CN114828671A

CN114828671A - Aerosol generating device

Info

Publication number: CN114828671A
Application number: CN202080087084.0A
Authority: CN
Inventors: K.阿戴尔; A.R.J.罗根; A.赖特
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2019-12-19
Filing date: 2020-12-18
Publication date: 2022-07-29
Also published as: JP2023507113A; EP4084637A1; US20230034238A1; WO2021123234A1

Abstract

An aerosol generating device for generating an aerosol by heating a liquid aerosol substrate, the device comprising: a reusable section (200) comprising a heating element (210, 610); and a consumable (100) comprising a liquid aerosol substrate (110), wherein the consumable is adapted to supply, in use, the liquid aerosol substrate to the heating element, wherein the consumable or reusable section comprises an aerosol-generating chamber (120, 620) comprising a heater cradle (160) adapted to hold the heating element, the heater cradle comprising a first opening (161) adapted to receive the heating element into the heater cradle, and a capillary opening (162) adapted to draw, in use, the liquid aerosol substrate into the heater cradle.

Description

Aerosol generating device

Technical Field

The present disclosure relates to devices for generating aerosols for inhalation by a user, such as electronic cigarettes. In particular, the present disclosure relates to aerosol-generating devices in which an aerosol is generated by heating a liquid substrate.

Background

Known aerosol-generating devices often use a heating component or heater to heat an aerosol-generating liquid in order to generate an aerosol or vapour for inhalation by a user. The heating element is typically made of an electrically conductive material that allows current to flow through it when electrical energy is applied across the heating element. When an electric current is passed through a conductive material, the resistance of the material causes heat to be generated, a process commonly referred to as resistance heating.

In aerosol generating devices using liquid substrates, the liquid substrate is consumed and must be supplied to the aerosol generating device periodically. This is typically achieved by providing a consumable comprising a liquid matrix.

One known type of consumable comprises both a liquid substrate and a heating element, such that the liquid substrate may remain inside the consumable when the consumable is used to generate an aerosol. This has the following advantages, for example: the liquid substrate is kept away from reusable components of the aerosol-generating device, such as a power source (e.g., a battery), which are disposed in a reusable section of the aerosol-generating device configured to cooperate with the consumable. Thus, when the consumable is replaced, the heating element is also replaced.

Such advanced heating elements may be more complex or expensive to manufacture, and it is desirable to avoid discarding such heating elements when consumables are replaced. It is therefore an object of the present invention to provide an aerosol-generating device having a mesh heating element, wherein the heating element is reusable.

Disclosure of Invention

According to a first aspect, the present disclosure provides an aerosol-generating device for generating an aerosol by heating a liquid aerosol substrate, the device comprising: a reusable section comprising a heating element; and a consumable comprising a liquid aerosol substrate, wherein the consumable is adapted to supply the liquid aerosol substrate to the heating element in use.

By providing a reusable section of the aerosol-generating device that includes a heating element, the heating element may be used with a plurality of consumables to generate an increased amount of aerosol over its lifetime.

Additionally, the reusable section or the consumable comprises an aerosol-generating chamber comprising a heater carrier adapted to hold a heating element, the heater carrier comprising a first opening adapted to receive the heating element into the heater carrier, and a capillary opening adapted to draw liquid aerosol substrate into the heater carrier in use.

By providing a heater cartridge with a capillary opening, a structure for controlling the supply of liquid substrate to the heating element may be provided.

Optionally, the heating element comprises a web of electrically conductive fibres configured, in use, to convey liquid through the heating element by capillary action.

By providing a heating element capable of transporting liquid through a capillary tube, the aerosol generating device can be simplified. Furthermore, by providing a mesh with a large surface area for contacting the liquid aerosol substrate, the heating efficiency can be improved.

Optionally, the reusable section further comprises a power source connected to the heating element.

Optionally, in the first embodiment: the consumable comprises an aerosol-generating chamber containing a liquid aerosol substrate and a consumable opening adapted to receive a heating element into the aerosol-generating chamber; and the reusable section comprises a loading mechanism configured to position the heating element in the aerosol-generating chamber.

By providing a consumable that is capable of receiving a heating element in its aerosol-generating chamber in use, the heating element can be used to generate an aerosol from a plurality of consumables whilst retaining the advantages of: the liquid substrate in the consumable is kept separate from other reusable components of the aerosol generating device.

Optionally: the loading mechanism is adapted to move between an open position and a closed position, the loading mechanism is configured to receive and hold the consumable in the open position, and the loading mechanism and the heating element are relatively arranged such that the heating element moves through the consumable opening when the loading mechanism moves from the open position to the closed position.

By providing a loading mechanism arranged such that the heating element moves through the consumable opening when the loading mechanism is operated, the heating element can be more efficiently positioned in the aerosol-generating chamber for generating an aerosol.

Optionally, the loading mechanism comprises a positioning element adapted to engage with a corresponding element on the consumable such that the consumable is aligned to receive the heating element.

By providing a positioning element, the likelihood of damage to the consumable and/or the heating element due to incorrect operation of the aerosol generating device is reduced.

Optionally, the consumable opening comprises a consumable seal.

By providing a seal over the consumable opening, leakage of liquid aerosol substrate through the opening is inhibited when the consumable opening is not used to position the heating element for aerosol generation.

Optionally, the heating element comprises a rigid front portion adapted to break the consumable seal when the heating element is moved through the consumable opening.

By providing a rigid front portion on the heating element, the consumable seal can be made stronger without limiting the material in the heating element that can be used for the web of conductive fibers.

Optionally, the consumable seal comprises an elastomer configured to reseal the consumable opening.

By providing an elastomeric seal, leakage of the liquid aerosol substrate through the consumable opening after the heating element has entered the aerosol-generating chamber is inhibited.

Optionally, the heating element comprises a closing portion adapted to close the consumable opening when the heating element is in the aerosol-generating chamber.

By providing a closure portion on the heating element, leakage of the liquid aerosol substrate through the consumable opening after the heating element has entered the aerosol-generating chamber is inhibited.

Optionally, the first opening is a capillary opening.

By moving the heating element into the heater carrier through the capillary opening, the supply of liquid substrate to the heating element can be controlled in the heater carrier without restricting how the heater carrier is arranged in the aerosol-generating chamber.

Optionally, the first opening is a consumable opening and the heating element comprises a rigid front portion adapted to break a capillary seal of the capillary opening when the heating element is moved through the consumable opening.

By combining the first opening with the consumable opening, it becomes unnecessary for the heating element to move through the liquid substrate contained in the aerosol-generating chamber before entering the heater bracket.

Optionally, the consumable comprises a plurality of electrical contacts adapted to supply power to the heating element when the heating element is in the aerosol-generating chamber, and the reusable section comprises a plurality of electrical contacts adapted to supply power to the consumable.

By providing power to the heating element via the consumable, it becomes unnecessary to have a direct electrical contact from the reusable section through the consumable opening to the heating element. This may improve safety and reliability, for example by keeping the electrical contacts away from the liquid aerosol substrate.

Optionally, the reusable section comprises a plurality of electrical contacts adapted to supply power directly to the heating element when the heating element is in the aerosol-generating chamber.

By providing power directly from the reusable section to the heating element, the consumable can be kept simple without any electrical elements.

Optionally, in a second embodiment, the reusable section further comprises: an aerosol-generating chamber, wherein the heating element is arranged in the aerosol-generating chamber, wherein the reusable section is adapted to receive the liquid aerosol substrate from the consumable into the aerosol-generating chamber.

By receiving the liquid substrate from the consumable into the reusable section, the heating element can be used with a plurality of consumables such that the total amount of aerosol generated over the life of the heating element can be increased.

Optionally, the reusable section is configured to compress the consumable in order to drive the liquid aerosol substrate into the aerosol-generating chamber.

By compressing the consumable, the consumable can be kept as sealed as possible. More specifically, the liquid aerosol substrate can be driven out of the consumable without providing a mechanism for pressure equalization inside the consumable.

Optionally, the consumable comprises a weak point or outlet for the liquid aerosol substrate.

By providing a weak point or outlet on the consumable, the liquid matrix is guided and it is not necessary to seal the consumable in the reusable section before compressing the consumable.

Optionally, the reusable section comprises a piercing element arranged to pierce the consumable.

By providing the piercing element in the reusable section, the use of the aerosol generating device with consumables may be simplified and waste of liquid aerosol substrate due to user error may be reduced.

Optionally, the consumable comprises an inlet for air.

By providing an inlet for air, the pressure within the consumable can be kept constant and the liquid aerosol substrate can be transferred into the aerosol-generating chamber in the reusable section without deforming the consumable.

Optionally, the reusable section is adapted to drive air into the consumable in order to drive the liquid aerosol substrate into the aerosol-generating chamber.

By having the reusable section adapted to drive air into the consumable, the transfer of liquid aerosol substrate from the consumable to the aerosol generating chamber can be controlled by the reusable section without deforming the consumable.

Optionally, the heating element is detachable from the reusable section.

In the case of a removable heating element, the heating element can be replaced if it becomes less effective, for example, due to the gradual accumulation of residue (from heating the liquid aerosol substrate). However, whenever the liquid aerosol substrate is exhausted, there is no need to replace the heating element with the consumable.

Optionally, the aerosol generating device comprises control circuitry configured to perform self-cleaning, wherein the control circuitry drives the heating element at a predetermined high power for a predetermined period of time so as to pyrolyse residue on the heating element.

By performing self-cleaning, the life of the heating element may be extended, and replacement of the heating element and/or the entire reusable section may become unnecessary.

Drawings

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

fig. 1A is a schematic cross-section of a consumable according to a first embodiment;

fig. 1B is a schematic illustration of a first side of a consumable;

FIG. 1C is a schematic illustration of a second side of the consumable;

figure 2 is a schematic presentation of a reusable section of an aerosol-generating device according to a first embodiment;

figure 3A is a schematic display of an aerosol-generating device according to a first embodiment;

figure 3B is a schematic cross-section of an aerosol-generating device;

fig. 4A is a schematic cross-section of a consumable according to a second embodiment;

figure 4B is a schematic cross-section of a portion of an aerosol-generating device according to a second embodiment;

figures 4C and 4D are schematic cross-sections of an aerosol generating device according to a second embodiment at the

planes

4C, 4D shown on figure 4B;

fig. 5A, 5B, 5C are schematic cross-sections of modifications of the second embodiment;

figure 6A is a schematic display of a reusable section of an aerosol-generating device according to a third embodiment;

figure 6B is a schematic cross-section of an aerosol-generating device according to a third embodiment;

figure 7A is a schematic display of a reusable section of an aerosol-generating device according to a fourth embodiment; and

figure 7B is a schematic cross-section of an aerosol-generating device according to a fourth embodiment.

Detailed Description

In the figures, the x-axis, y-axis and z-axis are used to indicate the viewpoint of relative rotation in the different figures. Such shaft markings have no further significance for the design of the embodiments.

Fig. 1A is a schematic cross section of a consumable according to a first embodiment. The consumable 100 comprises a liquid aerosol substrate 110 contained in an aerosol-generating chamber 120. The liquid aerosol substrate 110 can, for example, include an aerosolizing agent and a fragrance or medicament.

In this embodiment, the consumable 100 has a generally cubic shape, and the aerosol-generating chamber is also cubic. However, this is only a simple example and any suitable shape may be used for the exterior of the consumable 100 and for the aerosol-generating chamber. For example, the consumable may be approximately cylindrical.

Fig. 1B is a schematic illustration of the consumable from the perspective of the first side 131 facing on the exterior of the consumable. As shown in fig. 1B, first side 131 includes a consumable opening 140. The consumable opening 140 is adapted to receive a heating element (described later) in whole or in part into the aerosol-generating chamber 120.

In this embodiment, the consumable opening 140 takes the form of a slot or keyway. More generally, the consumable opening 140 must be large enough and appropriately shaped to pass a heating element (described later).

In this embodiment, the consumable opening 140 includes a frangible seal (consumable seal 141). The seal 141 prevents the liquid aerosol substrate from leaking out of the consumable 100 and can be broken in use to allow the heating element to move fully or partially through the consumable opening 140.

The seal 141 may be configured to reseal the consumable opening, for example, after the heating element has moved through the consumable opening. This has the following advantages: the consumable 100 does not leak through the consumable opening 140 even when the consumable is used to generate an aerosol in an aerosol generating device. This resealing may be embodied by the seal 141 being formed from two elastomers (e.g., rubber) that may be pushed apart to break the seal and then will return to their original sealing position.

In this embodiment, the first side 131 is the long side of the cubic consumable 100. More generally, however, the consumable opening 140 may be on any surface that may be positioned to receive a heating element (described later). For example, on a cylindrical consumable, the consumable opening 140 can be on a curved surface or on one of the flat ends.

A second side 132 and a third side 133 on the outside of the consumable are additionally marked in fig. 1B. In the present cube example of the consumable, the second side 132 and the third side 133 are adjacent to the first side 131. However, this is not essential. For example, in a cylindrical consumable, the first side 131, the second side 132, and the third side 133 may be different regions of a curved face, or may be a combination of a curved face and a flat face of a cylinder.

Two positioning elements 150 are shown on each of the second and

third sides

132, 133, adapted to engage with a loading mechanism on a reusable section of an aerosol-generating device (described later). These positioning elements may for example be physical structures (such as flanges, indentations or protrusions) or may be other engaging means (such as magnets) that may be attached to or embedded inside the consumable. In one particular example, the positioning element 150 may be a longitudinal ridge or groove. It is advantageous to use two pairs of positioning elements 150 on two

different sides

132, 133 of the consumable to securely engage with the loading mechanism. However, one or more positioning elements 150 on either side of the consumable may be engaged with the loading mechanism. Furthermore, in some embodiments, certain positioning elements 150 may be omitted, for example where the aerosol generating device is generally adapted to hold an outer surface of a consumable.

Fig. 1C is a schematic illustration of the third side 133 of the consumable, illustrating the arrangement of the positioning element 150 in this embodiment.

Figure 2 is a schematic display of a reusable section of an aerosol-generating device according to a first embodiment. Figure 3A is a schematic display of an aerosol-generating device according to a first embodiment comprising a reusable section together with a consumable as previously described. Figure 3B is a schematic cross-section of an aerosol-generating device. These will be described together to avoid repetition.

Reusable section 200 includes heating element 210 and loading mechanism 220.

The loading mechanism 220 is configured to control movement of the consumable 100 such that the heating element 210 is positioned in the aerosol-generating chamber 120.

More specifically, the loading mechanism 220 may be adapted to move between an open position (as shown in fig. 2) and a closed position (as shown in fig. 3A). The loading mechanism 220 is arranged relative to the heating element 210 such that when the loading mechanism 220 holds the consumable 100 and the loading mechanism 220 moves from an open position to a closed position, the heating element 210 moves through the consumable opening 140.

In the example shown in the figures, a hinge 222 is provided to control movement between the open and closed positions. In this arrangement, the consumable 100 rotates as it moves, and this must be taken into account in the design of the consumable opening 140 in order to allow the heating element 210 to enter the aerosol-generating chamber 120. Alternatively, the movement between the open and closed positions may be a non-rotational movement guided by one or more straight rails. With alternative arrangements, the size of the consumable opening 140 may be minimized to match the length of the heating element 210.

The loading mechanism 220 is configured to receive the consumable 100 and hold it in an open position in order to control the movement of the consumable 100. Additionally, the loading mechanism 220 may be configured to ensure that the consumable opening 140 is aligned with the heating element 210. More specifically, the loading mechanism may comprise, for each of the positioning elements 150 of the consumable 100, a corresponding positioning element 221, wherein each positioning element 221 is adapted to engage with a corresponding positioning element 150. For example, as shown in fig. 3A, positioning

elements

221 and 150 may be interlocking structures. Alternatively, the positioning element 221 of the loading mechanism 220 may be, for example, a magnet similar to the positioning element 150 of the consumable 100.

Additionally, in this embodiment, reusable section 200 further comprises a power source 230 connected to heating element 210. The power source 230 may be, for example, a battery. The reusable section 200 may further include control circuitry (not shown) for controlling the supply of power to the heating element. The control circuitry may include a user interface, such as a button or slider. Additionally, the power source may be rechargeable and the control circuitry may include an interface (e.g., a USB interface) on the exterior of the reusable section 200 for supplying power to recharge the power source 230.

In this embodiment, the reusable section 200 of the aerosol-generating device is adapted to be held in a user's hand and comprises a mouthpiece 240 for the user to inhale aerosol generated by the assembled aerosol-generating device.

The heating element 210 may be a wire or an array of webs formed into different shapes, such as a coil. In such embodiments, in use, the heating element is typically in contact with or in close proximity to a wicking element which draws aerosol-generating liquid to be vapourised from a reservoir or supply in the device. The wicking element typically has a fibrous or porous structure that causes liquid to be drawn from the liquid supply by capillary action.

Some heating elements, particularly web array heaters, combine a heating function and a wicking function, in which a sheet of, for example, electrically conductive porous material draws aerosol-generating liquid from a reservoir into a heating component using capillary action, which also provides heat when electrical energy is passed through the sheet. The sheet of electrically conductive porous material may be shaped to optimize the synergy between the heating function and the wicking function.

In such embodiments, the heating element comprises a web 211 of electrically conductive fibres configured to convey, in use, liquid through the heating element by capillary action. In a typical example, the heating element has a width of approximately 7.5mm to 8mm, a depth of approximately 1.5mm to 2mm, and a length of approximately 30 mm. The mesh 211 provides a wicking function to the heating element 210 and comprises a fibrous sheet of electrically conductive fibers. The fiber sheets may be formed, for example, in a square wave or zigzag arrangement. It is to be understood that the fibrous sheet is a woven fabric, but the sheet may also be provided as a non-woven fabric or as a bundle of conductive fibers. A plurality of slots may be provided in the mesh 211 to create a square wave arrangement.

The heating element 210 additionally comprises a first contact 212 and a second contact 213. In use, power is driven through the mesh 211 between the first contact 212 and the second contact 213 to provide resistive heating. In this embodiment, the first and

second contacts

212, 213 are also arranged as first and second supports for holding the mesh 211. In use, power is supplied to the mesh 211 from the power supply 230 through the first and second supports.

The heating element 210 additionally comprises a rigid front portion 214 adapted to break the consumable seal 141 of the consumable 100. This enables the heating element 210 to move through the consumable opening 140 of the consumable 100 to break the seal 141 without having to adapt the mesh 211 to be sufficiently strong, and thus the mesh 211 can be optimized for its wicking and heating functions. The rigid front portion 214 may be, for example, a solid blade of some material (e.g., metal) or may be a more rigid, thicker, or denser portion of the mesh 211. Alternatively, the rigid front portion may be a layered arrangement of two blades on either side of the mesh 211 extension. Preferably, the rigid front portion 214 is configured such that by including a mesh or gap in the rigid front portion 214, liquid can be wicked into the body of the mesh 211 through the rigid front portion 214.

The heating element 210 further comprises a closing portion 215 adapted to close the consumable opening when the heating element is in the aerosol-generating chamber. The closure portion 215 is particularly advantageous if the consumable seal 141 of the consumable 100 is not resealable, but may be omitted in other embodiments. The loading mechanism may be arranged to press the first side 131 of the consumable 100 against the closing portion 215 to create the seal. The closure portion 215 may include an absorbent material configured to absorb any liquid aerosol matrix leaking through the consumable opening 140. In such an absorption example, the closure portion 215 may also be replaceable.

Fig. 3A and 3B illustrate the assembled aerosol generating device of the first embodiment, having the consumable 100 and the reusable section 200, and the heating element 210 positioned in the aerosol generating chamber 120.

As shown in fig. 3A, the positioning elements 150 of the consumable 100 engage with the corresponding positioning elements 221 of the loading mechanism 220, as described above. Additionally, the first side 131 of the consumable 100 rests against the closing portion 215 of the heating element 210 to close the consumable opening 140.

Fig. 3A need not be in cross-section, as the consumable 100 need not be completely enclosed within the reusable section 200 of the aerosol-generating device, but rather the reusable section 200 may be opened as shown, in accordance with the present invention. Alternatively, reusable section 200 may form a closed box around consumable 100 when loading mechanism 220 is in the closed position.

Fig. 3B shows a cross section through the consumable from the same perspective as fig. 3A. In fig. 3B, the first and

second contacts

212, 213 extend through the consumable opening 140 into the liquid aerosol substrate 110 in the aerosol-generating chamber 120 so that power can be supplied to the mesh 211 to generate an aerosol or vapour within the aerosol-generating chamber 120. The generated aerosol is then directed to the mouthpiece 240. For example, the consumable 100 may comprise an air flow tube (not shown) arranged to be connected to the suction nozzle 240 through the reusable section 200, wherein the air flow tube is arranged to receive the generated aerosol or vapor from the mesh 211 and mix the aerosol or vapor with air directed to the suction nozzle 240.

Fig. 4A to 4D are schematic cross-sections of a portion of an aerosol-generating device according to a second embodiment. The second embodiment is similar to the first embodiment except that the consumable includes a heater cartridge 160. For simplicity, only consumable 100 is shown in fig. 4A, and most of reusable section 200 is not shown in fig. 4B, 4C, and 4D. Dashed

lines

4B, 4C and 4D show the relative position of each of the last three sections.

As shown in fig. 4A, the heater carrier 160 is an enclosure within the aerosol-generating chamber 120 surrounded by the liquid aerosol substrate 110. Internally, the heater carrier 160 comprises an air flow channel 170 which is connected to the aerosol-generating chamber 120 via the first opening 161 and the capillary opening 162. The first opening is aligned with the consumable opening 140 and is adapted to receive the heating element 210 into the heater cradle 160. The capillary opening 162 is adapted to draw the liquid aerosol substrate 110 into the heater cradle in use.

The heater carrier 160 may additionally comprise a first seal 163 and a capillary seal 164 arranged to prevent the liquid aerosol substrate 110 from entering the air flow channel 170 prior to use of the consumable 100 in an aerosol generating device. Alternatively, the first opening 161 and/or the capillary opening 162 may be sufficiently narrow or the air pressure in the air flow channel sufficiently high to prevent the liquid aerosol substrate 110 from entering the air flow channel 170 prior to use of the consumable 100.

Turning to fig. 4B, 4C and 4D, the heater carriage extends parallel to the first side 131 of the consumable 100 along the interior length of the aerosol generating chamber 120. This arrangement means that the heater carrier 160 is supported at each end where it meets the inner walls of the aerosol-generating chamber 120 and that the air flow channel 170 can be connected beyond the consumable 100 to provide the generated aerosol to the mouthpiece 240 of the reusable section 200.

Additionally, as with the first embodiment, the first and

second contacts

212, 213 of the heating element 210 extend into the aerosol-generating chamber 120. However, in this embodiment, the heater carrier 160 is adapted to hold the heating element such that the wick 211 can generate an aerosol in the air flow channel 170. This is shown in

cross-sections

4C and 4D, which are labeled in fig. 4B and shown in fig. 4C and 4D, respectively.

More specifically, in fig. 4C, the first contact 212 is shown extending through the consumable opening 140, the liquid aerosol substrate 110, the first opening 161, the air flow channel 170, and partially into the capillary opening 162. To enter the consumable 100 and reach this position, the first contact 212 breaks the consumable seal 141, the first seal 163, and the capillary seal 164. The absence of

seals

141, 163, and 164 is indicated in fig. 4C using brackets.

Similarly, in fig. 4D, mesh 211 is shown disposed in air flow channel 170, extending partially into first opening 161 and capillary opening 162. In this position, the liquid aerosol substrate 110 can be drawn into the web 211 from the first opening 161 and the capillary opening 162 at a rate controlled by the size of the first opening 161 and the capillary opening 162. To enter the consumable 100 and reach this location, the rigid leading edge 214 (not shown in this example) breaks the consumable seal 141, the first seal 163, and the capillary seal 164. However, the consumable seal 141 may reseal itself after the web 211 has passed through the consumable opening 140. The absence of

seals

163 and 164 is indicated in fig. 4D using brackets.

By adding the heater bracket 160, the consumable 100 is provided with both an air flow channel 170 for extracting aerosol and means for controlling the supply of liquid aerosol substrate 110 to the web 211. Thus, the efficiency of aerosol generation may be improved.

Fig. 5A, 5B, and 5C are schematic cross sections of example modifications of the second embodiment. The modification of fig. 5C may be combined with any one of the modifications of fig. 5A and 5B.

The consumable shown in fig. 5A is similar to that of fig. 4A, but there is only one opening in the heater tray 160 of fig. 5A. More specifically, capillary opening 162 has been removed, and first opening 161 performs the functions previously described for capillary opening 162. This modification has the following advantages: the rigid leading edge 214 need not provide capillary wicking because it passes all the way through the first opening 161 and therefore cannot block the liquid aerosol substrate 110 from reaching the web 211. Additionally, this modification has the following advantages: as the capillary opening 162 is removed and the associated volume of the heater carrier 160 decreases, the volume of liquid aerosol substrate in the consumable increases.

The consumable shown in fig. 5B is similar to the consumable of fig. 4A, except that the heater bracket 160 is directly connected to the consumable opening 140, and the first opening 161 has been removed. With this arrangement, the consumable seal 141 is not required, and the closure portion 215 may also be omitted. This is because the liquid aerosol substrate 110 can only enter the air flow channel 170 when 164 has been destroyed (i.e. when the heating element 210 has been positioned in the aerosol generating chamber). The heating element 210 will typically only be removed from the aerosol-generating chamber after the liquid aerosol substrate 110 has been used up, so there is no time in normal use of the consumable 100 at which there is a risk of leakage occurring through the consumable opening 140.

The aerosol-generating device shown in fig. 5C is similar to the aerosol-generating device of fig. 4B, except that the first and second electrical contacts have been replaced with a plurality of electrical contacts adapted to supply power to the consumable. For example, separate

electrical interfaces

170, 270 may be provided between the consumable 100 and the reusable section 200. Additionally, the consumable 100 comprises a plurality of electrical contacts adapted to supply power to the heating element when the heating element is in the aerosol-generating chamber. For example, when the heating element 210 is positioned inside the consumable 100, power may be supplied to the grid 211 via the heater cradle 160. The first support 212 and the second support 213 are still present, but no electrical connection need be provided. Such a modification may improve safety and reliability as the electrical contacts no longer need to extend through the consumable opening 140 or the liquid aerosol substrate 110.

Fig. 6A and 6B are schematic illustrations of a reusable section 200 and a consumable 100 of an aerosol-generating device according to a third embodiment. The loading mechanism 220, the power supply 230, and the suction nozzle 240 of the third embodiment may be the same as the first embodiment or the second embodiment, and only the differences from the foregoing embodiments will be described in detail.

The principle difference of the third embodiment from the previously described embodiments is that the heating element 610 is arranged within the aerosol generating chamber 620, and the aerosol generating chamber 620 is part of the reusable section 200 rather than the consumable 100. Thus, in this embodiment, the heating element 610 is not directly engaged with the consumable 100.

As with the previous embodiment, the heating element 610 includes a mesh 211 and first and second

electrical contacts

212, 213. However, since the heating element is fixed in the third embodiment, the rigid front part 214 and the closing part 215 may be omitted. Additionally, in the third embodiment, the mesh 211 may simply extend between the two ends of the aerosol-generating chamber 620, such that the

supports

212, 213 may be replaced with simple electrical connections on the inner surface of the aerosol-generating chamber 620.

To allow the heating element 610 to heat the liquid aerosol substrate 110, the reusable section 200 is adapted to receive the liquid aerosol substrate 110 from the consumable 110 into the aerosol generating chamber 620. More specifically, the reusable section 200 comprises a substrate channel 630 arranged to connect the consumable 100 to the aerosol generating chamber 620 and to allow the liquid aerosol substrate 110 to flow from the consumable 100 to the aerosol generating chamber 620.

The heating element 610 may additionally include a heater bracket 160 as previously described to help control the supply of the liquid aerosol substrate 110 to the web 211.

The consumable 100 may be a consumable as described for the previous embodiments. However, for the third embodiment, the consumable 100 need not be so complex, but may simply comprise a liquid aerosol substrate 110 contained in a housing.

As shown in fig. 6A, the substrate passage 630 may comprise a piercing element 631 arranged to pierce the consumable 100 so as to form a fluid connection between the consumable 100 and the aerosol generating chamber 620. The piercing element 631 need not be integral with the substrate channel 630, but may instead be part of the loading mechanism 220, for example. Additionally or alternatively, the consumable 100 may comprise a weak point, valve or outlet on its outer surface to facilitate transfer of the liquid aerosol substrate 110 into the aerosol-generating chamber 620.

Additionally, the reusable section 200 comprises a pressurizing element 640 configured to compress the consumable 100 in order to drive the liquid aerosol substrate 110 into the aerosol-generating chamber 620. As shown in fig. 6A, the pressing element 640 may be as simple as a plate mounted on one or more springs 641. The loading mechanism 220 may include a locking element (e.g., a latch) such that it may provide a counter force to the pressure on the consumable 100. By applying pressure in this manner, the aerosol-generating device may ensure that the liquid aerosol substrate 110 is transferred from the consumable 100 to the aerosol-generating chamber 620 until the consumable 100 is substantially empty.

Figures 7A and 7B are schematic illustrations of a reusable section of an aerosol-generating device according to a fourth embodiment. The fourth embodiment is similar to the third embodiment except that a different method is employed to transfer the liquid aerosol substrate 110 from the consumable 100 to the aerosol-generating chamber 620.

In the fourth embodiment, the reusable section 200 comprises an air channel 710 for allowing air to enter the consumable 100. The air channel 710 may comprise a piercing element 711 for creating an inlet 180 in the consumable 100 to allow air to enter the consumable 100 to replace the liquid aerosol matrix 110, and to equalize the pressure in the consumable 100. Thus, the liquid aerosol substrate 110 may be transferred into the aerosol-generating chamber 620 through the substrate channel 630 without the need for the pressurizing element 640. In some embodiments where the consumable 100 already comprises an inlet 180 for air (e.g., in the form of a one-way valve), the piercing element 711 may be omitted.

The air channel 710 may additionally be adapted to drive air into the consumable 100 in order to drive the liquid aerosol substrate 110 into the aerosol-generating chamber 620. For example, the air passage 710 may include a pump 720.

Additionally, or alternatively, in any of the third and fourth embodiments, a pump may be included in the substrate channel 630.

Further modifications are possible to reduce waste of resources in the aerosol generating device.

In the above embodiments, the

heating elements

210, 610 are retained for use with a plurality of consumables 100. However, the

heating elements

210, 610 may have a more limited life than the reusable section. To avoid the need to replace the entire reusable section 200, the

entire heating element

210, 610 or mesh 211 may be detachable from the reusable section 200. With this configuration, the consumable 100 can be replaced frequently, and the

heating elements

210, 610 can be replaced less frequently, while the remainder of the reusable section 200 is used for its full life.

Furthermore, one common reason for the need to replace the

heating element

210, 610 is that it gradually accumulates residue (from heating the liquid aerosol substrate 110). This residue reduces the surface area of the mesh 211 and/or reduces the heating efficiency of the

heating elements

210, 610. In order to delay or eliminate the need to replace the

heating element

210, 610, the aerosol-generating device may be provided with control circuitry configured to drive the

heating element

210, 610 in a self-cleaning mode. For example, the

heating element

210, 610 may be driven at a maximum power or a predetermined high power for a predetermined period of time. By driving high electrical power through the

heating element

210, 610, the heating element may reach temperatures above during its normal aerosol-generating operation, and may be high enough to pyrolyze or otherwise remove residue from the heating element. The residue may then be drawn in the air stream through the mouthpiece or washed out of the aerosol generating device.

In the above embodiments, the heating element comprises a web of electrically conductive fibres configured, in use, to convey liquid through the heating element by capillary action. However, this is generally not required by the present invention. As an alternative to a mesh capable of providing a wicking function, heating element 210 may comprise any other type of heating element.

The heating element may comprise a simple heating surface for supplying heat to the liquid aerosol substrate, for example using a ceramic heating element, a metal plate and/or a planar resistive track. This may be combined with a separate wicking element or other flow channel for drawing the liquid aerosol substrate to the heated surface.

Further, more complex heating elements may be used, such as induction heating elements remote from susceptors configured to provide heat to the liquid aerosol substrate.

Still further, the heating element need not be an electrical heating element. For example, the heating element may instead use a chemical reaction (e.g., burning a fuel) to supply heat.

Claims

1. An aerosol generating device for generating an aerosol by heating a liquid aerosol substrate, the device comprising:

a reusable section comprising a heating element; and

a consumable comprising the liquid aerosol substrate,

wherein the consumable is adapted to supply, in use, the liquid aerosol substrate to the heating element,

wherein the consumable or the reusable section comprises an aerosol-generating chamber comprising a heater carrier adapted to hold the heating element, the heater carrier comprising a first opening adapted to receive the heating element into the heater carrier, and a capillary opening adapted to draw the liquid aerosol substrate into the heater carrier in use.

2. An aerosol-generating device according to claim 1, wherein the reusable section further comprises a power source connected to the heating element.

3. The aerosol generating device of claim 1 or claim 2,

the consumable comprising the aerosol-generating chamber and the aerosol-generating chamber containing the liquid aerosol substrate and a consumable opening adapted to receive the heating element into the aerosol-generating chamber; and is

The reusable section includes a loading mechanism configured to position the heating element in the aerosol-generating chamber.

4. The aerosol generating device of claim 3,

the loading mechanism is adapted to move between an open position and a closed position,

the loading mechanism is configured to receive and hold the consumable in the open position, and

the loading mechanism and the heating element are relatively arranged such that the heating element moves through the consumable opening when the loading mechanism moves from the open position to the closed position.

5. An aerosol-generating device according to claim 4, wherein the loading mechanism comprises a locating element adapted to engage with a corresponding element on the consumable so that the consumable is aligned to receive the heating element.

6. An aerosol-generating device according to any of claims 3 to 5, wherein the consumable opening comprises a consumable seal.

7. An aerosol-generating device according to claim 6, wherein the heating element comprises a rigid front portion adapted to break the consumable seal when the heating element is moved through the consumable opening.

8. An aerosol-generating device according to claim 1, wherein the first opening is the capillary opening.

9. The aerosol generating device of claim 1 or claim 2,

the reusable section comprises the aerosol-generating chamber,

the heating element is disposed in the aerosol-generating chamber, and

the reusable section is adapted to receive the liquid aerosol substrate from the consumable into the aerosol-generating chamber.

10. An aerosol-generating device according to claim 9, wherein the reusable section is configured to compress the consumable in order to drive the liquid aerosol substrate into the aerosol-generating chamber.

11. An aerosol-generating device according to claim 10, wherein the consumable comprises a point of weakness or an outlet for the liquid aerosol substrate.

12. An aerosol-generating device according to any of claims 9 to 11, wherein the reusable section comprises a piercing element arranged to pierce the consumable.

13. An aerosol generating device according to any of claims 9 to 12, wherein the consumable comprises an inlet for air.

14. An aerosol-generating device according to claim 13, wherein the reusable section is adapted to drive air into the consumable to drive the liquid aerosol substrate into the aerosol-generating chamber.

15. An aerosol-generating device according to any preceding claim, wherein the heating element comprises a web of electrically conductive fibres configured to convey liquid through the heating element by capillary action in use.