RU2829719C1 - Cartridge for use in aerosol generating system, and aerosol generating system comprising said cartridge - Google Patents

Abstract

FIELD: liquid atomisation or spraying devices.

SUBSTANCE: group of inventions relates to the field of aerosol generation using an electrically controlled smoking system. Cartridge for use in an aerosol generating system comprises a porous ceramic body having porosity of 30 to 65%, and mesh heater engaged with porous ceramic body. Mesh heater contains multiple holes, each of which has size from 50 to 200 mcm and represents a hybrid mesh heater containing a mesh of wires and fibers. Fibers have a material composition different from that of the wires. Also provided is an aerosol generating system containing said cartridge.

EFFECT: higher efficiency of aerosol generation.

15 cl, 9 dwg

Description

The present invention relates to a cartridge for use in an aerosol generating system. The present invention also relates to an aerosol generating system that comprises said cartridge.

One type of aerosol-generating system is an electrically-controlled smoking system. Hand-held electrically-controlled smoking systems are known that consist of an aerosol-generating device containing a battery and control electronics, and a cartridge containing a source of aerosol-forming substrate and an electrically-controlled vaporizer. A cartridge containing both a source of aerosol-forming substrate and a vaporizer is sometimes called a "cartomizer". The vaporizer typically includes a coil of heater wire wound around an elongated wick impregnated with a liquid aerosol-forming substrate. The cartridge portion typically includes not only a source of aerosol-forming substrate and an electrically-controlled vaporizer, but also a mouthpiece through which, in use, the user draws to draw the aerosol into his or her mouth.

Document US 2019/0350256 A1 describes a sprayer and an aerosol delivery device. Said sprayer comprises a fluid transport element that is formed from a solid monolith that has a first side and a second side opposite to it. The sprayer also comprises a heater. The heater, in turn, provides a substantially flat heating surface that is located facing the first side of the solid monolith.

However, these cartridges can be relatively expensive to manufacture. This is because the wick and coil assembly can be complex to manufacture. Also, the electrical contacts between the heater wire coil and the electrical contacts through which the electrical current is supplied from the device part must be carefully machined during manufacture. Additionally, these cartridges contain a mouthpiece to protect the soft wick and coil assembly during shipping. Including a complete and secure mouthpiece in each cartridge means that each cartridge will have a high material cost.

It would be desirable to create a cartridge for use in an aerosol generating system that is simple, inexpensive to manufacture, and reliable. It would also be desirable to create a cartridge that can provide more efficient aerosol generation than known cartridges. It would also be desirable to create an aerosol generating system incorporating such a cartridge.

According to the present invention, a cartridge is provided. The cartridge may be suitable for use in an aerosol generating system. The cartridge may comprise a porous ceramic body. The porous ceramic body may have a porosity of 30% to 65%. The cartridge may comprise a mesh heater. The mesh heater may be engaged with the porous ceramic body. The mesh heater may comprise a plurality of holes. Each hole may have a size of 50 microns to 200 microns.

According to a first embodiment of the present invention, a cartridge is provided for use in an aerosol generating system. The cartridge comprises a porous ceramic body having a porosity of 30% to 65%. The cartridge comprises a mesh heater engaged with the porous ceramic body. The mesh heater comprises a plurality of holes, each hole having a size of 50 microns to 200 microns.

According to a second embodiment of the present invention, a cartridge is provided for use in an aerosol generating system. The cartridge comprises a porous ceramic body and a mesh heater engaged with the porous ceramic body. The mesh heater is a hybrid mesh heater comprising a mesh of wires and fibers, wherein the fibers have a material composition different from the material composition of the wires.

In the cartridge according to the second embodiment, the porous ceramic body may have a porosity of 30% to 65%. The mesh heater may contain a plurality of holes. Each hole may have a size of 50 microns to 200 microns.

The features described below with respect to the cartridge are applicable to the cartridge according to the first embodiment and the cartridge according to the second embodiment.

When used, the mesh heater can heat the liquid substrate that forms the aerosol. The mesh heater can heat the liquid substrate that forms the aerosol to form an aerosol or vapor that subsequently forms an aerosol. As an advantage, the mesh heater can ensure efficient aerosol generation.

The porosity of the porous ceramic body may allow the porous ceramic body to retain the aerosol-forming liquid substrate. The porous ceramic body may contain or may be configured to contain at least 0.05, 0.1, 0.2, 0.5, or 1 ml of the aerosol-forming liquid substrate.

Each hole has a size of 50 microns to 200 microns. The liquid aerosol-forming substrate can be drawn into the holes of the mesh heater. The liquid aerosol-forming substrate can be drawn into the holes of the mesh heater from the porous ceramic body. The liquid aerosol-forming substrate can be drawn into the holes of the mesh heater by capillary action, or wicking. As an advantage, this can improve the transfer of the liquid aerosol-forming substrate, for example, from the porous ceramic body to the holes of the mesh heater.

The mesh heater may comprise a system of holes defined by a solid material, such as wires. Each hole in the mesh heater may act as a capillary channel, thereby drawing the liquid aerosol-forming substrate into the hole. The liquid aerosol-forming substrate may be drawn into the holes by capillary action, or wicking. Thus, each hole in the mesh heater may be substantially completely filled with the liquid aerosol-forming substrate. This may not be the case, for example, if the holes are large. If the holes are larger, the liquid aerosol-forming substrate may form only a thin layer on the solid material defining each hole. Substantially completely filling the holes with the liquid aerosol-forming substrate helps to increase the efficiency of aerosol generation in the present invention.

As an advantage, the inventors have found that a porous ceramic body having a porosity of 30% to 65% and openings in a mesh heater, each of which has a size of 50 microns to 200 microns, provide a particularly effective transfer of a liquid substrate that forms an aerosol through the porous ceramic body and into the openings of the mesh heater and a particularly effective generation of an aerosol when heated by the mesh heater. Without being limited by theory, it is believed that there is a certain degree of synergy between the porous ceramic body having a porosity of 30% to 65% and the openings in the mesh heater having a size of 50 microns to 200 microns, which provides such an effective transfer of a liquid substrate that forms an aerosol.

In the context of this document, the term "aerosol" refers to a dispersion of solid particles or liquid droplets or combinations of solid particles and liquid droplets in a gas. An aerosol may be visible or invisible. An aerosol may contain vapors of substances that are normally liquid or solid at room temperature, as well as solid particles or liquid droplets or a combination of solid particles and liquid droplets.

In the context of this document, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds can be released by heating or burning the aerosol-forming substrate.

The aerosol-forming substrate may contain nicotine. The aerosol-forming substrate may contain a plant-based material. The aerosol-forming substrate may contain homogenized plant-based material. The aerosol-forming substrate may contain tobacco. The aerosol-forming substrate may contain a tobacco-containing material. The tobacco-containing material may contain volatile tobacco flavor compounds. These compounds may be released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may contain homogenized tobacco material. The aerosol-forming substrate may contain other additives and ingredients, such as flavoring agents.

In the context of this document, the term "hole size" refers to the size measured between two opposite surfaces of the hole. Thus, when the hole is limited, for example, by wires, the hole size does not include the thickness of the wires. The size can pass through the center of gravity of the cross-section of the hole. For example, if the hole has a substantially square cross-section, the hole size can be the length of a side of the square. If the hole has a substantially circular cross-section, the hole size can be the diameter of a circle. If the hole has a substantially rectangular cross-section, the hole size can be the longer side length or the shorter side length of the rectangle. If the hole has an irregular cross-section, the hole size can be the average size of the hole. The sizes of the holes mentioned in this document were measured using a microscope, although any suitable method can be used.

In the context of this document, the term "porosity" refers to a measure, expressed as a percentage, of the volume of accessible pores or void space of a body divided by the total volume of the body. The porosity referred to in this document was measured using mercury intrusion porosimetry.

A porous ceramic body may contain pores of varying shapes and sizes. The pore size distribution is defined as the statistical distribution of the diameter of the largest sphere that can fit inside the pore at a given point. In the context of this document, the term "average pore size" refers to the average of this pore size distribution. The pore sizes reported in this document were obtained using mercury intrusion porosimetry.

In the context of this document, the term "mesh heater" refers to a heater comprising an assembly of solid material that can be heated. The solid material is configured to have a plurality of holes passing through it. The mesh heater may, for example, comprise a wire mesh or a perforated sheet. The mesh heater may be heated in any suitable manner. For example, the mesh heater or parts thereof may be heated resistively or inductively.

In the context of this document, the term "capillary action" refers to the ability of a liquid to flow through a narrow space without the intervention of, or even in opposition to, external forces such as gravity. The effect of capillary action, or wicking, can be observed when liquids are drawn out of thin tubes and porous materials.

In the context of this document, the term "direction of movement of the main portion of the liquid aerosol-forming substrate" refers to the general direction of movement of the liquid aerosol-forming substrate.

In the context of this document, the term "planar" is used to denote a substantially two-dimensional object. A planar component may extend in a first direction and in a second direction perpendicular to the first direction at least two, five, or ten times further than in a third direction perpendicular to the first and second directions.

In the context of this document, the term "flat" is used to denote a substantially two-dimensional topological manifold. Thus, a flat mesh heater can extend in two dimensions along a surface substantially greater than in a third dimension. The dimensions of the flat mesh heater in two dimensions within the surface can be at least 2, 5 or 10 times greater than in the third dimension perpendicular to this surface. An example of a substantially flat mesh heater is a structure between two substantially parallel surfaces, wherein the distance between these two imaginary surfaces is substantially less than the extension within these surfaces. In some embodiments, the substantially flat mesh heater is planar. In other embodiments, the substantially flat mesh heater is curved along one or more dimensions, for example, forming a dome shape or a bridge shape. In embodiments, the substantially flat mesh heater can engage with the surface of the porous ceramic body.

In the context of this document, the term "heating assembly" refers to the mesh heater and the porous ceramic cartridge body.

In the context of this document, the term "average" refers to the unweighted average of the numbers unless otherwise stated. Thus, the "average" diameter of five wires would be equal to one-fifth of the sum of the diameters of the five wires.

The porous ceramic body has a porosity of from 30% to 65%. The porous ceramic body may have a porosity of less than 60%, 55%, 50% or 45%. Alternatively or in addition, the porous ceramic body may have a porosity of greater than 35%, 40% or 45%. For example, the porous ceramic body may have a porosity of from 30% to 60%, or from 30% to 55%, or from 30% to 50%, or from 35% to 65%, or from 35% to 60%, or from 35% to 55%, or from 35% to 50%, or from 40% to 65%, or from 40% to 60% or from 40% to 55%.

The porous ceramic body can be configured to provide a given flow rate of the liquid aerosol-forming substrate to the mesh heater used. For example, the porous ceramic body can be configured to supply at least 0.2, 0.5 or 1 microliter per second of the liquid aerosol-forming substrate to the mesh heater used. The porous ceramic body can be configured to supply less than 3, 5 or 10 microliters per second of the liquid aerosol-forming substrate to the mesh heater used. The porous ceramic body can be configured to supply from 1 to 3 microliters per second of the liquid aerosol-forming substrate to the mesh heater used.

The term "porous ceramic body" may refer to the entire ceramic component or to a portion thereof. For example, the term "porous ceramic body" may refer to only the portion of the ceramic component in which the liquid substrate that forms the aerosol is retained or transported to the mesh heater.

Each mesh heater hole can be 50 to 150 microns in size, or 50 to 100 microns, or 60 to 80 microns, or approximately 70 microns.

In use, the liquid substrate that forms an aerosol can be drawn into the holes of the mesh heater from the porous ceramic body. The liquid substrate that forms an aerosol can be drawn into the holes of the mesh heater by capillary action.

The mesh heater may be substantially flat. The mesh heater may be substantially planar. As an advantage, a flat or planar mesh heater can be easily processed during manufacture and can provide a robust structure for the heating unit.

In use, the direction of movement of the main part of the liquid substrate forming the aerosol may be substantially perpendicular to the plane of the mesh heater. This may advantageously improve the transfer of the liquid substrate forming the aerosol into the openings of the mesh heater.

The entire mesh heater or a portion thereof may be substantially parallel to the first surface of the porous ceramic body. This may advantageously improve the transfer of the liquid substrate forming the aerosol into the openings of the mesh heater from the pores in the porous ceramic body, for example from the openings of the pores on the first surface of the porous ceramic body.

The mesh heater or a portion thereof may be attached to the porous ceramic body or the first surface of the porous ceramic body in one or more of the following ways: adjacent, secured relative to them, fastened to them, engaged with them, and attached to them. For example, the mesh heater or a portion thereof may be embedded in the porous ceramic body. When the mesh heater or a portion thereof is embedded in the porous ceramic body, the first surface may not be an outer surface of the porous ceramic body. In the context of this document, the term "engaged with" may be used to mean "fixed relative to", "fastened with", "attached to", or "adhered to".

The mesh heater may be detachably engaged with the porous ceramic body. It may be possible to engage the mesh heater with the porous ceramic body and to disengage the mesh heater from it. Alternatively, the mesh heater may be permanently engaged with the mesh heater.

When engaged with the porous ceramic body, the position of the mesh heater may be fixed. When engaged with the porous ceramic body, the mesh heater may be adjacent to or in contact with the porous ceramic body.

The mesh heater may be attached to the porous ceramic body. The mesh heater may be attached to the porous ceramic body by any suitable method. The mesh heater may be attached to the porous ceramic body by one or more of the following: one or more soldering points, one or more mechanical fasteners such as clamps or bolts, and a ceramic coating layer. The mesh heater may be embedded in the porous ceramic body.

The porous ceramic body may comprise a second surface substantially opposite the first surface. In use, the liquid aerosol-forming substrate may move from the second surface to the first surface through the porous ceramic body. The liquid aerosol-forming substrate may pass through the porous ceramic body by capillary action. Alternatively or additionally, air flow along, across or around the porous ceramic body or mesh heater may cause a local pressure gradient in the porous ceramic body that facilitates the transfer of the liquid aerosol-forming substrate through the porous ceramic body.

The porous ceramic body may absorb or be configured to absorb a liquid aerosol-forming substrate. For example, the porous ceramic body may absorb or be configured to absorb at least 0.01, 0.02, 0.05, 0.1 or 0.5 ml of a liquid aerosol-forming substrate.

The cartridge may comprise a component for storing a liquid aerosol-forming substrate for storing a liquid aerosol-forming substrate. The component for storing a liquid aerosol-forming substrate may store a liquid aerosol-forming substrate. The component for storing a liquid aerosol-forming substrate may be in fluid communication with the porous ceramic body, for example, with a second surface of the porous ceramic body.

The component for storing the liquid aerosol-forming substrate may comprise a reservoir or container with the liquid aerosol-forming substrate. The porous ceramic body may be in fluid communication or in contact with the reservoir of the liquid aerosol-forming substrate.

The component for storing the liquid aerosol-forming substrate may comprise a material impregnated with the liquid aerosol-forming substrate. The component for storing the liquid aerosol-forming substrate may be arranged to supply the liquid to the porous ceramic body.

The component for storing the liquid substrate that forms the aerosol may have a fibrous or spongy structure. The component for storing the liquid substrate that forms the aerosol may comprise a capillary material. The component for storing the liquid substrate that forms the aerosol may comprise a capillary bundle. For example, the component for storing the liquid substrate that forms the aerosol may comprise one or more of a plurality of fibers, threads or tubes with narrow channels. The fibers, threads or tubes may typically be aligned to supply liquid to the porous ceramic body.

The component for storing the liquid substrate that forms the aerosol may comprise a sponge-like or foam-like material. The structure of the component for storing the liquid substrate that forms the aerosol may form a plurality of small channels or tubes through which the liquid can be transported by capillary action.

The component for storing the liquid aerosol-forming substrate may comprise any suitable material or combination of materials. Examples of suitable materials are sponge or foam material, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metal or plastic material, fibrous material, for example, made of twisted or extruded fibers such as acetyl cellulose, polyester or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics. The component for storing the liquid aerosol-forming substrate may have any suitable capillarity and porosity for use with different physical properties of the liquid.

The cartridge may comprise a component for storing a liquid aerosol-forming substrate, which may be impregnated with the liquid aerosol-forming substrate. The component for storing the liquid aerosol-forming substrate may be in contact with the porous ceramic body. The porous ceramic body may comprise a first portion. The first portion of the porous ceramic body may be located between the component for storing the liquid aerosol-forming substrate and the mesh heater. The first portion of the porous ceramic body may comprise a first surface and a second surface. The second surface may be opposite the first surface. The mesh heater may be engaged with the first surface. The component for storing the liquid aerosol-forming substrate may be in contact with the second surface. The mesh heater may comprise a metal, for example steel, such as stainless steel.

The mesh heater area can be less than 50, 40 or 30 ^mm2 . This can allow the mesh heater to be integrated into a hand held system.

The mesh heater may comprise a mesh of wires. The wires may be interwoven. The mesh heater may comprise a woven or non-woven wire mesh. The wires may be electrically conductive.

The wires can lie in one plane. The mesh heater can be planar. A planar mesh heater can be easily processed during manufacture, while providing a reliable design.

The holes may be defined as being bounded by wires. The wires may have a substantially circular, square, rectangular, hexagonal or irregular cross-section.

The wires may be formed individually and may be joined together. The wires may be formed by etching a sheet material such as foil. This may be particularly advantageous if the heater comprises a matrix of parallel wires. Alternatively, the wires may be stamped from an electrically conductive foil such as stainless steel.

The mesh heater or wires may be made of or contain any material with suitable electrical and mechanical properties. Suitable materials include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of a ceramic material and a metallic material. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, constantan, nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese and iron-containing alloys, as well as nickel-based, iron-based, cobalt-based superalloys, stainless steel, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation. The wires may be coated with one or more electrically insulating materials. Preferred materials for the mesh heater or wires may be stainless steel types 304, 316, 304L, 316L and graphite. In addition, the mesh heater or wires may contain combinations of the above materials. A combination of materials can be used to improve the resistance control of the mesh heater. For example, high resistivity materials can be combined with low resistivity materials. This can be advantageous if one of the materials is preferred for other reasons, such as cost, processability, or other physical and chemical parameters.

The mesh heater may comprise at least one wire made of a first material and at least one wire made of a second material different from the first material. This may be advantageous for electrical or mechanical reasons. For example, one or more wires may be formed of a material whose resistance varies greatly depending on the temperature, such as an iron-aluminum alloy. This enables the resistance value of the wires to be used to determine the temperature or temperature changes. This may be used in a puff detection system and to control the temperature of the heater to maintain it within the desired temperature range. Rapid temperature changes may also be used as an indicator for detecting changes in the air flow past the mesh heater as a result of the user puffing from the system.

The mesh heater may comprise two or more types of wires forming a wire mesh. The two types of wire may have different specific resistances. The wires with a higher specific resistance may be oriented in the direction of the electric current flow, for example, wires made of a chromium-nickel alloy. The wires with a lower specific resistance may be arranged substantially perpendicular to the wires with a higher specific resistance. For example, the low-resistance wires may be stainless steel wires. As an advantage, the relatively cheaper low-resistance wires form a support for the wires with a high electrical resistance. In addition, the wires with a high electrical resistance are generally less flexible than stainless steel wires, and thus they can be easily manufactured in the form of thin wires.

Alternatively, the mesh heater may include carbon fiber fabric. As an advantage, carbon fiber fabric is generally more flexible than metal mesh.

The wires may have an average diameter of at least 10, 16, 17 or 30 microns. The wires may have an average diameter of less than 100, 90, 80, 70, 60, 50, 40 or 30 microns. Preferably, the wires may have an average diameter of 15 to 30 microns or 15 to 20 microns, such as about 16 or 17 microns.

Each of the wires may have a minimum thickness of at least 10, 16, 17, or 30 microns. Each of the wires may have a minimum thickness of less than 100, 90, 80, 70, 60, 50, 40, or 30 microns.

The mesh heater may be a hybrid mesh heater. In the context of this document, the term "hybrid mesh heater" is used to denote a mesh heater comprising at least one wire and at least one fiber. The mesh heater may comprise a mesh of wires and fibers. The characteristics and properties of the wires described above apply equally to the wires in a hybrid mesh heater.

The fibers may have a material composition different from the wire. The wires and fibers may be intertwined. Thus, a mesh heater may comprise a woven mesh of wire and fiber. The fibers may have an average diameter of 80% to 120% of the average diameter of the wires. The wires and fibers may have substantially identical average diameters.

The wires may be substantially perpendicular to the grain.

The fibers may have an average diameter of at least 10, 16, 17 or 30 microns. The fibers may have an average diameter of less than 100, 90, 80, 70, 60, 50, 40 or 30 microns. Preferably, the fibers may have an average diameter of 15 to 30 microns or 15 to 20 microns, such as about 16 or 17 microns. The fibers may include glass fibers. The fibers may include viscose fibers.

Each fiber may have a minimum thickness of at least 10, 16, 17, or 30 microns. Each fiber may have a minimum thickness of less than 100, 90, 80, 70, 60, 50, 40, or 30 microns.

The thickness of the mesh heater may be at least 30, 40 or 48 microns. If the mesh heater contains wires, or wires and fibers, the thickness of the mesh heater may be approximately 3 times the average diameter of the wires or fibers. For example, the thickness of the mesh heater may be 2.5 to 3.5 times the average diameter of the wires or fibers. The thickness of the mesh heater may be less than 300, 250, 200, 150 or 100 microns. The thickness of the mesh heater may be from 45 to 100, or from 45 to 80, or from 45 to 60 microns.

The mesh heater may comprise a sheet. The sheet may be metallic. The sheet may comprise a metal such as stainless steel. The sheet may comprise a plurality of holes. The sheet may be perforated. The plurality of holes may comprise perforations in the sheet. The sheet may comprise a heating track, or the heating track may be applied to the sheet. In the context of this document, the term "heating track" is used to denote a track, path, or section of material that is configured to be heated in use. For example, in use, a current may be passed through the heating track to resistively heat the heating track. In this case, the heating track may comprise an electrically conductive material. Alternatively, the heating track may comprise a current-collecting material, and in use, the heating track may be inductively heated.

The mesh heater may be engaged with the porous ceramic body or the first surface of the porous ceramic body over substantially the entire surface of the mesh heater. The mesh heater may be in contact with the porous ceramic body or the first surface of the porous ceramic body. The mesh heater may be in contact with the porous ceramic body or the first surface of the porous ceramic body over substantially the entire surface of the mesh heater. The mesh heater may be engaged with the porous ceramic body or the first surface of the porous ceramic body in such a way that at no point does the distance between the porous ceramic body and the mesh heater exceed 500, 300, 100, 75, 50 or 25 microns. All points of the mesh heater may be within 500, 300, 100, 75, 50 or 25 microns of at least one point on the porous ceramic body or on the first surface of the porous ceramic body. As an advantage, minimizing any distance between the mesh heater and the porous ceramic body can improve the transfer of the liquid substrate forming the aerosol from the porous ceramic body to the openings of the mesh heater.

The porous ceramic body may comprise a material with a relatively low linear coefficient of thermal expansion, such as a linear coefficient of thermal expansion at 25 degrees Celsius that is less than 30, 20, or 10×10 ^-6 m / (m K). As an advantage, a lower coefficient of thermal expansion can reduce the risk of particles from the porous ceramic body being torn off from the body when the porous ceramic body is heated by a mesh heater. Where the mesh heater contacts the porous ceramic body, this risk may be particularly high at the contact points between the mesh heater and the porous ceramic body.

The porous ceramic body may contain a material that has a linear coefficient of thermal expansion at 25 degrees Celsius that is 30% to 300% of the linear coefficient of thermal expansion at 25 degrees Celsius of the mesh heater material. As an advantage, this can reduce the risk of particles from the porous ceramic body being torn off from the body when the porous ceramic body is heated by the mesh heater.

The porous ceramic body may contain one or more of steatite, aluminum oxide, and zirconium dioxide. These materials are advantageously chemically stable and have relatively low coefficients of thermal expansion.

The porous ceramic body may have pores that have an average pore size of less than 40, 30, 20, 10, or 8 microns. The porous ceramic body may have pores that have an average pore size of greater than 2.5, 5, 10, or 20 microns. The porous ceramic body may have pores with an average size of from 2.5 to 40 microns, or from 2.5 to 30 microns, or from 2.5 to 20 microns, or from 2.5 to 10 microns, or from 2.5 to 8 microns, or from 5 to 40 microns, or from 5 to 30 microns, or from 5 to 20 microns, or from 5 to 10 microns, or from 10 to 40 microns, or from 10 to 30 microns, or from 10 to 20 microns, or from 20 to 40 microns, or from 20 to 30 microns, or from 30 to 40 microns.

A preferred porous ceramic body may have a porosity of 30% to 60% and have pores with an average size of 5 to 30 microns. A particularly preferred porous ceramic body may have a porosity of 40% to 60% and have pores with an average size of 5 to 10 microns. Another particularly preferred porous ceramic body may have a porosity of 30% to 40% and have pores with an average size of 20 to 30 microns.

The porous ceramic body may comprise a first portion and a protruding portion. The protruding portion may be located on the periphery of the first portion. The protruding portion may extend substantially around the entire periphery of the first portion. The protruding portion may extend substantially perpendicularly from the surface of the first portion. As an advantage, the protruding portion may allow the porous ceramic body to withstand greater loads during manufacturing and assembly without failure.

The first part may have a length, a width perpendicular to the length, and a thickness perpendicular to the length and width. The length and width may be at least two, three, or five times the thickness.

The first part may have a substantially circular cross-section. The first part may have a diameter and a thickness. The diameter may be at least two, three, or five times the thickness.

The first part may have a thickness of at least 1, 1.5, 2 or 2.5 mm. As an advantage, a greater thickness may increase the strength of the first part of the porous ceramic body. The first part may have a thickness of less than 6, 5 or 4 mm. As an advantage, a smaller thickness may improve the capillary ability of the first part, thereby improving the transfer of the liquid substrate forming the aerosol through the first part. Thus, the first part may have a thickness of 1 to 6 mm, or 1 to 5 mm, or 1.5 to 5 mm, or 1.5 to 4 mm.

The protruding portion may have a width of at least 1, 1.5, 2 or 2.5 mm. The protruding portion may have a width of less than 6, 5 or 4 mm. Thus, the protruding portion may have a width of 1 to 6 mm, or 1 to 5 mm, or 1.5 to 5 mm, or 1.5 to 4 mm. The width of the protruding portion may be 50% to 150% of the thickness of the first portion.

The first part of the porous ceramic body may be located between the component for storing the liquid substrate that forms the aerosol and the mesh heater. The first part of the porous ceramic body may comprise a first surface and a second surface. The second surface may be opposite to the first surface. The mesh heater may be engaged with the first surface. The component for storing the liquid substrate that forms the aerosol may be in contact with the second surface. The projecting part may extend from the second surface. The projecting part may surround the component for storing the liquid substrate that forms the aerosol.

The porous ceramic body may comprise a channel passing through it. A first portion of the porous ceramic body may comprise a channel. The channel may pass through the first portion. The channel may extend substantially in the thickness direction of the first portion. The mesh heater may be substantially flat or planar, and the channel may extend substantially perpendicular to the plane of the mesh heater. The channel may have a diameter of at least 300, 400 or 500 microns. The channel may have a diameter of less than 800, 700 or 600 microns. As an advantage, the channel may increase the porosity of the porous ceramic body. This may allow the porous ceramic body to retain more of the liquid aerosol-forming substrate. In addition, the channel may improve the capillary capacity of the porous ceramic body. Thus, the channel may improve the transfer of the liquid aerosol-forming substrate through the porous ceramic body.

The mesh heater may be attached to the porous ceramic body by a soldering point or multiple soldering points. The soldering point or points may contain silver or tin.

The mesh heater may be attached to the porous ceramic body by: providing a segment or plurality of segments of metal between the porous ceramic body and the mesh heater (e.g., by applying the segment(s) of metal to the porous ceramic body or by coating the mesh heater with metal); positioning the mesh heater in engagement with the porous ceramic body; melting the segment(s) of metal, optionally while simultaneously pressing the mesh heater and the porous ceramic body together; and curing the segment(s) of metal. As the segment(s) of metal is cured, the segment(s) of metal adheres (adhere) the porous ceramic body to the mesh heater.

The mesh heater may be attached to the porous ceramic body by: providing a segment or plurality of segments of metal between the mesh heater and the porous ceramic body (e.g., by applying the segment(s) of metal to the porous ceramic body or by coating the mesh heater with metal); and pressing the mesh heater and the porous ceramic body together, if necessary, when heating the segment(s) of metal. The segment(s) of metal may adhere the porous ceramic body to the mesh heater.

If a plurality of metal segments are used, these segments may be spaced apart, such as spaced in the plane of the mesh heater. One or more segments may be or may comprise a drop or portion of metal on the porous ceramic body or on the mesh heater. Thus, there may be a plurality of spaced drops or portions of metal on the porous ceramic body or on the mesh heater, or on both the porous ceramic body and on the mesh heater.

Thus, by attaching the mesh heater to the porous ceramic body as described above, the cartridge may contain a metal segment between the porous ceramic body and the mesh heater. The metal segment may contain silver or tin. However, it should be noted that the cartridge may contain a metal segment between the porous ceramic body and the mesh heater for another reason.

The metal segment may adhere the porous ceramic body to the mesh heater. The metal segment may contain silver or tin.

The mesh heater or part thereof may contain a complete or partial metal coating. The metal coating may contain tin or silver. This may be the case when the segment(s) of metal is (are) applied by coating the mesh heater with metal.

The mesh heater may be attached to the porous ceramic body by: placing the mesh heater engaged with the porous ceramic body; and applying a coating layer of the second ceramic to the mesh heater in such a way that at least part of the mesh heater is located between the porous ceramic body and the coating layer of the second ceramic. Then, the porous ceramic body, or the coating layer of the second ceramic, or both the porous ceramic body and the coating layer of the second ceramic may be sintered. Alternatively or in addition, the porous ceramic body, or the coating layer of the second ceramic, or both the porous ceramic body and the coating layer of the second ceramic may be sintered before applying the coating layer of the second ceramic to the mesh heater.

The features and properties of the porous ceramic body can also be applied to the coating layer of the second ceramic. For example, the features and properties related to the material, the material properties, the pore sizes and the porosity, all of these can be applied to the coating layer of the second ceramic.

Thus, by attaching the mesh heater to the porous ceramic body as described above, the mesh heater can be located between the porous ceramic body and the coating layer of the second ceramic. However, it should be noted that the cartridge may contain the coating layer of the second ceramic for another reason.

The coating layer of the second ceramic may comprise a ceramic material. The porous ceramic body may also comprise a ceramic material. Thus, both the porous ceramic body and the coating layer of the second ceramic may comprise one or more of aluminum oxide, steatite, and zirconium dioxide.

The coating layer of the second ceramic may have a thickness of less than 5000, 1000, 500 or 200 microns. The coating layer of the second ceramic may have a thickness of at least 10, 100, 500 or 1000 microns. Thus, the coating layer of the second ceramic may have a thickness of 500 to 5000 microns, for example, 1000 to 2000 microns.

The second ceramic coating layer may be in contact with the mesh heater. The second ceramic coating layer may be in contact with the porous ceramic body. The mesh heater may be attached to the porous ceramic body by the second ceramic coating layer.

The coating layer of the second ceramic may cover less than 80%, or 65%, or 50% of the surface of the mesh heater. This can improve the aerosol generation compared to the coating layer of the second ceramic covering an even larger portion of the surface of the mesh heater.

The cartridge may comprise an air inlet. The cartridge may comprise an air outlet. The air inlet may be in fluid communication with the air outlet. The mesh heater may be located downstream of the air inlet. The mesh heater may be located upstream of the air outlet.

The cartridge may include a mouthpiece. The mouthpiece may be or may include an air outlet. In use, when the cartridge is connected to an aerosol generating device, the user may draw from the cartridge mouthpiece. This may cause air to flow through the air inlet, then through, over, past, or through the mesh heater, and then through the air outlet.

The cartridge may comprise first and second electrical contacts electrically connected to the mesh heater. The electrical contacts may comprise one or more of tin, silver, gold, copper, aluminum, steel such as stainless steel, phosphor bronze, tin-antimony alloy, tin-zirconium alloy, tin-bismuth alloy, or tin alloy with other components that increase resistance to organic acids.

Electrical contacts may be attached directly to the wires of the mesh heater. Electrical contacts may be located between the wires and a porous ceramic body. For example, the contacts may be made of tin or silver that is coated or otherwise attached to the porous ceramic body. The contacts may be easier to connect to the wire than the porous ceramic body. Electrical contacts may be integral with the wire. For example, the mesh heater may be formed by etching an electrically conductive sheet to form a plurality of wires between two electrical contacts.

The electrical contacts may be configured to form an electrical connection with corresponding electrical contacts on the aerosol generating device when the cartridge is connected to the device.

According to a third embodiment of the present invention, there is provided an aerosol generating system comprising an aerosol generating device and a cartridge. The cartridge may be a cartridge according to the first embodiment. The cartridge may be a cartridge according to the second embodiment.

The aerosol generating device may be configured to be connected to the cartridge. For example, the aerosol generating device may be configured to be connected to and disconnected from the cartridge. The aerosol generating device may be configured to be connected to and disconnected from the cartridge by means of a snap connection, a corresponding screw thread, or any other suitable method. The aerosol generating device may be configured to contain at least a portion of the cartridge. For example, the aerosol generating device may comprise a chamber configured to contain at least a portion of the cartridge.

The aerosol generating device may comprise an air inlet. The aerosol generating device may comprise an air outlet. The air outlet of the aerosol generating device may be in fluid communication with the air inlet of the cartridge.

The aerosol generating device may comprise a power source, such as a battery. When the cartridge is connected to the device, the power source may be configured to supply power to the mesh heater, such as to resistively heat the mesh heater.

The power source may be electrically connected to the first and second electrical contacts of the device. These first and second electrical contacts may be configured to form an electrical connection with the corresponding electrical contacts on the cartridge, when the cartridge is connected to the device. The mesh heater may be configured to resistively heat it. The mesh heater may be or may comprise wires or an electrically resistive track connected to the electrical contacts on the cartridge. The wires or track may be heated when the power source passes current through the wires or track. Thus, when the cartridge is connected to the aerosol generating device, the power source in the aerosol generating device may be configured to supply power to the mesh heater. That is, the power source may be capable of passing current through the mesh heater, or the wires or track of the mesh heater, and resistively heating the mesh heater.

The cartridge or aerosol generating device may contain an inductor, such as an induction coil. The mesh heater may be or contain a current-collecting material.

The power source may be configured to pass current through the inductor in such a way that the inductor generates an oscillating electromagnetic field. This, in turn, may lead to the occurrence of eddy currents and hysteresis losses in the current-receiving material. This may lead to heating of the current-receiving material. Thus, the power source and the inductor may be configured to inductively heat the mesh heater.

The current collecting material may be or may comprise any material that can be inductively heated to a temperature sufficient to generate an aerosol from an aerosol-forming substrate. Preferred current collecting materials may be heated to a temperature in excess of 100, 150, 200, or 250 degrees Celsius. Preferred current collecting materials may comprise a metal or carbon. A preferred current collecting material may comprise a ferromagnetic material, such as ferritic cast iron or ferromagnetic steel, or stainless steel. A suitable current collecting member may be made of or comprise aluminum. Preferred current collecting materials may be made of or comprise 400 series stainless steel grades, such as 410 series stainless steel, or 420 series stainless steel, or 430 series stainless steel. Different materials will dissipate different amounts of energy when located within electromagnetic fields having similar frequency and field strength values. Thus, the parameters of the current collector material, such as material type and size, can be changed to provide the desired power dissipation within a known electromagnetic field.

The inductor may be an induction coil. The induction coil may be located in a cartridge. The induction coil may be located around a mesh heater. For example, the induction coil may be wound in a spiral around the mesh heater. The inductor may be electrically connected to electrical contacts on the cartridge. When the cartridge is connected to an aerosol generating device, these electrical contacts may be electrically connected to corresponding electrical contacts on the device that are electrically connected to a power source in the device. Thus, when the cartridge is connected to the device, the power source of the device may be configured to pass current through the inductor to create an oscillating electromagnetic field and, thus, heat the current-receiving material of the mesh heater.

An inductor, such as an induction coil, can be located in the aerosol generating device. The inductor can be electrically connected to a power source. The aerosol generating device can comprise a chamber for containing at least a portion of the cartridge. The induction coil can be located around at least a portion of this chamber. For example, the induction coil can be spirally wound around at least a portion of the chamber. In essence, when the cartridge or a portion thereof is placed in the chamber, the induction coil can be located around the mesh heater or spirally wound around it. Thus, when the cartridge is connected to the device, the power source of the device can be configured to pass current through the inductor to create an oscillating electromagnetic field and, thus, heat the current-receiving material of the mesh heater.

The aerosol generating device may comprise a controller. The controller may be configured to control the power supply from the power source. Thus, the controller may control the heating of the mesh heater.

The following is a non-exhaustive list of non-limiting examples. These examples are set forth in paragraphs. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

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

a porous ceramic body having a porosity of 30% to 65%; and

a mesh heater engaged with a porous ceramic body, wherein the mesh heater comprises a plurality of holes, each of which has a size of from 50 microns to 200 microns.

B. A cartridge according to paragraph A, wherein in use the liquid substrate forming the aerosol is drawn into the openings of the mesh heater from the porous ceramic body.

C. A cartridge according to paragraph A or paragraph B, wherein in use the liquid substrate forming the aerosol is drawn into the openings of the mesh heater by capillary action.

D. A cartridge according to any one of the preceding paragraphs, wherein the mesh heater is substantially flat or substantially planar.

E. A cartridge according to paragraph D, wherein in use the direction of movement of the main portion of the liquid substrate forming the aerosol is substantially perpendicular to the plane of the mesh heater.

F. A cartridge according to any one of the preceding paragraphs, wherein the mesh heater or portion thereof is substantially parallel to the first surface of the porous ceramic body.

G. A cartridge according to paragraph F, wherein the mesh heater is attached to the first surface of the porous ceramic body.

H. The cartridge of paragraph F or paragraph G, wherein the porous ceramic body comprises a second surface substantially opposite the first surface.

I. A cartridge according to paragraph H, wherein in use the liquid substrate forming the aerosol moves in a direction from the second surface to the first surface, for example from the second surface to the first surface.

J. A cartridge according to any one of the preceding paragraphs, wherein the cartridge comprises a component for storing a liquid aerosol-forming substrate for storing a liquid aerosol-forming substrate.

K. The cartridge of paragraph J, wherein the component for storing the liquid aerosol-forming substrate is in fluid communication with the porous ceramic body.

L. A cartridge according to paragraph H or paragraph I, wherein the cartridge comprises a component for storing a liquid aerosol-forming substrate for storing a liquid aerosol-forming substrate, and the component for storing a liquid aerosol-forming substrate is in fluid communication with a second surface of the porous ceramic body.

M. A cartridge according to any of the preceding paragraphs, wherein the mesh heater comprises metal.

N. A cartridge according to item M, wherein the mesh heater comprises steel.

O. A cartridge according to any of the preceding paragraphs, wherein the mesh heater comprises a mesh of wires.

P. The cartridge according to paragraph O, wherein the mesh heater comprises a woven wire mesh.

Q. A cartridge according to any one of the preceding paragraphs, wherein the mesh heater is a hybrid mesh heater comprising a mesh of wires and fibers, and the fibers have a material composition different from the material composition of the wires.

R. A cartridge according to item Q, wherein the wires contain metal.

S. Cartridge according to item R, wherein the wires contain steel.

T. A cartridge according to any one of paragraphs Q-S, wherein the wires are substantially perpendicular to the fibers.

U. A cartridge according to any one of paragraphs Q-T, wherein the mesh heater comprises a woven wire and fiber mesh.

V. A cartridge according to any of paragraphs Q-U, wherein the fibers have an average diameter of from 80% to 120% of the average diameter of the wires.

W. A cartridge according to any one of paragraphs Q-V, wherein the fibers have an average diameter of at least 10 microns.

X. A cartridge according to any of paragraphs Q-W, wherein the fibers have an average diameter of less than 100 microns.

Y. A cartridge according to any one of paragraphs Q-X, wherein the fibers are glass fibers.

Z. A cartridge according to any one of paragraphs Q-X, wherein the fibers are viscose fibers.

AA. A cartridge according to any of paragraphs O-V, wherein the fibers have an average diameter of at least 10 microns.

AB. A cartridge according to any of paragraphs O-AA, wherein the wires have an average diameter of less than 100 microns.

AC. A cartridge according to any one of paragraphs A-N, wherein the mesh heater comprises a sheet.

AD. Cartridge according to point AC, wherein the sheet is metallic.

AE. A cartridge according to item AC or item AD, wherein the sheet comprises a plurality of openings.

AF. A cartridge according to any of the items AC-AE, wherein the sheet is perforated.

AG. A cartridge according to any of paragraphs AC-AF, wherein the sheet comprises a heating track applied thereto.

AH. A cartridge according to any of the preceding paragraphs, wherein the mesh heater is substantially flat or substantially planar and the thickness of the mesh heater exceeds 30 microns.

AI. A cartridge according to any of the preceding paragraphs, wherein the mesh heater is engaged with the porous ceramic body over substantially the entire surface of the mesh heater.

AJ. The cartridge according to item AI, wherein the mesh heater is in contact with the porous ceramic body over substantially the entire surface of the mesh heater.

AK. A cartridge according to any of the preceding paragraphs, wherein the porous ceramic body comprises one or more of steatite, aluminum oxide, and zirconium dioxide.

AL. A cartridge according to any of the preceding paragraphs, wherein the cartridge comprises pores with an average pore size of from 2.5 microns to 40 microns.

AM. A cartridge according to any of the preceding paragraphs, wherein the porous ceramic body comprises a first portion and a projecting portion.

AN. A cartridge according to paragraph AM, wherein the protruding part is located on the periphery of the first part.

AO. A cartridge according to paragraph AN, wherein the projecting portion extends substantially along the entire periphery of the first portion.

AP. A cartridge according to any one of paragraphs AM-AO, wherein the projecting portion extends substantially perpendicularly from the surface of the first portion.

AQ. A cartridge according to any one of paragraphs AM-AP, wherein the first part comprises a length, a width perpendicular to the length, and a thickness perpendicular to the length and width, wherein the length and width are at least twice the thickness.

AR. A cartridge according to any of paragraphs AM-AP, wherein the first portion has a substantially circular cross-section.

AS. A cartridge according to AR, wherein the first part has a diameter and a thickness, wherein the diameter is at least twice the thickness.

AT. A cartridge according to any of AM-AS, wherein the first part has a thickness of at least 1.5 mm.

AU. A cartridge according to any of the points AM-AT, wherein the first part has a thickness of less than 6 mm.

AV. A cartridge according to any of paragraphs AM-AU, wherein the projecting portion has a width of at least 1.5 mm.

AW. A cartridge according to any of the points AM-AV, wherein the protruding part has a width of less than 6 mm.

AX. A cartridge according to any of the preceding paragraphs, wherein the porous ceramic body comprises a channel passing therethrough.

AY. A cartridge according to any of the AM-AW clauses, wherein the first portion of the porous ceramic body comprises a channel passing therethrough.

AZ. A cartridge according to item AY, wherein the channel extends substantially in the direction of the thickness of the first part.

BA. A cartridge according to paragraphs AX, AY or AZ, wherein the mesh heater is substantially flat or substantially planar and the channel extends substantially perpendicular to the plane of the mesh heater.

BB. A cartridge according to any of paragraphs AX-BA, wherein the bore has a diameter of at least 300 microns.

BC. A cartridge according to any of the items AX-BB, wherein the bore has a diameter of less than 800 microns.

BD. A cartridge according to any of the preceding paragraphs, wherein the mesh heater is attached to the porous ceramic body by means of a soldering point.

BE. Cartridge according to item BD, wherein the soldering point contains silver or tin.

BF. A cartridge according to any of the preceding paragraphs, comprising a metal segment located between a porous ceramic body and a mesh heater.

BG. Cartridge according to item BF, wherein the mesh heater is glued to the porous ceramic body with a metal segment.

BH. A cartridge according to item B or item BG, wherein the metal segment contains silver or tin.

BI. A cartridge according to any of the preceding paragraphs, wherein the mesh heater is located between the porous ceramic body and a covering layer of a second ceramic.

BJ. The cartridge according to paragraph BI, wherein the covering layer of the second ceramic comprises a ceramic material, and the porous ceramic body comprises the same ceramic material.

BK. A cartridge according to item BI or item BJ, wherein the covering layer of the second ceramic has a thickness of less than 5000 microns.

BL. A cartridge according to BI, BJ or BK, wherein the coating layer of the second ceramic has a thickness of at least 10 microns.

BM. A cartridge according to any of paragraphs BI-BL, wherein the covering layer of the second ceramic covers less than 80% of the surface of the mesh heater.

BN. A cartridge according to any of paragraphs BI-BM, wherein the covering layer of the second ceramic is in contact with the mesh heater.

BO. A cartridge according to any of paragraphs BI-BN, wherein the mesh heater is attached to the porous ceramic body by a covering layer of a second ceramic.

BP. A cartridge according to any one of the preceding paragraphs, wherein the cartridge comprises an electrical contact electrically connected to the mesh heater.

BQ. A cartridge according to item BP, wherein the electrical contact comprises tin, silver, gold, copper, aluminum, steel such as stainless steel, phosphor bronze, tin-antimony alloy, tin-zirconium alloy, tin-bismuth alloy, or tin alloy with other components that increase resistance to organic acids.

BR. An aerosol generating system comprising an aerosol generating device and a cartridge according to any of the preceding paragraphs.

BS. An aerosol generating system according to BR, wherein the aerosol generating device is adapted to be connected to a cartridge.

BT. An aerosol generating system according to paragraph BR or paragraph BS, wherein the aerosol generating device comprises a power source configured to supply power to a mesh heater for resistively heating the mesh heater.

BU. An aerosol generating system according to paragraph BR or paragraph BS, wherein the aerosol generating device comprises a power source, and the cartridge or the aerosol generating device comprises an inductor, and the power source and the inductor are configured to inductively heat the mesh heater.

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

Fig. 1 shows a cross-sectional view of an aerosol generating system comprising a cartridge with a first heating unit;

Fig. 2 shows a cross-sectional view of a cartridge containing a first heating unit;

Fig. 3 shows a perspective view of the first heating unit;

Fig. 4 shows a cross-sectional view of the first heating unit;

Fig. 5 shows a perspective view of the second heating unit;

Fig. 6 shows a cross-sectional view of the second heating unit;

Fig. 7 shows a perspective view of the third heating unit;

Fig. 8 shows a cross-sectional view of the third heating unit; and

Fig. 9 shows a cross-sectional view of an aerosol generating system comprising a cartridge with a third heating unit.

Fig. 1 shows a cross-sectional view of an aerosol generating system 100. The aerosol generating system 100 comprises an aerosol generating device 150 and a cartridge 200. In this example, the aerosol generating system 100 is an electrically controlled smoking system.

The aerosol generating device 150 is portable and has a size comparable to the size of a traditional cigar or cigarette. The device 150 contains a battery 152, such as a lithium iron phosphate battery, and a controller 154 electrically connected to the battery 152. The device 150 also contains two electrical contacts 156, 158, which are electrically connected to the battery 152. This electrical connection is wired and is not shown in Fig. 1.

The cartridge 200 comprises an air inlet 202, an air outlet 204 and a first heating unit 300. The air inlet 202 is in fluid communication with the air outlet 204. The heating unit 300 is located downstream of the air inlet 202 and upstream of the air outlet 204. The heating unit 300 comprises a porous ceramic body 302 and a substantially planar mesh heater 304 connected to the porous ceramic body 302.

The mesh heater 304 comprises a hybrid mesh comprising stainless steel wires 306 and glass fibers 308. The stainless steel wires 306 are intertwined with the glass fibers 308 and are substantially perpendicular to them. Thus, the mesh heater 304 comprises a braided hybrid mesh. The mesh heater 304 is connected to the porous ceramic body 302 by two soldering points 310, 312. In this example, the soldering points 310, 312 are made of tin, although silver or another suitable material could be used. Each of these soldering points 310, 312 is electrically connected to an electrical contact 214, 216 on the cartridge. This electrical connection is wired and is not shown in Fig. 1. Through this electrical connection, the 306 stainless steel wires are electrically connected to the electrical contacts 214, 216.

The porous ceramic body 302 comprises a number of pores. The liquid substrate forming the aerosol is retained in the pores of the porous ceramic body 302.

In Fig. 1, the aerosol generating device 150 is connected to the cartridge 200. In this example, the cartridge 200 is connected to the aerosol generating device 150 by means of projections 206, 208 forming a snap connection with corresponding openings 160, 162 on the aerosol generating device 150.

The cartridge 200 further comprises a component 288 for storing a liquid aerosol-forming substrate, which is in fluid communication with the porous ceramic body 302. The component 288 for storing a liquid aerosol-forming substrate is in contact with the first portion 320 of the porous ceramic body 302. The component 1008 for storing a liquid aerosol-forming substrate may be glued to the porous ceramic body 302 using an adhesive, or may be held in place by friction, or may be held in place by another suitable method. The component 288 for storing a liquid aerosol-forming substrate in this example is a capillary material having a fibrous or spongy structure, although in other embodiments a reservoir or container with a liquid aerosol-forming substrate may be used. The capillary material is made of polyester, although any suitable material can be used. The capillary material is impregnated with the aerosol-forming substrate. Thus, in Fig. 1, the aerosol-forming substrate is stored in the pores of the porous ceramic body 302 and in the component 288 for storing the liquid aerosol-forming substrate.

In use, the user takes a puff from the air outlet 204 of the cartridge 200. At the same time, the user presses a button (not shown) on the aerosol generating device 150. Pressing this button sends a signal to the controller 154, as a result of which power is supplied from the battery 152 to the mesh heater 302 through the electrical contacts 156, 158 of the device and the electrical contacts 214, 216 of the cartridge. This causes current to flow through the stainless steel wires 306 of the mesh heater 304, thereby causing resistive heating of the stainless steel wires 306 and causing heating of the mesh heater 304 as a whole. In other examples, an air flow sensor or a pressure sensor is located in the cartridge 200 and is electrically connected to the controller 154. The air flow sensor or the pressure sensor detects that the user is taking a puff through the air outlet 204 of the cartridge 200 and sends a signal to the controller 154 to supply power to the mesh heater 304. Thus, in these examples, the user does not need to press a button to heat the mesh heater 304. The liquid aerosol-forming substrate held in the pores of the porous ceramic body 302 is drawn into the openings of the mesh heater 304 by capillary action. The mesh heater 304 heats this liquid aerosol-forming substrate to evaporate the aerosol-forming substrate.

As the liquid aerosol-forming substrate is drawn from the porous ceramic body 302 into the openings of the mesh heater 304 and evaporates, the liquid aerosol-forming substrate is also drawn from the liquid aerosol-forming substrate storage component 288 into the porous ceramic body 302. Thus, the user may be able to generate more aerosol than if the liquid aerosol-forming substrate storage component 288 were not present.

When the user takes a puff from the air outlet 204 of the cartridge 200, air is drawn into the air inlet 202. This air then passes around the heating unit 300 and is directed to the air outlet 204. This air flow captures the vapor formed when the liquid substrate that forms the aerosol is heated by the mesh heater 304. This captured vapor is then cooled and condensed to form an aerosol. This aerosol is then supplied to the user through the air outlet 204.

Fig. 2 shows a cross-sectional view of a cartridge 200 containing a first example of a heating unit 300. In Fig. 2, the cartridge 200 is no longer connected to the aerosol generating device 150.

Fig. 3 and 4 show a perspective view and a cross-sectional view of the first heating unit 300, respectively. Fig. 3 also shows a component 288 for storing a liquid substrate that forms an aerosol. The heating unit 300 comprises a porous ceramic body 302 and a mesh heater 304. The mesh heater 304 is in contact with the porous ceramic body 302 over substantially the entire surface of the mesh heater 304.

The stainless steel wires 306 and the glass fiber 308 of the mesh heater 304 are intertwined. Thus, the mesh heater 304 comprises a braided hybrid mesh. The stainless steel wires 306 and the glass fiber 308 of the mesh heater 304 have diameters of approximately 17 microns. The thickness of the mesh heater 304 is approximately 51 microns. In Fig. 3, the holes 309 of the mesh heater are visible. Each of these holes 309 has a size of approximately 70 microns. In this example, the holes 309 have a substantially square cross-section, and the size is equal to the length of the side of the square cross-section.

The porous ceramic body 302 is made entirely of aluminum oxide. The porous ceramic body 302 contains pores with pore sizes from 2.5 microns to 40 microns. The average pore size is approximately 10 microns. The porosity of the porous ceramic body 302 is approximately 40%.

The porous ceramic body 302 comprises a first portion 320 and a projecting portion 322. The first portion 320 has a substantially circular cross-section. This circular cross-section has a diameter of approximately 15 mm. The first portion 320 has a thickness of approximately 2 mm.

The projecting part 322 has a substantially annular or annular cross-section. The projecting part 322 is located on the periphery of the first part 320 and extends substantially around the entire periphery of the first part 320. The projecting part 322 extends approximately 10 mm substantially perpendicularly from the surface of the first part 320. The projecting part 322 has a width of approximately 2 mm. The width of the substantially annular projecting part is the difference between the outer and inner radii of the annular space.

The first part 320 of the porous ceramic body 302 contains a channel 314 passing through it. The channel 314 passes substantially in the thickness direction of the first part 320. Thus, the channel 314 passes substantially perpendicular to the plane of the mesh heater 304. The channel 314 has a diameter of approximately 500 microns.

Fig. 5 and 6 show a perspective view and a cross-sectional view of the second heating unit 500, respectively. Fig. 5 also shows a component 288 for storing a liquid substrate that forms an aerosol.

The second heating unit 500 comprises a porous ceramic body 502 and a mesh heater 504. The porous ceramic body 502 is identical to the porous ceramic body 302 of the first heating unit 300.

The mesh heater 504 comprises a hybrid mesh comprising stainless steel wires 506 and viscose fibers 508. The stainless steel wires 506 are intertwined with the viscose fibers 508 and are substantially perpendicular to them. The mesh heater 504 is connected to the porous ceramic body 502. In particular, the mesh heater 504 is attached to the porous ceramic body 502. To attach the mesh heater 504 to the porous ceramic body 502, two metal segments 510, 512 are applied to the porous ceramic body 502. In this example, the metal segments 510, 512 are made of tin, although silver or other suitable materials could be used. Then, the mesh heater 504 is positioned so that the metal segments 510, 512 are located between the porous ceramic body 502 and the mesh heater 504. Then, the mesh heater 504 is pressed against the porous ceramic body 502 and pushed into the metal segments 510, 512. The metal segments 510, 512 adhere the porous ceramic body 502 to the mesh heater 504. In some examples, the metal segments cover the mesh heater. In some examples, heating is applied simultaneously with pressing the mesh heater against the porous ceramic body.

The second heating unit 500 also comprises two electrodes 511, 513. These electrodes are made of tin and are in contact with several stainless steel wires 506 and viscose fibers 508 of the mesh heater 504. When the second heating unit 500 replaces the first heating unit 300 in the cartridge 200 shown in Figs. 1 and 2, each of the electrodes 511, 513 is electrically connected to an electrical contact 214, 216 on the cartridge 200. This electrical connection is wired and is not shown in Fig. 1 or 2. The stainless steel wires 506 are electrically connected to the electrical contacts 214, 216 through this electrical connection.

The stainless steel wires 506 and the viscose fibers 508 of the mesh heater 504 have diameters of approximately 17 microns. The thickness of the mesh heater 504 is approximately 51 microns. In Fig. 5, the holes 509 of the mesh heater are visible. Each of these holes has a size of approximately 70 microns. In this example, the holes 509 have a substantially square cross-section, and the size is equal to the length of a side of the square cross-section.

The mesh heater 504 is in contact with the porous ceramic body 502 over substantially the entire surface of the mesh heater 504. In use, the liquid substrate forming the aerosol, held in the pores of the porous ceramic body 502, is drawn into the openings 509 of the mesh heater 504.

In use, the second heating assembly 500 functions in much the same way as the first heating assembly 300. The second heating assembly 500 may replace the first heating assembly 300 shown in the aerosol generating system of Fig. 1. In this case, in use, the system 100 functions in an identical manner, but power is supplied to the mesh heater 504 of the second heating assembly 500 via the tin electrodes 511, 513 (rather than via the soldering points 310, 312 of the first heating assembly 300).

Fig. 7 and 8 show a perspective view and a cross-sectional view of the third heating unit 700. Fig. 7 also shows a component 1008 for storing a liquid aerosol-forming substrate.

The third heating unit 700 comprises a porous ceramic body 702 and a mesh heater 704. The porous ceramic body 702 is identical to the porous ceramic body of the first heating unit 302.

The mesh heater 704 comprises a perforated plate 706 made of stainless steel. The stainless steel of the plate 706 of the mesh heater 704 is an effective current-collecting material. Thus, the plate 706 acts as a current collector.

In order to attach the plate 706 to the porous ceramic body 702, the plate 706 is placed in contact with the porous ceramic body 702. Then, a coating layer 708 of ceramic paste is applied to the plate 706. Part of the paste is located on the plate 706, and part of the paste is located on the porous ceramic body 702. The paste applied to the porous ceramic body 702 can be applied beyond the periphery of the plate 706 or through the openings 709 of the plate 706, or, as in this example, in both ways. At least a part of the plate 706 is located between the coating layer 708 and the porous ceramic body 702. Then, the coating layer 708 is sintered. At the same time, the porous ceramic body 702 is sintered. In this example, the covering layer 708 is formed from aluminum oxide identical to the aluminum oxide of the porous ceramic body 702. The covering layer 708 adheres the porous ceramic body 702 to the plate 706.

The perforations in the plate 706 form openings 709 with substantially circular cross-sections. In Fig. 7, openings 709 of the mesh heater 704 are visible. Each of these openings has a size of approximately 75 microns. In this example, openings 709 have a substantially circular cross-section, and the size is equal to the diameter of the circular cross-section.

The mesh heater 704 is in contact with the porous ceramic body 702 over substantially the entire surface of the mesh heater 704.

Fig. 9 shows a cross-sectional view of an aerosol generating system 900. The aerosol generating system 900 comprises an aerosol generating device 950 and a cartridge 1000 with a third heating unit 700. In this example, the aerosol generating system 900 is an electrically controlled smoking system.

The aerosol generating device 950 is portable and has a size comparable to the size of a traditional cigar or cigarette. The device 950 comprises a battery 952, such as a lithium iron phosphate battery, and a controller 954 electrically connected to the battery 952. The device 950 also comprises an induction coil 956 electrically connected to the battery 952. The device 950 also comprises an air inlet 958 and an air outlet 960 in fluid communication with the air inlet 958.

The cartridge 1000 comprises an air inlet 1002, an air outlet 1004 and a third heating unit 700. The air inlet 1002 is in fluid communication with the air outlet 1004. The heating unit 700 is located downstream of the air inlet 1002 and upstream of the air outlet 1004. When the cartridge 1000 is connected to the aerosol generating device 950, as shown in Fig. 9, the air outlet 960 of the device 950 is adjacent to the air inlet 1002 of the cartridge 1000. Thus, in use, when the user takes a puff from the air outlet 1004 of the cartridge 1000, the air passes through the air inlet 958 of the device 950, then through the air outlet 960 of the device 950, then through the air inlet 1002 of the cartridge 1000, then past the heating unit 700, then through the air outlet 1004 of the cartridge 1000.

In Fig. 9, the cartridge 1000 is connected to the aerosol generating device 950 by mating the screw thread 1006 of the cartridge 1000 with the corresponding screw thread 962 of the aerosol generating device 950.

The cartridge 1000 further comprises a component 1008 for storing a liquid aerosol-forming substrate, which is in fluid communication with the porous ceramic body 702. The component 1008 for storing a liquid aerosol-forming substrate is in contact with the first portion 720 of the porous ceramic body 702. The component 1008 for storing a liquid aerosol-forming substrate may be glued to the porous ceramic body 702 using an adhesive, or may be held in place by friction, or may be held in place in another suitable way. The component 1008 for storing a liquid aerosol-forming substrate in this example is a capillary material having a fibrous or spongy structure. The capillary material is made of polyester, although any suitable material can be used. The capillary material is impregnated with the aerosol-forming substrate. Thus, in Fig. 9 the aerosol-forming substrate is stored in the pores of the porous ceramic body 702 and in the component 1008 for storing the liquid aerosol-forming substrate.

In use, the user takes a puff from the air outlet 1004 of the cartridge 1000. At the same time, the user presses a button (not shown) on the aerosol generating device 950. Pressing this button sends a signal to the controller 954, causing the battery 952 to supply a high-frequency electric current to the induction coil 956. This causes the induction coil to generate an oscillating electromagnetic field. The mesh heater 704 is located inside this field. Thus, this oscillating electromagnetic field generates eddy currents and hysteresis losses in the stainless steel plate 706, which acts as a current-collecting heating element in the cartridge 1000. Thus, the plate 706 is heated inductively. In other examples, an air flow sensor or a pressure sensor is located in the device 950 and is electrically connected to the controller 954. The air flow sensor or the pressure sensor detects that the user takes a puff through the air outlet 1004 of the cartridge 1000 and sends a signal to the controller 954 to supply power to the mesh heater 704. Thus, in these examples, the user does not need to press a button to heat the mesh heater 704. The liquid aerosol-forming substrate held in the pores of the porous ceramic body 702 is drawn into the openings of the plate 706 of the mesh heater 704 due to capillary action. The mesh heater 704 heats this liquid aerosol-forming substrate to evaporate the aerosol-forming substrate.

When the user takes a puff through the air outlet 1004 of the cartridge 1000, air is drawn into the air inlet 958 of the device 950, then through the air outlet 960 of the device 950, then through the air inlet 1002 of the cartridge 1000. This air then passes around the heating unit 700 and is directed to the air outlet 1004. This air flow captures the vapor formed when the liquid substrate forming the aerosol is heated by the mesh heater 704. This captured vapor is then cooled and condensed to form an aerosol. This aerosol is then supplied to the user through the air outlet 1004.

As the liquid aerosol-forming substrate is drawn from the porous ceramic body 702 into the openings 709 of the mesh heater 704 and evaporates, the liquid aerosol-forming substrate is also drawn from the component 1008 for storing the liquid aerosol-forming substrate into the porous ceramic body 702. Thus, the user may be able to generate more aerosol than if the component 1008 for storing the liquid aerosol-forming substrate were not present.

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." Furthermore, all ranges include the disclosed minimum and maximum points and include any intermediate ranges therein that may or may not be specifically recited herein. Accordingly, in this context, the number A is to be understood as A ± 10% of A.

Claims (17)

1. A cartridge for use in an aerosol generating system, the cartridge comprising: a porous ceramic body having a porosity of from 30 to 65%; and a mesh heater engaged with the porous ceramic body, wherein the mesh heater comprises a plurality of holes, wherein each hole has a size of from 50 to 200 μm, wherein the mesh heater is a hybrid mesh heater comprising a mesh of wires and fibers, wherein the fibers have a material composition different from the material composition of the wires. 2. The cartridge according to item 1, characterized in that, during use, the liquid substrate forming the aerosol is drawn into the openings of the mesh heater from the porous ceramic body due to capillary action. 3. A cartridge according to any of the preceding claims, characterized in that the fibers contain either glass fibers or viscose fibers, or both. 4. A cartridge according to any of the preceding paragraphs, characterized in that the mesh heater is engaged with the porous ceramic body over substantially the entire surface of the mesh heater. 5. The cartridge according to item 4, characterized in that the mesh heater is in contact with the porous ceramic body over substantially the entire surface of the mesh heater. 6. A cartridge according to any of the preceding paragraphs, characterized in that the cartridge contains pores with an average pore size of 2.5 to 40 microns. 7. A cartridge according to any of the preceding paragraphs, characterized in that the porous ceramic body comprises a first portion and a protruding portion. 8. The cartridge according to item 7, characterized in that the protruding portion is located on the periphery of the first part and extends essentially along the entire periphery of the first part. 9. A cartridge according to any of the preceding paragraphs, characterized in that the porous ceramic body contains a channel passing through it, having a diameter of from 300 to 800 microns. 10. A cartridge according to any one of the preceding claims, comprising a metal segment located between a porous ceramic body and a mesh heater. 11. A cartridge according to any of the preceding claims, further comprising a ceramic coating layer, wherein the mesh heater is located between the porous ceramic body and said ceramic coating layer. 12. The cartridge according to item 11, characterized in that the mesh heater is attached to the porous ceramic body by the said ceramic covering layer. 13. An aerosol generating system comprising an aerosol generating device and a cartridge according to any of the preceding claims. 14. An aerosol generating system according to claim 13, characterized in that the aerosol generating device comprises a power source configured to supply power to the mesh heater for resistively heating the mesh heater. 15. An aerosol generating system according to claim 13, characterized in that the aerosol generating device contains a power source, and the cartridge or aerosol generating device contains an inductor, and the power source and inductor are designed with the possibility of inductively heating the mesh heater.