72, 76 arranged in parallel. A small focusing zone 74 on the active surface of the piezoelectric substrate 2 is indicated by a cross and is located near the transducer 70, but on the opposite section of the lateral surface of the piezoelectric substrate 2.

Fig. 10a and 10b show schematic illustrations of aerosol generators 1 according to other embodiments of the present invention.

The aerosol generator according to Fig. 10a is similar to the aerosol generator 1 according to Figs. 1 and 2a, and like reference numerals are used to designate like elements. The aerosol generator 1 shown in Fig. 4a differs from the aerosol generator 1 shown in Figs. 1 and 2a in that the air inlet openings 4 are arranged so as to direct air into the chamber 8 away from the plane of the aerosol generating element 2. Both air inlet openings 4 are oriented to direct air into the chamber at an angle α to the plane of the aerosol generating element 2. The air inlet openings 4 are also oriented relative to the central longitudinal axis of the chamber at an angle β. In this embodiment, the angle α is approximately 30 degrees, and the angle β is approximately 60 degrees. By directing air into the chamber away from the aerosol-generating element, the aerosolized aerosol-forming substrate generated in the chamber from the aerosol-generating element flows away from the aerosol-generating element, improving the aerosol generation rate. In this embodiment, the air inlet openings are also formed by air passages having a length. The air passages are depicted as extending into chamber 8; however, it should be understood that in some embodiments, the air passages may not extend into chamber 8.

The aerosol generator of Fig. 10b is similar to the aerosol generator 1 of Fig. 4a, and like reference numerals are used to designate like elements. The aerosol generator 1 shown in Fig. 4b differs from the aerosol generator 1 shown in Fig. 4a in that the air inlet openings 4 are arranged to direct air into the chamber 8 away from the plane of the aerosol generating element 2, as described above for Fig. 10a.

For the purposes of the present description and the appended claims, except where otherwise indicated, all numbers expressing quantities, amounts, percentages, etc., are to be understood as modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points and include any intermediate ranges therebetween, which may or may not be specifically listed herein. Therefore, in this context, the number A is understood as A ± {5%} A. In this context, the number A can be considered to include numerical values that are within the normal standard error for measuring the property that the number A modifies. The number A, in some instances, when used in the appended claims, may deviate by the percentages listed above, provided that the amount by which A deviates does not materially affect the fundamental and novel characteristic(s) of the claimed invention. Also, all ranges include the disclosed maximum and minimum points and include any intermediate ranges therebetween, which may or may not be specifically listed herein.

Claims (38)

1. An aerosol generator configured to generate an aerosol from an aerosol-forming substrate, wherein the aerosol generator comprises: a non-thermal aerosol generating element configured to convert an aerosol-forming substrate into an aerosol; at least one air inlet; at least one air outlet; a chamber between at least one air inlet and at least one air outlet, wherein the aerosol generating element is located in the chamber and is configured to release the aerosolized aerosol-forming substrate into the chamber; an air flow path passing through the chamber between the air inlet and at least one air outlet, through the non-thermal aerosol generating element; and a side wall surrounding the aerosol generating element, wherein the side wall has a curved surface that forms a curved surface of the chamber, and wherein at least one air inlet extends through the side wall and is configured to direct air into the chamber in a direction tangential to the curved surface of the chamber. 2. An aerosol generator according to claim 1, wherein the chamber comprises a mouthpiece end and an aerosol generating end opposite the mouthpiece end, wherein at least one air outlet is located at the mouthpiece end, and wherein the width of the chamber at the mouthpiece end is less than the width of the chamber at the aerosol generating end. 3. An aerosol generator according to claim 2, wherein the aerosol generating element is located at the aerosol generating end of the chamber. 4. An aerosol generator according to any one of claims 1-3, wherein at least one air inlet is configured to direct air around the periphery of the chamber. 5. An aerosol generator according to claim 1, wherein the chamber extends along a central longitudinal axis and at least one air inlet is configured to direct air into the chamber in a direction that does not intersect with the central longitudinal axis of the chamber. 6. An aerosol generator according to any one of claims 1 to 5, wherein the non-thermal aerosol generating element comprises a mesh element having a plurality of nozzles. 7. The aerosol generator of claim 6, wherein the aerosol generating mesh element is a vibrating mesh element capable of oscillating. 8. An aerosol generator according to claim 7, further comprising an actuator coupled to the mesh and configured to impart vibrations to the mesh element generating the aerosol. 9. An aerosol generator according to claim 6, comprising an oscillating chamber having: a cavity for containing a liquid to be converted into an aerosol; a liquid inlet for providing the liquid to be sprayed into the cavity; elastically deformable element; an aerosol generating mesh element; and an actuator positioned so as to impart vibrations to an elastically deformable element, In this case, the oscillation of the elastically deformable element by the actuator changes the pressure inside the cavity. 10. An aerosol generator according to claim 8 or 9, wherein the actuator is a piezoelectric transducer. 11. An aerosol generator according to any one of paragraphs 1-5, comprising a surface acoustic wave (SAW) atomizer, comprising: a substrate containing an active surface; and at least one transducer located on the active surface of the substrate for generating surface acoustic waves on the active surface of the substrate, In this case, the aerosol-generating element forms a substrate. 12. An aerosol generator according to any one of claims 1-11, wherein the non-thermal aerosol generating element is a flat aerosol generating element extending in a plane. 13. An aerosol generator according to claim 12, wherein at least one air inlet is configured to direct air into the chamber in a direction away from the flat aerosol generating element. 14. A cartridge for an aerosol generating system, the cartridge comprising: a reservoir for holding a liquid substrate that forms an aerosol; an aerosol generator according to any one of paragraphs 1-13; and a liquid supply element configured to supply liquid from the reservoir to the aerosol generating element. 15. An aerosol generating system configured to generate an aerosol from an aerosol forming substrate, wherein the aerosol generating system comprises: a reservoir for holding a liquid substrate that forms an aerosol; an aerosol generator according to any one of paragraphs 1-13; a liquid supply element configured to supply liquid from the reservoir to the aerosol generating element; a power supply unit coupled to the aerosol generator for supplying power to the aerosol generator; and a control circuit configured to control the supply of power from the power supply to the aerosol generator.