RU2818397C2 - Fluid-permeable heater assembly for aerosol-generating system and method for assembling fluid-permeable heater for aerosol-generating system - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: disclosed is a cartridge for an aerosol-generating system, comprising: a container portion for storing a liquid comprising a housing comprising a liquid aerosol-forming substrate, wherein the housing has an open end; and a fluid-permeable heater assembly comprising: (1) an electric heating element configured to heat the liquid aerosol-forming substrate to form an aerosol, wherein the electric heating element includes a planar thread structure having one or more electrically conductive filaments, (2) an electrically insulating base comprising a ceramic material and having a planar attachment surface, wherein the thread structure is in contact with said planar attachment surface, and (3) connectors located on opposite ends of electric heating element and forming two separate electrical contacts, made with possibility of supplying power to thread structure, wherein fluid-permeable heater assembly is arranged above housing open end. Invention also relates to an aerosol-generating system comprising the disclosed cartridge, a main housing, an electric circuit, a microprocessor and a power supply.

EFFECT: invention is cheap and easy to use.

21 cl, 11 dwg

Description

The present invention relates to a fluid permeable heater assembly for aerosol generating systems and to a method for assembling a fluid permeable heater. More particularly, the present invention relates to a fluid-permeable heater assembly for hand-held aerosol-generating systems, such as electrically controlled smoking systems.

Some aerosol generating systems, such as electrically controlled smoking devices, may include a battery and control electronic circuits, a cartridge containing a supply of aerosol-forming substrate, and an electrically controlled vaporizer. The substance is evaporated from the aerosol-forming substrate, for example by means of a heating element. The heating element may be a heater that is at least partially fluid permeable, such as a flat coil embedded in a ceramic material. However, such heaters are expensive to manufacture.

There is a need for a fluid-permeable heater assembly for aerosol generating systems that is inexpensive and easy to manufacture. There is also a need for a suitable method for assembling fluid permeable heaters.

According to a first aspect of the present invention, a fluid-permeable heater assembly is provided for aerosol generating systems, preferably electrically controlled smoking systems. The fluid-permeable heater assembly contains a base, preferably an electrically insulating base. This base contains an opening through this base. The heater assembly further comprises an electrically conductive, substantially flat filament structure located over the hole in the base. This thread structure is mechanically fixed to the base by means of fastening means. The fastening means are also electrically conductive and serve as electrical contacts to provide heating current through the filament structure, as well as to stabilize the filament structure fixed to the base.

Preferably, the heater assembly is assembled using only mechanical means. Fixing the thread structure and the base on each other, as well as ensuring electrical contact between the thread structure and the contact of an external power source, for example, a battery, is carried out by mechanical fixation. The fastening means ensure strong fixation of the thread structure and reliable contact between the thread structure and these fastening means. By mechanically securing and ensuring electrical contact with the filament structure by mechanical means, the need for soldering, welding or etching of electrical contacts is eliminated. This makes it possible to facilitate the manufacture and reduce the cost of manufacturing parts of the heater assembly. Additionally, it is also possible to increase the machinability of the heater unit or its parts. In addition, mechanical fixing provides the ability to improve the reliability of the heater assembly by eliminating problem areas common in soldering and welding, such as cold solder joints or cold welds. These locations are known for their low strength, low load capacity, and unstable electrical resistance. In addition, the filament structure does not come into direct contact with the battery connectors of the aerosol generating system, and thus the filament structure is prevented from breaking when the heater is inserted into the system.

In combination with the method of assembling such a fluid-permeable heater according to the present invention, it is possible to achieve three objectives in one cost-effective means: securing the filament structure to the substrate, stabilizing the filament structure, and providing an electrical connector for a power source, such as an electronic cigarette battery. The fastening means, the corresponding mechanism for fixing the filament structure to the base and the corresponding assembly process are economical, resistant to manufacturing manipulation, functionally effective, durable and compatible with the relatively small area of the heater assembly.

The term "substantially planar" is used throughout the present description to refer to a filamentary structure that has the shape of a substantially two-dimensional topological manifold. Thus, the essentially flat filament structure is elongated in two directions along the surface significantly more than in the third direction. In particular, the dimensions of the substantially flat filament structure in two directions along the surface are approximately 5 times larger than in the third direction, which is the direction normal to that surface. An example of a substantially planar filament structure is a structure between two substantially parallel imaginary planes, in which the distance between the two imaginary planes is significantly less than the extent along those planes. In some embodiments, the substantially flat filament structure is planar. In other embodiments, the substantially flat filament structure is curved along one or more directions, forming, for example, a dome shape or a bridge shape.

The term "filament" (filament) is used throughout this specification to refer to the electrical path located between two electrical contacts. The thread can, if necessary, branch and split into multiple paths or threads, respectively, or multiple electrical paths can converge into a single path. The thread can have a round, square, flat or any other cross section. The thread can be located straight or curved.

The term "thread structure" is used throughout the description to refer to a structure of one or, preferably, multiple threads. The thread structure can be a matrix of threads located, for example, parallel to each other. Preferably, the threads may form a network. This mesh can be woven (woven) or non-woven (non-woven). Preferably, the thread structure has a thickness of from about 0.5 microns to about 500 microns.

As a general rule, when the term “about” is used in conjunction with a specific value throughout this application, it should be understood that the value following the term “about” does not have to be exactly equal to the specific value for technical reasons. However, the term “about” when used in conjunction with a specific quantity should always be understood to include and expressly express the specific quantity following the term “about.”

For example, the shape of the base and the thread structure fixed to the base can be adapted to the shape of the end of the cartridge containing the aerosol-forming substance. This end of the cartridge may be planar, but it may also be curved, eg convex in shape.

The hole in the base can be of substantially any shape. Preferably, this hole has a simple shape that is easy to manufacture, such as a round, oval or rectangular shape, in other words, it is a cylinder having a round, oval or rectangular base extending through the base. Preferably, the hole in the base includes at least a central portion of the base. This central part includes the imaginary center of gravity of the base. Alternatively or additionally, said central portion may comprise a longitudinal axis, for example a rotation axis, such as the rotation axis of a circular disk base.

The substantially flat filament structure is secured over at least a portion of said opening by means of fastening means. The base comprises a fastening surface on which a substantially flat filament structure is placed in a fixed state. Preferably, the fastening surface is part of the upper surface of the base. The mounting surface may include said hole, as well as portions of the upper surface of the base adjacent to the hole. Preferably, the mounting surface is planar. The fastening means apply a tensile force to the thread structure. This tensile force is directed at least in a direction coplanar to the fastening surface. Preferably, the tensile force is applied to the filament structure during assembly of the heater and, preferably, while the filament structure is secured. The tensile force maintains the planar arrangement of the thread structure and helps stabilize the thread structure in the warp plane. Preferably, the fastening means apply opposing tensile forces to the thread structure, stretching and stabilizing the thread structure in plane.

The fastening means may comprise several separately located fastening elements, preferably two separately located fastening elements. Preferably, the individual fastening elements are not in direct contact with each other so that these elements are separated from the two contacts for supplying power to the heater and heating the filament structure. Two or more fastening elements may serve as the first electrical contact for the thread structure. Two or more fastening elements can serve as a second electrical contact for the thread structure. Preferably, the fastening means are two electrically conductive fastening elements, preferably in the form of clips, clips or clips. Preferably, the fastening means provide fastening action along a line, thereby preventing damage or breakage of the threads due to the presence of only one fixing point. Preferably, the two fastening elements are located opposite each other, for example on opposite sides of the base. Preferably, the heater assembly contains only a few components, for example a base, a filament structure and two fastening elements. The fastening means may also be shaped to match the shape of the external connector to facilitate connection and improve external electrical contact.

Fluid-permeable heater units are suitable for evaporating liquids from various types of cartridges. For example, the cartridge may include a liquid or a liquid-containing transport material, such as a capillary material, as the aerosol-forming substrate. Such transport material and capillary material actively transport liquid and are preferably oriented in the cartridge so as to transport liquid to the heater assembly. The thread structure is positioned adjacent to the liquid or liquid-containing capillary material in such a way as to allow the liquid to evaporate under the influence of heat generated by the thread structure. Preferably, the filament structure and the aerosol-forming substrate are arranged to allow liquid to flow into the filament structure by capillary action. The thread structure may also be in physical contact with the capillary material.

The electrically conductive threads may form spaces between each other, and these spaces may have a width of from 10 microns to 100 microns. Preferably, the threads create a capillary effect in said spaces and thus the liquid to be evaporated is drawn into these spaces when used, increasing the contact area between the heater assembly and the fluid. The electrically conductive filaments can form a mesh with sizes ranging from 160 US mesh to 600 US mesh (plus or minus 10 percent (that is, from 160 to 600 threads per inch (plus or minus 10 percent))). The width of said spaces is preferably between 75 microns and 25 microns.

The relative open area of the mesh, which is the ratio of the area of the interstices to the total area of the mesh, is preferably from 25 to 60 percent. The mesh can be made using various types of woven or lattice structures.

The thread structure may also be characterized by its ability to retain liquid, as is well known in the art.

The electrically conductive filaments may have a diameter of from 10 microns to 100 microns, preferably from 8 microns to 50 microns, and more preferably from 8 microns to 40 microns. The area of the filament structure can be small, preferably no more than 25 square millimeters, allowing the structure to be integrated into a hand-held system. The thread structure can be, for example, rectangular and have dimensions of 5 millimeters by 2 millimeters in the fixed state. Preferably, the filament structure occupies an area of from 10 percent to 50 percent of the area of the heater assembly. More preferably, the filament structure occupies an area of 15 to 25 percent of the area of the heater assembly.

The thread structure can be made by etching a sheet material such as foil. This may be particularly advantageous if the heater assembly contains a matrix of parallel filaments. If the heater assembly contains a mesh, the threads can be made separately and tied or woven together.

The filaments of the heater assembly can be made of any material with suitable electrical properties. Suitable materials include, but are not limited to: semiconductors such as doped ceramics, electrically conductive ceramics (eg, such as molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made from ceramic material and metal material. Such composite materials may contain alloyed or unalloyed ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and platinum group metals. Examples of suitable metal alloys include stainless steel, constantan, nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese - and iron-containing alloys, as well as superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, alloys based on iron and aluminum and alloys based on iron, manganese and aluminum. Timetal® is a registered trademark of Titanium Metals Corporation. The threads may be coated with one or more insulators. The preferred materials for electrically conductive filaments are 304, 316, 304L, 315L stainless steel and graphite.

The electrical resistance of the filament structure is preferably from 0.3 ohms to 4 ohms. More preferably, the electrical resistance of the filament structure is from 0.5 ohm to 3 ohm, and even more preferably about 1 ohm. The electrical resistance of the thread structure is preferably at least an order of magnitude, and more preferably at least two orders of magnitude, greater than the electrical resistance of the contact parts. In this way, it is ensured that the heat generated by the passage of current through the heater assembly is localized in the filament structure. It is advantageous to have a low overall resistance of the heater assembly if the system is powered by a battery. The low resistance, high current system allows high power to be supplied to the heating element. This ensures the possibility of rapid heating of the electrically conductive filament structure by the heating element to the desired temperature.

The heater assembly may comprise at least one filament made of a first material and at least one filament made of a second material different from the first material. This may be beneficial for electrical or mechanical reasons. For example, one or more filaments may be made of a material whose resistance varies greatly with temperature, such as an alloy of iron and aluminum. This makes it possible to use the resistance value of the threads to determine temperature or changes in temperature. This can be used in a puff detection system. Alternatively or additionally, this can be used to regulate the heater temperature to maintain it within the desired temperature range. Temperature changes may also be used as indicators to detect changes in air flow downstream of the heater assembly as a result of a user's puff on an electrically controlled smoking system. A preferred embodiment of this type of thread material is, for example, a matrix of parallel threads of a first material located above a matrix of parallel threads of a second material, the matrices being rotated relative to each other to form a mesh. A combination of materials can also be used to improve the adjustability of the resistance of the substantially flat filament structure. For example, materials with high intrinsic resistance can be combined with materials with low intrinsic resistance. This may provide an advantage if one of the materials is preferred for other reasons, such as cost, processability, or other physical and chemical parameters. For example, one of the materials may be stainless steel.

Preferably, the base of the heater assembly is electrically insulating. This electrical insulating substrate may comprise any suitable material, and preferably the material is capable of withstanding high temperatures (in excess of 300 degrees Celsius) and sudden changes in temperature. An example of a suitable material is a film of a polyimide material such as Kapton®, polyetheretherketone (PEEK) or a ceramic material, preferably an open cell electrically insulating ceramic material. Preferably, the base material is non-brittle. The base material may have capillary action against the liquid to be evaporated.

Preferably, the base is substantially flat. Preferably, the base is a disk, which can be, for example, round, oval or rectangular. This disk can be planar or curved. Preferably, the base also includes a planar mounting surface oriented, when placed, toward the cartridge enclosing the aerosol-forming substrate, such that the heater assembly and the cartridge or cartridge cover, respectively, have a planar contact surface. This ensures the possibility of flush placement of the cartridge and the heater assembly.

In accordance with an aspect of the fluid-permeable heater assembly of the present invention, the fastening means mechanically securing the filament structure to the substrate provides a shape-matched or press-fit closure to the substrate. Shape-matching or press fit closures are two types of mechanical locking that are simple and reliable in mechanically locking components to each other. These two types of closure can be combined. When closed with a matching shape, the fastening means and the base have corresponding shapes. The fixation may be effected mainly or exclusively by frictional forces between the contact surfaces of the fastening means and the base in the contact area. However, shape-matched closure can also be achieved, for example by enveloping the threads and the warp with fastening means. When press-fitted, the fastening means and/or the base may comprise resilient parts, such as flexible legs or spring elements. The force applied by the fastening means or parts of the fastening means holds the thread structure in a state of fixation on the base.

Shape-matched and press-fit closures can also be combined in the fastening mechanism of the fastening means and the base. For example, the fastening means may include parts made of elastic material. Alternatively or additionally, the fastening means may have a shape that differs from the shape of the corresponding part of the base. For example, the tapered leg of the fastening means may be inserted into a recess of the base having parallel inner walls.

In accordance with another aspect of the fluid-permeable heater assembly of the present invention, the attachment means extend over a portion of the side of the base and include resilient legs. These elastic legs press the thread structure against the upper surface of the warp. In this case, the thread structure and the base are located between the elastic legs. The thread structure and the base are fixed between elastic legs, for example, legs in the form of leaf springs, fastening means. The elastic force created by the elastic legs determines the fastening force. The part of the fastening means protruding from the side of the base can be used as an electrical contact for an external power source. This makes it possible to make electrical contact with the heater assembly from the top or bottom side and, at the same time, from the side or only from the side. Thus, it is possible to simplify the contact of the heater assembly with electrical connectors located along the inner surface of the walls of the main body of the aerosol generating system. Contact may also be improved by allowing the connectors to contact more than one side of the heater assembly.

In accordance with yet another aspect of the fluid-permeable heater assembly of the present invention, the base includes recesses to receive the filament structure and fastening means. The recesses provide the possibility of improving the fixation of the thread structure and contact with it by localizing the area of contact with the fastening means on or within the base. The recesses also provide the ability to help define the contact area, such as the position or size of the contact area. The recesses also provide the possibility, for example, of limiting or preventing movement, for example sliding, of the fastening means from the base or along the thread structure during the assembly process or in the assembled state. Recesses may be provided in the surface of the base, preferably in the upper surface of the base and the bottom surface of the base. The recesses can be made in part of the base in depth or they can extend through the entire base. The recesses may be, for example, grooves, holes or slits.

In accordance with an aspect of the fluid-permeable heater assembly according to the present invention, the fastening means are staple elements that are inserted into recesses of the base. These staple elements are essentially U-shaped and have three legs and a bridge portion between the legs. Bracket elements are easy to manufacture and cheap. The staple elements can be easily attached to the base, for example by a linear pressing action. In this way, it is possible to insert the legs of the staple elements into the holes or recesses of the base while the thread structure is located between the base and the staple elements. During the assembly process there is no danger of the thread structure shifting, since it is fixed in contact with the fastening means and the base. Bracket elements allow various fastening mechanisms or variations thereof. For example, in the case of shape-matching closure, the legs may be inserted into holes in the base and the protruding ends of the legs may be folded onto the bottom surface of the base to provide additional fixation of the fastening means to the base. Moreover, in the case of using staple elements, the fixation of the thread structure as well as the surfaces for electrical contact between the thread structure and the fastening means can be improved by simple means. In some preferred embodiments, this is accomplished by means of recesses and staple elements containing corresponding but non-planar contact surfaces. As used herein, the term "non-planar contact surfaces" is to be understood to include contact surfaces that are composed of multiple local contact surfaces, and these local contact surfaces may be planar but are angled to each other such that the resulting contact surface is non-planar.

The increased contact area ensures good electrical contact between the threads and the fastening means. Thanks to the additional structure on the contact surface, it is also possible to improve the fixation of the thread structure. It is possible to increase the tensile force acting on the thread structure, which increases the stability of the thread structure. The side of the staple element facing the base recess may have a non-planar shape. The side of the staple element that is to be brought into contact with the battery connector may also have a non-planar shape. This makes it possible to increase and optimize the contact area between the fastening means and the external connector.

In accordance with another aspect of the fluid-permeable heater assembly of the present invention, said recesses are one or a combination of longitudinal recesses extending through at least a portion of the upper surface of the substrate, individual through holes within the substrate, or recesses in the circumferential surface of the substrate. Different types of recesses allow a wide choice of fastening mechanisms and various options for base shapes and fastening means. Preferably, longitudinal recesses formed in the upper surface of the base provide large contact areas. The longitudinal recesses may extend through part or all of the upper surface of the base. In addition, longitudinal recesses can be made in the lower surface. The longitudinal recesses allow the use of flat heater assembly designs due to the countersinking available for mounting means in the recesses. Longitudinal recesses in the upper surface of the base are particularly preferred for fastening means that extend over the side of the base, and for fastening means having protruding resilient legs that are fully inserted into the recesses. In the latter versions, the fastening force acts inside the base. The longitudinal recesses also provide the possibility of improving fixation when the longitudinal edges of the fastening means are pressed against the upper surface and lower surface of the base.

Holes or recesses in the circumferential surface of the base allow for a form-fitting fit between the fastening means and the base by providing fastening means on the top surface and on the bottom surface, but without adding material to the side of the heater assembly. Thus, the use of a heater unit will not require restrictions on the size of, for example, the main body of the system.

In some preferred embodiments of the fluid-permeable heater assembly, the mounting means comprise resilient legs that are positioned and secured within longitudinal recesses. In these embodiments, the fastening force acts in the transverse direction of the base and inside the base. The fastening means, in particular the fastening action of the elastic legs located inside the recesses, are well protected from the influence of external elements, for example, system elements located on the upper or lower surface of the heater assembly. In this way, it is possible to prevent the effect of weakening the fastening action, for example by pressing the housing wall against the fastening means. Preferably, the fastening means are recessed into the base, even more preferably substantially completely recessed into the base, except for a flat contact area. This makes it easier to manipulate the base during the production of a very compact heater assembly.

The thread structure may partially or completely extend over the hole in the base. Preferably, the thread structure occupies from about 50 percent to about 95 percent of the area of said hole, for example, it occupies from about 70 percent to about 90 percent of the area of the hole in the base.

If the filament structure occupies the entire area of the hole, the maximum accessible area of the surface of the liquid or aerosol-forming substrate located next to the heater is heated. This ensures strong evaporation as the heat is applied to a larger area. In addition, depending on the type of aerosol-forming substrate, for example in the case of capillary material transporting liquid to the heater, due to the large heated area, it is possible to support homogeneous drainage of the aerosol-forming substrate. However, the area not occupied by the substantially flat filament structure may otherwise influence aerosol generation through flow rate and droplet size. This can be useful for optimizing the generation of an aerosol with predefined characteristics in a reproducible manner. For example, if the filament structure does not occupy the entire area of the hole, it is possible to more easily pass the evaporated liquid through the heater assembly in those areas that are not occupied by the filament structure. In this way, it is possible to support aerosol formation.

Preferably, the substantially flat filament structure is in direct contact with the capillary material transporting the liquid to the heater. This facilitates the creation of a continuous flow of liquid to the substantially flat filament structure to generate the aerosol. Preferably, the transport medium is homogeneous.

In some preferred embodiments of the fluid-permeable heater assembly of the present invention, the filament structure comprises a plurality of filaments forming a mesh.

This mesh provides stability and strength to the thread structure. It also allows for easier manipulation during manufacturing than, for example, a matrix of threads arranged parallel to each other. In addition, it is possible to select and vary the ability of the mesh to retain liquid between the threads, for example, by varying the type of weave or the structure of the mesh. The mesh is robust in a structural sense: the mesh thus has excellent fault-tolerant properties due to the redundancy of available electrical paths. Even if one mesh thread is torn or is not in full contact with the heater, the thread structure can continue to function with only a slight change in the overall electrical and thermal characteristics.

In some preferred embodiments of the fluid-permeable heater assembly of the present invention, the support is an electrically insulating, substantially flat, preferably disk-shaped element. The flat heater assembly is compact and allows easy handling during the manufacture and assembly of the system.

According to another aspect of the present invention, there is provided a method for assembling a mesh heater for an aerosol generating system. This method comprises the steps of providing a base, making an opening through the base, and placing electrically conductive threads over the hole in the base. At the next stages of the method, the threads are mechanically fixed to the base using fastening means, thus pressing the threads to the base, and electrical contact with the threads is ensured through the fastening means.

In accordance with an aspect of the method according to the present invention, the method further comprises the step of making recesses in the substrate and pressing the fastening means into these recesses. By means of this indentation, it is possible to apply the attachment means to the warp-thread structure as a result of linear movement. This makes it possible to assemble the heater in one fixation step. The indentation may be substantially perpendicular to the substrate or substantially parallel to the substrate. Indentation substantially perpendicular to the substrate refers to indentation into the top surface from a point above the substrate. Indentation substantially parallel to the warp refers to the application of fastening means to the side of the warp or to the application of fastening means by sliding them along the warp-thread structure.

Preferably, during the insertion step of the fastening means, a tensile force is applied in the direction of the plane of the substantially flat thread structure. This provides the advantage of stretching the essentially flat thread structure to a predetermined degree of tension. This allows for improved surface contact between the substantially flat filament structure and the base. Additionally, this allows for improved surface contact between the thread structure and the transport medium.

In accordance with another aspect of the method according to the present invention, the fastening force is applied in a direction substantially perpendicular to the top surface of the base. Typical examples of such options are sandwich fastening means, where the thread structure and the warp are clamped between parts of the fastening means.

According to another aspect of the method of the present invention, the fastening force is applied in a direction substantially parallel to the top surface and within the base. Examples of such embodiments are fastening means that are placed within the base, preferably within a recess of the base designed to receive the fastening means or part of the fastening means provided for fixing. Another part of the fastening means, provided for electrical contact with the fastening means, is then placed outside said recess.

According to another aspect of the method of the present invention, the thread structure includes a first portion and second portions that form a combined thread, the second portions being located at either end of the thread structure and the first portion being located between the second portions. As used herein, the term “integrated” means that the first part and the second parts form a single body that provides an electrical path from one second part to the other second part through the first part.

In such a configuration, the second parts may be made of a different material than the first part, or, alternatively or additionally, they may be made of the same material but have a different shape. For example, if the thread structure contains a mesh, the second parts may differ in shape from the first part due to the higher density of the mesh compared to the first part. Alternatively, the thread structure can be made using two different materials for the first part and for the second parts, the material forming the second parts being more ductile and easier to deform than the material of the first part. In this case, for example, the first part may be made of stainless steel and the second parts may be made of copper. Alternatively, the second parts may be made of foil and a first part may be positioned between them such that the first part and the second parts form an integrated thread.

If the thread structure comprises first and second parts, the thread structure may be subjected to an additional processing step in which sufficient force is applied to the second parts so that they form a foil-like material. As used herein, a “foil material” is a material that has been subjected to a force that flattens the material while maintaining a consolidated strand.

Additional aspects and advantages of the method of the present invention have been disclosed above with respect to the fluid-permeable heater assembly and will not be described again.

According to another aspect of the present invention, an aerosol generating system, preferably an electrically controlled smoking system, is provided. The aerosol generating system includes a container portion (storage) having a housing for storing a liquid aerosol-forming substrate, the housing having an open end. The system further comprises a fluid-permeable heater assembly according to the present invention described above. This heater assembly is located downstream of said housing such that the filament structure of the fluid-permeable heater assembly is positioned over the open end of the housing. The system further includes a power supply connector for electrically connecting means for attaching the fluid-permeable heater assembly to the power source.

The advantages and aspects of the aerosol generating system have been described above with respect to the heater assembly and will not be described again. Thanks to the available variants of the fastening means and the corresponding variants of the heater assembly, it is possible to adapt and manufacture the heater assembly, for example, in such a way that it is suitable for existing main bodies of the mentioned systems. These main bodies may already include a cartridge containing the aerosol-forming substrate, electrical circuitry, a power supply, and electrical connectors for contact with the heater assembly.

The container portion preferably encloses capillary material. 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 filaments or other thin tubes with channels. The fibers or filaments may be substantially aligned to transfer fluid to the heater. Alternatively, the capillary material may comprise a sponge-like or foam-like material. The structure of capillary material forms 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 materials, fibrous material, for example made from twisted or extruded fibers such as cellulose acetate, polyester, terylene or polypropylene fibers, nylon fibers, or ceramics. The capillary material can have any suitable capillarity so that it can be used for liquids with different physical properties. A fluid has physical properties, including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, that enable the fluid to be transported across a capillary material by capillary action.

Preferably, the capillary material is in contact with the electrically conductive threads. The capillary material may extend within the spaces between the threads. The heater assembly may draw the liquid aerosol-forming substrate into said spaces by capillary action. The capillary material may be in contact with the electrically conductive threads throughout substantially the entire length of said opening. The cartridge may include two or more different capillary materials, with a first capillary material in contact with the heating element having a higher thermal decomposition temperature and a second material in contact with the first capillary material but not in contact with the heating element. heating element, has a lower thermal decomposition temperature. The first capillary material effectively acts as a separator separating the heating element from the second capillary material such that the second capillary material is not exposed to temperatures above its thermal decomposition temperature. As used herein, the term "thermal decomposition temperature" means the temperature at which a material begins to decompose and lose mass as a result of the formation of gaseous products. The second capillary material provides the advantage of being able to occupy more volume than the first capillary material and being able to hold more aerosol-forming substrate than the first capillary material. The second capillary material may have superior capillary performance compared to the first capillary material. The second capillary material may be less expensive than the first capillary material. The second capillary material may be polypropylene.

The first capillary material may separate the heater assembly from the second capillary material by a distance of at least 1.5 millimeters, preferably from 1.5 millimeters to 2 millimeters, to provide sufficient temperature reduction behind the first capillary material.

The container part may be located on one side of the electrically conductive threads, and the air flow channel on the opposite side of the electrically conductive threads relative to the container part so that the air flow after the electrically conductive threads captures the evaporated aerosol-forming substrate.

The system may further comprise electrical circuitry coupled to the heater assembly and an electrical power source; this electrical circuit is configured to control the electrical resistance of the heater assembly or one or more filaments of the heater assembly, and to control the supply of power to the heater assembly, depending on the electrical resistance of the heater assembly or one or more filaments.

The electrical circuit may include a microprocessor, which may be a programmable microprocessor. The electrical circuit may contain additional electronic components. The electrical circuit can be configured to regulate the power supply to the heater assembly. Power may be supplied to the heater assembly continuously after activation of the system, or may be supplied intermittently, for example from puff to puff.

Power can be supplied to the heater unit in the form of electric current pulses.

The advantage of the system is that it contains the power source, usually a battery, inside the main body. Alternatively, the power source may be another type of charge storage device, such as a capacitor. The power source may have a capacity large enough to allow continuous generation of the aerosol for a period of approximately 6 minutes. In another example, the power supply may have sufficient capacity to enable a predetermined number of activations of the heater assembly.

Next, the present invention will be described in relation to its embodiments, which are illustrated by the following graphics, where:

In fig. 1 shows an embodiment of the heater unit;

In fig. Figure 2 shows the heater assembly according to claim 1 in the installed state;

In fig. 3a, 3b show details of the fastening mechanisms;

In fig. 4a-4d show additional fastening means and fastening mechanisms.

In fig. 5a, 5b show top views of the heater assembly;

In fig. 6a-6c show a heater assembly with lateral sliding means (Fig. 6a) for fastening; details of the mechanism (Fig. 6b) fastening; and means (Fig. 6c) of fastening;

In fig. 7a, 7b show a heater assembly with staples as clamping means and details of the cross-sectional parts of the base;

In fig. 8 shows another embodiment of a heater assembly with brackets as fastening means;

In fig. 9 shows heater units with installed brackets;

In fig. 10 shows another embodiment of a heater assembly with brackets as fastening means;

In fig. 11a to 11d show thread structures having first and second parts and methods for producing the combined threads.

In the drawings, like reference numerals are used to designate the same or similar elements.

In fig. 1 and fig. Figure 2 shows a heater unit, including an electrically insulating base 1, a heating element, a thread structure in the form of a mesh 2 and two clamps 3 for attaching the mesh to the base. The base 1 is in the shape of a circular disk and includes a centrally located hole 100. The base also includes two slits 4 parallel to each other adjacent to the corresponding sides of the square hole 100. A strip-shaped mesh 2 is located over the hole and slits 4. The width of the mesh is less than the width of the opening 100, and thus, on both sides of the mesh, open portions 101 of the said hole are formed, not covered by the mesh. The two clamps 3 contain flat contact parts 31, which should be parallel to the upper surface of the base. The contact parts 31 are designed to contact the heater assembly via an electrical connector extending from the battery. The two clamps 3 also contain longitudinal curved fastening parts 30, which are inserted into the slots 4 of the base 1.

The clamps 3 can be made by bending a metal blank, such as a stainless steel sheet or a copper sheet, for example.

In fig. Figure 2 shows the heater assembly in the assembled state, with the mesh 2 pressed inside the slots 4 when the clamps 3 are pressed perpendicular to the upper surface of the base into the slot (the direction of pressing is shown by arrows in Fig. 1). Using clamps 3, a tensile force 5 is provided acting on the mesh 2 in a direction coplanar to the upper surface of the base 1. Both clamps 3 create tensile forces 5 acting in mutually opposite directions. Tensile forces 5 support the planar arrangement of the mesh 2 and help stabilize the mesh in the plane of the base 1.

In fig. 3a shows a detailed view of the clip 3 inserted into the slot 4. The end portions 20 of the mesh 2 are pressed into the slots by the clip fastening parts 30 and are firmly fixed in the slots. The bent fastening parts 30 apply a fastening force 50 to the walls of the slots in a direction parallel to the upper surface of the base, into the inside of the base. The edges 301 of the clamps 3 can act as spikes, further securing the mesh in the slots and improving the strength of the electrical contact of the clamps 3 with the mesh 2.

In fig. 3b shows an alternative embodiment of the bent part 30 of the fastening of the clamp 3, inserted into the longitudinal slot 4. The slot has convex walls 6, which press the clip in the narrowest bent area 7 of the inserted part 30 of fastening. In this embodiment, the narrowest bent part 7 is located approximately in the middle of the height of the base 1. In this way, the bent part 8 (larger), inserted as deep as possible into the slot 4, is additionally protected from coming out of the slot.

In fig. 4a-4d show variants of clamps 3 that fix the mesh on the upper surface and on the lower surface of the base 1. The upper and lower edges 9, 10 of the fastening are pressed into the upper and lower surface of the base 1. The mesh 2 is located between at least the upper edge 9 of the fastening and the upper surface of the base. The top edge 9 is slightly deflected in the rearward direction so as to provide a more stable structure when the mesh 2 is tensioned opposite to this rearward direction.

The clamps 3 include side portions 32 located on the side or circumferential side of the base 1. The side portions 32 of the clips provide additional support for the fixation and contact of the mesh 2 by contacting the side of the base 1.

In fig. 4a and 4b, the mesh 2 is wrapped around the circumferential surface of the base 1 and fixed on both sides of the base. Edges 9, 10 of fastening clamp 3 in Fig. 4b are not extended along the entire length of the clamp in the longitudinal direction. These edges are formed by cutouts in the clamp sheet blank and are bent towards the upper and lower surfaces of the base 1, respectively.

The side walls of the clamp 3 in Fig. 4c are smoothly curved, thus changing the elasticity of the clamp. The upper and lower surfaces of the base 1 have longitudinal recesses 12, 13 in the form of grooves to accommodate the edges 9, 10 of the clamp, as well as the mesh 2 (the upper recess 9 exists only in this embodiment).

Side 32 of clamp 3 in FIG. 4d is in close contact with the side of the base as well as part of the bottom surface of the base 1. On the bottom surface of the base, the clamp forms a triangle 33 in the side view. The length of the triangle 33 can be adapted and changed to change the clamping force of the clamp 3.

As shown in FIG. 4a-4d, a heater assembly equipped with clamps can be assembled by placing the mesh 2 on top of the base 1 and bending the clamps at the same time as installing the heater. When bending the clamps, a tensile force is applied to the mesh.

In fig. 5a and 5b show top views of heater assemblies with clamps having longitudinal fastening parts, such as those shown in the embodiments of FIGS. 4a-4d and figs. 6a-6c. Clamps 3 in Fig. 5 have a substantially rectangular shape in top and bottom views. These clips are easy to make; for example, they are obtained by bending a rectangular piece of sheet material or wire. As shown in FIG. 5b, the clamps have a shape adapted to the shape of the base. Thus, the circular base is equipped with clamps corresponding to the circular shape of the circumferential surface of the base. This heater unit is very compact and takes up little space also in the lateral directions.

In fig. 6a-6c show the heater assembly and clamping brackets; these clamping brackets are able to slide over a prepared structure of base 1 and mesh 2. The base has longitudinal recesses 12, 13 in the form of grooves in the upper surface and in the lower surface. The recesses 12, 13 are located parallel to each other and the hole 100 in the surface and extend across the entire surface of the base 1. The recesses 12, 13 facilitate the lateral sliding of the clamping clips 3 along the mesh and base structure. Preferably, the mesh 2 is tightly stretched before the clamps 3 slide into the base 1. To prevent the mesh from tearing or getting stuck in the mesh when sliding along it, the edges 15 of the clamp are rounded. This can be seen in Fig. 6c, which shows a prefabricated clamp 3 as a fastening means.

In fig. 7a, 7b, 8 and 10 show fastening means 3 in the form of two brackets and corresponding recesses 12 in the base 1. A mesh (not shown) is placed over at least part of the base opening 100. The staples are inserted vertically into the recesses 12 of the base. In the fixed position, the staple bridges are placed in longitudinal recesses 12 made in the upper surface of the base 1. These legs have a length greater than the thickness of the base 1. The protruding ends of the legs are bent and recessed in the corresponding recesses 19 in the lower surface of the base. Thanks to the bending of the legs around the base, reliable fixation and contact with the mesh 2 through staples is ensured. In fig. 7a and 8, four legs of two staples are inserted into four recesses 121 located in the circumferential surface of the disc-shaped base. In fig. 7a, the bracket bridges have a stamped roof-shaped protrusion 17. This shape can closely match the shape of the battery connectors. The longitudinal recesses 12 in the base also have a corresponding roof-shaped protrusion 18 at the bottom, as can be seen in the cross-section detailed in FIG. 7b.

In fig. 8, the staple bridges have an engraved v-shaped recess 20, which corresponds to an engraved v-shaped recess 21 of the recesses 12.

The stretching of the mesh is due to the corresponding protrusions and recesses 17,18; 20, 21 in brackets and recesses 12.

In fig. 9 shows in an assembled state two heater units shown in FIG. 7a and 8. In this case, the heater unit shown in FIG. 7a corresponds to the variant shown in FIG. 9 below, and the heater assembly shown in Fig. 8 corresponds to the variant shown in FIG. 9 at the top.

In fig. 10 shows another version of the heater assembly with brackets as fastening means 3. The base has two longitudinal recesses 12 to accommodate the bridge parts of the brackets. The base also has one hole 122 at each end of the longitudinal recesses 12. The legs of the staples are pressed into the holes 122 and fix the mesh (not shown) in contact between the recesses 12 and the staples. The staples 3 may be attached to the base 1 by the shape match between the staple legs and the holes 122. However, the bottom surface of the base may also have recesses to accommodate the ends of the legs folded toward the bottom surface of the base.

In fig. 11a to 11d show methods for producing a joint yarn having first and second parts. In fig. 11a, the first portion is shown as a mesh 1101 and the second portions are shown as a higher density mesh 1103. For example, the first portion may contain a mesh of lower density than the second portions, however, both the first and second portions may be made of the same material, such as stainless steel. In fig. 11b, the first portion is shown as a mesh 1101 containing a first material, and the second portions 1105 are shown as end portions made of a second material different from the first material. In this case, the second material is more ductile than the first material. As an example, the first portion 1101 may be made of stainless steel and the second portion 1105 may be made of copper. In fig. 11c shows force being applied to the second portions 1108 by the pressing members 1107 such that the second portions 1108 are deformed into a foil-type material 1109 as shown in FIG. 11d.

After obtaining a completed pooled yarn comprising the first portion 1101 and the second portions 1103, 1105, and 1109, the pooled thread may be secured to the base using one of the methods described above by positioning the second portions 1103, 1105, 1109 such that the clamps 3 are electrically connected to these second parts.

The present invention has been described in detail on the basis of embodiments illustrated by drawings. However, other variants of fastening mechanisms and their corresponding fastening means and base shapes may be considered. For example, the mesh can be secured to the base using screws. These screws are electrically conductive and serve as electrical contacts for the filament structure and as connectors for the battery. A locking engagement between the fastening means and the base can also be used in the form of, for example, push buttons or latches. In this case, the fastening means form one part of the latch, and the base is equipped with a corresponding other part of the latch.

Claims (29)

1. A cartridge for an aerosol generating system, containing: a liquid storage container portion comprising a housing containing a liquid aerosol-forming substrate, the housing having an open end; And a heater unit permeable to fluid, containing: an electric heating element configured to heat a liquid aerosol-forming substrate to form an aerosol, the electric heating element including a planar filament structure having one or more electrically conductive filaments, an electrically insulating body comprising a ceramic material and having a planar fastening surface, the filament structure being disposed in contact with the planar fastening surface, and connectors located at opposite ends of the electric heating element and forming two separate electrical contacts configured to supply power to the filament structure, wherein the fluid-permeable heater assembly is located on top of the open end of the housing. 2. The cartridge according to claim 1, in which the connectors mechanically fix the filament structure to the electrical insulating base and serve as electrical contacts configured to supply heating current through the filament structure. 3. The cartridge according to claim 1, wherein said one or more electrically conductive threads have a flat cross-section. 4. The cartridge according to claim 3, in which said one or more electrically conductive threads are arranged in a curvilinear manner. 5. The cartridge according to claim 1, in which said one or more electrically conductive threads are arranged in a curvilinear manner. 6. The cartridge according to claim 1, in which the electrical insulating base additionally contains an open-pore ceramic material. 7. The cartridge according to claim 1, in which the electrical insulating base additionally contains capillary material. 8. The cartridge according to claim 1, in which the electrical insulating base has a hole. 9. The cartridge of claim 8, wherein the flat mounting surface includes said hole. 10. The cartridge according to claim 8, in which said hole in the electrical insulating base has a rectangular shape. 11. The cartridge according to claim 8, wherein said hole of the electrical insulating body extends through the electrical insulating body. 12. The cartridge according to claim 8, in which the thread structure passes partially over the hole of the electrical insulating base. 13. The cartridge according to claim 8, in which the thread structure extends completely over the hole of the electrical insulating base. 14. The cartridge according to claim 1, in which the electrical insulating base has recesses formed in it, and the connectors fit into these recesses. 15. The cartridge according to claim 14, in which the recesses are holes passing partially through the electrical insulating base. 16. The cartridge according to claim 1, wherein the filament structure has a first part and second parts, the second parts being provided at both ends of the first part of the filament structure, the first and second parts constituting a combined electrical path. 17. The cartridge according to claim 1, wherein the filament structure has a first part and second parts, the second parts being provided at both ends of the first part of the filament structure, the second parts being in the form of foil. 18. The cartridge according to claim 1, in which the connectors are screws. 19. The cartridge according to claim 1, in which the connectors are spikes. 20. An aerosol generating system containing a cartridge according to claim 1; main building; electrical diagram; microprocessor; and power supply. 21. Aerosol generating system according to claim 20, wherein a liquid storage container portion is located on a first side of said one or more electrically conductive threads, and wherein an air flow channel is located on the opposite side of said one or more electrically conductive threads.