RU2820665C2 - Electrically heated aerosol generating system, and kit for such system - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: group of inventions relates to an electrically heated aerosol-generating system and a kit for such a system. Electrically heated aerosol-generating system comprises a consumable cartridge, an electrically heated device and a heater assembly. Consumable cartridge comprises a storage portion having an aerosol-forming substrate, the storage portion having a fluid-permeable inner surface surrounding an open-ended passage passing through the cartridge. Electrically heated aerosol generating device for use with consumable cartridge, wherein said device comprises a body having a cavity to receive at least a portion of the cartridge. Heater assembly is arranged in the cavity and comprises an electroconductive hollow part of the rod connected to the body and defining an air flow passage forming part of the air flow path through the device. Hollow part of the rod is located for passage into the passage with an open end of the cartridge located in the cavity. At least one electric heater is located along the hollow part of the rod. Electric heater comprises at least one heating element for heating the aerosol-forming substrate of the cartridge placed in the cavity, wherein the hollow part of the rod has a plurality of holes. At least one heating element is formed by one or more narrow areas of the hollow part of the rod between adjacent holes. With such an arrangement, the hollow part of the rod provides support for at least one electric heater and provides an air flow channel. This provides a compact device and promotes cost-effective mass production.

EFFECT: availability of the air flow passage in the hollow part of the rod allows to minimize heat losses from the device and allows to easily maintain such temperature of the device housing, at which it is convenient to hold it by the user.

15 cl, 8 dwg

Description

The present invention relates to an electrically heated aerosol generating system, as well as a kit for an electrically heated aerosol generating system. In particular, the present invention relates to an electrically heated aerosol generating device for use with a consumable cartridge having an internal channel and containing an aerosol generating substrate. The present invention also relates to consumable cartridges for use with an aerosol generating device, an electrically heated aerosol generating system comprising an electrically heated aerosol generating device and a consumable cartridge, and a kit for an electrically heated aerosol generating system comprising an electrically heating device. , generating an aerosol, and many consumable cartridges.

Electrically heated smoking systems that are portable and activated by heating an aerosol-forming substrate in an aerosol-generating article or cartridge are well known in the art. For example, WO 2009/132793 describes an electrically heated smoking system comprising a casing and a replaceable mouthpiece. The shell contains a power supply unit and an electrical circuit. The mouthpiece includes a liquid storage portion and a capillary wick having a first end and a second end. The first end of the wick projects into the liquid storage portion to contact the liquid therein. The mouthpiece also includes a heating element for heating the second end of the capillary wick, an air outlet, and an aerosol generating chamber located between the second end of the capillary wick and the air outlet. The wick and heating element create a heater assembly that heats the substrate to form the aerosol. The heating element is usually a coil of wire wound around a wick. When the sheath and mouthpiece are connected to each other, the heating element is electrically coupled to the power supply through an electrical circuit that defines an air flow path from the at least one air inlet to the air outlet through the aerosol generating chamber. During use, liquid moves from the liquid storage portion toward the heating element by capillary action in the wick. The liquid at the second end of the capillary wick is evaporated by the heating element. The resulting supersaturated vapor is mixed with and carried by the air flow from the at least one air inlet to the aerosol generating chamber. In the aerosol-generating chamber, steam condenses to form an aerosol, which is released through an air outlet into the user's mouth.

The specific characteristics of the heater assembly are important to achieve the required performance. Therefore, the ability to produce heater assemblies efficiently and consistently is important to maintaining reliable operation of different aerosol generating systems of the same type. For example, in heater assemblies having a heating coil, the heating coils must be manufactured to uniform dimensions to reduce product variability. In known systems, production of the heater assembly may require a large number of manufacturing steps, some may require manual execution by skilled workers, such as when the heating coil must be connected to electrical contacts by welding.

According to a first aspect of the present invention, there is provided an electrically heated aerosol generating device for use of a consumable cartridge comprising a storage portion containing an aerosol-generating substrate, the storage portion having a fluid permeable interior surface surrounding an open-ended passage extending through the cartridge , wherein the device comprises: a housing having a cavity for accommodating at least part of the cartridge; and a heater assembly located in the cavity, the heater assembly comprising: an electrically conductive hollow rod portion coupled to the housing and defining a passage for air flow forming a portion of the stroke for air flow through the device, wherein the hollow rod portion is disposed to pass into the passage with an open end of the cartridge located in the cavity, and at least one electric heater located along the hollow portion of the rod, wherein the electric heater includes at least one heating element for heating the aerosol-forming substrate of the cartridge located in the cavity, the hollow portion of the rod contains a plurality of holes, wherein at least one heating element is formed by one or more narrow regions of the hollow part of the rod between adjacent holes.

Advantageously, having the heater assembly with one or more integral electrical heaters may require fewer manufacturing steps and allow the heater assembly to be manufactured on an automated assembly line. According to the present invention, this can enable faster and easier fabrication of the aerosol generating device with greater reproducibility and stability. The aerosol generating device of the present invention can be simpler, more reliable and less expensive than devices in which the heater assembly has complex and potentially fragile connections. Additionally, by providing electric heaters as part of the device, cartridges for use with the device can be simpler, more reliable, and less expensive than cartridges that include an electric heater. Accordingly, reducing the cost of cartridges, even if it requires a more expensive device, can lead to significant cost savings for both manufacturers and consumers.

The hollow portion of the rod has an internal air flow passage forming part of the stroke for air flow through the device. With this arrangement, the hollow portion of the rod may support at least one electrical heater and provide a passage for air flow. This provides a compact device and facilitates cost-effective mass production. Providing an air flow passage in the hollow portion of the rod may minimize heat loss from the device and allow the body of the device to be easily maintained at a temperature that is comfortable to hold by the user. Moreover, the aerosol generating substrate evaporated in the air flow passing through the hollow portion of the rod may begin to cool within the aerosol generating air flow passage, thereby reducing the overall length of the device.

Holes may be made in the hollow portion of the rod after forming the hollow portion of the rod, for example, by punching, drilling, milling, etching, electric discharge machining, cutting, or laser cutting. The holes may be formed integrally with the hollow rod portion during formation of the hollow rod portion, for example, by casting or molding the hollow rod portion with holes, or by forming the hollow rod portion with holes by deposition, such as electrodeposition.

As used herein, "electrically conductive" means formed from a material having a resistivity of 1×10 ^-4 ohm.m or less. As used herein, “electrically insulating” means formed from a material having a resistivity of 1×10 ⁴ ohm⋅m or greater.

The at least one electric heater may be located on the hollow portion of the rod in any suitable manner. At least one electric heater may be located around the circumference of the hollow portion of the rod. This may provide more uniform heating of the aerosol-forming substrate in the cartridge relative to devices in which at least one electrical heater is not located around the circumference of the hollow portion of the rod. At least one electric heater may continuously surround the hollow portion of the rod. At least one electric heater may discontinuously surround the hollow rod portion in the form of a plurality of electric heaters spaced apart from each other in a circumferential direction of the hollow rod portion. In other embodiments, the at least one electrical heater may extend around only part of the circumference of the hollow rod portion.

The at least one electric heater may extend along only part of the length of the hollow rod portion. Thus, the at least one electric heater occupies only part of the length of the hollow part of the rod. At least one electric heater may extend along substantially the entire length of the hollow rod portion. This arrangement may provide more uniform heating of the aerosol-forming substrate in the cartridge relative to devices in which at least one electrical heater extends along only a portion of the length of the hollow rod portion. This may also allow the device to heat portions of the cartridge that would not be heated by devices in which at least one electrical heater extends along only a portion of the length of the hollow shaft portion, allowing more of the aerosol-forming substrate to evaporate in each cartridge, reducing waste. At least one electric heater may extend continuously along substantially the entire length of the hollow rod portion. At least one electric heater may extend intermittently along substantially the entire length of the hollow rod portion in the form of a plurality of electric heaters spaced apart from each other in the longitudinal direction of the hollow rod portion.

At least one electrical heater may surround the hollow rod portion and extend along substantially the entire length of the hollow rod portion.

The heater assembly may comprise a single electrical heater comprising at least one heating element for heating the aerosol-forming substrate cartridge located in the cavity. Preferably, the heater assembly includes a plurality of electrical heaters spaced apart from each other along the length of the hollow rod portion to heat the aerosol-forming substrate cartridge located in the cavity.

Advantageously, this arrangement may provide more uniform heating of the aerosol-forming substrate in the cartridge relative to devices that provide only one electrical heater or that provide multiple electrical heaters that are not spaced along the length of the hollow rod portion. This may also allow the device to heat parts of the cartridge that would not be heated by devices with only a single heater, allowing more of the aerosol-forming substrate to evaporate in each cartridge, reducing waste. Additionally, when used with cartridges having a plurality of different aerosol-forming substrates stored separately, a plurality of longitudinally spaced electrical heaters can provide separate heating of the different aerosol-forming substrates to create an aerosol with particularly desired properties.

If the heater assembly includes a plurality of electrical heaters spaced apart along the length of the hollow rod portion, one or more electrical heaters may be aligned along the longitudinal direction of the hollow rod portion. For example, a plurality of electric heaters may comprise a first row of electric heaters aligned in the longitudinal direction of the hollow rod portion, and one or more additional rows of electric heaters aligned in the longitudinal direction of the hollow rod portion, the first row being spaced from the second row around the circumference of the hollow rod portion. rod.

If the heater assembly includes a plurality of electric heaters spaced apart along the length of the hollow rod portion, the electric heaters may be offset relative to each other along the circumference of the hollow rod portion.

Preferably, the plurality of electric heaters are electrically isolated from each other so that each heater can be heated independently. With such an arrangement, the heater assembly can vary the power supply to each electric heater, for example, according to which of the electric heaters is in the best condition to generate the aerosol in the most efficient manner. This may minimize variations in aerosol properties caused by variations in the distribution of the aerosol-forming substrate within the cartridge. It can also reduce the overall energy consumption of the device by allowing energy to be selectively extracted from the electric heaters in the most efficient manner. By electrically insulating each of the plurality of electrical heaters such that each plurality can be heated independently, the risk of damage to one or more electrical heaters due to overheating can be reduced by selectively reducing power supply to the one or more electrical heaters.

The at least one electric heater may be coupled to the power supply in any suitable manner. For example, the heater assembly may include a plurality of electrical conductors extending along the length of the hollow rod portion for connecting at least the electrical heater to the power supply. The plurality of electrical conductors may comprise a plurality of wires or multiple strips of electrically conductive material attached to the hollow rod portion, for example by spraying, printing, or laminating the hollow rod portion, such as with a foil laminate. The laminated foil can then be shaped or bent to create a hollow rod portion.

Preferably, the hollow rod portion is at least partially divided into a plurality of electrically insulated sections for connecting the at least one electric heater to the power supply, the electrically insulated sections being electrically insulated from each other by one or more insulating gaps formed in the hollow rod portion. If the heater assembly includes a plurality of electrical heaters, preferably the hollow rod portion is at least partially divided into a plurality of electrically insulated sections for connecting the plurality of electrical heaters to the power supply, the electrically insulated sections being electrically insulated from each other by one or more insulating gaps formed in the hollow portion rod. Thus, at least one electric heater or a plurality of electric heaters and means for connecting at least the electric heater to the power supply unit are integral to the hollow rod portion. With such an arrangement, the hollow rod portion can perform the additional function of connecting the at least one electric heater to the power supply without requiring additional manufacturing steps to attach additional conductive components to the heater assembly.

The insulating gaps can be air gaps. Typically, insulating clearances can be simply the distance between adjacent electrically insulated sections. In other examples, one or more insulating gaps may be completely or partially filled with electrical insulating material.

Insulating gaps may be provided in the hollow portion of the rod to at least partially divide the hollow portion of the rod into a plurality of electrically insulated sections after creating the hollow portion of the rod, for example, by punching, drilling, milling, etching, electric discharge machining, cutting, or laser cutting. The insulating gaps may be integral with the hollow rod portion during the creation of the hollow rod portion, for example, by casting or molding the hollow rod portion with the insulating gaps, or by molding the hollow rod portion using deposition, such as electrodeposition.

Preferably, the hollow shaft portion has a piercing surface at its distal end. This allows the hollow shaft portion to conveniently and easily pierce the end of a cartridge inserted into the cavity, for example by piercing the frangible seal on the end of the cartridge as the cartridge is inserted. Thus, the hollow part of the rod can function as an elongated piercing element. To facilitate piercing of the cartridge or part of the cartridge, such as a frangible seal, the distal end of the hollow shaft portion on which the piercing surface is located preferably has a smaller cross-sectional area than the area of the hollow shaft portion in close proximity to the piercing surface. Preferably, the cross-sectional area of the hollow shaft portion tapers toward a tapered tip at the distal end of the hollow shaft portion. The cross-sectional area of the hollow rod portion may taper toward a point at the distal end of the hollow rod portion.

The heater assembly may be constructed from several individual components that are assembled together to create the heater assembly. Preferably, the heater assembly is a single integral component. Advantageously, this may require fewer manufacturing steps than existing systems in which the heater assembly is constructed from many individual components. It can also enable the complete heater assembly to be manufactured on an automated assembly line, so such devices can be produced more quickly and with greater repeatability.

The device preferably includes a power supply coupled to the heater assembly. For example, the power supply may be a battery, such as a lithium iron phosphate battery, or another form of charge storage device, such as a capacitor. The power supply is preferably located in the housing. The power pack may need to be recharged and may have a capacity that can store enough energy for one or more smoking sessions. For example, the power supply may have sufficient capacity to continuously generate an aerosol for a period of approximately six minutes, which corresponds to the typical time required to smoke a conventional cigarette, or for a period that is a multiple of six minutes. In another example, the power supply may have sufficient capacity to allow a predetermined number of puffs or individual activations to occur.

The devices of the present invention may include electrical circuitry coupled to a heater assembly and a power supply. The electrical circuit may contain a microprocessor, which may be a programmable microprocessor, a microcontroller, or a specialized

integrated circuit (ASIC) or other electronic circuit configured to perform control. The electrical circuit may contain additional electronic components. The electrical circuitry may be configured to regulate the supply of power to the heater assembly. Power may be supplied to the heater assembly continuously after activation of the device or intermittently, such as from puff to puff. The electrical circuit may advantageously comprise a DC-AC converter, which may comprise a Class D or Class E power amplifier.

The device may include a power supply connected to the heater assembly and electrical circuitry connected to the power supply and the heater assembly.

If the heater assembly includes a plurality of electrical heaters that are spaced along the length of the hollow rod portion, the electrical circuitry is preferably configured to measure one or more electrical parameters of the plurality of electrical heaters and calculate an estimated residual amount of aerosol-forming substrate in a cartridge located in the cavity , or the expected distribution of the aerosol-forming substrate within the cartridge based on measured electrical parameters.

As used herein, the term "electrical parameter" is used to describe an electrical property, value or index that can be determined by measuring, for example, resistivity, conductivity, impedance, specific capacitance, current, voltage and resistance.

Preferably, with this arrangement, the electric heaters can perform the dual function of heating and sensing. This may allow the device to determine at any time the amount of aerosol-forming substrate remaining in the cartridge. Based on this, the device may operate differently by allowing the electrical circuitry to maintain the desired properties of the aerosol or by informing the user of the current state of the aerosol-forming substrate so that the user can take necessary action, such as replacing the cartridge or orienting the device to avoid negative impact on the aerosol. aerosol properties.

In such embodiments, the electrical circuitry may be configured to separately measure one or more electrical parameters of each of the plurality of electrical heaters and calculate an estimated residual amount or estimated distribution, or both the estimated residual amount and estimated distribution, based on the differences in the electrical parameter measurements in two or more sets of electric heaters.

If the device includes a power supply coupled to the heater assembly and electrical circuitry coupled to the power supply and heater assembly, the device preferably further includes a user indicator,

connected to the power supply. The electrical circuitry may be configured to control a custom indicator in response to an estimated residual amount or estimated distribution. The user indicator may have any suitable configuration, for example, the user indicator may be a display, an audio output, a tactile output, or a combination thereof. This may allow the device to communicate information to the user about the estimated residual amount or expected distribution, or both, of the liquid aerosol-forming substrate in the cartridge.

The electrical circuitry may be configured to control a user indicator when the estimated residual quantity falls below a threshold to alert the user and prompt the cartridge to be replaced. The control circuitry may also be configured to control a user indicator when the expected distribution means that the device has been held at a certain angle for too long so that the user is alerted to change the position of the device, at least temporarily, so that the aerosol-forming substrate can be redistributed into storage parts.

The control circuitry may be configured to notify a user of the estimated residual amount or estimated distribution via a communication link with a third-party device, such as a smartphone, smart watch, tablet, desktop computer, or similar device.

If the device contains an electrical circuit,

coupled to a power source and configured to measure one or more electrical parameters of the plurality of electrical heaters and calculate an estimated residual amount or estimated distribution, the electrical circuitry may be further configured to control the supply of electrical power to the one or more plurality of electrical heaters individually in response to the estimated residual quantity or estimated distribution.

Advantageously, this may allow the device to determine which of the electrical heaters is in the best state to generate the aerosol in the most efficient manner and change the power supply accordingly. This may minimize variations in aerosol properties caused by variations in the distribution of the aerosol-forming substrate within the cartridge. It can also reduce the overall energy consumption of the device by allowing energy to be selectively extracted from the electric heaters in the most efficient manner. The electrical circuitry may be configured to increase power supply to one or more pluralities of electrical heaters in response to an estimated residual amount or estimated distribution.

The electrical circuit may be configured to reduce power supply to one or more plurality of electrical heaters in response to an estimated residual amount or estimated distribution.

Advantageously, this may provide a selective reduction in the energy consumption of one or more electric heaters, for example, if the estimated residual quantity or estimated distribution indicates that a particular electric heater is not positioned appropriately for aerosol generation. This may also reduce the risk of damage to electric heaters due to overheating, for example, if, when using a liquid aerosol-forming substrate, electrical parameters indicate that one or more electric heaters are dry or partially dry.

The electrical circuit may be configured to decrease or increase the power supply to one or more plurality of electrical heaters in response to an estimated residual amount or estimated distribution. The electrical circuit may be configured to reduce power supply to one or more pluralities of electrical heaters while increasing power supply to another one or more pluralities of electrical heaters, in response to an estimated residual amount or estimated distribution.

As used herein, the term “aerosol generating device” refers to a device that interacts with an aerosol generating article, such as a consumable cartridge, to generate an aerosol.

Preferably, the aerosol generating device is portable. The aerosol-generating device may be comparable in size to a conventional cigar or cigarette. The aerosol generating device may have an overall length of from about 30 mm to about 150 mm. The aerosol generating device may have an outer diameter ranging from about 5 mm to about 30 mm.

The heater assembly can be connected to the device body or be inseparable from it. In other embodiments, the heater assembly may be removably attached to the housing. This may allow the heater assembly to be at least partially detached from the device, for example, for maintenance, cleaning, or replacement of the heater assembly. The heater assembly may be removably coupled to the housing by one or more electrical and mechanical connecting means.

The heater assembly contains one or more electrical heaters. For example, the heater assembly may include one, two, three, four, five, six or more electric heaters located in the hollow portion of the rod. If the heater assembly contains a plurality of electric heaters, the electric heaters may be spaced along the length of the hollow rod portion. Each electric heater contains at least one heating element. Each electric heater may contain more than one heating element, such as two, three, four, five, six or more heating elements. The heating element or heating elements may be suitably positioned to most effectively heat the aerosol-forming substrate cartridge inserted into the cavity of the main body.

The heating elements preferably have a diameter of from 0.10 to 0.15 mm, preferably about 0.125 mm. The hollow portion of the rod is preferably made of an electrically resistive material such as 904 or 301 stainless steel. Examples of other suitable metals include titanium, zirconium, tantalum and platinum group metals. Examples of other suitable metal alloys include constantan, nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese and iron-containing alloys, as well as superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, iron-aluminum alloys and iron-manganese-aluminium alloys. Timetal® is a registered trademark of Titanium Metals Corporation, 1999 Broadway Suite 4300, Denver, Colorado.

The at least one heating element may operate by resistive heating. In other words, the material and dimensions of the heating element can be selected so that when a certain current passes through the heating element, the temperature of the heating element increases to the desired temperature. Current through the heating element may be supplied from the battery by conduction, or it may be induced in the heating element by applying an alternating magnetic field around the circumference of the heating element.

In the devices of the present invention, at least one heating element of each electric heater is made of one or more narrow regions of the hollow rod portion between adjacent holes in the hollow rod portion. The holes preferably have a width ranging from about 10 microns to about 100 microns, preferably from about 10 microns to about 60 microns. Preferably, the holes create capillary action so that when in use, the material, eg liquid, to be evaporated is drawn into the holes, increasing the contact area between the electric heater and the liquid. As used herein, the term "hole length" refers to the size of the hole in the longitudinal direction. That is, in the direction of its maximum size. The term "hole width" refers to the size of the hole in a direction transverse to its length.

The hollow part of the rod can be made of a single tubular body. In some embodiments, the hollow rod portion may be made of first and second hollow rod portions attached to a body that extend along a single longitudinal axis and meet at a junction. In such embodiments, the body may comprise a main body in which a cavity is formed, and a cover body configured to engage the main body to close the cavity, the first hollow rod portion being coupled to the main body and the second hollow rod part being coupled to the main body. closing body. The closure body may function as a conventional lid to close the cavity. Preferably, the closure body forms a mouthpiece portion with which air can be drawn through the air flow passage of the aerosol generating device.

The first and second hollow shaft portions may have first and second piercing surfaces at their respective distal ends. This may enable the first and second hollow shaft portions to conveniently and easily pierce the end of a cartridge inserted into the cavity, for example by piercing the frangible seals at both ends of the cartridge when the cartridge is inserted. Thus, the hollow part of the rod can function as an elongated piercing element. To facilitate piercing of the cartridge or cartridge portion, such as a frangible seal, the distal ends of the first and second hollow shaft portions on which the piercing surfaces are located preferably have a smaller cross-sectional area than the area of the corresponding hollow shaft portion in close proximity to the piercing surface. In a particularly preferred embodiment, the cross-sectional area of each hollow shaft portion tapers towards a tapered tip at its distal end. The cross-sectional area of each hollow part of the rod may taper towards a point at its distal end.

Preferably, having a two-piece hollow shaft portion with piercing surfaces can make it easier for the user to pierce the seals on both ends of the cartridge. While not wishing to be bound by theory, it is believed that piercing the seals toward the center of the cartridge prevents the seals from moving in the hollow portions of the rod, and the forces applied by the first and second piercing surfaces are increased, allowing the seals to be pierced more easily.

If the first and second hollow rod portions are sized to meet at the junction, the distal ends of the first and second hollow rod portions are preferably uniformly shaped such that a seal is formed around the junction. With such an arrangement, the air flow can be significantly limited by the internal air flow passage through the elongated piercing assembly rather than by the cartridge storage portion, thereby facilitating delivery of a uniform aerosol. The distal ends of the first and second hollow shaft portions may have any suitable uniform piercing shape. Preferably, the distal end of one of the first and second hollow portions of the rod has an inwardly tapering outer surface, and the distal end of the other of the first and second hollow portions of the rod has an outwardly expanding inner surface, wherein the inner and outer surfaces are shaped such that the inwardly tapering outer surface is placed within the outwardly expanding inner surface to form a seal when the closure body comes into contact with the main body. This can enable easy mating of the first and second hollow rod portions. For example, the distal end of the first hollow rod portion may have an inwardly tapering outer surface, and the distal end of the second hollow rod portion may have an outwardly flaring inner surface, wherein the inner and outer surfaces are shaped such that the inwardly tapering outer surface fits within the outwardly flaring inner surface. to form a seal when the closing body comes into contact with the main body.

The body can be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more such materials, or thermoplastic materials suitable for use in the food or pharmaceutical industries, for example polypropylene, polyetheretherketone (PEEK) and polyethylene. Preferably, the material is light and non-fragile.

The body may include a mouthpiece. The mouthpiece may include at least one air inlet and at least one air outlet. The mouthpiece may contain more than one air inlet. The one or more air inlets may reduce the temperature of the aerosol before delivery to the user and may reduce the concentration of the aerosol before delivery to the user. As used herein, the term “mouthpiece” refers to a portion of an aerosol-generating device that is placed in the mouth of a user to directly inhale the aerosol generated by the aerosol-generating device from an aerosol-generating article located in a housing cavity.

According to a second aspect of the invention, there is provided an electrically heated aerosol generating system comprising an aerosol generating device according to any of the above-described embodiments and a consumable cartridge having a storage portion containing an aerosol generating substrate, wherein the storage portion has a fluid permeable interior a surface surrounding an open-ended passage through the cartridge.

As used herein, the term “fluid permeable surface” refers to a surface that allows a liquid or gas to pass through it. The inner surface may have a plurality of holes provided therein to allow fluid to pass through.

The system contains a consumable cartridge. The consumable cartridge may be removably attached to the aerosol generating device. As used herein, the term “removably coupled” means that the cartridge and the device can be interconnected and disconnected without causing significant damage to either the device or the cartridge. The cartridge may be removed from the aerosol generating device when the aerosol generating substrate is used up.

The cartridge can be disposable. The cartridge can be reusable. The cartridge may be configured to be refilled with an aerosol-forming substrate. The cartridge can be replaced in the aerosol generating device.

The aerosol generating system may include an aerosol generating chamber in which the supersaturated vapor is formed into an aerosol that is then transferred to the user's mouth. The air inlet, the air outlet and the chamber are preferably arranged to define an air flow path from the air inlet to the air outlet through the aerosol generating chamber to transport the aerosol to the air outlet and into the mouth user. The aerosol generating chamber may be defined by one or both of the cartridge and the aerosol generating device.

As used herein, the term “aerosol-forming substrate” refers to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds can be released by heating the substrate to form an aerosol. The aerosol-forming substrate may conveniently be part of an aerosol-generating article, such as a cartridge or smoking article.

The aerosol-forming substrate is preferably an aerosol-forming liquid. As used herein, the terms “aerosol-forming liquid” and “aerosol-forming liquid substrate” are used interchangeably. The storage portion preferably includes a capillary wick forming part or all of the inner surface for moving the aerosol-forming liquid substrate from the storage portion to the heater assembly.

The storage portion may contain one aerosol-forming substrate. The storage portion may contain two or more aerosol-forming substrates stored separately. For example, the storage portion may contain three aerosol-forming substrates stored separately, four aerosol-forming substrates stored separately, five aerosol-forming substrates stored separately, or six or more aerosol-forming substrates stored separately. If the storage portion contains two or more aerosol-forming substrates stored separately, the heater assembly preferably includes a plurality of electrical heaters spaced along the length of the elongated piercing assembly, the plurality of electrical heaters including at least one electrical heater for each of the aerosol-forming substrates. an aerosol, and each of the electric heaters is configured to heat its corresponding aerosol-forming substrate. This can provide independent heating of the aerosol-forming substrate.

The storage portion of the consumable cartridge may include first and second aerosol-forming substrates stored separately; The heater assembly includes a plurality of electrical heaters spaced along the length of the elongated piercing assembly, the plurality of electrical heaters comprising a first electrical heater for heating a first aerosol-forming substrate to create a first aerosol, and a second electrical heater for heating a second aerosol-forming substrate to creating a second aerosol.

In the aerosol generating system according to the present invention, the storage portion is preferably compressible, and the diameter of the open-ended passage passing through the cartridge is smaller than the outer diameter of the hollow rod portion. With this arrangement, the storage portion may be compressed radially by the heater assembly to provide a tight fit between the cartridge and the hollow rod portion. This can improve the contact between the electric heater and the aerosol-forming substrate in the storage portion to ensure stable aerosol properties. It may also restrict or eliminate air flow between the cartridge and the outside of the hollow shaft portion, thereby facilitating delivery of a uniform aerosol.

Preferably, the aerosol-forming substrate is an aerosol-forming liquid.

If the aerosol-forming substrate is an aerosol-forming liquid, the storage portion preferably includes a capillary wick for transporting the aerosol-forming liquid to the heater assembly, wherein the capillary wick forms all or part of the inner surface.

The upstream and downstream ends of the cartridge may be coated with frangible seals. The cartridge may further include an O-ring at one or both of the upstream and downstream ends of the open-end passage.

The cartridge may include a first sealed compartment containing a first aerosol-forming substrate and a second sealed compartment containing a second aerosol-forming substrate. The first compartment and the second compartment are preferably arranged in series from an upstream end to a downstream end of the cartridge. That is, the second compartment is located downstream of the first compartment. Preferably, both the first compartment and the second compartment comprise a frangible partition at each end. Preferably, each frangible partition is made of a metal film and, more preferably, an aluminum film. The first compartment and the second cartridge compartment may be adjacent to each other. The first compartment and the second compartment may be spaced apart from each other. The volume of the first compartment and the second compartment may be the same or different. Preferably, the volume of the second compartment is larger than the volume of the first compartment.

The storage portion may create an annular space surrounding an internal passage with an open end. The cartridge may have a generally cylindrical shape and may have any desired cross-section, such as circular, hexagonal, octagonal or decagonal. The storage portion may comprise a tubular porous member into which the liquid substrate is absorbed to form an aerosol. The storage portion preferably comprises a capillary wick and a capillary material containing an aerosol-forming liquid substrate. The capillary wick may define an internal surface surrounding the open-ended passage. A capillary material is a material that actively transports liquid from one end of the material to the other. The capillary material may preferably be oriented into the storage portion to transfer the aerosol-forming liquid substrate into the open-ended passage. The capillary material may have a fibrous structure. The capillary material may have a spongy structure. The capillary material may comprise a bundle of capillaries. The capillary material may contain a plurality of fibers. The capillary material may contain multiple filaments. The capillary material may comprise tubes with a narrow channel. The capillary material may contain a combination of fibers, filaments and tubes with narrow channels. Fibers, filaments and tubes with narrow channels can generally be aligned to transport fluid to an electric heater. The capillary material may comprise sponge-like material. The capillary material may comprise a foam-like material. The structure of the capillary material may form many small channels or tubes through which liquid can be transported by capillary action.

The capillary material 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 from twisted or extruded fibers such as cellulose acetate, polyester or bonded polyolefin, polyethylene , terylene or polypropylene fibers, nylon fibers or ceramics. The capillary material can be made from a polymer compound, including medical grade polymers such as ALTUGLAS® medical grade polymer polymethyl methacrylate (PMMA), Chevron Phillips K-Resin® styrene-butadiene copolymer (SBC), Pebax® specialty polymers, Rilsan ®, and Arkema's Rilsan® Clear, DOW Low Density Polyethylene (LDPE) (Health+™), DOW™ LDPE 91003, DOW™ LDPE 91020 (MFI 2.0; 923 density), ExxonMobil™ Polypropylene (PP) PP1013H1, PP1014H1 and PP9074MED , polycarbonate (PC) 2060-SERIES from Trinseo CALIBRE™. The capillary material may be made of a metal alloy, such as aluminum alloys or stainless steel for medical use. The capillary material may have any suitable capillarity and porosity for use with liquids having different physical properties. The aerosol-forming liquid substrate has physical properties, including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, that enable the liquid to be transported through the capillary material by capillary action. The capillary material may be configured to transport the aerosol-forming substrate to the nebulizer.

In the aerosol generating system of the present invention, the aerosol-forming substrate may be an aerosol-forming liquid. In such embodiments, preferably the storage portion is a liquid storage portion for storing an aerosol-forming liquid.

The liquid substrate forming the aerosol may contain nicotine. The liquid substrate that forms the aerosol containing nicotine may be a matrix of nicotine salt. The aerosol-forming liquid substrate may contain material of plant origin. The aerosol-forming liquid substrate may contain tobacco. The liquid aerosol-forming substrate may comprise tobacco-containing material containing volatile tobacco aromatic compounds that are released from the aerosol-forming substrate when heated. The aerosol-forming liquid substrate may comprise homogenized tobacco material. The aerosol-forming liquid substrate may contain non-tobacco material. The aerosol-forming liquid substrate may contain homogenized plant material.

The liquid aerosol-forming substrate may contain at least one aerosol-forming substance. An aerosol generating agent is any suitable known compound or mixture of compounds which, when in use, promotes the formation of a dense and stable aerosol and which is substantially resistant to thermal degradation at the operating temperature of the system. Suitable aerosol-forming agents are well known in the art and include, but are not limited to: polyhydric alcohols such as triethylene glycol, 1,3-butanediol and glycerol, polyhydric alcohol esters such as glycerol mono-, di- or triacetate, and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol formers may be polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1,3-butanediol and glycerol. The aerosol-forming liquid substrate may contain other additives and ingredients such as flavoring agents.

The aerosol-forming substrate may contain nicotine and at least one aerosol-forming agent. The aerosol-forming agent may be glycerol. The aerosol generating agent may be propylene glycol. The aerosol-forming agent may contain both glycerin and propylene glycol. The concentration of nicotine in the aerosol-forming substrate may range from about 2% to about 10%.

Although liquid aerosol-forming substrates are mentioned above, those of ordinary skill in the art will appreciate that other forms of aerosol-forming substrate may be used with other embodiments. For example, the aerosol-forming substrate may be a solid aerosol-forming substrate.

The aerosol-forming substrate may contain both solid and liquid components. The aerosol-forming substrate may comprise tobacco-containing material containing volatile tobacco aromatic compounds that are released from the substrate when heated. The aerosol-forming substrate may contain non-tobacco material. The aerosol-forming substrate may further comprise an aerosol-forming agent. Examples of suitable aerosol-forming substances are glycerin and propylene glycol.

If the aerosol-forming substrate is a solid aerosol-forming substrate, then the solid aerosol-forming substrate may comprise, for example, one or more of the following: powder, granules, beads, grains, thin tubes, strips or sheets containing one or more of the following: herbal leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco,

extruded tobacco, molded leaf tobacco and expanded tobacco. The solid aerosol-forming substrate may be in loose form or may be provided in a suitable container or cartridge. If desired, the solid aerosol-forming substrate may contain additional tobacco or non-tobacco volatile aromatic compounds released when the substrate is heated. The solid aerosol-forming substrate may also contain capsules that contain, for example, additional tobacco or non-tobacco volatile aromatic compounds, and such capsules may melt when the solid aerosol-forming substrate is heated.

As used herein, the term “homogenized tobacco” refers to the material formed by agglomerating particulate tobacco. Homogenized tobacco may be in leaf form. The homogenized tobacco material may contain more than 5% aerosol forming agent on a dry weight basis. Alternatively, the homogenized tobacco material may contain from about 5% to about 30% aerosol forming agent on a dry weight basis. Sheets of homogenized tobacco material may be formed by agglomerating particulate tobacco obtained by grinding or otherwise comminuting one or both of the tobacco leaf layers and tobacco leaf stems. Alternatively or in addition, the sheets of homogenized tobacco material may contain one or more of the following: tobacco dust, tobacco fines and other particulate tobacco waste generated, for example, during the processing, handling and shipping of tobacco. Sheets

homogenized tobacco material may contain one or more internal binders, i.e. tobacco endogenous binders, one or more external binders, i.e. tobacco exogenous binders, or a combination thereof, which promotes agglomeration of tobacco in the form of particles; in other examples or additionally, the sheets of homogenized tobacco material may contain other additives, including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavoring agents, fillers, aqueous and non-aqueous solvents, and combinations thereof.

Optionally, the solid aerosol-forming substrate may be provided on or embedded in a thermally stable carrier. The carrier may be in the form of powder, granules, beads, grains, thin tubes, strips or sheets. In other examples, the carrier may be a tubular carrier having a thin layer of solid substrate applied to its inner surface and/or its outer surface. Such a tubular carrier may be formed, for example, from paper or paper-like material, non-woven carbon fiber oilcloth, lightweight open cell metal mesh, or perforated metal foil, or any other heat-stable polymer matrix.

The solid aerosol-forming substrate may be applied to the surface of the carrier in the form of, for example, a sheet, foam, gel or suspension. The solid aerosol-forming substrate may be applied to the entire surface of the carrier, or alternatively may be applied in a pattern to provide non-uniform delivery of aroma during use.

According to a third aspect of the present invention, there is provided a kit for an electrically heated aerosol generating system, the kit comprising an aerosol generating device according to any of the above-described embodiments, and a plurality of consumable cartridges for use in the aerosol generating device, each cartridge comprising a storage portion having an aerosol-forming substrate and a fluid-permeable interior surface surrounding an open-ended passage extending through the cartridge.

As used herein, the terms "upstream" and "downstream" are used to describe the relative positions of components or parts of components of cartridges, aerosol generating devices, and aerosol generating systems according to the present invention relative to the direction of air drawn through the cartridges, devices aerosol-generating systems and aerosol-generating systems when used. The terms "distant" and "proximal" are used to describe the relative positions of components of aerosol generating devices and aerosol generating systems with respect to their connection to the device, such that the proximal end of the component is at the "fixed" end that is attached to the device. and the far end is at the "free" end opposite the near end. If a component is attached to a device at the downstream end of the component, the downstream end may be considered the "proximal" end and vice versa.

As used herein, the terms “longitudinal” and “length” refer to the direction between opposite ends of a cartridge, device, or device component, for example, between its downstream or proximal end and its opposite, upstream or distal end. The term "transverse" is used to describe a direction perpendicular to the longitudinal direction.

The upstream and downstream ends of the cartridge and the aerosol generating device are determined relative to the air flow when the user takes a puff from the mouth end of the aerosol generating device. Air is drawn into the cartridge or device at the upstream end, passes downstream through the cartridge or device, and exits the cartridge or device at the downstream end.

As used herein, the term “air inlet” is used to describe one or more openings through which air can be drawn into the aerosol generating system.

As used herein, the term "air outlet" is used to describe one or more openings through which air can be drawn from the aerosol generating system.

The features described in relation to one or more aspects may be equally applied to other aspects of the present invention. In particular, the features described with respect to the aerosol generating device according to the first aspect can be equally applied to the aerosol generating system according to the second aspect and the set according to the fourth aspect, and vice versa.

Thus, according to the first aspect of the present invention, an electrically heated aerosol generating system is provided, comprising:

a consumable cartridge comprising a storage portion containing an aerosol-forming substrate, the storage portion having a fluid-permeable interior surface surrounding an open-ended passage extending through the cartridge; And

an electrically heated aerosol generating device for use with a consumable cartridge, the device comprising:

a housing having a cavity for receiving at least a portion of the cartridge; And

a heater assembly located in the cavity, wherein the heater assembly contains:

an electrically conductive hollow rod portion coupled to the housing and defining an air flow passage forming a portion of the stroke for air flow through the device, the hollow rod portion being disposed to pass into the open end passage of a cartridge disposed in the cavity, and

at least one electric heater located along the hollow portion of the rod, wherein the electric heater includes at least one heating element for heating the aerosol-forming substrate, the cartridge located in the cavity,

wherein the hollow rod portion comprises a plurality of holes, wherein the at least one heating element is formed by one or more narrow regions of the hollow rod portion between adjacent holes.

Preferably, at least one electric heater surrounds the hollow portion of the rod.

Preferably, at least one electric heater extends along substantially the entire length of the hollow rod portion.

Preferably, the heater assembly comprises a plurality of electrical heaters spaced apart from each other along the length of the hollow rod portion for heating the aerosol-forming substrate cartridge housed in the cavity.

Preferably, the plurality of electric heaters are electrically isolated from each other so that each heater can be heated independently.

Preferably, the hollow rod portion is at least partially divided into a plurality of electrically insulated sections for connecting the plurality of electrical heaters to the power supply, the electrically insulated sections being electrically insulated from each other by one or more insulating gaps formed in the hollow rod portion.

Preferably, the heater assembly is arranged in a grid pattern.

Preferably, the heater assembly includes one electrical heater extending along substantially the entire length of the hollow rod portion and surrounding the hollow rod portion.

Preferably, the hollow shaft portion has a piercing surface at its distal end, whereby the hollow shaft portion functions as an elongated piercing element when the cartridge is inserted into the cavity.

Preferably, the heater assembly is a single integral component.

Preferably, the device further comprises a power supply coupled to the heater assembly.

Preferably, the storage portion is compressible, with the diameter of the open-ended passage through the cartridge being smaller than the outer diameter of the hollow shaft portion.

Preferably, the aerosol-forming substrate is an aerosol-forming liquid.

Preferably, the storage portion includes a capillary wick for transporting the aerosol-forming liquid to the heater assembly, the capillary wick forming all or part of the inner surface.

According to a second aspect of the present invention, there is provided a kit for an electrically heated aerosol generating system, the kit comprising an aerosol generating device of the above-described aerosol generating system, and a plurality of consumable cartridges for use in the aerosol generating device, each cartridge including a storage portion, containing an aerosol-forming substrate and having a fluid-permeable interior surface surrounding an open-ended passage through the cartridge.

The present invention will now be described solely by way of example, with reference to the accompanying drawings, in which:

Fig. 1 is a longitudinal cross-section of an aerosol generating system according to the first embodiment;

Fig. 2 is a longitudinal cross-section of a consumable cartridge for use in an aerosol generating system of FIG. 1;

Fig. 3A is a perspective view of a first embodiment of a heater assembly for an aerosol generating system of FIG. 1;

Fig. 3B is an enlarged partial side view of the heater assembly of FIG. 3A;

Fig. 4 is an enlarged partial perspective view of a second embodiment of a heater assembly for an aerosol generating system of FIG. 1;

Fig. 5A and 5B illustrate a method for inserting a consumable cartridge into an aerosol generating device of the aerosol generating system of FIG. 1; And

Fig. 5C is a longitudinal cross-section of the cartridge and heater assembly of the system of FIG. 5A and 5B, in which the system is held in an inclined position.

In fig. 1 schematically shows an aerosol generating system 10 according to a first embodiment of the present invention, comprising an aerosol generating device 100 and an aerosol generating article in the form of a consumable cartridge 200.

The device 100 includes a main body 102 containing a battery 104 and electronic control circuits 106. The housing 102 also defines a cavity 108 within which the cartridge 2 00 is housed. The device 100 further includes a mouthpiece portion 110 containing an outlet 112. In this example, the mouthpiece portion 110 is attached to the main body 102 by a threaded connection, but any suitable type of connection may be used. such as a swivel joint or a clamp joint. The device 100 further includes a heater assembly 300 comprising an elongated piercing element 302 in the form of a hollow rod portion 304 coupled to the housing 102, and a plurality of electric heaters 350 spaced apart along the length of the hollow rod portion 304. The heater assembly 300 is centrally located in the cavity 108 of the device 100 and extends along the longitudinal axis of the cavity 108. The hollow rod portion 304 defines a passage 306 for air flow. Air inlets 114 are located upstream of the main body 102 of the heater 300 assembly and are in fluid communication with the outlet 112 through an air flow passage 306.

As best seen in FIG. 2, cartridge 200 includes a storage portion 202 containing a tubular capillary wick 204 surrounded by a tubular capillary material 206 containing a liquid aerosol-forming substrate. The cartridge 200 has a hollow cylindrical shape through which an inner channel 208 extends. A capillary wick 204 surrounds the inner channel 208 such that the inner channel 208 is at least partially defined by the inner surface of the capillary wick 204. The upstream and downstream ends of the cartridge 200 are covered with frangible seals 210, 212. Cartridge 20 further includes O-rings 214, 216 on each upstream and downstream ends of the inner channel 208.

As best seen in FIG. 3A and 3B, the hollow portion 304 of the heater rod assembly 300 has a piercing surface 308 at the distal or downstream end. In this example, the piercing surface 308 is created by using a sharp tip at the distal end of the hollow shaft portion 304. The hollow rod portion 304 contains a plurality of holes 310 and is partially divided into a plurality of electrically insulated sections 318 that are separated from each other by insulating gaps 320. The plurality of holes are arranged into a plurality of groups of holes spaced apart from each other along the length of the hollow rod portion. In this example, the holes are arranged in a first group 312 near the proximal end of the hollow rod portion 304 and a second group 314 near the distal end of the hollow rod portion 304. Each of the groups of holes defines an electric heater 350. As shown in FIG. 3B, each electric heater 350 includes a plurality of heating elements 352 defined by narrow regions of a hollow rod portion between adjacent openings 310. The heating elements 352 have a width 354 and the openings have a width 356. The opening width size 356 is preferably selected such that when a liquid substrate is used the aerosol is drawn toward the electric heater 350 by capillary action through the openings 310. In the example shown in FIG. 3A, the first and second sets of holes 310 are offset around the circumference of the hollow rod portion 304. In other examples, two or more sets of holes 310 may be aligned around the circumference of the hollow shaft portion 304.

The hollow rod portion 304 is at least partially divided into a plurality of electrically insulated sections 318 that are electrically coupled to a battery in the device. Heating elements 352 are connected at one end to one of the electrically insulated sections 318, and at the other end to the other of the electrically insulated sections. Thus, the electric heaters 350 are electrically coupled to the device. The electrically insulated sections 318 may be electrically isolated from each other by insulating gaps 320. Thus, the electrical heaters 350 may be electrically isolated from each other to provide separate operation, control, or monitoring without the need for separate electrical wiring for each heater. In this example, the gaps 320 are air gaps. In other words, the gaps 320 do not contain any insulating material. In other examples, one or more gaps 320 may be completely or partially filled with electrical insulating material.

In fig. 4 is a partial view of an assembled heater 400 according to a second embodiment of the present invention. Similar to the heater assembly 300, the heater assembly 400 includes an elongated piercing element in the form of a hollow rod portion 404 defining an air flow passage 406 and having a plurality of holes 410 along its length. However, unlike the heater assembly 300, the heater assembly 400 includes a single electrical heater 450 extending along substantially the entire length of the hollow rod portion 404 and surrounding the hollow rod portion 404. The electric heater 450 also includes a plurality of heating elements 452 defined by narrow regions of the hollow rod portion 404 between adjacent openings 410. However, in the case of the heater 400 assembly, the heating elements 452 are arranged in a grid pattern.

According to FIG. 5A and 5B, insertion of the cartridge 200 into the device 100 of the system 10 will not be described.

To insert the cartridge 200 into the device 100, and thus assemble the system 10, the first step is to remove the mouthpiece portion 110 from the main body 102 of the device 100 and insert the article 200 into the cavity 108 of the device 100, as shown in FIG. 5A. Upon insertion of the cartridge 200 into the cavity 108, the piercing surface 308 at the distal end of the piercing element 302 breaks the frangible seal at the upstream end of the cartridge 200. Because the cartridge 200 is further inserted into the cavity 108 and the piercing element 302 is further extended into the internal channel 208 of the cartridge, the piercing surface 308 contacts a frangible seal at the downstream end of cartridge 200 to create an opening in the frangible seal.

The cartridge 200 is then fully inserted into the cavity 108, and the mouthpiece portion 110 is again secured to and connected to the main body 102 to enclose the cartridge 200 in the cavity 108, as shown in FIG. 5V. When the cartridge 200 is fully inserted into the cavity 108, each of the holes in the frangible seals at the upstream and downstream ends of the cartridge 200 has a diameter approximately equal to the outer diameter of the hollow rod portion 304. O-rings on the upstream and downstream ends of the cartridge 200 create a seal around the hollow shaft portion 304. Together with frangible seals, this reduces or prevents leakage of liquid aerosol-forming substrate from the cartridge 200 and system 10. The cartridge 200 may be fully pressed into the cavity 108 by the user before the mouthpiece portion 110 is reattached to the main body 102. Alternatively, the cartridge 200 may be partially inserted into the cavity 108, and the mouthpiece portion 110 may be used to push the cartridge 200 into the cavity 108 until it is fully inserted. This may be more user friendly.

As shown in FIG. 5B, when the cartridge 200 is fully inserted into the cavity 108 of the aerosol generating device 100, the air flow path shown by the arrows in FIG. 5B is generated through the aerosol generating system 10. The air flow path extends from the air inlet ports 114 to the outlet ports 112 through an internal passage 208 in the cartridge 200 and an air flow passage 306 in the heater assembly 300. As further shown in FIG. 5 V, when the cartridge 200 is fully inserted, the electric heaters 350 are in fluid communication with the cartridge 200 storage portion 202 on the inner surface of the inner channel 208.

In use, the liquid aerosol-forming substrate moves from the storage portion 202 to the electric heaters 350 and may be retained in the openings of each electric heater 350 by capillary action. In this example, the outer diameter of the hollow rod portion 304 is larger than the inner diameter of the inner channel 208 of the cartridge 200, so the storage portion 202 of the cartridge 200 is compressed by the hollow rod portion 304. This provides direct contact between the electric heaters 350 and the storage portion 202 to facilitate transfer of the aerosol-forming liquid substrate to the electric heaters 350. The battery supplies electrical energy to the heating elements of each electric heater 350. The heating elements are heated to vaporize the liquid substrate in the capillary wick 204 to form supersaturated steam. At the same time, the evaporated liquid is replaced by another liquid moving through the capillary wick 204 of the liquid storage portion 202 by capillary action. (This is sometimes referred to as a "pumping action.") When a user takes a puff on the tip portion 110, air is drawn through the air inlet ports 114, through the air flow passage of the hollow rod portion 304, past the electric heaters 350, into the tip portion 110, and out of the outlet port 112. The vaporized aerosol-forming substrate is entrained in the air flowing through the air flow passage of the hollow rod portion 304 and condenses in the mouthpiece portion 110 to form a respirable aerosol that is transferred to the outlet 112 and into the user's mouth.

The device may be operated by a user-operated switch (not shown) on device 100. Alternatively or in addition, the device may include a sensor for detecting tightening by the user. When tightening is detected by the sensor, electronic control circuitry controls the flow of electrical energy from the battery to the electric heaters 350. The sensor may include one or more separate components. In some examples, the puff detection function is performed by the heating elements of the heater and wick assemblies. For example, by electronic control circuitry measuring one or more electrical parameters of the heating elements and determining a specific change in the measured electrical parameters that indicates a puff has occurred.

When using the system, the distribution of the aerosol-forming liquid substrate in the cartridge may change. For example, if the aerosol-forming liquid substrate in the storage portion is consumed during use, or if the system is held at an angle for a significant amount of time. This change in the distribution of the aerosol-forming liquid substrate can result in differences in the amount of liquid in the capillary body of each electric heater and, therefore, in the temperature of the heating element of each electric heater. This is described below with reference to Figure 5C.

In fig. 5C shows a longitudinal cross-section of the cartridge 200 and heater 300 assembly of the aerosol generating system after the system has been held in an inclined position. As shown, the remaining liquid 203 in the cartridge 200 has settled in the storage portion 202 at an angle to the heater assembly 300. Since the electric heaters are spaced apart along the length of the cartridge 200, the volume of the aerosol-forming liquid substrate in the region of the storage portion 202 adjacent the electric heaters is not uniform. Specifically, the region of the storage portion 202 at the upstream end of the cartridge adjacent the first pair of electric heaters 360 is saturated with a liquid substrate forming an aerosol, while the region of the storage portion 202 adjacent the second pair of electric heaters 370 located midway along the length of the heater assembly 300 is only partially saturated with the aerosol-forming liquid substrate, and the area of the storage portion 202 adjacent to the third pair of electric heaters 380 at the downstream end of the heater assembly 300 is dry. Therefore, electric heaters 360, 370, 380 can operate at different temperatures. Since the electrical parameters of each electric heater, such as the electrical resistance of the heating element, can change depending on the temperature, the distribution of the aerosol-forming liquid substrate or the remaining amount of the aerosol-forming liquid substrate can be calculated by the control circuit by measuring the electrical parameters each electric heater. The electronic control circuits are configured to separately measure one or more electrical parameters of each electric heater in use and calculate an estimated residual amount or expected distribution of the liquid aerosol-forming substrate in the cartridge based on differences in the measured electrical parameters of the electric heaters. Thus, electric heaters function as both heaters and sensors.

The device includes a user indicator (not shown), such as a display, an audio output, or a tactile output coupled to the control circuitry, which can be used to communicate to the user information about the estimated residual amount of liquid aerosol-forming substrate in the cartridge 200. When the estimated residual amount drops below a threshold value, the electrical circuitry may also be configured to operate as a user indicator to alert the user and prompt the user to replace the cartridge in need of replacement. The control circuitry may also be configured to calculate the distribution of the liquid aerosol-forming substrate in the cartridge based on differences in electrical parameter measurements of the electric heaters, and may act as a custom indicator when the estimated distribution indicates that the system has been held at a certain angle for too long, such that the user is alerted to the need to change the position of the device 100 at least temporarily so that the aerosol-forming liquid substrate can be redistributed to the storage portions. In this or other examples, the control circuitry may be configured to notify a user of the estimated residual amount or estimated allocation via a communication link with a third-party device, such as a smartphone, smart watch, tablet, desktop computer, or similar device.

In addition to determining differences in the electrical parameters of the electric heaters and calculating the estimated residual amount or expected distribution of the liquid aerosol-forming substrate in the cartridge 200, the control circuit 106 is also configured to control the supply of electrical power to each electric heater in response to the estimated residual amount or expected distribution. In particular, if the measured electrical parameters indicate that one or more electric heaters are partially dry, the control circuit 106 is configured to reduce the power supply to the electric heater. This allows the system 10 to determine which of the electrical heaters is in the best condition to generate the aerosol in the most efficient manner. This makes it possible to minimize negative changes in the properties of the aerosol generated by the system 10 caused by fluctuations in humidity and temperature in electric heaters. This may also reduce the energy consumption of the system 10 and the risk of damage to electrical heaters due to overheating. If electrical parameters indicate that one or more electric heaters are dry, control circuit 106 is configured to reduce the electrical supply to that electric heater to zero.

The above specific embodiments and examples illustrate, but do not limit, the invention. It should be understood that other embodiments of the present invention are possible, and the specific embodiments and examples described herein are not exhaustive.

Claims (18)

1. An electrically heated aerosol generating system containing: a consumable cartridge comprising a storage portion containing an aerosol-forming substrate, the storage portion having a fluid-permeable interior surface surrounding an open-ended passage extending through the cartridge; And an electrically heated aerosol generating device for use with a consumable cartridge, the device comprising a housing having a cavity to accommodate at least a portion of the cartridge; And a heater assembly disposed in a cavity, the heater assembly comprising an electrically conductive hollow rod portion coupled to the housing and defining an air flow passage forming a portion of a stroke for air flow through the device, the hollow rod portion disposed to pass into an open-ended passage cartridge located in the cavity, and at least one electric heater located along the hollow portion of the rod, wherein the electric heater includes at least one heating element for heating the aerosol-forming substrate of the cartridge located in the cavity, wherein the hollow portion of the rod contains a plurality of holes, wherein the at least one heating element is formed by one or more narrow regions of the hollow rod portion between adjacent holes. 2. The electrically heated aerosol generating system of claim 1, wherein at least one electrical heater surrounds the hollow portion of the rod. 3. The electrically heated aerosol generating system of claim 1 or 2, wherein at least one electrical heater extends along substantially the entire length of the hollow rod portion. 4. The electrically heated aerosol generating system of any one of the preceding claims, wherein the heater assembly comprises a plurality of electrical heaters spaced apart along the length of the hollow portion of the rod for heating the aerosol generating substrate cartridge disposed in the cavity. 5. The electrically heated aerosol generating system of claim 4, wherein the plurality of electrical heaters are electrically isolated from each other such that each heater can be heated independently. 6. The electrically heated aerosol generating system of claim 5, wherein the hollow rod portion is at least partially divided into a plurality of electrically insulated sections for connecting the plurality of electrical heaters to the power supply, wherein the electrically insulated sections are electrically insulated from each other by one or more insulating gaps , formed in the hollow part of the rod. 7. An electrically heated aerosol generating system according to any one of claims. 1-3, in which the heater assembly is arranged according to a grid pattern. 8. An electrically heated aerosol generating system according to any one of claims. 1-3 and 7, wherein the heater assembly includes one electrical heater extending along substantially the entire length of the hollow rod portion and surrounding the hollow rod portion. 9. The electrically heated aerosol generating system of any one of the preceding claims, wherein the hollow shaft portion has a piercing surface at a distal end such that the hollow shaft portion functions as an elongated piercing element when the cartridge is inserted into the cavity. 10. An electrically heated aerosol generating system as claimed in any one of the preceding claims, wherein the heater assembly is a single integral component. 11. The electrically heated aerosol generating system of any one of the preceding claims, wherein the device further comprises a power supply coupled to the heater assembly. 12. The electrically heated aerosol generating system of any one of the preceding claims, wherein the storage portion is compressible and the diameter of the open-ended passage through the cartridge is less than the outer diameter of the hollow rod portion. 13. The electrically heated aerosol generating system of any one of the preceding claims, wherein the aerosol-forming substrate is an aerosol-forming liquid. 14. The electrically heated aerosol generating system of claim 13, wherein the storage portion comprises a capillary wick for transporting the aerosol-generating liquid to the heater assembly, wherein the capillary wick forms all or a portion of the internal surface. 15. A kit for an electrically heated aerosol generating system, wherein the kit contains an aerosol generating device of an aerosol generating system according to any one of claims. 1-14 and a plurality of consumable cartridges for use in an aerosol generating apparatus, each cartridge comprising a storage portion containing an aerosol-generating substrate and having a fluid-permeable interior surface surrounding an open-ended passage extending through the cartridge.