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WO2024189342A1 - Ensemble dispositif de chauffage, système de fourniture d'aérosol et procédé - Google Patents

Ensemble dispositif de chauffage, système de fourniture d'aérosol et procédé Download PDF

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Publication number
WO2024189342A1
WO2024189342A1 PCT/GB2024/050660 GB2024050660W WO2024189342A1 WO 2024189342 A1 WO2024189342 A1 WO 2024189342A1 GB 2024050660 W GB2024050660 W GB 2024050660W WO 2024189342 A1 WO2024189342 A1 WO 2024189342A1
Authority
WO
WIPO (PCT)
Prior art keywords
heater assembly
heater
aerosol
centre
substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/GB2024/050660
Other languages
English (en)
Inventor
Ugurhan Yilmaz
Howard ROTHWELL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nicoventures Trading Ltd
Original Assignee
Nicoventures Trading Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nicoventures Trading Ltd filed Critical Nicoventures Trading Ltd
Priority to KR1020257030557A priority Critical patent/KR20250139888A/ko
Publication of WO2024189342A1 publication Critical patent/WO2024189342A1/fr
Priority to MX2025010785A priority patent/MX2025010785A/es
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/48—Fluid transfer means, e.g. pumps
    • A24F40/485—Valves; Apertures
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/10—Devices using liquid inhalable precursors
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/44—Wicks
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46—Shape or structure of electric heating means

Definitions

  • the present disclosure relates to electronic aerosol provision systems such as nicotine delivery systems (e.g. electronic cigarettes and the like).
  • nicotine delivery systems e.g. electronic cigarettes and the like.
  • Electronic aerosol provision systems such as electronic cigarettes (e-cigarettes) generally contain a reservoir of a source liquid containing a formulation, typically including nicotine, from which an aerosol is generated, e.g. through heat vaporisation.
  • An aerosol source for an aerosol provision system may thus comprise a heater having a heating element arranged to receive source liquid from the reservoir, for example through wicking I capillary action. While a user inhales on the device, electrical power is supplied to the heating element to vaporise source liquid in the vicinity of the heating element to generate an aerosol for inhalation by the user.
  • Such devices are usually provided with one or more air inlet holes located away from a mouthpiece end of the system.
  • Such electronic aerosol provision systems are provided with heater assemblies suitable for heating the source liquid to form an aerosol.
  • a heater assembly is a wick and coil heater assembly, which is formed of a coil of wire (typically nichrome NiCr 8020) wrapped or coiled around a wick (which typically comprises a bundle of collected fibres, such as cotton fibres, extending along the longitudinal axis of the coil of wire). Ends of the wick extend either side of the coil of wire and are inserted into the reservoir of source liquid.
  • Such heater assemblies are not necessarily suited for all applications or all configurations of electronic aerosol provision systems. Such problems associated with these heater assemblies typically concern burning or charring of the wick material caused by the heater operating at too high a temperature, particularly when insufficient liquid is supplied to the heater assembly. In addition, the performance characteristics of these heater assemblies are generally not considered optimal and alternative solutions which are capable of providing more optimal aerosol delivery are desired. Various approaches are described which seek to help address some of these issues.
  • a heater assembly for an aerosol provision system, the heater assembly defining a three-dimensional object having a plurality of outer surfaces.
  • the heater assembly includes a substrate; a heater layer configured to generate heat when supplied with energy, the heater layer provided on the substrate at a first outer surface of the heater assembly; one or more capillary tubes extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, the second outer surface substantially opposite the first outer surface; and one or more distribution channels extending from a third outer surface of the substrate to at least one capillary tube for supplying aerosol-generating material to the one or more capillary tubes.
  • the third outer surface is a side surface of the heater assembly, the side surface sharing an edge with at least one of the first outer surface and the second outer surface, and wherein the distance from the centre of the third outer surface to the centre of the heater assembly is shorter than a distance between the centre of any other side surface of the heater assembly to the centre of the heater assembly.
  • an aerosol provision system wherein the aerosol provision system includes the heater assembly of the first aspect and an aerosol-generating material storage portion for storing aerosol-generating material, wherein the heater assembly is arranged relative to the aerosol-generating material storage portion such that aerosol-generating material is capable of being fed to the third outer surface.
  • a method for manufacturing a heater assembly for an aerosol provision system the heater assembly defining a three-dimensional object having a plurality of outer surfaces.
  • the method includes providing a substrate; providing a heater layer on the substrate at a first outer surface of the heater assembly, the heater layer configured to generate heat when supplied with energy; providing one or more capillary tubes extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, the second outer surface substantially opposite the first outer surface; and providing one or more distribution channels extending from a third outer surface of the substrate to at least one capillary tube for supplying aerosol-generating material to the one or more capillary tubes.
  • the third outer surface is a side surface of the heater assembly, the side surface sharing an edge with at least one of the first outer surface and the second outer surface, and wherein the distance from the centre of the third outer surface to the centre of the heater assembly is shorter than a distance between the centre of any other side surface of the heater assembly to the centre of the heater assembly.
  • a heater means for an aerosol provision system the heater means defining a three-dimensional object having a plurality of outer surfaces.
  • the heater means includes a substrate; heater layer means configured to generate heat when supplied with energy, the heater layer means provided on the substrate at a first outer surface of the heater means; capillary means extending from a second outer surface of the heater means through the heater layer means provided on the first outer surface of the heater means, the capillary means for supplying aerosol-generating material to the heater layer means for vaporisation, the second outer surface substantially opposite the first outer surface; and distribution means extending from a third outer surface of the substrate to the capillary means for supplying aerosol-generating material to the capillary means.
  • the third outer surface is a side surface of the heater means, the side surface sharing an edge with at least one of the first outer surface and the second outer surface, and wherein the distance from the centre of the third outer surface to the centre of the heater means is shorter than a distance between the centre of any other side surface of the heater means to the centre of the heater means.
  • Figure 1 is a perspective view of an aerosol provision system in accordance with aspects of the present disclosure
  • Figure 2 is an exploded perspective view of a cartomiser suitable for use in the aerosol provision system of Figure 1;
  • Figures 3a and 3b schematically show parts of the cartomiser of Figures 1 and 2 in more detail, where Figure 3a shows a cross-sectional view of a lower part of the cartomiser, and Figure 3b shows a cross-sectional view of the lower surface of the upper clamping unit and heater assembly, in particular showing the elongate recess of the upper clamping unit;
  • Figure 4 is a perspective view of a heater assembly in accordance with a first aspect of the present disclosure, wherein the heater assembly comprises a substrate, an electrically resistive layer, capillary tubes extending through the substrate and electrically resistive layer, and one or more distribution channels formed via interconnected pores in the substrate;
  • Figure 5 is a perspective view of a heater assembly in accordance with a second aspect of the present disclosure, wherein the heater assembly comprises a substrate, an electrically resistive layer, capillary tubes extending through the substrate and electrically resistive layer, and one or more distribution channels formed via an engineering process in the substrate;
  • Figure 6 shows a top-down view of a heater assembly identifying the various dimensions/distances from side surfaces of the heater assembly to the centre;
  • Figures 7a and 7b schematically shows a second implementation of a cartomiser including a heater assembly, whereby the air flow is across the heater layer of the heater assembly and whereby the entire side surfaces are exposed to the aerosol-generating material storage portion;
  • Figure 8 is a method in accordance with aspects of the present disclosure for forming a heater assembly.
  • a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
  • the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device, electronic cigarette or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
  • END electronic nicotine delivery system
  • e-cigarette is sometimes used but this term may be used interchangeably with aerosol (vapour) provision system.
  • the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated.
  • Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.
  • the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosolgenerating material.
  • the solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
  • the or each aerosol-generating material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
  • the active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response.
  • the active substance may for example be selected from nutraceuticals, nootropics, psychoactives.
  • the active substance may be naturally occurring or synthetically obtained.
  • the active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
  • the active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
  • the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
  • the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
  • botanical includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.
  • the material may comprise an active compound naturally existing in a botanical, obtained synthetically.
  • the material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like.
  • Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon
  • the mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v..Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
  • the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
  • the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.
  • the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.
  • flavour and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch,
  • the flavour comprises menthol, spearmint and/or peppermint.
  • the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.
  • the flavour comprises eugenol.
  • the flavour comprises flavour components extracted from tobacco.
  • the flavour comprises flavour components extracted from cannabis.
  • the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect.
  • a suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
  • the aerosol-former material may comprise one or more constituents capable of forming an aerosol.
  • the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
  • the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
  • An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol.
  • the aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.
  • the aerosol-modifying agent may, for example, be an additive or a sorbent.
  • the aerosolmodifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent.
  • the aerosol-modifying agent may, for example, be a solid, a liquid, or a gel.
  • the aerosol-modifying agent may be in powder, thread or granule form.
  • the aerosol-modifying agent may be free from filtration material.
  • the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
  • the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
  • the non-combustible aerosol provision system such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller.
  • the power source may, for example, be an electric power source.
  • the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
  • the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, and/or an aerosol-modifying agent.
  • An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material.
  • the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.
  • a heater assembly which includes one or more capillary tubes extending through the heater assembly from one side to another side of the heater assembly.
  • the function of the capillary tubes is to supply liquid aerosol-generating material (or any other aerosol-generating material capable of flowing) from the first side of the heater assembly to a second side of the heater assembly where a heater layer (i.e. a layer that is configured to increase its temperature in response to application of electrical power) is capable of vaporising the liquid aerosol-generating material.
  • a heater layer i.e. a layer that is configured to increase its temperature in response to application of electrical power
  • One or more distribution channels are provided in the substrate forming the heater assembly.
  • the distribution channels are provided on a side surface of the heater assembly, and more particularly a side surface (or surfaces) that has the shortest distance between the centre of that surface and the centre of the heater assembly. In other words, the distance from the centre of the given side surface to the centre of the heater assembly is shorter than a distance between the centre of any other side surface of the heater assembly to the centre of the heater assembly. For a rectangular cuboid shaped heater assembly, these are the two surfaces with the second greatest surface area.
  • the distribution channels are configured to supply aerosol-generating material to the capillary tubes passing through the heater assembly.
  • an aerosol provision system encompassing the heater assembly (such as in a cartomiser of the aerosol provision system) can be arranged such that the one or more distribution channels on the side surfaces of the heater assembly are provided in direct contact with the aerosol-generating material storage portion for storing the aerosolgenerating material.
  • distribution channels which typically have a much shorter distance to the centre to the heater assembly can be supplied with aerosol-generating material to feed the capillary tubes (that subsequently feed the heater layer) to thereby enable a more rapid (and larger, i.e., by mass) supply of aerosol-generating material to the heater layer.
  • the distribution channels for feeding the capillary tubes are provided on the surface that has the second largest surface area, a larger number of distribution channels may be provided thereby further enhancing the supply of aerosolgenerating material to the heater layer. Therefore, it can be seen that providing the heater assembly with one or more distribution channels on the side surface of a substrate of the heater assembly and exposing this side surface to the aerosol-generating material storage portion may help improve the performance of the heater assembly, in terms of the ability to transport liquid aerosol-generating material to the heater layer.
  • FIG. 1 schematically shows an aerosol provision system 1 in accordance with aspects of the present disclosure.
  • the aerosol provision system 1 comprises an aerosol provision device 2 and a consumable 3, herein shown and referred to as a cartomiser 3.
  • the aerosol provision device 2 and the cartomiser 3 together form the aerosol provision system 1.
  • the cartomiser 3 is configured to engage and disengage with the aerosol provision device 2. That is, the cartomiser 3 is releasably connected I connectable to the aerosol provision device 2. More specifically, the cartomiser 3 is configured to engage I disengage with the aerosol provision device 2 along the longitudinal axis L1.
  • the cartomiser 3 and aerosol provision device 2 are provided with suitable interfaces to allow the cartomiser 3 and aerosol provision device 2 to engage I disengage from one another, e.g., a push fit interface, a screwthread interface, etc.
  • the cartomiser 3 comprises a reservoir which stores an aerosol-generating material. Accordingly, the reservoir may also be referred to as an aerosol-generating material storage portion.
  • the aerosol-generating material is a liquid aerosol-generating material.
  • the liquid aerosol-generating material (herein sometimes referred to simply as liquid, source liquid or e-liquid) may be a conventional e-liquid which may or may not contain nicotine. However, it should be appreciated that other liquids and / or aerosol-generating materials may be used in accordance with the principles of the present disclosure.
  • the cartomiser 3 is able to be removed from the aerosol provision device 2 when, for example, the cartomiser 3 requires refilling with liquid or replacement with another (full) cartomiser 3.
  • the aerosol provision device 2 comprises a power source (such as a rechargeable battery) and control electronics.
  • the cartomiser 3 comprises an electrically powered heater assembly.
  • the control electronics of the aerosol provision device 2 are configured to supply electrical power to the heater assembly of the cartomiser 3 to cause the heater assembly to generate an aerosol from the liquid aerosol-generating material supplied thereto.
  • the control electronics may be provided with various components to facilitate I control the supply of power to the cartomiser 3.
  • control electronics may be provided with an airflow sensor (not shown) configured to detect when a user of the aerosol provision system 1 inhales on the aerosol provision system and to supply power in response to such a detection and / or a push button (not shown) which is pressed by the user and to supply power in response to such a detection.
  • Additional functions may be controlled by the control electronics depending on the configuration of the aerosol provision device 2 (for example, the control electronics may be configured to control I regulate recharging of the power source, or to facilitate wireless communication with another electronic device, such as a smartphone).
  • the features and functions of the aerosol provision device 2 are not of primary significance in respect of the present disclosure.
  • FIG 2 shows an example cartomiser 3 suitable for use in the aerosol provision system of Figure 1. From the exploded view of Figure 2, it may be seen that the cartomiser 3 is assembled from a stack of components: an outer housing 4, an upper clamping unit 5, a heater assembly 6, a lower support unit 7 and an end cap 8.
  • the cartomiser 3 has a top end 31 and a bottom end 32 which are spaced apart along the longitudinal axis L1 , which is the longitudinal axis of the cartomiser as well as being the longitudinal axis of the aerosol provision system 1.
  • the top end 31 of the cartomiser 3 defines a mouthpiece 33 of the aerosol provision system 1 (around which a user may place their mouth and inhale).
  • the mouthpiece 33 includes a mouthpiece orifice 41 which is provided at the top end 42 of outer housing 4 in the centre of a top face 43.
  • the outer housing 4 includes a circumferential side wall 44 which leads down from the top end 42 to a bottom end 45 of the outer housing 4 and which defines an internal reservoir 46 for holding the liquid aerosol-generating material.
  • the bottom end 45 of the outer housing Prior to assembly of the cartomiser 3, the bottom end 45 of the outer housing is open, but upon assembly the bottom end 45 is closed by a plug formed by the upper clamping unit 5 and the lower support unit 7 which are stacked together with the heater assembly 6 positioned therebetween.
  • the upper clamping unit 5 is an intermediate component of the stack of components.
  • the upper clamping unit 5 includes a foot 51 in the form of a block and an upwardly extending air tube 52.
  • the foot 51 On each side of the air tube 52, the foot 51 includes a well 53 which descends from a flat top surface 54 to a flat bottom surface (not shown in Figure 2) of the foot 51.
  • each well 53 At the bottom surface, each well 53 is open and, specifically, opens into an elongate recess formed in the bottom surface, with the depth of the recess broadly matching the thickness of the heater assembly 6.
  • the recess is provided to accommodate the heater assembly 6 when the upper clamping unit 5 is engaged with the lower support unit 7, however the recess portion is also sized so as to provide a gap around at least a part of the periphery of the heater assembly 6 when the heater assembly 6 is located in the recess portion.
  • the foot 51 is designed to engage with the outer housing 4 (more specifically, such that the outer circumferential surface of the foot is pressed against an inner circumferential surface of the outer housing 4).
  • the foot 51 may have a suitable shape and include suitable sealing components to reduce or prevent liquid from leaking between the outer surface of the foot 51 and the inner surface of the housing 4.
  • the air tube 52 extends up from the bottom of the wells 53 and defines an internal air passage 58.
  • the air tube 52 extends up to and encircles the mouthpiece orifice 41.
  • the outer housing 4 and/or the air tube 52 may be suitably configured so as to provide a liquid- (and optionally air-) tight seal between the two.
  • air I aerosol is intended to pass along the air tube 52 and out of the mouthpiece orifice 41 , while the space around the air tube 52 and within the outer housing 4 defines the reservoir 46 for storing the liquid aerosolgenerating material.
  • the reservoir 46 is a sealed volume defined by the outer housing 4, the outer surface of the air tube 52, and the foot 51.
  • the lower support unit 7 is in the form of a block having a broadly flat top surface 71 and a flat bottom surface 72.
  • a central air passage 73 extends upwardly from the bottom surface 72 to the top surface 71.
  • the block of the lower support unit 7 includes a through hole 74.
  • a co-moulded contact pad 75 in the form of a pin is inserted into the through holes 74. More specifically, each contact pad 75 is press fit in its respective through hole 74.
  • Each contact pad 75 provides an electrical connection path from the bottom surface 72 to a respective end portion of the heater assembly 6 when the heater assembly 6 is sandwiched between the top surface 71 of the lower support unit 7 and the recess of the bottom surface 55 of the upper clamping unit 5.
  • the lower support unit 7 is designed to engage with the outer housing 4 (more specifically, such that the outer circumferential surface of the lower support unit 7 is pressed against an inner circumferential surface of the outer housing 4).
  • the lower support unit 7 may have a suitable shape and include suitable sealing components to reduce or prevent liquid from leaking between the outer surface of the lower support unit 7 and the inner surface of the housing 4.
  • the foot 51 of the upper clamping unit 5 and the lower support unit 7 combine together to form a plug which seals the bottom end of the reservoir 46.
  • the cartomiser 3 includes an end cap 8 at its bottom end.
  • the end cap 8 is made of metal and serves to assist with retaining the cartomiser 3 in the aerosol provision device 2 when the cartomiser 3 is plugged in to the top end of the aerosol provision device 2, because, in this example, the aerosol provision device 2 is provided with magnets which are attracted to the metal of the end cap 8.
  • the end cap 8 has a bottom wall 81 with a central opening 82 (not shown in Figure 2).
  • the end cap 8 also has a circumferential side wall 83 which has two opposed cut-outs 84 which latch onto corresponding projections 49 on the outer surface of the bottom end of the side wall 44 of the outer housing 4, so that the end cap 8 has a snap-fit type connection onto the bottom end of the outer housing 4.
  • the cartomiser 3 could be provided with indentations which engage with projections at the top end 21 of the main housing 2, so that a releasable connection is provided between the cartomiser and the main housing.
  • the cartomiser 3 is provided what may more generally be referred to as a device interface which is a part of the cartomiser 3 that interfaces with the main housing 2 (or aerosol-generating device 2).
  • the device interface may include the metal cap 8 including the bottom wall 81 and circumferential side wall 83 and I or the lower support unit 7 including the bottom surface 72.
  • the device interface of the cartomiser 3 may encompass any part or parts of the cartomiser 3 that contact, abut, engage or otherwise couple to the main housing 2.
  • an overall air passage exists from the bottom end 32 to the top end 31 of the cartomiser 3 and it is formed by the air passage 73 leading to the air passage 58 which, in turn, leads to the mouthpiece orifice 41. Where the air passage 73 meets the air passage 58, the air flow bifurcates as it passes around the side edges of the heater assembly 6.
  • the top end 21 of the aerosol provision device 2 includes an air inlet hole 22 on each side of the aerosol provision device 2 (with one of the two air inlet holes 22 being visible in Figure 1). Air can enter the air inlet holes 22 and flow transversely inwards to the longitudinal axis L1 so as to enter the bottom end of the air passage 73 of the lower support unit 7 and to start to flow in the direction of the longitudinal axis L1 towards the mouthpiece 33.
  • Figure 3a schematically shows a part of the cartomiser 3 of Figures 1 and 2 in cross-section. Specifically, Figure 3a shows a part of the cartomiser 3 corresponding to the lower part of the cartomiser 3, where “lower” as used here refers to a part of the cartomiser 3 closer to the cap 8 than the mouthpiece 33.
  • the cross-section shown is that of a plane extending along the longitudinal axis L1 of the cartomiser 3 and perpendicular to the longitudinal extent of the heater assembly 6.
  • Figure 3b schematically shows a view along the longitudinal axis L1 of the cartomiser 3 towards the bottom surface 55 of the upper clamping unit 5 with the heater assembly 6 in position (note, this view is along the direction shown in Figure 3a and labelled “B”). Certain features of cartomiser 3 of Figures 1 and 2 have been omitted for clarity.
  • Figures 3a and 3b show the relative arrangement of the heater assembly 6, the upper clamping unit 5 and lower support unit 7, and in particular, the position of the well 53 and well openings 53a formed in the foot 51 of the upper clamping unit 5 relative to the ends of the heater assembly 6.
  • the heater assembly 6 is located in the elongate recess provided in the foot 51 of the upper clamping unit 5.
  • the heater assembly 6 is provided such that, when the cartomiser 3 is assembled, a first surface 6a of the heater assembly 6 abuts the top surface 71 of the lower support unit 7.
  • the foot 51 of the upper clamping unit 5 includes the elongate recess which is suitable for accommodating the heater assembly 6.
  • the elongate recess is sized such that it has a depth approximately equal to the depth or thickness of the heater assembly 6, a width approximately equal to the width of the heater assembly 6, and a length approximately equal to the length of the heater assembly 6.
  • elongate recess has a portion where the width of the recess is greater than the width of the heater assembly 6.
  • Figure 3b shows the elongate recess as having a width greater than the width of the heater assembly 6 in the regions corresponding to the well openings 53a (that is, where the well openings 53a overlap the heater assembly 6).
  • This region where the recess is wider than the width of the heater assembly 6 is shown in Figure 3b as being towards either end of the heater assembly 6.
  • at least a part of the longer side surfaces of the heater assembly 6 are exposed to the wells 53 and, therefore, are exposed to liquid aerosol-generating material stored in the reservoir 46.
  • the heater assembly 6 is sandwiched between the lower surface of the air tube 52 and the foot 51 of the upper clamping unit 5 and the top surface 71 of the lower support unit 7.
  • the lower surface of the air tube 52 and the lower surface of the foot 51 contact a second surface 6b of the heater assembly 6, where the second surface 6b of the heater assembly 6 is opposite the first surface 6a of the heater assembly 6.
  • the lower surface of the air tube 52 together with the recess portion of the foot 51 create a seal between the reservoir 46 and the air channel 581 air channel 73.
  • the heater assembly 6 i.e., the regions of the heater assembly 6 overlapping the wells 53 / well openings 53a
  • a portion of the heater assembly 6 i.e., a central portion of the heater assembly 6
  • the wells 53 and well openings 53a allow liquid aerosol-generating material to contact the parts of the heater assembly 6 that overlap with the openings 53a of the wells 53.
  • the second surface 6b of the heater assembly 6 is able to contact the liquid aerosolgenerating material in the reservoir 46 and, by virtue of the fact that the elongate recess is sized to be wider than the heater assembly 6 in regions overlapping the wells 531 well openings 53a, a third (outer) surface 6c of the heater assembly 6 is also able to contact the liquid aerosol-generating material in the reservoir 46.
  • the third surface 6c is the surface of the heater assembly 6 provided along either side of the heater assembly 6 and extending broadly in the direction of the longitudinal axis L1 (seen best in Figure 3b). In particular, the third surface 6c is defined by the length and thickness of the heater assembly 6.
  • Heating of the liquid to achieve vaporisation or aerosol generation is performed at least in the central portion of the heater assembly 6 such that vaporised liquid is able to be entrained in air passing around the central portion of the heater assembly 6 from air passage 73 that subsequently passes to air passage 58.
  • the heater assembly 6 is arranged in the cartomiser 3 such that multiple surfaces (or parts thereof) of the heater assembly 6 are provided in direct contact with the reservoir 46. It should be appreciated that the multiple surfaces (or parts thereof) of the heater assembly 6 are provided in contact with the liquid aerosol-generating material in the reservoir 46 only in the event that the liquid aerosol-generating material is present in the wells 53. For example, if the cartomiser 3 is inverted during use (i.e., rotated 180° about an axis perpendicular to the longitudinal axis L1), then any air within the reservoir 46 will likely occupy the well 53 instead of liquid aerosol-generating material.
  • a wicking material such as cotton or glass fibres, formed as a layer may be provided between the heater assembly 6 and the upper clamping unit 5, where the wicking material is in contact with the wells 53 and capable of transporting the liquid aerosol-generating material in the longitudinal direction of the wicking material I heater assembly 6 (along the longitudinal axis of the heater assembly 6).
  • the heater assembly 6 may be formed from a porous substrate (such as a sintered material or a ceramic).
  • the heater assembly 6 is a microfluidic heater assembly.
  • Figures 4 and 5 schematically illustrate the microfluidic heater assembly 6 in more detail, and in particular in a perspective view.
  • Figures 4 and 5 show certain elements of the heater assembly 6 in an exaggerated manner for the purposes of aiding understanding of the features of the heater assembly 6.
  • Figure 4 shows the microfluidic heater assembly 6 according to a first implementation
  • Figure 5 shows the microfluidic heater assembly 6 according to a second implementation.
  • the microfluidic heater assembly 6 comprises a substrate 62 and an electrically resistive layer 64 disposed on a surface of the substrate 62.
  • the substrate 62 is formed from a non-conductive material, such as quartz (silicon dioxide); however, it should be appreciated that other suitable non- conductive materials may be used, such as ceramics, for example. In other implementations, the substrate may be formed from a conductive material.
  • a non-conductive material such as quartz (silicon dioxide); however, it should be appreciated that other suitable non- conductive materials may be used, such as ceramics, for example.
  • the substrate may be formed from a conductive material.
  • the electrically resistive layer 64 is formed from any suitable electrically conductive material, for example a metal or a metal alloy such as titanium or nickel chromium.
  • the electrically resistive layer 64 may be formed on the surface of the substrate 62 in any suitable way.
  • the electrically resistive layer 64 may be provided as a film that is adhered or otherwise bonded to the surface of the substrate 62.
  • the electrically resistive layer 64 may be formed though a deposition technique, such as chemical or vapour deposition. The way in which the electrically resistive layer 64 is formed and the materials it is made therefrom is not of primary significance to the principles of the present disclosure.
  • the heater assembly 6 is planar and in the form of a rectangular cuboidal block, elongate in the direction of a longitudinal axis L2.
  • the heater assembly 6 has the shape of a strip and has parallel sides.
  • the heater assembly 6 has parallel upper and lower major (planar) surfaces (first surface 6a and second surface 6b) and parallel side surfaces (third surface 6c) and parallel end surfaces (fourth surface 6c). More particularly, the first and second surfaces 6a, 6b are defined by the width and length of the heater assembly 6, the third surfaces 6c are defined by the length and thickness of the heater assembly 6, and the fourth surfaces 6d are defined by the width and thickness of the heater assembly 6.
  • the third and fourth surfaces 6c, 6d are side surfaces of the heater assembly 6 and extend between the first and second surfaces 6a, 6b.
  • the third and fourth surfaces 6c, 6d may more generally be defined as surfaces that share an edge with the first and second surfaces 6a, 6b.
  • the first surface 6a, one third surface 6c and one fourth surface 6d are shown in Figures 4 and 5.
  • the length of the heater assembly 6 is 10 mm, its width is 1 mm, and its thickness is 0.12 mm (where the thickness of the substrate 62 is approximately 0.10 mm, and the thickness of the electrically resistive layer 64 is approximately 0.02 mm).
  • the small size of the heater assembly 6 enables the overall size of the cartomiser 3 to be reduced and the overall mass of the components of the cartomiser to be reduced.
  • the heater assembly 6 may have different dimensions and I or shapes depending upon the application at hand.
  • the heater assembly 6 may be a 3 x 3 mm chip.
  • the heater assembly 6 has a central portion 67 and first and second end portions 68, 69.
  • the length of the central portion 67 (relative to the lengths of the end portions 68, 69) has been exaggerated for reasons of visual clarity.
  • the central portion 67 is positioned in the air passage 73 and air passage 58.
  • the central portion 67 extends across the top end of the air passage 73 of the lower support unit 7 and across the bottom end of the air passage 58 of the upper clamping unit 5.
  • the end portions 68, 69 are positioned between the wells 53 of the upper clamping unit 5 and the lower support unit 7.
  • a plurality of capillary tubes 66 are provided in the central portion 67 of the heater assembly 6, a plurality of capillary tubes 66 are provided. Only the openings of the capillary tubes 66 are shown in Figures 4 and 5 (and in an exaggerated way for clarity), but the capillary tubes 66 extend from one side of the heater assembly 6 to the other. More specifically, the capillary tubes extend from the side of the heater assembly 6 opposite the electrically resistive layer 64 (the second surface 6b not shown in Figures 4 and 5), through the substrate 62 toward the face of the substrate 62 on which the electrically resistive layer 64 is disposed, and then through the electrically resistive layer 64 (the first surface 6a).
  • the plurality of capillary tubes 66 extend substantially linearly through the heater assembly 6 (that is, the capillary tubes 66 follow substantially linear paths). By substantially, it is meant that the capillary tubes 66 follow pathways that are within 5 %, within 2 % or within 1 % of a straight line. This measure may be obtained in any suitable way, e.g., by comparison of the length of the distance from a first point to a second point along the extent of the capillary tube 66 and the corresponding distance that the central axis of the capillary tube 66 extends between the same two points.
  • the capillary tubes 66 are formed in the heater assembly 66 via a manufacturing process.
  • the capillary tubes 66 do not naturally exist in the substrate material 62 or electrically resistive layer 64, but rather, the capillary tubes 66 are formed in the substrate material 62 and electrically resistive layer 64 through a suitable process.
  • a suitable process for forming the capillary tubes 66, particularly when forming capillary tubes that substantially follow a linear path, is laser drilling.
  • any other suitable technique may be employed in order to generate the capillary tubes 66.
  • the capillary tubes 66 are configured so as to transport liquid from one surface of the heater assembly 6 (i.e. , the second surface 6b) to the electrically resistive layer 64.
  • the exact dimensions of the capillary tubes 66, and in particular the diameter, may be set in accordance with the liquid to be stored in the reservoir 46 of the cartomiser 3 and subsequently used with the heater assembly 6.
  • the properties of the liquid aerosol-generating material (e.g., viscosity) in the reservoir 46 of the cartomiser 3 may dictate the diameter of the capillary tubes 66 to ensure that a suitable flow of liquid is provided to the electrically resistive layer 64.
  • the capillary tubes 66 may have a diameter on the order to tens of microns, e.g., between 10 pm to 250 pm, between 10 pm to 150 pm, or between 10 pm to 100 pm.
  • capillary tubes 66 in other implementations may be set differently based on the properties of the liquid to be vaporised and / or a desired supply of liquid to the electrically resistive layer 64.
  • FIG 4 shows a first implementation of a heater assembly 6 whereby the heater assembly 6 comprises a substrate 62 formed from or comprising a porous material.
  • the porous substrate 62 may be formed from naturally porous materials, such as sponges, porous stones or ceramics etc., or via materials that are engineered to be porous, such as sintered metals or other materials. These materials, either formed naturally or engineered, have pores or hollow regions which are interconnected and define passages that follow a substantially random path through the material.
  • the substrate 62 is formed from sintered quartz (silicon dioxide).
  • the interconnected pores or voids of the porous substrate 62 provide one or more distribution channels (shown representatively by reference sign 62a in Figure 4). More particularly, the interconnected pores or voids of the porous substrate 62 provide one or more naturally-formed distribution channels 62a in that these distribution channels 62a are either naturally occurring (e.g., in a porous ceramic) or occur naturally as a result of forming the substrate (e.g., a sintered quartz).
  • the one or more distribution channels 62a extend from the surface of the substrate 62 (e.g., the second surface 6b, third surface 6c or fourth surface 6d) through the substrate 62 following a substantially random path.
  • any liquid aerosol-generating material within the interconnected pores or voids that is able to travel along a path that intersects a capillary tube 66 is capable of being supplied to the capillary tube 66, and subsequently to the electrically resistive layer 64 via the capillary tube 66.
  • the naturally-formed distribution channels 62a are capable of supplying liquid-aerosol generating material to the capillary tubes 66, thereby aiding the wicking performance of the capillary tubes 6 6and the heater assembly 6.
  • Figure 5 shows a second implementation of a heater assembly 6 whereby the heater assembly 6 comprises a substrate 62 formed from a material that is substantially impermeable or impermeable.
  • the substantially impermeable substrate 62 is formed from a material that does not permit liquids (particularly liquid aerosol-generating material) to flow through it. It should be appreciated this relates only to the material from which the substrate 62 is made from.
  • the presence of the capillary tubes 66 allow for liquid aerosol-generating material to flow from one side of the substrate 62 to the other, but in the context of the material from which the substrate 62 is formed, liquid aerosol-generating material is not permitted to flow into or through the material itself.
  • Any suitable material may be used to provide the impermeable substrate 62; for example, bulk quartz (silicon dioxide) may be used.
  • the substrate 62 is provided with one or more distribution channels 62a.
  • the distribution channels 62 bare artificially-formed (or engineered) distribution channels. That is, the distribution channels 62b are formed by performing an engineering process, such as drilling, machining, etching etc. to form the distribution channels 62b.
  • the distribution channels 62b may be formed through the same process as forming the capillary tubes 66; for example, via laser drilling.
  • the distribution channels 62b extend from an opening in the side surface (in particular, the longitudinal side surface 6c) into the substrate 62. The distribution channels may pass all the way through the width of the substrate 62, or may only pass part way through the width of the substrate 62.
  • the distribution channels 62b are formed such that they intercept at least one capillary tube 66. That is, much like in the implementation of Figure 4, any liquid aerosol-generating material within the distribution channels 62b (for example, that enters via the opening on the third surface 6c of the heater assembly 6) is able to travel along a path that intersects a capillary tube 66, and is therefore capable of being supplied to the capillary tube 66, and subsequently to the electrically resistive layer 64 via the capillary tube 66.
  • the artificially-formed (engineered) distribution channels 62b are capable of supplying liquid-aerosol generating material to the capillary tubes 66, thereby aiding the wicking performance of the capillary tubes 66 and the heater assembly 6.
  • the distribution channels 62b are formed extending along a predetermined path as opposed to a more random path that is provided by the interconnected pores or voids.
  • the porous substrate 62 of the first implementation may be provided with the artificially-formed distribution channels 62b of the second implementation.
  • at least some of the random paths provided by the interconnected pores or voids may additionally or alternatively intersect the artificially-formed distribution channels 62a, and thereby be capable of supplying liquid aerosol-generating material to the capillary tubes 66.
  • the distribution channels 62a, 62b are configured such that they permit the flow of liquid aerosolgenerating material along the distribution channels 62a, 62b.
  • the average pore size and/or properties of the substrate 62 may be selected so as to encourage liquid along the random paths formed by the interconnected pores.
  • the size and shape (e.g., cross-section) of the distribution channels 62b may be chosen to so as to encourage liquid along the predetermined paths formed by the distribution channel 62b. It should be appreciated, however, that the properties of the liquid aerosol-generating material that the heater assembly 6 is to be used with may dictate the actual sizes, dimensions, etc. of the distribution channels 62a, 62b.
  • one or more distribution channels 62a, 62b are provided extending from the third outer surface 6c of the heater assembly 6.
  • the one or more distribution channels 62a, 62b extend from the third outer surface 6c of the heater assembly 6 at least to a position within the substrate 62, whereby liquid aerosolgenerating material is capable of being supplied to the capillary tubes 66 via the one or more distribution channels 62a, 62b.
  • the one or more distribution channels 62a, 62b are provided with inlets or openings that are present on the third outer surface 6c of the heater assembly 6, whereby the distance from the centre of the third outer surface 6c to the centre of the heater assembly 6 is shorter than a distance between the centre of any other side surface (e.g., the fourth outer surface 6d) of the heater assembly 6 to the centre of the heater assembly 6.
  • Figure 6 shows a top-down view of the substrate 62 of a heater assembly 6.
  • Figure 6 is provided for the purposes of explanation only; and thus is should be appreciated that the substrate 62 may be either of the substrates 62 from Figures 4 or 5.
  • Figure 6 shows the substrate 62 comprising the end portions 68, 69 and the central portion 67 (which comprises the capillary tubes 66 as described above). Additionally, the third surface 6c and the fourth surface 6d are also shown.
  • Figure 6 also illustrates two distances, d1 and d2.
  • the distance d1 is the distance between the centre of the third surface 6c and the centre of the heater assembly 6 (in a plane that is parallel to the first or second surfaces 6a, 6b), while the distance d2 is the distance between the centre of the fourth surface 6d and the centre of the heater assembly 6 (in a plane that is parallel to the first or second surfaces 6a, 6b).
  • the distance d2 is greater than the distance d1. Accordingly, when providing the distribution channels 62a and 62b, distribution channels 62a, 62b that are provided extending from the third surface 6c of the heater assembly 6 extend a shorter distance to the centre of the heater assembly 6 (i.e.
  • distribution channels 62a, 62b may enable liquid aerosol-generating material to be more rapidly provided to the capillary tubes 66 by virtue of the fact that the one or more distribution channels extend a shorter distance to the capillary tubes 66.
  • the distances d1 and d2 of Figure 6 do not necessarily represent the distances that the one or more distribution channels 62a, 62b extend.
  • the wells 53 / well openings 53a are generally provided at regions of the heater assembly 6 that may be beyond the central portion 67 comprising the capillary tubes 66 (that is, the wells 53 / well openings 53a do not overlap the central region 67 of the heater assembly 6).
  • the central portion 67 may be located within the air passage 58.
  • the one or more distribution channels 62a, 62b may instead be provided extending from suitable regions of the third surface 6c (i.e.
  • the distance that such a distribution channel extends is typically less than the distance that a distribution channel extending from the fourth surface 6d to the central portion 67, or at least is comparable.
  • a cartomiser 3 accommodating the heater assembly 6 in the orientation shown is provided as an example configuration of such a cartomiser 3 incorporating the heater assembly 6.
  • the principles of the present disclosure apply to other configurations of the cartomiser 3 (for example, comprising similar or different components to those as shown in Figures 1 and 2, and a similar or different layout to that shown in Figure 2).
  • a cartomiser is likely to comprise a top end (having the mouthpiece orifice 41) and a bottom end.
  • the heater assembly 6 is arranged to be below the reservoir 46, substantially horizontal to the longitudinal axis of the cartomiser 3, and arranged in an airflow path that is substantially perpendicular to longitudinal axis of the heater assembly.
  • the cartomiser 3 may be configured differently depending on the particular design and application at hand.
  • the heater assembly 6 may be arranged such that airflow is substantially parallel to the longitudinal axis of the heater assembly, e.g., along the exposed surface of the electrically resistive layer 64.
  • the upper clamping unit 5 may not be provided with the central air passage 58 and instead the air passage may be provided to one side of the upper clamping unit 5.
  • Air may enter the cartomiser 3 by a suitable inlet and flow along the longitudinal surface of the heater assembly 6 (and along the electrically resistive layer 64) before passing in a substantially vertical direction through the air passage 58 positioned at one end of the upper clamping unit 5 (e.g., the end opposite the air inlet).
  • the outer housing 4 and mouthpiece orifice 41 may be suitably configured.
  • the entirely of the second surface 6b of the heater assembly may be exposed to the reservoir 46.
  • the capillary tubes 66 may be disposed across the heater assembly 6, not just within the central portion 67 of the heater assembly 6 (provided the electrically resistive layer 64 is capable of coupling to a power source).
  • Figures 7a and 7b show, highly schematically, such an example of a cartomiser 3.
  • Figure 7a shows a cross-sectional view of the cartomiser 3 and in particular of the heater assembly 6’ located between an upper clamping unit 5’ and a lower support unit 7’
  • Figure 7b shows a perspective view of the heater assembly 6’ located in a recessed portion of the lower clamping unit 7’.
  • Certain other features of the cartomiser 3 are not shown for clarity.
  • the heater assembly 6’, upper clamping unit 5’ and lower support unit 7’ are configured in a similar manner to their counterparts described in respect of Figures 1 through 6, and only vary in their physical arrangement as will be described below.
  • the heater assembly 6’ is shown located between the lower support unit 7’ and the upper clamping unit 5’.
  • the lower clamping unit 7’ comprises an elongated recess provided to accommodate the heater assembly 6’ (although alternatively, the elongated recess could instead be provided in the upper clamping unit 5’).
  • the upper clamping unit 5’ provides a liquid-tight seal with the upper surface of the lower clamping unit 7’ and/or the heater assembly 6’ (in a broadly similar manner as described above with respect to Figures 1 to 6).
  • a reservoir 46’ holding liquid aerosol-generating material.
  • air may enter the cartomiser via an air inlet 7a’, schematically shown as passing through the sidewall of the lower clamping unit 7’ in Figure 7a.
  • the air flows into the air passage 73’ which is directed past the heater assembly 6’ (and in particularly the surface comprising the electrically resistive layer 64) before passing through an air outlet 5a’ schematically shown as passing through the sidewall of the lower supporting unit 7’ and upper clamping unit 5’.
  • the air flow is represented by the arrows in Figure 7a.
  • the outer housing 4 of the cartomiser 3 may be suitably adapted to receive the air flow from the air outlet 5a’; for example, the air tube 52 may be adapted accordingly to guide air flow to the mouthpiece orifice 41.
  • the air flow in this example does not bifurcate around the surfaces of the heater assembly but is instead generally in a direction parallel to the surface of the heater assembly 6’.
  • the heater assembly 6’ may have capillary tubes extending substantially throughout the heater assembly 6’ (for example, in the region that is exposed to the reservoir 46’).
  • FIG 7b shows in more detail the arrangement of the heater assembly 6’ with respect to the lower support unit 7’.
  • the heater assembly 6’ is located in the elongate recess as described above, but it should also be noted that the elongate recess is wider than the heater assembly 6’.
  • wells 53’ and well openings 53a’ are formed in the lower support unit 7’ either side of the heater assembly 6’. More particularly, it can be seen that the third outer surface 6c’ of the heater assembly 6’ is left exposed and is in direct fluid communication with the wells 53’ / well openings 53a’. As compared to the arrangement in Figures 1 to 6, and in particular with reference to Figure 3b, the entirety of the third outer surface 6c’ of the heater assembly 6’ is exposed and in direct fluid communication with the wells 53’, 53a’.
  • liquid-aerosol generating material from the reservoir 46’ is capable of penetrating the heater assembly 6’ via the second surface of the heater assembly 6’ (the largest surface shown in Figure 7b), via either the capillary tubes 66 and/or interconnected pores or voids if the substrate 62 is formed from a porous material, and via the third surface 6c’ of the heater assembly 6’ via either the distribution channels 62a and/or 62b.
  • Both of the arrangements of the heater assembly 6 and 6’ in Figures 1 to 6 and 7a to 7b, respectively, are arranged with at least a part of the third surface 6c, 6c’ exposed to the reservoir 46, 46’.
  • Configuring the heater assembly 6, 6’ such that any side surface (6c, 6c’ or 6d) is exposed to the reservoir 46, 46’ allows for the possibility of more liquid aerosolgenerating material penetrating the heater assembly 6, 6’ (through the exposed surface(s)), thereby leading to increased wetting of the heater assembly 6, 6’.
  • configuring the heater assembly 6, 6’ such that it is the third surface 6c, 6c’ that is exposed to the reservoir 46, 46’ (as opposed to the fourth surface 6d) allows for the possibility of more rapid liquid uptake I wetting of the heater assembly 6, 6’ due to the relatively shorter distances the liquid aerosol-generating material has to travel to reach the centre of the heater assembly 6, 6’ (as discussed with respect to Figure 6).
  • the third surface 6c, 6c’ is by definition generally larger than the fourth surface 6d of the heater assembly 6, 6’, there is a greater surface area that is exposed to the reservoir 46, 46’ and therefore a greater surface area through which liquid is able to penetrate the heater assembly 6, 6’.
  • the heater assembly 6, 6’ enables a potential improvement in the ability of the heater assembly 6, 6’ to take up (absorb) liquid, otherwise known as wetting.
  • the heater assembly 6, 6’ is provided as a structure having a rectangular cuboid shape.
  • the first outer surface 6a and the second outer surface 6b are the surfaces of the rectangular cuboid having the largest surface area (i.e., the largest faces of the heater assembly 6, 6’).
  • the third outer surface 6c, 6c’ is (one or both of) the two surfaces having the second largest surface area.
  • the fourth outer surface 6d is (one or both of) the two surfaces having the smallest surface area.
  • surface area in this context refers to the area defined by the perimeter of the respective surfaces (as opposed to the surface area which may encompass ridges, grooves or pores or the like).
  • the present disclosure is not limited to heater assemblies having a rectangular cuboid shape.
  • the heater assembly may take any suitable three-dimensional shape comprising at least first, second and side outer surfaces.
  • the advantages of the present disclosure may still be realised when the third outer surface comprises one or more distribution channels and is exposed to the reservoir (where the distance from the centre of the third outer surface to the centre of the heater assembly is shorter than a distance between the centre of any other side surface of the heater assembly to the centre of the heater assembly).
  • the heater assembly may comprise one or more distribution channels on surfaces other than the third outer surface.
  • the heater assembly 6, 6’ may also include one or more distribution channels extending from the fourth surface 6d, in addition to those channels extending from the third surface 6c, 6c’.
  • the one or more distribution channels 62a, 62b extend in a direction from an opening in the third outer surface 6c, 6c’ towards the longitudinal axis L2 of the heater assembly 6, 6’.
  • This in part, is due to the fact that the third outer surface 6c, 6c’ runs parallel to the longitudinal axis L2 in the example of the rectangular cuboid shaped heater assembly.
  • side surfaces that run substantially parallel to the longitudinal axis are likely to offer a shorter distance to the electrically resistive layer 64.
  • the one or more distribution channels 62a, 62b extend in a direction perpendicular to the longitudinal axis L2 of the heater assembly. In some implementations, the one or more distribution channels 62a, 62b extend in a direction substantially towards the centre of the heater assembly 6, 6’. This may be along a two-dimensional plane relative to the heater assembly (in other words, for a three dimensional structure, the centre lies on an axis that passes through each of the two- dimensional planes). Alternatively, the centre may be a point centre in the centre of the heater assembly.
  • the one or more distribution channels 62b may be formed through an engineering process (such as drilling or machining). In such cases, the one or more distribution channels 62b follow a predetermined path formed in the substrate via the engineering process. In some implementations, the one or more distribution channels 62b follow a (substantially) linear path. This may particularly be the case where the one or more distribution channels 62b are formed via an engineering process, e.g., by drilling into a bulk material, simply due to the physical limitations of the engineering process. However, even when the one or more distribution channels 62b are formed via an engineering process, it may be possible to form the channels in a non-linear manner.
  • the distribution channels may be formed by etching a pattern into the surfaces of two substrates (or two halves of a substrate) and subsequently joining or abutting the two substrates together whereby the etched patterns on the surfaces of the substrates are aligned to form the distribution channel.
  • more complex patterns, and subsequently distribution channels 62b that may not necessarily follow a linear path, are achievable.
  • the one or more distribution channels 62a may follow a random path formed in the substrate 62 via a series of interconnected pores (for example, when the substrate 62 is formed form a porous material).
  • the porous substrate 62 may be treated or otherwise modified to remove or enhance some of the interconnected voids (forming the distribution channels).
  • the fourth surface 6d of the heater assembly may be sealed, for example by applying a coating or the like, on the fourth surface 6d to seal pores close to the surface 6d.
  • the heater assembly 6, 6’ as described above is to be sued in a cartomiser 3 (or more generally an aerosol provision system 1).
  • the heater assembly 6, 6’ is arranged relative to the reservoir 46 (or more generally, an aerosol-generating material storage portion) such that aerosol-generating material is capable of being fed to the third outer surface 6c, 6c’ of the heater assembly 6, 6’.
  • the reservoir 46 includes one or more wells 53, the one or more wells 53 configured to allow aerosol-generating material to be supplied to at least one region of the heater assembly 6, 6’, wherein the heater assembly 6, 6’ is arranged such that third outer surface is provided in direct fluid communication with the one or more wells 53.
  • the heater assembly 6, 6’ as described above is generally provided as a relatively small component having a relatively small footprint (as compared to more traditional heater assemblies, such as a wick and coil).
  • the capillary tubes 66 are formed via a manufacturing process in the heater assembly 6, 6’ (i.e. , the capillary tubes are engineered, e.g., through a laser drilling process), and the distribution channels are provided to the heater assembly 6, the heater assembly 6 can provide similar if not improved liquid delivery characteristics and/or aerosol formation characteristics despite its relatively small size.
  • material wastage e.g., when the cartomiser 3 is disposed of
  • the contact pads 75 directly contact the electrically resistive layer 64 of the heater assembly 6.
  • the cartomiser 3 may be provided with any suitable arrangement that facilitates the electrical contact between the aerosol provision device 2 and the heater assembly 6.
  • electrical wiring or other electrically conductive elements may extend between the electrically resistive layer 64 and the contact pads 75 of the cartomiser 3. This may particularly be the case when the heater assembly 6 has its largest dimension (e.g., its length) less than a minimum distance between the contact pads 75. The distance between the contact pads 75 may be dictated by the electrical contacts on the aerosol provision device 2.
  • the heater assembly 6 may be provided in the aerosol provision device 2 itself.
  • the aerosol provision device 2 may comprise the heater assembly 6 and a removable cartridge (containing a reservoir of liquid aerosol-generating material).
  • the heater assembly 6 is provided in fluid contact with the liquid in the cartridge (e.g., via a suitable wicking element or via another fluid transport mechanism).
  • the aerosol provision device 2 may include an integrated liquid storage area in addition to the heater assembly 6 which may be refillable with liquid.
  • the aerosol provision system (which encompasses a separable aerosol provision device and cartomiser / cartridge or an integrated aerosol provision device and cartridge) includes the heater assembly.
  • the above has described a heater assembly 6 in which an electrically resistive layer 64 is provided on a surface of the respective substrate.
  • electrical power is supplied to the electrically resistive layer 64 via the contact pads 75. Accordingly, an electrical current is able to flow through the electrically resistive layer 64 from one end to the other to cause heating of the electrically resistive layer 64.
  • electrical power for the purposes of causing the electrically resistive layer 64 to heat may be provided via an alternative means, and in particular, via induction.
  • the aerosol provision system 1 is provided with a coil (known as a drive coil) to which an alternating electrical current is applied. This subsequently generates an alternating magnetic field.
  • the electrically resistive layer 64 When the electrically resistive layer 64 is exposed to the alternating magnetic field (and it is of sufficient strength), the alternating magnetic field causes electrical current (Eddy currents) to be generated in the electrically resistive layer 64. These currents can cause Joule heating of the electrically resistive layer 64 owing to the electrical resistance of this layer 64. Depending on the material which the electrically resistive layer 64 is formed, heating may additionally be generated through magnetic hysteresis (if the material is ferro- or ferrimagnetic). More generally, the electrically resistive layer 64 is an example of a heater layer of the heater assembly 6 which is configured to generate heat when supplied with energy (e.g., electrical energy), which, for example, may be provided through direct contact or via induction. Additional ways of causing the heater layer to generate heat are also considered within the principles of the present disclosure.
  • energy e.g., electrical energy
  • an additional layer or layers may be disposed on top of the electrically resistive layer 64.
  • the capillary tubes 66 still extend to an opening on the electrically resistive layer 64 but may additionally extend through the additional layer(s). More broadly, the capillary tubes 66 extend through the heater assembly 6 to an opening at a surface of a side of the heater assembly 6 comprising the electrically resistive layer 64, which includes an opening in the electrically resistive layer 64 itself as well as an opening in any additional layer(s) positioned above the electrically resistive layer 64.
  • Figure 8 depicts an example method for manufacturing a heater assembly 6, 6’.
  • the method begins at step S1 by providing a substrate 62.
  • the way in which the substrate 62 is formed is not significant to the principles of the present disclosure.
  • the substrate 62 may be cut from a portion of cultured quartz or formed via a sintering process by sintering quartz powders I fibres, for example.
  • step S2 the one or more distribution channels 62a, 62b are provided.
  • the one or more distribution channels 62a may be naturally formed in the substrate 62; that is, as a result of forming the substrate 62 in a certain manner (e.g., forming the substrate 62 from a naturally porous material or via sintering).
  • step S2 may be inherently performed with step S1.
  • the one or more distribution channels 62b may be formed via an engineering process, e.g., via laser drilling. In such implementations, step S2 follows step S1.
  • the method proceeds to step S3, where the electrically resistive layer 64 is provided on a surface of the substrate 62.
  • the electrically resistive layer 64 may be a sheet of metal (e.g., titanium) adhered, welded, or the like to the substrate 62.
  • the electrically resistive layer 64 may be formed through a vapour or chemical deposition technique using the substrate 62 as a base.
  • step S2 may be performed after the electrically resistive layer 64 is deposited on the substrate 62 at step S3. It should also be appreciated that step S3 may also occur before step S1 (and step S2). For example, a further alternative is to grow or culture the substrate 62 using the electrically resistive layer 64 as a base. Subsequent processing steps, such as step S2, may be performed thereafter.
  • step S3 the method proceeds to step S4.
  • step S4 one or more capillary tubes 66 are formed in the substrate 621 electrically resistive layer 64.
  • the capillary tubes 66 extend from a surface (surface 6b) of the substrate 62 I heater assembly 6, through the electrically resistive layer 64 provided on the first surface of the substrate 62. That is, the capillary tubes 66 extend all the way through the heater assembly 6.
  • the capillary tubes 66 may be formed by laser drilling, as noted above, or any other suitable technique.
  • the capillary tubes 66 may be formed in such a way as to align with the one or more distribution channels 62a, 62b formed in the substrate 62 (this may particularly be the case where the one or more distribution channels 62b are engineered), such that the capillary tubes 66 are essentially in fluid communication with the one or more distribution channels 62a, 62b as described above.
  • step S4 may be performed prior to steps S2 and S3 (and equally step S4 may follow step S1 where step S3 is performed prior to step S1). That is to say, the capillary tubes 66 may be formed in the substrate 62 prior to forming the distribution channels 62a, 62b and/or applying the electrically resistive layer 64.
  • step S4 the heater assembly 6 is formed, and subsequently may be assembled to form the cartomiser 3 (or more generally, the heater assembly 6 may be positioned in an aerosol provision system 1).
  • the heater assembly for an aerosol provision system, the heater assembly defining a three-dimensional object having a plurality of outer surfaces.
  • the heater assembly includes a substrate; a heater layer configured to generate heat when supplied with energy, the heater layer provided on the substrate at a first outer surface of the heater assembly; one or more capillary tubes extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, the one or more capillary tubes for supplying aerosol-generating material to the heater layer for vaporisation, the second outer surface substantially opposite the first outer surface; and one or more distribution channels extending from a third outer surface of the substrate to at least one capillary tube for supplying aerosol-generating material to the one or more capillary tubes.
  • the third outer surface is a side surface of the heater assembly, the side surface sharing an edge with at least one of the first outer surface and the second outer surface, and wherein the distance from the centre of the third outer surface to the centre of the heater assembly is shorter than a distance between the centre of any other side surface of the heater assembly to the centre of the heater assembly. Also described is an aerosol provision system, and a method for manufacturing a heater assembly.

Landscapes

  • Resistance Heating (AREA)
  • Disinfection, Sterilisation Or Deodorisation Of Air (AREA)
  • Surface Heating Bodies (AREA)

Abstract

Un ensemble dispositif de chauffage pour un système de fourniture d'aérosol est décrit, l'ensemble dispositif de chauffage définissant un objet tridimensionnel ayant une pluralité de surfaces externes. L'ensemble dispositif de chauffage comprend un substrat ; une couche de dispositif de chauffage conçue pour générer de la chaleur lorsqu'elle est alimentée en énergie, la couche de dispositif de chauffage étant disposée sur le substrat au niveau d'une première surface externe de l'ensemble dispositif de chauffage ; un ou plusieurs tubes capillaires s'étendant à partir d'une seconde surface externe de l'ensemble dispositif de chauffage à travers la couche de dispositif de chauffage disposée sur la première surface externe de l'ensemble dispositif de chauffage, ledit tube capillaire étant destiné à fournir un matériau de génération d'aérosol à la couche de dispositif de chauffage pour qu'il soit vaporisé, la seconde surface externe étant sensiblement opposée à la première surface externe ; et un ou plusieurs canaux de distribution s'étendant d'une troisième surface externe du substrat à au moins un tube capillaire pour fournir un matériau de génération d'aérosol audit tube capillaire. La troisième surface externe est une surface latérale de l'ensemble dispositif de chauffage, la surface latérale partageant un bord avec la première surface externe et/ou la seconde surface externe, et la distance entre le centre de la troisième surface externe et le centre de l'ensemble dispositif de chauffage étant plus courte qu'une distance entre le centre de toute autre surface latérale de l'ensemble dispositif de chauffage et le centre de l'ensemble dispositif de chauffage. Un système de fourniture d'aérosol et un procédé de fabrication d'un ensemble dispositif de chauffage sont également décrits.
PCT/GB2024/050660 2023-03-13 2024-03-12 Ensemble dispositif de chauffage, système de fourniture d'aérosol et procédé Pending WO2024189342A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
KR1020257030557A KR20250139888A (ko) 2023-03-13 2024-03-12 가열기 조립체, 에어로졸 제공 시스템, 및 방법
MX2025010785A MX2025010785A (es) 2023-03-13 2025-09-11 Conjunto de calentamiento, sistema de suministro de aerosol y metodo

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB2303640.3 2023-03-13
GBGB2303640.3A GB202303640D0 (en) 2023-03-13 2023-03-13 Heater assembly, aerosol provision system, and method

Publications (1)

Publication Number Publication Date
WO2024189342A1 true WO2024189342A1 (fr) 2024-09-19

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KR (1) KR20250139888A (fr)
AR (1) AR132105A1 (fr)
GB (1) GB202303640D0 (fr)
MX (1) MX2025010785A (fr)
TW (1) TW202512950A (fr)
WO (1) WO2024189342A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020065077A1 (fr) * 2018-09-28 2020-04-02 Philip Morris Products S.A. Dispositif de chauffage pour système de génération d'aérosol
CN111109665A (zh) * 2020-01-17 2020-05-08 深圳麦克韦尔科技有限公司 电子雾化装置及其雾化器和发热体
US20220125114A1 (en) * 2019-08-13 2022-04-28 Shanghai QV Technologies Co., Ltd. Atomization core
CN114451586A (zh) * 2022-01-17 2022-05-10 惠州市新泓威科技有限公司 具有纳米金属镀膜层的雾化芯

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020065077A1 (fr) * 2018-09-28 2020-04-02 Philip Morris Products S.A. Dispositif de chauffage pour système de génération d'aérosol
US20220125114A1 (en) * 2019-08-13 2022-04-28 Shanghai QV Technologies Co., Ltd. Atomization core
CN111109665A (zh) * 2020-01-17 2020-05-08 深圳麦克韦尔科技有限公司 电子雾化装置及其雾化器和发热体
CN114451586A (zh) * 2022-01-17 2022-05-10 惠州市新泓威科技有限公司 具有纳米金属镀膜层的雾化芯

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GB202303640D0 (en) 2023-04-26
KR20250139888A (ko) 2025-09-23
MX2025010785A (es) 2025-10-01
AR132105A1 (es) 2025-05-28
TW202512950A (zh) 2025-04-01

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