A CARTRIDGE FOR USE IN AN AEROSOL-GENERATING SYSTEM AND AN AEROSOL-GENERATING SYSTEM COMPRISING SAID CARTRIDGE

Abstract

A cartridge for an aerosol-generating system is provided, the cartridge including: a porous ceramic body having a porosity of between 30% and 65%; and a mesh heater engaged with the porous ceramic body, the mesh heater including a plurality of apertures, each aperture having a dimension between 50 microns and 200 microns, in which the mesh heater is a hybrid mesh heater including a network of wires and fibres, the fibres having a different material composition from the wires. An aerosol-generating system, including an aerosol-generating device and the cartridge, is also provided.

Claims

1.-15. (canceled)

16. A cartridge for an aerosol-generating system, the cartridge comprising: a porous ceramic body having a porosity of between 30% and 65%; and a mesh heater engaged with the porous ceramic body, the mesh heater including a plurality of apertures, each aperture having a dimension between 50 microns and 200 microns, wherein the mesh heater is a hybrid mesh heater comprising a network of wires and fibres, the fibres having a different material composition from the wires.

17. The cartridge according to claim 16, wherein, in use, liquid aerosol-forming substrate is drawn into apertures of the plurality of apertures of the mesh heater from the porous ceramic body by capillary action.

18. The cartridge according to claim 16, wherein the fibres comprise one or both of glass fibres and rayon fibres.

19. The cartridge according to claim 16, wherein the mesh heater is engaged with the porous ceramic body over substantially an entirety of a face of the mesh heater.

20. The cartridge according to claim 19, wherein the mesh heater is in contact with the porous ceramic body over substantially the entirety of the face of the mesh heater.

21. The cartridge according to claim 16, wherein the porous ceramic body comprises pores with an average pore size between 2.5 microns and 40 microns.

22. The cartridge according to claim 16, wherein the porous ceramic body comprises a first portion and a projection.

23. The cartridge according to claim 22, wherein the projection is located at a periphery of the first portion and extends around substantially a whole of the periphery of the first portion.

24. The cartridge according to claim 16, wherein the porous ceramic body comprises a channel extending therethrough, the channel having a diameter of between 300 microns and 800 microns.

25. The cartridge according to claim 16, further comprising a segment of metal located between the porous ceramic body and the mesh heater.

26. The cartridge according to claim 16, wherein the mesh heater is located between the porous ceramic body and a covering layer of a second ceramic.

27. The cartridge according to claim 26, wherein the mesh heater is attached to the porous ceramic body by the covering layer of the second ceramic.

28. An aerosol-generating system, comprising an aerosol-generating device and a cartridge according to claim 16.

29. The aerosol-generating system according to claim 28, wherein the aerosol-generating device comprises a power supply configured to supply power to the mesh heater to resistively heat the mesh heater.

30. The aerosol-generating system according to claim 28, wherein the aerosol-generating device comprises a power supply, and the cartridge or the aerosol-generating device comprise an inductor, and the power supply and the inductor are configured to inductively heat the mesh heater.

Description

[0187] Examples will now be further described with reference to the figures in which:

[0188] FIG. 1 shows a cross-sectional view of an aerosol-generating system incorporating a cartridge with a first heater assembly;

[0189] FIG. 2 shows a cross-sectional view of the cartridge incorporating the first heater assembly;

[0190] FIG. 3 shows a perspective view of the first heater assembly;

[0191] FIG. 4 shows a cross-sectional view of the first heater assembly;

[0192] FIG. 5 shows a perspective view of a second heater assembly;

[0193] FIG. 6 shows a cross-sectional view of the second heater assembly;

[0194] FIG. 7 shows a perspective view of a third heater assembly;

[0195] FIG. 8 shows a cross-sectional view of the third heater assembly; and

[0196] FIG. 9 shows a cross-sectional view of an aerosol-generating system incorporating a cartridge with the third heater assembly.

[0197] FIG. 1 shows a cross-sectional view of an aerosol-generating system 100. The aerosol-generating system 100 comprises an aerosol-generating device 150 and a cartridge 200. In this example, the aerosol-generating system 100 is an electrically operated smoking system.

[0198] The aerosol-generating device 150 is portable and has a size comparable to a conventional cigar or cigarette. The device 150 comprises a battery 152, such as a lithium iron phosphate battery, and a controller 154 electrically connected to the battery 152. The device 150 also comprises two electrical contacts 156, 158 which are electrically connected to the battery 152. This electrical connection is a wired connection and is not shown in FIG. 1.

[0199] The cartridge 200 comprises an air inlet 202, an air outlet 204, and a first heater assembly 300. The air inlet 202 is in fluid communication with the air outlet 204. The heater assembly 300 is positioned downstream of the air inlet 202 and upstream of the air outlet 204. The heater assembly 300 comprises a porous ceramic body 302, and a substantially planar mesh heater 304 engaged with the porous ceramic body 302.

[0200] The mesh heater 304 comprises a hybrid mesh comprising stainless steel wires 306 and glass fibres 308. The stainless steel wires 306 are interwoven with, and substantially perpendicular to, the glass fibres 308. Thus, the mesh heater 304 comprises a woven hybrid mesh. The mesh heater 304 is attached to the porous ceramic body 302 by two solder points 310, 312. In this example, the solder points 310, 312 are formed from tin, though silver or another suitable material could be used. Each of these solder points 310, 312 is electrically connected to an electrical contact 214, 216 on the cartridge. This electrical connection is a wired connection and is not shown in FIG. 1. Via this electrical connection, the stainless steel wires 306 are electrically connected to the electrical contacts 214, 216.

[0201] The porous ceramic body 302 comprises a number of pores. A liquid aerosol-forming substrate is held in the pores of the porous ceramic body 302.

[0202] In FIG. 1, the aerosol-generating device 150 is coupled with the cartridge 200. In this example, the cartridge 200 is coupled with the aerosol-generating device 150 via protrusions 206, 208 which form a snap-fit connection with corresponding apertures 160, 162 on the aerosol-generating device 150.

[0203] The cartridge 200 additionally comprises a liquid aerosol-forming substrate storage component 288 which is in fluid communication with the porous ceramic body 302. The liquid aerosol-forming substrate storage component 288 is in contact with a first portion 320 of the porous ceramic body 302. The liquid aerosol-forming substrate storage component 1008 may be adhered to the porous ceramic body 302 with glue, or may be held in place by friction, or may be held in place by another suitable means. The liquid aerosol-forming substrate storage component 288 in this example is a capillary material having a fibrous or spongy structure, though in other embodiments a reservoir or tank of liquid aerosol-forming substrate could be used. The capillary material is formed form polyester, though any suitable material could be used. The capillary material is soaked with aerosol-forming substrate. Thus, in FIG. 1, aerosol-forming substrate is stored in the pores of the porous ceramic body 302 and in the liquid aerosol-forming substrate storage component 288.

[0204] In use, a user puffs on the air outlet 204 of the cartridge 200. At the same time, the user presses a button (not shown) on the aerosol-generating device 150. Pressing this button sends a signal to the controller 154, which results in power being supplied from the battery 152 to the mesh heater 302 via the electrical contacts 156, 158 of the device and the electrical contacts 214, 216 of the cartridge. This causes a current to flow through the stainless steel wires 306 of the mesh heater 304, thereby resistively heating the stainless steel wires 306 and causing the mesh heater 304 as a whole to heat up. In other examples, an air flow sensor, or pressure sensor, is located in the cartridge 200 and electrically connected to the controller 154. The air flow sensor, or pressure sensor, detects that a user is puffing on the air outlet 204 of the cartridge 200 and sends a signal to the controller 154 to provide power to the mesh heater 304. In these examples, there is therefore no need for the user to press a button to heat the mesh heater 304. The liquid aerosol-forming substrate held in the pores of the porous ceramic body 302 is drawn into apertures of the mesh heater 304 by capillary action. The mesh heater 304 heats this liquid aerosol-forming substrate to vaporise the aerosol-forming substrate.

[0205] As liquid aerosol-forming substrate is drawn from the porous ceramic body 302 into the apertures of the mesh heater 304 and vaporised, liquid aerosol-forming substrate is also drawn from the liquid aerosol-forming substrate storage component 288 into the porous ceramic body 302. Thus, a user may be able to generate more aerosol than if the liquid aerosol-forming substrate storage component 288 were not present.

[0206] As the user puffs on the air outlet 204 of the cartridge 200, air is drawn into the air inlet 202. This air then travels around the heater assembly 300 and towards the air outlet 204. This flow of air entrains the vapour formed by heating of the liquid aerosol-forming substrate by the mesh heater 304. This entrained vapour then cools and condenses to form an aerosol. This aerosol is then delivered to the user via the air outlet 204.

[0207] FIG. 2 shows a cross-sectional view of the cartridge 200 incorporating the first example of a heater assembly 300. In FIG. 2, the cartridge 200 is no longer coupled with the aerosol-generating device 150.

[0208] FIGS. 3 and 4 show a perspective view and a cross-sectional view of the first heater assembly 300, respectively. FIG. 3 also shows the liquid aerosol-forming substrate storage component 288. The heater assembly 300 comprises the porous ceramic body 302 and the mesh heater 304. The mesh heater 304 is in contact with the porous ceramic body 302 over substantially an entirety of a face of the mesh heater 304.

[0209] The stainless steel wires 306 and the glass fibres 308 of the mesh heater 304 are interwoven. Thus, the mesh heater 304 comprises a woven hybrid mesh. The stainless steel wires 306 and the glass fibres 308 of the mesh heater 304 have diameters of around 17 microns. The thickness of the mesh heater 304 is approximately 51 microns. In FIG. 3, the apertures 309 of the mesh heater are visible. These apertures 309 each have a dimension of around 70 microns. In this example, the apertures 309 have a substantially square cross-section and the dimension is equal to the length of a side of the square cross-section.

[0210] The porous ceramic body 302 is formed entirely from alumina. The porous ceramic body 302 comprises pores with pore sizes between 2.5 microns and 40 microns. The average pore size is around 10 microns. The porosity of the porous ceramic body 302 is around 40%.

[0211] The porous ceramic body 302 comprises the first portion 320 and a projection 322. The first portion 320 has a substantially circular cross-section. This circular cross-section has a diameter of about 15 mm. The first portion 320 has a thickness of about 2 mm.

[0212] The projection 322 has a substantially annular, or ring-like, cross-section. The projection 322 is located at a periphery of the first portion 320 and extends around substantially a whole of the periphery of the first portion 320. The projection 322 extends about 10 mm substantially perpendicularly from a surface of the first portion 320. The projection 322 has a width of about 2 mm. The width of the substantially annular projection is the difference between the outer and inner radii of the annulus.

[0213] The first portion 320 of the porous ceramic body 302 comprises a channel 314 extending therethrough. The channel 314 extends substantially in a thickness direction of the first portion 320. As such, the channel 314 extends substantially perpendicularly to the plane of the mesh heater 304. The channel 314 has a diameter of about 500 microns.

[0214] FIGS. 5 and 6 show a perspective view and a cross-sectional view of a second heater assembly 500, respectively. FIG. 5 also shows the liquid aerosol-forming substrate storage component 288.

[0215] The second heater assembly 500 comprises a porous ceramic body 502, and a mesh heater 504. The porous ceramic body 502 is identical to the porous ceramic body 302 of the first heater assembly 300.

[0216] The mesh heater 504 comprises a hybrid mesh comprising stainless steel wires 506 and rayon fibres 508. The stainless steel wires 506 are interwoven with, and substantially perpendicular to, the rayon fibres 508. The mesh heater 504 is engaged with the porous ceramic body 502. Specifically, the mesh heater 504 is attached to the porous ceramic body 502. To attach the mesh heater 504 to the porous ceramic body 502, two segments of metal 510, 512 are applied to the porous ceramic body 502. In this example, the segments of metal 510, 512 are formed from tin, though silver or other suitable materials could be used. The mesh heater 504 is then positioned such that the segments of metal 510, 512 are between the porous ceramic body 502 and the mesh heater 504. The mesh heater 504 is then forced towards the porous ceramic body 502 and into the segments of metal 510, 512. The segments of metal 510, 512 adhere the porous ceramic body 502 to the mesh heater 504. In some examples, the segments of metal are coated onto the mesh heater. In some examples, heat is applied at the same time as forcing the mesh heater towards the porous ceramic body.

[0217] The second heater assembly 500 also comprises two electrodes 511, 513. These electrodes are formed from tin and are in contact with several stainless steel wires 506 and rayon fibres 508 of the mesh heater 504. When the second heater assembly 500 replaces the first heater assembly 300 in the cartridge 200 shown in FIGS. 1 and 2, the electrodes 511, 513 are each electrically connected to an electrical contact 214, 216 on the cartridge 200. This electrical connection is a wired connection and is not shown in FIG. 1 or 2. The stainless steel wires 506 are electrically connected to the electrical contacts 214, 216 through this electrical connection.

[0218] The stainless steel wires 506 and the rayon fibres 508 of the mesh heater 504 have diameters of around 17 microns. The thickness of the mesh heater 504 is approximately 51 microns. In FIG. 5, the apertures 509 of the mesh heater are visible. These apertures each have a dimension of around 70 microns. In this example, the apertures 509 have a substantially square cross-section and the dimension is a equal to the length of a side of the square cross-section.

[0219] The mesh heater 504 is in contact with the porous ceramic body 502 over substantially the entirety of the face of the mesh heater 504. In use, liquid aerosol-forming substrate held in the pores of the porous ceramic body 502 is drawn into the apertures 509 of the mesh heater 504.

[0220] In use, the second heater assembly 500 functions in much the same way as the first heater assembly 300. The second heater assembly 500 may replace the first heater assembly 300 shown in the aerosol-generating system of FIG. 1. In this case, in use, the system 100 functions in an identical manner but power is supplied to the mesh heater 504 of the second heater assembly 500 through the tin electrodes 511, 513 (rather than through the solder points 310, 312 of the first heater assembly 300).

[0221] FIGS. 7 and 8 show a perspective view and a cross-sectional view of a third heater assembly 700. FIG. 7 also shows a liquid aerosol-forming substrate storage component 1008.

[0222] The third heater assembly 700 comprises a porous ceramic body 702, and a mesh heater 704. The porous ceramic body 702 is identical to the porous ceramic body of the first heater assembly 302.

[0223] The mesh heater 704 comprises a stainless steel perforated plate 706. The stainless steel of the plate 706 of the mesh heater 704 is an effective susceptor material. Thus, the plate 706 acts as a susceptor.

[0224] To attach the plate 706 to the porous ceramic body 702, the plate 706 is placed in contact with the porous ceramic body 702. A covering layer 708 of a ceramic paste is then applied over the plate 706. Some of the paste is located on the plate 706 and some of the paste is located on the porous ceramic body 702. The paste applied to the porous ceramic body 702 may be applied beyond a periphery of the plate 706, or through the apertures 709 of the plate 706, or, as in this example, both. At least a portion of the plate 706 is located between the covering layer 708 and the porous ceramic body 702. The covering layer 708 is then sintered. The porous ceramic body 702 is sintered at the same time. In this example, the covering layer 708 is formed from alumina identical to the alumina of the porous ceramic body 702. The covering layer 708 adheres the porous ceramic body 702 to the plate 706.

[0225] The perforations in the plate 706 form apertures 709 with substantially circular cross-sections. In FIG. 7, the apertures 709 of the mesh heater 704 are visible. These apertures each have a dimension of around 75 microns. In this example, the apertures 709 have a substantially circular cross-section and the dimension is equal to the diameter of the circular cross-section.

[0226] The mesh heater 704 is in contact with the porous ceramic body 702 over substantially the entirety of a face of the mesh heater 704.

[0227] FIG. 9 shows a cross-sectional view of an aerosol-generating system 900. The aerosol-generating system 900 comprises an aerosol-generating device 950 and a cartridge 1000 with the third heater assembly 700. In this example, the aerosol-generating system 900 is an electrically operated smoking system.

[0228] The aerosol-generating device 950 is portable and has a size comparable to a conventional cigar or cigarette. The device 950 comprises a battery 952, such as a lithium iron phosphate battery, and a controller 954 electrically connected to the battery 952. The device 950 also comprises an induction coil 956 electrically connected to the battery 952. The device 950 also comprises an air inlet 958 and an air outlet 960 in fluid communication with the air inlet 958.

[0229] The cartridge 1000 comprises an air inlet 1002, an air outlet 1004, and the third heater assembly 700. The air inlet 1002 is in fluid communication with the air outlet 1004. The heater assembly 700 is positioned downstream of the air inlet 1002 and upstream of the air outlet 1004. When the cartridge 1000 is coupled with the aerosol-generating device 950, as shown in FIG. 9, the air outlet 960 of the device 950 is adjacent to the air inlet 1002 of the cartridge 1000. Thus, in use, when a user puffs on the air outlet 1004 of the cartridge 1000, air flows through the air inlet 958 of the device 950, then through the air outlet 960 of the device 950, then through the air inlet 1002 of the cartridge 1000, then past the heater assembly 700, then through the air outlet 1004 of the cartridge 1000.

[0230] In FIG. 9, the cartridge 1000 is coupled with the aerosol-generating device 950 by mating a screw thread 1006 of the cartridge 1000 with a corresponding screw thread 962 of the aerosol-generating device 950.

[0231] The cartridge 1000 additionally comprises a liquid aerosol-forming substrate storage component 1008 which is in fluid communication with the porous ceramic body 702. The liquid aerosol-forming substrate storage component 1008 is in contact with the first portion 720 of the porous ceramic body 702. The liquid aerosol-forming substrate storage component 1008 may be adhered to the porous ceramic body 702 with glue, or may be held in place by friction, or may be held in place by another suitable means. The liquid aerosol-forming substrate storage component 1008 in this example is a capillary material having a fibrous or spongy structure. The capillary material is formed form polyester, though any suitable material could be used. The capillary material is soaked with aerosol-forming substrate. Thus, in FIG. 9, aerosol-forming substrate is stored in the pores of the porous ceramic body 702 and in the liquid aerosol-forming substrate storage component 1008.

[0232] In use, a user puffs on the air outlet 1004 of the cartridge 1000. At the same time, the user presses a button (not shown) on the aerosol-generating device 950. Pressing this button sends a signal to the controller 954, which results in the battery 952 supplying a high frequency electrical current to the induction coil 956. This causes the induction coil to create a fluctuating electromagnetic field. The mesh heater 704 is positioned within this field. Thus, this fluctuating electromagnetic field generates eddy currents and hysteresis losses in the stainless steel plate 706, which acts as a susceptor heating element in the cartridge 1000. The plate 706 is therefore inductively heated. In other examples, an air flow sensor, or pressure sensor, is located in the device 950 and electrically connected to the controller 954. The air flow sensor, or pressure sensor, detects that a user is puffing on the air outlet 1004 of the cartridge 1000 and sends a signal to the controller 954 to provide power to the mesh heater 704. In these examples, there is therefore no need for the user to press a button to heat the mesh heater 704. The liquid aerosol-forming substrate held in the pores of the porous ceramic body 702 is drawn into apertures of the plate 706 of the mesh heater 704 by capillary action. The mesh heater 704 heats this liquid aerosol-forming substrate to vaporise the aerosol-forming substrate.

[0233] As the user puffs on the air outlet 1004 of the cartridge 1000, air is drawn into the air inlet 958 of the device 950, then through the air outlet 960 of the device 950, then through the air inlet 1002 of the cartridge 1000. This air then travels around the heater assembly 700 and towards the air outlet 1004. This flow of air entrains the vapour formed by heating of the liquid aerosol-forming substrate by the mesh heater 704. This entrained vapour then cools and condenses to form an aerosol. This aerosol is then delivered to the user via the air outlet 1004.

[0234] As liquid aerosol-forming substrate is drawn from the porous ceramic body 702 into the apertures 709 of the mesh heater 704 and vaporised, liquid aerosol-forming substrate is also drawn from the liquid aerosol-forming substrate storage component 1008 into the porous ceramic body 702. Thus, a user may be able to generate more aerosol than if the liquid aerosol-forming substrate storage component 1008 were not present.

[0235] For the purpose of the present description and the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A±10% of A.