BR112018077417B1 - FLUID PERMEABLE HEATER ASSEMBLY FOR AN AEROSOL GENERATING SYSTEM, CARTRIDGE FOR AN AEROSOL GENERATING SYSTEM AND CARTRIDGE FOR AN AEROSOL GENERATING SYSTEM - Google Patents

Abstract

The present invention relates to the fluid permeable heater assembly (10) for an aerosol generating system, the heater assembly (10) comprising a lid (12) comprising a hollow body (14) with a first (16) and a second (18) lid opening, wherein the first lid opening (16) is opposite the second lid opening (18), and a substantially flat electrically conductive and fluid permeable heating element (20), wherein the heating element (20) is configured to vaporize the aerosol-forming substrate (22), and wherein the heating element (20) is mounted in the lid (12) such that the heating element (20) extends through the first opening of cover (16). The present invention further relates to a cartridge (40) for an aerosol generating system, the cartridge (40) comprising the heater assembly (10), a liquid storage portion (36) for storing liquid aerosol forming substrate ( 22), a nozzle (38) for retaining the liquid storage portion (36), and a retainer (42) for retaining the components of the heater assembly (10) and for maintaining the heater assembly (10) in contact with the portion liquid storage system (36). The present invention further relates to an aerosol generating system, comprising a main unit and the cartridge, in which the cartridge (40) is removably coupled (...).

Description

[0001] The present invention relates to aerosol generating systems, such as electrically operated portable smoking systems. In particular, the present invention relates to heater assemblies for aerosol generating systems in which the aerosol-forming substrate is liquid and vaporized.

[0002] Electrically operated portable aerosol generating systems are known that consist of a device portion comprising a battery and control electronics, a cartridge portion comprising a supply of aerosol-forming substrate held in a liquid storage portion, and a electrically operated heater assembly acting as a vaporizer. A cartridge comprising both a supply of aerosol-forming substrate maintained in a liquid storage portion and a vaporizer is sometimes referred to as a "cartomizer." The heater assembly may comprise a fluid permeable heating element that is in contact with a capillary medium such as an elongated wick embedded in the aerosol-forming substrate maintained in the liquid storage portion. The cartridge portion typically comprises not only the aerosol-forming substrate supply and an electrically operated heater assembly, but also a mouthpiece, which the user sucks on during use to swallow the aerosol into his or her mouth.

[0003] A heater assembly with a fluid-permeable heating element may have a fragile structure. The components of the heater assembly can move easily during transport, packaging and use. Manufacturing a cartridge with such a heater assembly can be difficult.

[0004] It would be desirable to provide an improved heater assembly for an aerosol generating system that allows easier manufacturing at lower costs and provides a more rigid structure to prevent displacement of the heater assembly components.

[0005] In accordance with a first aspect of the present invention, a fluid-permeable heater assembly is provided for an aerosol generating system, the heater assembly comprising a lid, the lid comprising a hollow body with a first and a second lid opening. , wherein the first lid opening is opposite the second lid opening, and a substantially flat, electrically conductive, fluid-permeable heating element, wherein the heating element is configured to vaporize the aerosol-forming substrate and wherein the heating element is mounted on the lid such that the heating element extends through the first lid opening.

[0006] The solution provided here is to attach a lid with a hollow body over the heating element to improve the stability of the heating element and to provide guidance for a capillary medium that can be arranged in the hollow body of the lid. The use of a cover can simplify fabrication of the heater assembly and can improve the rigidity of the heater assembly.

[0007] An additional purpose of the heater assembly according to the present invention may be to cap a full cartridge. The idea is to pre-assemble all parts of the heater assembly and then manipulate this one-piece component to facilitate closing the cartridge.

[0008] As used herein, "substantially flat" means initially formed in a single plane and not wrapped or otherwise conforming to fit a curved or non-planar shape. As used herein, "electrically conductive" means formed from a material with a resistivity of 1x10-4 Qm or less. As used herein, "electrically insulating" means formed from a material with a resistivity of 1x104 Qm or more. As used herein, "fluid permeable", in relation to a heater assembly, means that the aerosol-forming substrate, in a gas phase and possibly in a liquid phase, can readily pass through the heating element of the heater assembly.

[0009] The heater assembly comprises a lid formed from a material with a high thermal decomposition temperature and which is capable of tolerating rapid temperature changes. The heating element is supported in the lid. Preferably, the lid is molded from plastic granules. The plastic granules can be made of polyether ether ketone (PEEK), liquid crystal polymers (LCP) or any other polymeric material. Preferably, the lid material is overmolded onto the bottom of the heating element. Most preferably, the lid is made from VICTREX PEEK by overmolding onto a strip of mesh. The bottom of the heating element is oriented towards the opening of the first cover. Overmolding the cover onto the bottom of the heating element is advantageous as no additional mounting materials such as terminals are required to secure the heating element to the cover.

[00010] Preferably, the lid is of a size sufficient to distance the liquid storage portion from the heating element by a distance of at least 1.5 mm and preferably between 3 and 6 mm in order to provide a temperature drop enough through the lid. Advantageously, in such an embodiment, the liquid storage portion may be made of a more economically profitable material with a lower thermal decomposition temperature, such as, for example, polyethylene or polypropylene.

[00011] The heater assembly further comprises a substantially flat heating element that allows simple manufacturing. Geometrically, the term "substantially flat" electrically conductive heating element is used to refer to an electrically conductive array of filaments in the form of a substantially two-dimensional topological distributor. Thus, the substantially flat electrically conductive heating element extends in two dimensions over a surface substantially more than in a third dimension. In particular, the dimensions of the substantially flat heating element in the two dimensions at the surface are at least five times larger than in the third dimension, normal to the surface. An example of a substantially flat heating element is a structure between two substantially parallel imaginary surfaces, wherein the distance between these two imaginary surfaces is substantially less than the extent between the surfaces. In some embodiments, the substantially flat heating element is planar. In other embodiments, the substantially flat heating element is curved along one or more dimensions assuming, for example, a dome shape or bridge shape.

[00012] The term "filament" is used throughout the specification to refer to an electrical path between two electrical contacts. A filament can arbitrarily branch and diverge into multiple trajectories or filaments respectively or can converge from multiple electrical trajectories to one trajectory. A filament can be round, square, flat or any other cross-sectional shape. A filament can be arranged straight or curved.

[00013] The term "heating element" is used throughout the specification to refer to an arrangement of one or preferably a plurality of filaments. The heating element may be an array of filaments, for example, arranged parallel to each other. The heating element may be fluid permeable. The heating element may be cut to provide open areas when mounting the heating element through the first lid opening. Preferably, the open areas are manufactured by cutting out chamfered window openings on each side of the heating element. Preferably, the filaments can form a mesh. The mesh can be woven or non-woven. The mesh can be formed using different types of fabric or lattice structures. Alternatively, the electrically conductive heating element consists of an array of filaments arranged parallel to each other. The mesh, matrix or fabric of electrically conductive filaments can also be characterized by its ability to retain liquid.

[00014] In a preferred embodiment, a substantially flat heating element may be constructed from a wire which is given the shape of a wire mesh. Preferably, the mesh has a plain weave design. Preferably, the heating element is a wire grid made from a strip of mesh.

[00015] The electrically conductive filaments can define interstices between the filaments and the interstices can have a width between 10 micrometers and 100 micrometers. Preferably, the filaments give rise to capillary action in the interstices, so that, during use, the liquid to be vaporized is drawn into the interstices, increasing the contact area between the heating element and the liquid aerosol-forming substrate.

[00016] The electrically conductive filaments can form a mesh size between 60 and 240 filaments per centimeter (+/- 10 percent). Preferably, the mesh density is between 100 and 140 filaments per centimeter (+/- 10 percent). More preferably, the mesh density is approximately 115 filaments per centimeter. The width of the interstices may be between 100 micrometers and 25 micrometers, preferably between 80 micrometers and 70 micrometers, more preferably approximately 74 micrometers. The percentage of open area of the mesh, which is the ratio of the area of the interstices to the total area of the mesh, may be between 40 percent and 90 percent, preferably between 85 percent and 80 percent, more preferably approximately 82 percent. cent. Throughout this specification, the density of such a mesh is referred to as "first mesh density".

[00017] Additionally, the mesh may have one or more sections with higher mesh density, referred to as "second mesh density", where the interstices between the filaments are below 5 micrometers, preferably below 2 micrometers, and more preferably approximately 1 micrometer. The one or more sections of the mesh with greater mesh density are referred to as "dense areas" throughout this specification.

[00018] The electrically conductive filaments can have a diameter between 8 micrometers and 100 micrometers, preferably between 10 micrometers and 50 micrometers and, more preferably, between 12 micrometers and 25 micrometers. The filaments may have a round cross-section or they may have a flat cross-section.

[00019] The area of the mesh, matrix or fabric of electrically conductive filaments may be small, for example, less than or equal to 50 square millimeters, preferably less than or equal to 25 square millimeters, more preferably approximately 15 millimeters squares. The size is chosen in such a way as to incorporate the heating element into a portable system. Sizing the electrically conductive filament mesh, matrix, or fabric smaller than or equal to 50 square millimeters reduces the amount of total power required to heat the electrically conductive filament mesh, matrix, or fabric while still ensuring sufficient mesh, matrix, or fabric contact of electrically conductive filaments with the liquid aerosol-forming substrate. The mesh, matrix or fabric of electrically conductive filaments may, for example, be rectangular and have a length between 2 millimeters and 10 millimeters and a width between 2 millimeters and 10 millimeters. Preferably, the mesh has dimensions of approximately 5 millimeters by 3 millimeters. The mesh or array of electrically conductive filaments may cover an area of between 30 percent and 90 percent of the open area of the first lid opening through which the heating element extends. Preferably, the mesh or array of electrically conductive filaments covers an area between 50 percent and 70 percent of the open area of the first lid opening. More preferably, the mesh or array of electrically conductive filaments covers an area between 55 percent and 65 percent of the open area of the first lid opening.

[00020] The heating element filaments can be formed from any material with suitable electrical properties. Suitable materials include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of a ceramic material and a metallic material . Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and platinum group metals.

[00021] Examples of suitable metal alloys include stainless steel, constantan, alloys containing nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese and iron, and base superalloys nickel, iron, cobalt, stainless steel, Timetal®, iron and aluminum-based alloys and iron, manganese and aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation. The filaments can be coated with one or more insulators. Preferred materials for electrically conductive filaments are stainless steel and graphite, most preferably 300 series stainless steel such as AISI 304, 316, 304L, 316L. Furthermore, the electrically conductive heating element may comprise combinations of the above materials. A combination of materials can be used to improve resistance control of the substantially flat heating element. For example, materials with a high intrinsic resistance can be combined with materials with a low intrinsic resistance. This may be advantageous if one of the materials is more beneficial from other perspectives, for example price, machinability or other physical and chemical parameters. Advantageously, a substantially flat filament arrangement with enhanced resistance reduces parasitic losses. Advantageously, high resistivity heaters allow more efficient use of battery power.

[00022] Preferably, the filaments are made of yarn. More preferably, the wire is made of metal, most preferably being made of stainless steel.

[00023] The electrical resistance of the mesh, matrix or fabric of electrically conductive filaments of the heating element is preferably between 0.3 Ohms and 4 Ohms. Preferably, the electrical resistance is equal to or greater than 0.5 ohms. More preferably, the electrical resistance of the electrically conductive filament mesh, matrix or fabric is between 0.6 Ohms and 0.8 Ohms, and most preferably about 0.68 Ohms. The electrical resistance of the electrically conductive filament mesh, matrix or fabric is preferably at least one order of magnitude and more preferably at least two orders of magnitude greater than the electrical resistance of the electrically conductive contact areas. This ensures that the heat generated by the current passing through the heating element is localized in the mesh or array of electrically conductive filaments. It is advantageous to have a low total resistance for the heating element if the system is powered by a battery. A low resistance, high current system allows high power delivery to the heating element. This allows the heating element to quickly heat the electrically conductive filaments to a desired temperature.

[00024] The hollow body of the lid can be configured to retain a capillary medium. Preferably, the heater assembly comprises a piece of host material made from the capillary medium for retaining the liquid aerosol-forming substrate. At least a portion of the piece of host material may be disposed in the hollow body between the first and second lid openings.

[00025] Advantageously, the lid and the piece of host material can be sized to have approximately the same cross-sectional area. As used herein, approximately the same size means that a cross-sectional area of the cap comprising the first cap opening can be up to 30 percent smaller or larger than the capillary material. The shape of the interior space of the hollow body of the lid may also be similar to the shape of the capillary material so that the assembly and the material substantially overlap. Preferably, the piece of host material is substantially the same size and shape as the interior space of the hollow body. Preferably, the interior space of the hollow body is substantially cylindrical in shape. The volume of the interior space of the hollow body may be between 50 cubic millimeters and 500 cubic millimeters, preferably between 100 cubic millimeters and 250 cubic millimeters, more preferably approximately 150 cubic millimeters.

[00026] The piece of host material may be provided at least partially in contact with the heating element. When the assembly and material are substantially similar in size and shape, manufacturing can be simplified and the robustness of the manufacturing process improved.

[00027] Preferably, the heater assembly comprises a piece of transport material made from a capillary means for transporting liquid aerosol-forming substrate from the piece of host material to the heating element. The piece of carrier material may be provided in contact with the heating element. Preferably, the piece of carrier material is disposed between the heating element and the piece of host material. In this case, the host material is not in direct contact with the heating element.

[00028] The piece of transport material may be made of a material capable of ensuring that there is liquid aerosol-forming substrate in contact with at least a portion of the surface of the heating element extending through the first lid opening. The piece of carrier material may be in contact with the electrically conductive filaments. The piece of carrier material may extend into the interstices between the filaments. The heating element can engulf the liquid aerosol-forming substrate into the interstices by capillary action. Preferably, the piece of carrier material may be in contact with the electrically conductive filaments over substantially the entire extent of the open area of the first lid opening.

[00029] A capillary material is a material that actively transports liquid from one end of the material to the other. The capillary material may be guided, directly or indirectly, through another capillary medium, in contact with a liquid storage portion to transport liquid aerosol-forming substrate towards the heating element.

[00030] The capillary material may include even more than two capillary materials including one or more layers of the capillary material directly in contact with the mesh, matrix or fabric of electrically conductive filaments of the heating element in order to promote aerosol generation .

[00031] The capillary material may have a fibrous or spongy structure. The capillary material preferably comprises a bundle of capillaries. For example, the capillary material may comprise a plurality of fibers or threads or other fine bore tubes. The fibers or lines may generally be aligned to transport liquid aerosol-forming substrate to the heating element. Alternatively, the capillary material may comprise spongy or foamy material. The structure of the capillary material forms a plurality of holes or small tubes, through which the liquid aerosol-forming substrate can be transported by means of capillary action. The capillary material may comprise any suitable material or combination of suitable materials. Examples of suitable materials are a sponge or foam material, or graphite-based materials in the form of sintered fibers or powder, foamed metal or plastic material, a fibrous material, for example made of yarn or extruded fibers, such as cellulose acetate , polyester or polyolefin fibers, bonded polyethylene, terylene or polypropylene, nylon or ceramic fibers. The capillary material may have any capillarity and porosity suitable for use with different liquid physical properties. The liquid aerosol-forming substrate has physical properties, including but not limited to viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, that allow the liquid to be transported through the capillary medium by capillary action.

[00032] At least one of the capillary materials may be of sufficient volume in order to ensure that a minimum amount of liquid aerosol-forming substrate is present in said capillary material to prevent "dry heating" which occurs if aerosol-forming substrate insufficient liquid is supplied to the capillary material in contact with the electrically conductive filament mesh, matrix or fabric. A minimum volume of said capillary material may be provided to allow between 20 to 40 puffs by the user. An average volume of liquid aerosol-forming substrate volatilized during a puff of a length of between 1 to 4 seconds is typically between 1 to 4 mg of liquid aerosol-forming substrate. Thus, providing at least one capillary material with a retention volume between 20 to 160 mg of the liquid aerosol-forming substrate can prevent dry heating.

[00033] The cap may contain two or more different capillary materials, wherein the piece of carrier material, when in contact with the heating element, has a higher thermal decomposition temperature and the piece of host material, when in contact with the piece of carrier material but not in contact with the heating element, it may have a lower thermal decomposition temperature. The piece of carrier material effectively acts as a spacer, separating the heating element from the piece of host material so that the piece of host material is not exposed to temperatures above its thermal decomposition temperature. As used herein, "thermal decomposition temperature" means the temperature at which a material begins to decompose and lose mass through the generation of product gases. The piece of host material may advantageously occupy a greater volume than the piece of carrier material and may retain more aerosol-forming substrate than the piece of carrier material. The host material piece can have superior capillary absorption performance compared to the carrier material piece. The host material piece may be cheaper than the carrier material piece. The piece of host material may be polypropylene.

[00034] The piece of carrier material may separate the heating element from the piece of host material by a distance of at least 0.5 millimeters, preferably between 0.5 millimeters and 2 millimeters, and most preferably approximately 0.75 millimeters, in order to provide a sufficient temperature drop across the entire piece of conveying material.

[00035] Preferably, the lid comprises a support with a support opening. The support may be a planar disk covering at least the first opening of the lid and having a thickness of between 0.25 millimeters and 5 millimeters, preferably between 0.5 millimeters and 2.5 millimeters, and most preferably approximately 0.8 millimeters. The holder opening may have a size between 10 square millimeters and 50 square millimeters, preferably between 20 square millimeters and 30 square millimeters, and most preferably approximately 25 square millimeters. The support may cover the first lid opening so that the support opening coincides with at least a portion of the first lid opening. The heating element can be mounted on the bracket. One surface of the support is in contact with the heating element and represents a contact area that enlarges the contact area compared to a cover without a support. The bracket reduces the size of the first lid opening to the size of the support opening. Enlarging the contact area between the support and the heating element can improve the rigidity of the heater assembly and can facilitate its assembly. Preferably, the lid including the support is overmolded onto the bottom of the heating element.

[00036] Preferably, the lid is formed integrally. The integrally formed lid may include the support.

[00037] Preferably, the piece of transport material is disposed in the support opening. Preferably, the piece of carrier material is substantially the same size and shape as the support opening.

[00038] Preferably, the lid comprises at least one wall forming the hollow body extending from the support. Preferably, the wall extends perpendicular to the support. Preferably, the wall extends perpendicular to a plane of the heating element.

[00039] The heating element may have at least two electrically conductive contact areas. The electrically conductive contact areas may be positioned in an edge area of the heating element.

[00040] Preferably, the two electrically conductive contact areas are positioned in a dense area of the heating element. Electrically conductive contact areas can be positioned at the ends of the heating element. An electrically conductive contact area can be attached directly to the electrically conductive filaments. An electrically conductive contact area may include a tin patch. Alternatively, an electrically conductive contact area may be integrated into the electrically conductive filaments.

[00041] In accordance with a second aspect of the present invention, there is provided a cartridge for an aerosol generating system, the cartridge comprising the heater assembly in accordance with the first aspect of the present invention, a liquid storage portion for storing forming substrate of liquid aerosol, and a retainer for retaining the components of the heater assembly and for keeping the heater assembly in contact with the liquid storage portion.

[00042] Preferably, the cartridge comprises a nozzle for retaining the liquid storage portion.

[00043] Preferably, a piece of host material is disposed in the interior space of the hollow body of the heater assembly lid. A piece of shipping material may be disposed in the support opening of a support covering the first lid opening. The lid acts as a rigid compartment for the carrier material piece and the host material piece. The retainer keeps the heater assembly in contact with the liquid storage portion through the transport material piece and the host material piece. Preferably, a proximal end of the lid wall adheres to the support and a distal end of the lid wall engages the liquid storage portion.

[00044] The cartridge may be a disposable article to be replaced with a new cartridge as soon as the liquid storage portion of the cartridge is empty or below a minimum volume threshold. Preferably, the cartridge is preloaded with liquid aerosol-forming substrate. The cartridge can be refillable.

[00045] The cartridge and its components can be made from thermoplastic polymers, such as polyether ether ketone (PEEK).

[00046] According to a third aspect of the present invention, there is provided an aerosol generating system, comprising a main unit and the cartridge according to the second aspect of the present invention, wherein the cartridge is removably coupled to the main unit .

[00047] The aerosol generating system may be an electrically operated smoking system.

[00048] As used herein, the cartridge that is "removably coupled" to the device means that the cartridge and the main unit can be coupled and uncoupled from each other without significantly damaging the main unit or the cartridge.

[00049] The aerosol generating system may further include electrical circuits connected to the heater assembly and an electrical power source, the electrical circuits being configured to monitor the electrical resistance of the heater assembly or one or more filaments of the heater assembly and to control the supply of energy to the heater assembly dependent on the electrical resistance of the heater assembly or the one or more filaments.

[00050] The electrical circuits may comprise a microprocessor, which may be a programmable microprocessor. Electrical circuits may include more electronic components. The electrical circuit may be configured to regulate a power supply to the heater assembly. Power may be supplied to the heater assembly continuously after system activation or may be supplied intermittently, such as on a puff basis. Energy can be supplied to the heater assembly in the form of pulses of electrical current.

[00051] The aerosol generating system advantageously comprises a power source, normally a battery, within the main body of the compartment. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power supply may require recharging and may have a capacity that allows sufficient energy to be stored for one or more smoking experiences; for example, the power supply may have sufficient capacity to permit continuous generation of the aerosol for a period of about six minutes 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 discrete activations of the heater assembly.

[00052] Preferably, the aerosol generating system comprises a compartment. Preferably, the compartment is elongated. The compartment may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials that contain one or more of those materials, or thermoplastics that are suitable for pharmaceutical or food applications, for example, polypropylene, polyether ether ketone (PEEK) and polyethylene. Preferably, the material is light and not fragile.

[00053] Preferably, the aerosol generating system is portable. The aerosol generating system can be comparable in size to a conventional cigar or cigarette. The smoking system may have a total length of between approximately 30 millimeters and approximately 150 millimeters. The smoking system may have an external diameter of between approximately 5 millimeters and approximately 30 millimeters.

[00054] The aerosol-forming substrate is a substrate capable of releasing volatile compounds that can form an aerosol. Volatile compounds can be released by heating the aerosol-forming substrate.

[00055] The aerosol-forming substrate may comprise a plant-based material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavoring compounds, which are released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may alternatively comprise a non-tobacco containing material. The aerosol-forming substrate may comprise a homogenized plant-based material. The aerosol-forming substrate may comprise a homogenized tobacco material. The aerosol-forming substrate may comprise at least one aerosol former. The aerosol-forming substrate may comprise other additives and ingredients, such as flavorings.

[00056] In accordance with a fourth aspect of the present invention, there is provided a method for manufacturing a fluid permeable heater assembly in accordance with the first aspect, the method comprising a step of providing a substantially flat electrically conductive heating element, and a step of overmolding a lid in edge areas of one side of the heating element. The lid comprises a hollow body with a first and a second lid opening. The first lid opening is opposite the second lid opening. The heating element is mounted on the lid such that the heating element extends through the first opening lid.

[00057] The step of providing a heating element may comprise providing a mesh strip. The mesh strip may comprise an alternating sequence of mesh sections of a first mesh density and a second mesh density. Having sections of a higher density can increase the stability of the mesh when handling it.

[00058] The step of providing the heating element may further comprise shaping and cutting beveled window openings on each side of a mesh section of the first mesh density, and removing loose threads from the cut mesh sections of the first mesh density.

[00059] Preferably, the first mesh density is lower than the second mesh density.

[00060] Preferably, the step of overmolding a lid in edge areas of one side of the heating element comprises preheating plastic granules, injecting the plastic granules into a mold to make the lid, and overmolding the lid on the bottom of a mesh section of the second mesh density.

[00061] Preferably, the step of overmolding a lid in the edge areas of one side of the heating element further comprises cutting out the heater assembly from the mesh strip, and removing debris from the heater assembly.

[00062] Preferably, the step of cutting out the heater assembly from the mesh strip comprises cutting out a mesh from the mesh strip, wherein the heating element comprises the mesh, and wherein the mesh is cut into a mesh section of the second mesh density such that the mesh comprises a mesh section of the first mesh density that is bounded by mesh sections of the second mesh density at each of the two ends of the cut mesh.

[00063] Preferably, the method of manufacturing a fluid permeable heater assembly according to the first aspect of the present invention further comprises joining at least two electrically conductive contact areas each to an edge area on the other side of the heating element. heating.

[00064] The step of joining at least two electrically conductive contact areas each to an edge area on the other side of the heating element may comprise providing a strip of tin foil, cutting patches of tin foil from a strip of tin foil, of tin in a size that matches the shape and size of the mesh section of the second mesh density, and compress a patch of the tin foil onto the mesh section of the second mesh density. It may be advantageous for the foil strip to be made of a softer material than the heating element material.

[00065] Preferably, the method for manufacturing a fluid permeable heater assembly in accordance with the first aspect of the present invention further comprises inspecting the heater assembly.

[00066] Preferably, the step of inspecting the heater assembly comprises transporting the heater assembly to inspection stations, measuring the electrical resistance of the heating element of the manufactured heater assembly, visually inspecting the heating element for correct wire count, cutting mesh clean, correct mesh integrity, debris and tin foil attachment, and reject the heater assembly if the heater assembly fails at least one of the expected electrical resistance of the heating element and the expected result of visual inspection.

[00067] In accordance with a fifth aspect of the present invention there is provided an apparatus for manufacturing a fluid permeable heater assembly in accordance with the fourth aspect.

[00068] In order to manufacture a heater assembly comprising a lid and a substantially flat electrically conductive heating element with a mesh, the apparatus for manufacturing a fluid permeable heater assembly may comprise at least one of the following equipment units:

[00069] a mesh strip coil feed unit for supplying a mesh strip, the mesh strip comprising an alternating sequence of mesh sections of a first mesh density and a second mesh density,

[00070] a tin foil strip coil feeding unit for supplying a tin foil strip,

[00071] a tin foil cutting station for indexing a length of tin foil to be positioned over the mesh section of the second mesh density and for cutting tin patches from the provided tin foil strip,

[00072] a tin foil pressing station for compressing to join the tin patches on the upper surface of the mesh section of the second mesh density,

[00073] a mesh window cutting station for shaping and cutting beveled window openings on each side of a mesh section of the first mesh density,

[00074] a first cleaning station to remove loose threads from the cut mesh sections of the first mesh density, small particles, dust, or debris by air pressure cleaning and vacuuming the surfaces of the cut mesh sections to remove the debris ,

[00075] an injection molding machine for preheating plastic granules and injecting them into a mold to make the lid,

[00076] a mesh injection overmolding tool (possibly with a single cavity or multiple cavities) for overmolding the lid onto the bottom of the mesh section of the second mesh density,

[00077] a heater assembly cutting station for cutting the heater assembly from the mesh strip, shaping and cutting a mesh from the mesh strip, the heating element comprising the mesh, and the mesh being cut into a mesh section of the mesh. second mesh density such that the mesh comprises a mesh section of the first mesh density that is bounded by mesh sections of the second mesh density at each of the two ends of the cut mesh,

[00078] a second cleaning station for removing loose wires from the mesh, air pressure cleaning and vacuuming the surfaces of the heater assembly to remove debris,

[00079] a transfer unit for transporting the heater assembly to a heater assembly inspection station, the heater assembly inspection station may comprise a heater assembly resistance measuring station, a heater assembly visual inspection station and a heater assembly reject station,

[00080] a mesh indicator pressure test station,

[00081] a heater assembly resistance measuring station for measuring the electrical resistance of the mesh and the tin foil strip of the manufactured heater assembly,

[00082] a visual inspection of the heater assembly to visually inspect the heater assembly, and

[00083] a heater assembly rejection station for rejecting a heater assembly that does not comply with the specification.

[00084] In a preferred manufacturing process, the equipment automatically manufactures a heater assembly from a strip of mesh, a strip of tin foil, and plastic granules. The heater assembly comprises a lid and a substantially flat electrically conductive heating element.

[00085] A preferred manufacturing process in accordance with the fourth aspect of the present invention may comprise manually loading at least one mesh strip coil, one tin strip coil and plastic granules. The preferred manufacturing process may further comprise at least one of the method steps that are automatically performed by the manufacturing equipment:

[00086] provide a mesh strip, the mesh strip comprising an alternating sequence of mesh sections of a first mesh density and a second mesh density,

[00087] provide a strip of tin foil,

[00088] index a length of tin foil to be positioned over the mesh section of the second mesh density,

[00089] cut tin patches from the supplied tin foil strip,

[00090] compress to join the tin patches on the upper surface of the mesh section of the second mesh density,

[00091] shape and cut out beveled window openings on each side of a mesh section of the first mesh density,

[00092] remove loose threads from the cut mesh sections of the first mesh density, small particles, dust or debris, clean with air pressure and vacuum the surfaces of the cut mesh sections to remove debris,

[00093] preheat plastic granules,

[00094] inject the plastic granules into a mold to make the lid,

[00095] overmold the lid onto the bottom of a mesh section of the second mesh density,

[00096] cutting out the heater assembly from the mesh strip, cutting out a mesh from the mesh strip, the heating element comprising the mesh, and the mesh being cut within a mesh section of the second mesh density so that the mesh comprises a mesh section of the first mesh density that is bounded by mesh sections of the second mesh density at each of the two ends of the cut mesh,

[00097] remove loose mesh threads, small particles, dust, or debris by air pressure cleaning and vacuuming the mesh surfaces to remove debris,

[00098] transport the heater assembly to an inspection station,

[00099] measure the electrical resistance of the fabric of the manufactured heater assembly,

[000100] visually inspect the heater assembly for correct wire count, clean mesh cut, correct mesh integrity, debris and tin foil attachment, and

[000101] reject the heater assembly if it does not comply with the specification.

[000102] The characteristics described in relation to one aspect may be equally applicable to other aspects of the invention.

[000103] Embodiments of the invention will be described below exclusively by way of example, with reference to the attached figures, in which:

[000104] Figure 1A is a perspective top side view of a heater assembly in accordance with an embodiment of the present invention;

[000105] Figure 1B is a perspective bottom side view of a heater assembly in accordance with an embodiment of the present invention;

[000106] Figure 1C is an exploded perspective view of a heater assembly in accordance with an embodiment of the present invention;

[000107] Figure 2 is a top side cross-sectional view in perspective of a lid and a support in accordance with an embodiment of the present invention;

[000108] Figure 3 is a top side view of a support, a heating element and contact areas in accordance with an embodiment of the present invention;

[000109] Figure 4 is a top side view of a mesh with two different mesh densities, according to an embodiment of the present invention;

[000110] Figure 5 is a top side view of a strip of mesh for manufacturing a mesh in accordance with an embodiment of the present invention; It is

[000111] Figure 6 is an exploded perspective view of a cartridge for an aerosol generating system according to an embodiment of the present invention.

[000112] Fig. 1A shows a heater assembly 10 comprising a lid 12 with a first lid opening 16 on the upper side of the lid and a second lid opening 18 on the lower side of the lid 12. The first lid opening 16 is covered by a support 28 with a support opening 30. The heater assembly 10 further comprises a heating element 20 extending through the support opening 30.

[000113] Fig. 1B shows the heating assembly 10 from a bottom view. The inner space of the hollow body 14 of the lid 12 becomes visible.

[000114] Fig. 1C shows the components of the heating element 20 comprising a mesh 32. The mesh 32 has a first mesh section 44 of a first mesh density and, at each of its two ends, a second section of mesh 46 of a second mesh density, wherein the second mesh density is greater than the first density. A patch of tin foil 50 is joined to each of the two mesh sections 46 of the second mesh density. The heating element 20, respectively its mesh 32, is disposed through the support opening 30 of the support 28 in the upper part of the cover 12. The entire mesh section 44 of the first mesh density is disposed above the support opening 30.

[000115] Fig. 2 shows the cover 12 and its support 28. The support 28 may be a separate part. Preferably, the support 28 is an integral part of the lid 12. The inner body of the hollow body 14 of the lid 12 is cylindrical in shape. Sections A-A and B-B of Fig. 2 show the lid 12 and its support 28 integrally formed, wherein the perspective view of Fig. 2 shows the support 28 as a separate part. Sections A-A and B-B of Fig. 2 show the first lid opening 16, partially closed by the support 28, so that only a minor portion, referred to as the support opening 30, of the first lid opening 16 remains open and through which a heating element can extend.

[000116] Fig. 3 shows the support 28 formed as a separate part of the cover 12, in which the heating element 20 is mounted so that the mesh section 44 of the first mesh density extends through the support opening 30 .

[000117] Fig. 4 shows a mesh 32 of the heating element 20. The mesh 32 comprises a mesh section 44 of a first mesh density and, at each of its two ends, a second mesh section 46 of a second mesh density.

[000118] Fig. 5 shows a strip of mesh 42 from which a number of meshes 32 can be shaped and cut.

[000119] Fig. 6 shows a cartridge 40 according to an embodiment of the present invention. The cartridge 40 comprises the heater assembly 10 with a lid 12 and a heating element 20 disposed in a support 28 of the lid 12. A piece of carrier material 26 is disposed in a support opening 30 of the support 28. A piece of host material 24 is disposed in a support opening 30 of the support 28. disposed in the interior space of the hollow body 14 of the lid 12. The lid 12 acts as a rigid compartment for the piece of transport material 26 and the piece of host material 24. A cartridge 40 further comprises a liquid storage portion for storing a liquid aerosol-forming substrate. A retainer 42 is used to retain the components of the heater assembly 10 and to keep the heater assembly 10 in contact with the liquid storage portion 36 through the transport material piece 26 and the host material piece 24. Furthermore, the cartridge 40 comprises a nozzle 38 in which the liquid storage portion 36 is disposed.

[000120] The examples of modalities described above exemplify, but are not limiting. Considering the exemplary embodiments discussed above, other embodiments consistent with the exemplary embodiments above will become apparent to those skilled in the art.

Claims (12)

1. Fluid permeable heater assembly (10) for an aerosol generating system, characterized in that the heater assembly (10) comprises: a lid (12) comprising a hollow body (14) with a first (16) and a second lid opening (18), wherein the first lid opening (16) is opposite the second lid opening (18), wherein the lid (12) further comprises a support (28) with a support opening (30 ), and wherein the support (28) covers the first lid opening (16), such that the support opening (30) coincides with at least a portion of the first lid opening (16); wherein the lid (12) and support (28) are integrally formed; a substantially flat electrically conductive and fluid permeable heating element (20), wherein the heating element (20) is configured to vaporize the liquid aerosol-forming substrate, and wherein the heating element (20) is mounted on the support (28) so that the heating element (20) extends through the first lid opening (16); and a piece of host material (24) configured to retain the liquid aerosol-forming substrate, wherein at least a portion of the piece of host material (24) is disposed in the hollow body (14) between the first (16) and the second (18) lid opening. 2. Heater assembly (10) according to claim 1, characterized in that the piece of host material (24) has substantially the same size and shape as the interior space of the hollow body (14). 3. Heater assembly (10) according to claim 1, characterized in that the interior space of the hollow body (14) is substantially cylindrical in shape. 4. Heater assembly (10) according to any one of claims 1 to 3, characterized in that the piece of host material (24) is provided at least partially in contact with the heating element (20). 5. Heater assembly (10) according to any one of claims 1 to 3, characterized in that it further comprises a piece of transport material (26) configured to transport the liquid aerosol-forming substrate from the piece of host material (24 ) for the heating element (20), and wherein the piece of carrier material (26) is provided in contact with the heating element (20) and is disposed between the heating element (20) and the piece of material host (24). 6. Heater assembly (10) according to any one of claims 1 to 5, characterized in that the piece of transport material (26) is disposed in the support opening (30). 7. Heater assembly (10) according to any one of claims 1 to 6, characterized in that the piece of transport material (26) has substantially the same size and shape as the support opening (30). 8. Heater assembly (10) according to any one of claims 1 to 7, characterized in that the heating element (20) comprises a mesh (32) with at least two electrically conductive contact areas each positioned in a edge area of the heating element (20), and wherein the mesh (32) extends over at least a portion of the first lid opening (16). 9. Heater assembly (10) according to claim 8, characterized in that at least the two electrically conductive contact areas are each positioned in a dense area of the heating element (20). 10. Cartridge (40) for an aerosol generating system, characterized in that the cartridge (40) comprises: the heater assembly (10) as defined in any one of claims 1 to 9; a liquid storage portion (36) for storing the liquid aerosol-forming substrate; and a retainer (42) for retaining components of the heater assembly (10) and for maintaining the heater assembly (10) in contact with the liquid storage portion (36). 11. Cartridge (40) according to claim 10, characterized in that the cartridge (40) further comprises: a nozzle (38) for retaining the liquid storage portion (36). 12. Aerosol generating system, characterized in that it comprises a main unit and the cartridge (40) as defined in claim 10 or 11, wherein the cartridge (40) is removably coupled to the main unit.