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(11) | EP 4 529 784 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | HEATER ASSEMBLY |
| (57) A heater assembly (34, 100, 200, 300 ,432) for an aerosol generating apparatus (1)
is provided. The heater assembly (34, 100, 200, 300 ,432) comprises a wicking body
(110, 210, 310) comprising a pocket (111, 211, 311), and a heating element (140, 240)
mounted within said pocket (111. 211. 311). Also provided is a kit of parts for forming
the heater assembly (34, 100, 200, 300 ,432). The kit of parts comprises a wicking
body (110, 210, 310) comprising a pocket (111, 211, 311); and one or more of heating
elements (140, 240), the pocket (111, 211, 311) being configured to house any one
of the one or more heating elements (140, 240). Also provided is a method of assembling
the heater assembly (34, 100, 200, 300 ,432), an aerosol generating component (430)
comprising the heater assembly (34, 100, 200, 300 ,432) and an aerosol generating
apparatus (1) comprising the component (430).
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FIELD
[0001] The present disclosure relates to a heater assembly for an aerosol generating apparatus, a kit of parts for forming a heater assembly for an aerosol generating apparatus, and a method of assembling a heater assembly for an aerosol generating apparatus. It also relates to an aerosol generating component and an aerosol generating apparatus each comprising the disclosed heater assembly.
BACKGROUND
[0002] A typical aerosol generating apparatus may comprise a power supply, an aerosol generating unit e.g. a vaporiser that is driven by the power supply, and an aerosol precursor, which in use is aerosolised by the aerosol generating unit/vaporiser to generate an aerosol.
[0003] In some aerosol generating apparatus, the vaporiser comprises a heater supplied with aerosol precursor liquid from a tank or liquid reservoir (i.e. a storage portion), typically using a wicking body that is interposed between the liquid reservoir and the heater to supply the liquid thereto. The wicking body transports liquid under capillary action. Commonly, the heater is integrally formed with, or otherwise attached to, an external surface of the wicking body. For example, it is known to form a vaporiser by printing a heater track formed of a metal alloy onto a ceramic wicking body followed by sintering of the resulting composite vaporiser.
[0004] A drawback with such known vaporisers is that due to the differing coefficients of thermal expansion of the heater track and the ceramic wicking body, the heater track may crack, break or lift from the ceramic wicking body as a result of being heated (i.e. as a result of the heater track expanding by a different amount to the ceramic surface it is attached to). This cracking, breaking and/or lifting leads to a degradation in vapour generation performance of the vaporiser.
SUMMARY
[0006] In a first aspect, the present disclosure provides an aerosol generating unit i.e. a heater assembly for an aerosol generating apparatus, wherein the heater assembly comprises a wicking body, the wicking body comprising a pocket, and a heating element mounted within said pocket.
[0007] In this way, the heater assembly may facilitate the heating element being positioned adjacent the wicking element without (at least the majority of) the heating element being attached, fastened, or bonded to the wicking body. Instead, the pocket provides an internal space within the wicking body for housing of the heating element without requiring direct attachment of the heating element to the wicking body. Accordingly, the heating element can expand to a different extent to the wicking body upon heating without the heating element and/or wicking body cracking, lifting or breaking.
[0008] The heating element may comprise one or more surfaces, e.g. an upper heating element surface, a lower heating element surface and/or a side heating element surface. In some examples, the heating element may be mounted in the pocket such that a major portion of the surface area a surface of the heating element (i.e. greater than or equal to 50% of the surface area of that surface) is not directly and/or not indirectly attached to the wicking body, for example, a major portion of the surface area of plural, or each, of the surfaces of the heating element may not be directly and/or not indirectly attached to the wicking body. That is, the heating element may be mounted in the pocket such that a major portion of the surface area of a (or each) heating element surface is not joined, bonded, affixed, adhered or fastened to the wicking body. In some embodiments, a major portion of a, or each, heating element surface is not directly attached (e.g. unattached) to the wicking body i.e. greater than 50% such as greater than 60% or 70%, for example greater than 80% or 90% e.g. 100% of the surface area of the, or each, heating element surface is not attached to the wicking body.
[0009] This may mean that the major portion the heating element is movable within the pocket (i.e. the heating element may move/flex/expand relative to the wicking body and independently of the wicking body within the pocket). In this way, where the coefficients of thermal expansion of the wicking body and heating element differ from each other, the generation of an interfacial stress between the wicking body and heating element from changes in temperature of these components can be avoided. Consequently, the likelihood of the heating element cracking, breaking or lifting as a result of the temperatures of the heating element and wicking body changing is reduced. Moreover, because the major portion of the heating element is not attached to the wicking body, the heating element may be intentionally removed from the wicking body, for example, for replacement with another heating element.
[0010] The pocket may open to an external surface of the wicking body, i.e. the wicking body may comprise an opening on an external surface of the wicking body. The opening facilitates insertion of the heating element into the pocket during manufacture of the heating assembly as discussed below.
[0011] The opening may be an elongate opening i.e. the opening may be a slotted opening. The slotted opening may be substantially rectangular.
[0012] The pocket may extend to a depth away from its opening, e.g. to an end pocket surface opposing the opening. The end pocket surface is an internal surface of the wicking body. The depth of the pocket may be greater than any dimension of the opening e.g. the depth of the pocket may be greater than the length of an elongate/slotted opening.
[0013] The pocket may be fully enclosed by the wicking body other than at its opening, i.e. the pocket opens to the outside of the wicking body only at the opening. That is, the pocket may be a blind hole into the wicking body.
[0014] The pocket may be defined by internal surfaces of the wicking body along its depth direction. The pocket may have an upper pocket surface (i.e. defined by an internal surface of the wicking body) which may be planar. The pocket may have an opposing, lower pocket surface (i.e. defined by an opposing internal surface of the wicking body) which may be planar. The upper and lower pocket surfaces are preferably parallel surfaces.
[0015] The upper and lower pocket surfaces may be spaced by opposing, side pocket surfaces (i.e. defined by opposing internal surfaces of the wicking body). The side pocket surfaces may be substantially planar and may be perpendicular to the upper and lower pocket surfaces. In this way, the pocket may have a substantially rectangular cross-section transverse to its depth direction. The pocket may have a height defined by the spacing between the upper and lower pocket surfaces and a width defined by the spacing between the side pocket surfaces. In some embodiments, the height of the pocket is less than the width. For example, the width of the pocket may be twice or more, for example, 5 times or more such as 7 or 10 times or more the height of the pocket.
[0016] The wicking body may be a cuboid shape or may have a cuboid portion. The pocket provides a hollow space within the cuboid wicking body or cuboid portion of the wicking body. The cuboid wicking body or cuboid portion of the wicking body has a longest dimension (length) that preferably extends parallel to the depth direction of the pocket. The cuboid wicking body or cuboid portion of the wicking body has a height and width perpendicular to its length. The axial end faces of the cuboid wicking body or cuboid portion are defined by edges extending in its height and width directions. The opening into the pocket is preferably provided on one of the axial end faces of the cuboid wicking body or cuboid portion of the wicking body. The length direction of the elongate/slotted opening preferably extends on this axial end face in the width direction of the cuboid wicking body/cuboid portion of the wicking body.
[0017] In some examples, the wicking body may comprise a porous material e.g. a ceramic material. In this way, the wicking body is configured to transport liquid by capillary action.
[0018] In some examples, the heating element may be formed from a different material / have a different composition to the wicking body. In this way, the heating element may have a different coefficient of thermal expansion (CTE) to that of the wicking body. In some examples, the CTE of the heating element is 50% or more greater than the CTE of the wicking body. The percentage difference in TEC may be calculated as: (heating element CTE - wicking body CTE) / (wicking body CTE) x 100. The CTE of the heating element may be greater than the CTE of the wicking body by 75 % or more, 100 % or more, 150 % or more, 200 % or more, or 300 % or more. In this way, having the heating element mounted in the pocket of the wicking body such that the heating element can be positioned adjacent the wicking body without the major portion of the surface area of one, or each, of the surfaces of the heating element being attached, fastened or bonded to the wicking body allows the risk of cracking, breaking or lifting of the heating element that may occur with such a difference in CTE to be reduced compared to if the heating element was not provide in a pocket and therefore needed to be attached to the wicking body in order to be positioned adjacent the wicking element.
[0019] In some examples, the heating element may be electrically connectable (or connected) to a power source. Thus, in operation, the power source may supply electricity to (i.e. apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wicking body to be heated so as to form a vapour and become entrained in a fluid flowing past the heater assembly along an airflow path. This vapour may subsequently cool to form an aerosol in the airflow path.
[0020] The heating element may comprise one or more electrode contacts to facilitate the connection of the heating element to the power source. Where the heating element comprises a plurality of electrode contacts (for example, first and second electrode contacts) the heating element may further comprise one or more filament sections extending between the plurality electrode contacts (e.g. between the first and second electrode contacts). The filament section(s) may have a higher electrical resistance than the electrode contacts (e.g. the cross-sectional area of the filament section perpendicular to a current flow direction may be smaller than the cross-sectional area of the electrode contacts perpendicular to a current flow direction, or the length of the filament section in a current flow direction may be greater than the length of the electrode contacts in a current flow direction). The filament section(s) may be in the form of a wire or a track.
[0021] The heating element e.g. the electrode contacts and/or the filament section may rest against/abut the lower pocket surface. As discussed above, a major portion of the surface area of one, plural, or each of the surfaces of the the heating element may not be directly attached (e.g. is unattached) to the wicking body. In some examples, greater than 50% such as greater than 60% or 70%, for example greater than 80% or 90% e.g. 100% of the surface area of the one, or each, surface of the heating element in the filament section (i.e. the area of a surface of the heating element between the first and second electrode contacts) is unattached to the wicking body. The surface area of one, plural or each of the surfaces of the heating element where the one or both of the electrode contacts are provided may additionally be unattached to the wicking body. In this way, less than 50% such as less than 40% or 30% for example less than 20% or 10% e.g. 0% of the surface area of a, plural, or each, surface of the filament section, electrode contact, or heating element adjacent a pocket surface (e.g. the lower pocket surface) is attached to the wicking body.
[0022] In some examples, the heating element may be retained in the pocket, for example, by retaining means and/or by the heating element forming an interference fit with the pocket, e.g. if the thickness and/or width of the heating element is such that it forms an interference fit with the height and/or width of the pocket, respectively. In this way, the frequency of instances of unintentional dislodging of the heating element from the pocket can be reduced. By way of example, where the pocket comprises an opening e.g. a slotted opening, the retaining means may be a plug partially or completely received in the opening such as to close the pocket. Such a plug may be received by, and retained in, the opening by forming an interference fit with the wicking body. Additionally, or alternatively, the retaining means may be one or more biasing elements configured to bias the heating element against one or more of the pocket surfaces, such that friction between the heating element and a pocket surface resists movement of the heating element within the pocket.
[0023] In some examples, the heating element has a longest dimension (length) which may extend between the first and second electrode contacts. The aforementioned filament section then extends in the length direction. The heating element may be mounted within the pocket such that its length direction is substantially parallel to the depth direction of the pocket into the wicking body. In this way, the heater assembly is configured such that the likelihood of the heating element becoming unintentionally dislodged from the pocket may be reduced by increasing the distance that the heating element would be required to move within the pocket in order to become dislodged (i.e. move out of the pocket).
[0024] In some examples, the heating element may be completely received within the pocket (i.e. having no portion of the heating element exposed externally of the wicking body).
[0025] In some examples, the heating element may be planar and comprise upper and lower planar heating element surfaces. The heating element may be mounted in the pocket such that its upper and lower planar heating element surfaces are parallel to the upper and lower pocket surfaces. In this way, the likelihood of the heating element becoming dislodged from the pocket may be reduced.
[0026] In some examples, the wicking body may further comprise one or more through holes extending therethrough. The through hole(s) may extend in a direction perpendicular to the depth direction of the pocket. For example, it/they may extend from an upper and/or lower external surface of the wicking body e.g. an upper or lower external surface of the cuboid wicking body/cuboid portion. In this way, the surface area of the wicking body may be increased and additionally the passage of air over surfaces of the wicking body can be modified. This can be used to control the interaction of the airflow with the heater assembly and/or to control the liquid (i.e. aerosol precursor) saturation of the wicking body.
[0027] Where the wicking body is porous, the through hole(s) may be distinguished from the pores of the wicking body by their size: the through hole(s) may be macroscopic, whereas the pores in the wicking body may be microscopic. By way of example, a through hole may have a largest dimension in a cross section parallel to a depth of the through hole that is greater than 0.2 mm, typically greater than 0.5 mm. In contrast, a pore in the wicking body may have a largest dimension in a cross section parallel to a depth of the pore that is less than 0.1 mm. Any through hole is preferably sized such that the heating element mounted in the pocket cannot be dislodged from the pocket via the through hole. In this way, any through hole does not increase the probability of the heating element being inadvertently dislodged from the pocket.
[0028] Additionally, or alternatively, the through hole(s) may be differentiated from pores in the wicking body by their geometry: the through hole(s) may have a constant cross-section along their length and/or extend in a straight line (i.e. have a linear longitudinal axis), whereas the pores in the wicking body may form tortuous passages through the wicking body, the tortuous passages having (typically highly) variable cross-sections along their length. For example, the tortuosity (arc-chord ratio) of a through hole may be less than about 1.5, typically less than 1.2, and the tortuosity (arc-chord ratio) of a pore may be greater than about 1.5
[0029] The one or more through holes may extend from an external surface of the wicking body to a pocket surface. In this way, the through hole(s) may provide a passage between an external surface of the wicking body (e.g. the upper and/or lower external surface of the wicking body) and a pocket surface. Such a passage can be used to provide an airflow and/or other components of the heater assembly into the pocket.
[0030] In some examples, a first through hole opens into the pocket at a position coincident with the first electrode contact. In this way, the heater assembly may be configured such that a first electrode can extend through the first through hole and into the pocket to contact the first electrode contact of the heating element. Thus, an electrical connection can be made to the heating element when it is mounted in the pocket such that it can be provided with power via the first electrode.
[0031] In some examples, the wicking body may further comprise a second through hole which opens into the pocket at a position coincident with the second electrode contact of the heating element. In this way, the heater assembly may be configured such that a second electrode can extend into the wicking body in order to contact the second electrode contact to form a second electrical connection to the heating element when it is mounted in the pocket.
[0032] The first and second through holes may each extend from the lower external surface of the wicking body e.g. from the lower external surface of the cuboid wicking body/cuboid portion of the wicking body.
[0033] The angle between the longitudinal axis of the first and/or second through hole and the depth direction of the pocket into the wicking body may be greater than or equal to 30 degrees, greater than or equal to 45 degrees, greater than equal to 60 degrees, or equal to 90 degrees. The closer the angle is to 90 degrees, the lower the likelihood of another component of the heater assembly extending through the first and/or second through hole to contact the heating element causing the heating element to be dislodged from the pocket.
[0034] In some examples, the wicking body may comprise one or more through holes extending from an external surface of the wicking body to another external surface of the wicking body. Additionally, or alternatively, the wicking body may comprise one or more through holes extending from an external surface of the wicking body to a pocket surface pocket, but which are configured not to receive an electrode, for example, by having a shape or size that does not allow it to receive an electrode intended for use with the heater assembly (e.g. having a non-linear longitudinal axis), or not aligning with an electrode contact of the heater. In this way, the airflow through the heater assembly and the saturation of the wicking body with liquid (i.e. aerosol precursor) can be controlled by the arrangement of said one or more through holes.
[0035] The heater assembly may further comprise the first electrode, the first electrode extending from an external surface (e.g. a lower external surface) of the wicking body into the pocket to contact the heating element.
[0036] In this way, the heater assembly may facilitate the heating element being positioned adjacent the wicking element without the heating element being attached, fastened, or bonded to the wicking body, but whilst still allowing an electrical connection to be made to the heating element from outside the wicking body, for example, for the purpose of providing power to the heating element. Accordingly, the heating element can expand to a different extend to the wicking body upon heating without the heating element and/or wicking body cracking, lifting or breaking.
[0037] In some examples, the first electrode may contact the first electrode contact on the heating element.
[0038] In some examples, the first electrode may extend from outside the wicking body into the pocket through the first through hole. In this way, an electrical connection to the heating element can be made using the first electrode without the first electrode extending through the pocket opening (i.e. the aperture through which the heating element may be mounted in the pocket).
[0039] In some examples, the heater assembly may comprise the second electrode, the second electrode extending from outside the wicking body into the pocket. In this way, two electrical connections may be made with the heating element from outside the heater assembly, facilitating the heating element forming part of a closed electrical circuit.
[0040] In some examples, the second electrode may extend from outside the wicking body into the pocket through the second through hole. In this way, an electrical connection to the heating element can be made using the second electrode without the second electrode extending through the pocket opening (i.e. the aperture through which the heating element may be mounted in the pocket). In some examples, the second electrode may contact the second electrode contact on the heating element.
[0041] In some examples, where the first electrode extends through the first through hole to contact the first electrode contact of the heating element (and, optionally, where the second electrode extends through the second through hole to contact the second electrode contact of the heating element), the electrode may bias a heating element surface that is opposite the electrode contact against a pocket surface. In this way, a frictional force generated between the pocket surface and the heating element surface may resist movement of the heating element within the pocket, thereby reducing the likelihood of the heating element becoming dislodged from the pocket. Moreover, such an arrangement can also provide a secure electrical connection of the electrode(s) to the heating element.
[0042] In some examples, the first and/or second electrode may be rigid, for example taking the form of an electrode pin. In this way, the electrode may exert a biasing force on the heating element rather than deforming.
[0043] In some examples, the first and/or second electrode may comprise a respective contact portion configured to contact the electrode contact of the heating element and a respective connection portion configured to be connected to a power source, for example a battery. Where the heater assembly is configured to be incorporated into a component of an aerosol generating apparatus that is couplable to a smoking substitute device containing a power source, the first and/or second electrode may be configured such as to connect to the power source via the connection portion(s) of the first and/or second electrodes when the component is coupled to the device.
[0044] In a second aspect, the present disclosure provides a kit of parts for forming a heater assembly of the first aspect, the kit of parts comprising: a wicking body comprising a pocket; and one or more heating elements, the pocket being configured to house any one of the one or more heating elements.
[0046] In some examples, each heating element within the kit of parts is configured to be mountable within said pocket such that said heating element is not attached to the wicking body. That is, the heating element may be mounted in the pocket such that it is not directly or indirectly joined, bonded, affixed, adhered and/or fastened to the wicking body.
[0047] In some examples, the kit of parts comprises a plurality of heating elements. The plurality of heating elements may differ from each other, for example, each heating element may have a different shape, a different composition, a different electrical resistance, a different thickness, a different number of filament sections, a different filament section length and/or a different filament section cross-sectional area to the other heating elements. In this way, each of the heating elements, on mounting in the pocket of the wicking body, may provide a heater assembly having one or more different performance characteristics (e.g. different vapour generation characteristics, different power consumption characteristics and/or aerosol-precursor residue generation characteristics).
[0048] In a third aspect, the present disclosure provides a method of assembling a heater assembly according to the first aspect, the method comprising the steps of: providing a wicking body comprising a pocket; providing a heating element; and positioning the heating element within the pocket.
[0050] In this way, the heating element may be positioned adjacent the wicking element without the heating element being attached, fastened, or bonded to the wicking body. Assembly of the heater assembly is simplified because an attachment, fastening or bonding step (e.g. a sintering step) may be omitted and fewer constraints are placed on the materials of, and manufacturing processes to provide, the wicking body and heating element, because they do not need to be able to be attached to each other.
[0051] In some examples, the step of providing a wicking body comprising a pocket may be conducted such that the wicking body and the pocket therein are formed in a single step. For example, where the wicking body is ceramic, a sintering process may be used to form the wicking body with the pocket. In this way, this step may involve fewer manufacturing processes. Alternatively, this step may comprise first providing a wicking body not having a pocket and subsequently providing the pocket in the wicking body e.g. via a machining step. In this way, the shape of the pocket may be controlled independently of controlling the shape of the wicking body (e.g. where the wicking body is formed by sintering, changing the shape of the pocket does not necessarily require changing the shape of the sintering tool for the wicking body).
[0052] The pocket may open to an external surface of the wicking body, i.e. the wicking body may comprise an opening on an external surface of the wicking body. The method may further comprise inserting the heating element into the pocket via the opening.
[0053] The method may further comprise inserting the heating element into the pocket via the opening such that the length of the heating element is substantially parallel to the depth direction of the pocket into the wicking body (i.e. the heating element may be inserted through the opening lengthways into the pocket).
[0054] The method may further comprise inserting the heating element into the pocket such that the heating element is completely received within the pocket (i.e. having no portion of the heating element protruding out of the pocket).
[0055] The method may further comprise retaining the heating element in the pocket, for example, by retaining means and/or by the heating element forming an interference fit with the pocket. By way of example, where the pocket comprises an opening e.g. a slotted opening, the retaining means may be a plug and the method may comprise partially or completely inserting the plug into the opening such as to close the pocket. Such a plug may be received by, and retained in, the opening by forming an interference fit with the wicking body.
[0056] The method may further comprise electrically connecting the heating element to one or more electrodes. In this way, the heating element can be provided with an electrical current to generate heat.
[0057] In some examples, where the wicking body comprises one or more through holes extending from an external surface of the wicking body into the pocket, the step of electrically connecting the heating element to one or more electrodes may comprise inserting respective electrodes through the one or more through holes to contact the heating element mounted in the pocket.
[0058] The method may further comprise biasing a heating element surface against a pocket surface using the one or more electrodes.
[0059] In a fourth aspect, the present disclosure provides an aerosol-generating component comprising a heater assembly according to the first aspect and a liquid storage portion.
[0061] In some examples, the component may comprise a component housing having an upstream portion and a downstream base portion. In further examples, the upstream portion and base portion may be integrally formed.
[0062] In some examples, the component may comprise an airflow path that extends from an air inlet to an outlet. The heater assembly is mounted in the airflow path. The air inlet may be provided in the base portion. The outlet may be provided in a mouthpiece of the upstream portion. Together the mouthpiece and a flow path through it to the outlet provide a delivery system operative to deliver an aerosol to a user In this respect, a user may draw fluid (e.g. air) into and along the airflow path by inhaling at the outlet (i.e. at the mouthpiece). The air flow path passes the heater assembly between the air inlet and the outlet. The heater assembly may be housed in a vaporising chamber. The vaporising chamber may form part of the airflow path.
[0063] In some examples, the airflow path may comprise a first portion extending from the air inlet towards the heater assembly. A second portion of the airflow path passes through the vaporising chamber and/or over/through/around the heating assembly e.g. over/around the lower external surface of the wicking body. The airflow path comprises a third portion extending from the heater assembly/vaporising chamber to the outlet. The third portion of the airflow path may comprise a conduit. The conduit may extend along the axial centre of the component downstream of the heater assembly. Thus, the second and third portions of the airflow path are downstream of the first portion of the airflow path.
[0064] In some examples, the component may comprise a storage portion (e.g. a tank) for housing the aerosol precursor (e.g. a liquid aerosol precursor). The storage portion may be defined by the downstream portion of the component.
[0065] In some examples, the aerosol precursor may comprise an e-liquid, for example, comprising a base liquid and e.g. nicotine. In further examples, the base liquid may include an aerosol former such as propylene glycol and/or vegetable glycerine.
[0066] In some examples, the conduit may extend through the tank with the conduit walls defining an inner region of the tank. In this respect, the tank may surround the conduit e.g. the tank may be annular.
[0067] In some examples, the tank may be defined by one or more tank side walls (e.g. laterally opposed first and second tank side walls) extending longitudinally from the mouthpiece. In some examples, the tank may further comprise opposing front and rear tank walls spaced by the laterally opposed first and second tank side walls. In some examples, the tank walls may be integrally formed with the mouthpiece and/or with the base portion.
[0068] In some examples, the distance between the first and second tank side walls may define a width of the tank. The distance between the front and rear tank walls may define a depth of the tank. The width of the tank may be greater than the depth of the tank.
[0069] In some examples, the length of the tank/component housing may be greater than the width of the tank/component housing. The depth of the tank/component housing may be smaller than each of the width and the length.
[0070] In some examples, the tank walls may be integrally formed and may additionally be integrally formed with the mouthpiece portion. In this way, the component may be easily manufactured using injection moulding.
[0071] In some examples, the tank may be transparent or translucent. In this way, the user may be able to observe a liquid level within the tank.
[0072] In some examples, the component housing may comprise a lower shell that at least partly forms the base portion of the component. The lower shell may overlap the tank walls. In some examples, the wicking body may form the base of the tank so that the aerosol precursor may be in contact with the wicking body.
[0073] In some examples, the wicking body may be in fluid communication with the tank. For example, the upper external surface of the wicking body e.g. the upper external surface of the cuboid wicking body or the upper external surface of the cuboid portion of the wicking body may face the tank.
[0074] The wicking body e.g. at least a portion of the lower external surface and/or at least a portion of at least one external side wall extending between the upper and lower external surfaces (in a height direction of the wicking body) may be exposed to airflow in the second portion of the airflow path. Through holes provided in the wicking body may allow at least some of the air flowing along the second portion of the airflow path to also pass through the wicking body via said through holes.
[0075] In some examples, the component may be an aerosol-generating (e.g. a smoking substitute) consumable i.e. in some embodiments the component may be a consumable component for engagement with the aerosol-generating (e.g. a smoking substitute) device to form the aerosol-generating (e.g. a smoking substitute) apparatus.
[0076] In some examples, the device may be configured to receive the consumable component. For example, the device and the consumable component may be configured to be physically coupled together. For example, the consumable component may be at least partially received in a recess of the device, such that there is snap engagement between the device and the consumable component. Alternatively, the device and the consumable component may be physically coupled together by screwing one onto the other, or through a bayonet fitting. Thus, the consumable component may comprise one or more engagement portions for engaging with the device.
[0077] In some examples, the device and consumable component may be coupled together by magnetic attraction. For example, the device may comprise one or more magnets whilst the component may comprise a magnet or ferrous metal plate/portion.
[0078] In other embodiments, the component may be integrally formed with the aerosol-generating (e.g. a smoking substitute) device to form the aerosol-generating (e.g. s smoking substitute) apparatus.
[0079] In such embodiments, the aerosol precursor (e.g. e-liquid) may be replenished by re-filling a tank that is integral with the device (rather than replacing the consumable). Access to the tank (for re-filling of the e-liquid) may be provided via e.g. an opening to the tank that is sealable with a closure (e.g. a cap).
[0080] In a fifth aspect, the present disclosure provides an aerosol-generating apparatus comprising a component according to the fourth aspect and a housing for receipt of at least a portion of the component.
[0081] The aerosol-generating apparatus may comprise a power source, for example a power source contained in the housing.
[0082] The component may be electrically coupled to the power source when the component is received in the housing.
[0083] The aerosol-generating apparatus may further comprise a controller configured to control the power delivered to the component from the power source. The controller may be contained in the housing.
[0084] In some examples, the aerosol-generating apparatus (e.g. a smoking substitute apparatus) may comprise an aerosol generating device (e.g. a smoking substitute device).
[0085] The aerosol-generating device may comprise one or more of the housing, the power source and the controller. Where the aerosol-generating device comprises the housing, the housing may contain one or more of the power source and the controller.
[0086] The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0087] Aspects, features, and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.
Fig. 1 is a block system diagram showing an example aerosol generating apparatus.
Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol generating apparatus is configured to generate aerosol from a liquid precursor.
Figs. 3A and 3B are schematic diagrams showing an example implementation of the apparatus of Fig. 2.
Fig. 4 is a schematic diagram showing an example heater assembly.
Fig. 5 is a schematic diagram showing an example kit of parts for forming a heater assembly.
Figs. 6A, 6B and 6C are schematic diagrams showing an example wicking body.
Fig. 7 is a schematic diagram showing an example heater assembly.
Fig. 8 is a schematic diagram showing a modification of the heater assembly in Fig. 7.
Fig. 9 is a schematic diagram showing an example component.
Fig. 10 is a flow chart showing an example method of assembling a heater assembly.
DETAILED DESCRIPTION OF EMBODIMENTS
[0088] Before describing several examples that implement the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and/or methods described herein could be embodied differently and/or be practiced or carried out in various alternative ways.
[0089] Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.
[0090] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.
[0091] All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.
[0092] The use of the term "a" or "an" in the claims and/or the specification may mean "one," as well as "one or more," "at least one," and "one or more than one." As such, the terms "a," "an," and "the," as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.
[0093] The use of the term "or" in the present disclosure (including the claims) is used to mean an inclusive "and/or" unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition "A or B" is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
[0094] As used in this specification and claim(s), the words "comprising, "having," "including," or "containing" (and any forms thereof, such as "comprise" and "comprises," "have" and "has," "includes" and "include," or "contains" and "contain," respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
[0095] Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s).
[0096] Moreover, this also applies to the phrase "in one embodiment," "according to an embodiment," and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an,' 'one,' or 'some' embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.
[0097] The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably:
As used herein, an "aerosol generating apparatus" (or "electronic(e)-cigarette") may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally/alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and/or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and/or an airflow sensor.
[0098] Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an "activation" of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength/duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).
[0099] The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.
[0100] As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to/include a vapour. An aerosol may include one or more components of the precursor.
[0101] As used herein, a "precursor" may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and/or glycerine. The term "flavouring" may refer to a component that provides a taste and/or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.
[0102] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.
[0103] As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.
[0104] As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.
[0105] As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.
[0106] As used herein, a "puff" (or "inhale" or "draw") by a user may refer to expansion of lungs and/or oral cavity of a user to create a pressure reduction that induces flow through the flow path.
[0107] As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heater assembly / vaporiser or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol generating apparatus.
[0108] As used herein, a "heater assembly" may refer to an arrangement of one or more heating elements, each of which is operable to aerosolise a precursor once heated. The one or more heating elements may be electrically resistive to produce heat from the flow of electrical current therethrough. The one or more heating elements may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.
[0109] As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. With liquid or gel implementations of the precursor, e.g. an e-liquid, the consumable may be referred to as a "capsule" or a "pod" or an "e-liquid consumable". The capsule/pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.
[0110] As used herein "heat-not-burn" (or "HNB" or "heated precursor") may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).
[0111] As used herein a "principal axis" may refer to axes passing through the centre of mass or volume of a feature or element of the present disclosure and being an axis of rotational symmetry of that feature or element and/or lying on a plane of symmetry of that feature or element.. As used herein, a "longitudinal axis" may referto the longest dimension of a feature or element of the present disclosure along a principal axis thereof.
[0112] As used herein, "downstream" in relation to the airflow path is intended to referto the direction towards the outlet/mouthpiece portion. Conversely, as used herein, "upstream" is intended to refer to the direction towards the air inlet.
[0113] As used herein, "upper", "lower", "above" or "below" are intended to refer to the component when in an upright/vertical orientation i.e. with elongate (longitudinal/length) axis of the component vertically aligned and with the mouthpiece vertically uppermost.
[0114] Referring to Fig. 1, an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 (e.g. a heater assembly) that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and/or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.
[0115] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.
[0116] Fig. 2 shows an implementation of the apparatus 1 of Fig. 1, where the aerosol generating apparatus 1 is configured to generate aerosol from a liquid precursor.
[0118] In this example, the body 10 includes the power supply 4. The body may additionally include any one or more of electrical circuitry 12, a memory 14, a wireless interface 16, one or more other components 18.
[0119] The electrical circuitry 12 may include a processing resource for controlling one or more operations of the body 10 and consumable 30, e.g. based on instructions stored in the memory 14.
[0120] The wireless interface 16 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.
[0121] The other component(s) 18 may include one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 3).
[0122] The consumable 30 includes a storage portion implemented here as a tank 32 which stores the liquid precursor 6 (e.g. e-liquid). The consumable 30 also includes a heater assembly34, one or more air inlets 36, and a mouthpiece 38. The consumable 30 may include one or more other components 40.
[0123] The body 10 and consumable 30 may each include a respective electrical interface (not shown) to provide an electrical connection between one or more components of the body 10 with one or more components of the consumable 30. In this way, electrical power can be supplied to components (e.g. the heater assembly 34) of the consumable 30, without the consumable 30 needing to have its own power supply.
[0124] In use, a user may activate the aerosol generating apparatus 1 when inhaling through the mouthpiece 38, i.e. when performing a puff. The puff, performed by the user, may initiate a flow through a flow path in the consumable 30 which extends from the air inlet(s) 34 to the mouthpiece 38 via a region in proximity to the heater assembly 34.
[0125] Activation of the aerosol generating apparatus 1 may be initiated, for example, by an airflow sensor in the body 10 which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the mouthpiece), or by actuation of an actuator included in the body 10. Upon activation, the electrical circuitry 12 (e.g. under control of the processing resource) may supply electrical energy from the power supply 2 to the heater assembly 34 which may cause the heater assembly 34to heat liquid precursor 6 drawn from the tank 32 to produce an aerosol which is carried by the flow out of the mouthpiece 38.
[0126] In some examples, the heater assembly34 may include a heating filament and a wick, wherein a first portion of the wick extends into the tank 32 in order to draw liquid precursor 6 out from the tank 32. The heating filament may be configured to heat up liquid precursor 6 drawn out of the tank 32 by the wick to produce the aerosol.
[0127] In this example, the aerosol generating unit 4 is provided by the above-described heater assembly34 and the delivery system 8 is provided by the above-described flow path and mouthpiece 38.
[0128] In variant embodiments (not shown), any one or more of the precursor 6, heating assembly 34, air inlet(s) 36 and mouthpiece 38, may be included in the body 10. For example, the mouthpiece 36 may be included in the body 10 with the precursor 6 and heating system 32 arranged as a separable cartomizer.
[0129] Figs. 3a and 3b show an example implementation of the aerosol generating device 1 of Fig. 2. In this example, the consumable 30 is implemented as a capsule/pod, which is shown in Fig. 3A as being physically coupled to the body 10, and is shown in Fig. 3B as being decoupled from the body 10.
[0130] In this example, the body 10 and the consumable 30 are configured to be physically coupled together by pushing the consumable 30 into an aperture in a top end 11 the body 10, with the consumable 30 being retained in the aperture via an interference fit.
[0131] In other examples (not shown), the body 10 and the consumable 30 could be physically coupled together in other ways, e.g. by screwing one onto the other, through a bayonet fitting, or through a snap engagement mechanism, for example.
[0133] The body 10 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a light 15, which may e.g. be configured to illuminate when the apparatus 1 is activated. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.
[0134] In this example, the consumable 30 has an opaque cap 31, a translucent tank 32 and a translucent window 33. When the consumable 30 is physically coupled to the body 10 as shown in Fig. 3A, only the cap 31 and window 33 can be seen, with the tank 32 being obscured from view by the body 10. The body 10 includes a slot 15 to accommodate the window 33. The window 33 is configured to allow the amount of liquid precursor 6 in the tank 32 to be visually assessed, even when the consumable 30 is physically coupled to the body 10.
[0135] Referring to Fig. 4, a heater assembly 100, which may be implemented in any of the preceding examples, comprises a wicking body 110, the wicking body 110 comprising a pocket 111, and a heating element 140 mounted within the pocket 111.
[0136] The wicking body 110 in Fig. 4 has a cuboidal shape (although it can be appreciated that other geometries can also be used). Provided on an external sidewall of the wicking body 110 is an opening 112 that defines the entrance to the pocket 111 and opens the pocket 111 to the external sidewall of the wicking body 110. The opening is an elongate (i.e. slotted) opening having a substantially rectangular profile, with the length direction of the opening 112 being parallel to the width direction of the cuboid wicking body.
[0137] The pocket 111 is a recess in the wicking body 110 that has a depth direction extending away from its opening 112 (i.e. the dimension substantially perpendicular to the sidewall of the wicking body 110 where the opening 112 is provided. The depth direction is along the longitudinal axis of the pocket 111. The pocket 111 extends in the depth direction to an end pocket surface opposing the opening. The end pocket surface is an internal surface of the wicking body 110. In Fig. 4, the depth of the pocket 111 is greater than the dimensions of the opening 112 along the other principal axes of the pocket 111, i.e. the height of the opening 112 (the vertical direction, parallel to the height of the wicking body 110, in Fig. 4) and the length of the opening 112 (the horizontal direction parallel to the sidewall containing the opening 112, parallel to the width of the wicking body 110, in Fig. 4). In this way, the pocket provides a hollow space inside the wicking body. A heating element 140 can be mounted in the pocket 111 by inserting it through the opening 112 into the pocket 111.
[0138] The pocket 111 is a blind hole and is thus fully enclosed by the wicking body 110 other than at its opening i.e. the pocket 111 is defined by internal surfaces of the wicking body 110 along its depth. In addition to the end pocket surface , in Fig. 4 the rectangular cross-section of the pocket 111 transverse to its depth means that the pocket 111 also has an upper pocket surface that is planar, and an opposing lower pocket surface that is also planar. The upper and lower pocket surfaces are spaced apart by opposing side pocket surfaces. The side pocket surfaces are also substantially planar, lie perpendicular to the upper and lower surfaces, and extend from the opening 112 to the end pocket surface. The spacing between the upper and lower pocket surfaces defines the pocket's height, and the spacing between the opposing side pocket surfaces define the pocket's width. As with the opening 112, in Fig. 4, the width of the pocket 111 is greater than its height.
[0139] The heater assembly further comprises the heating element 140. Typically, the wicking body 110 is porous, such that it is able to convey aerosol precursor liquid to the heating element 140 by capillary action, where the aerosol precursor liquid is vaporised. In Fig. 4 the heating element comprises a first electrical contact 141a and a second electrical contact 141b at opposite ends of the longitudinal axis of the heating element 140, each electrical contact 141a-b configured to provide an electrical interface for an electrode to connect to the heating element 140 in order to be able to provide power to the heating element 140. Extending between the electrical contacts 141a-b is a filament section 142 (e.g. a wire or track). When the heater assembly is being operated, an electrical current (typically DC) is provided to the electrical contacts 141a-b that then flows along the length of the filament section 142. Because the filament section 142 has a reduced cross-sectional area perpendicular to the current flow direction (e.g. a direction substantially parallel to the longitudinal axis of the heating element 140 in the case of Fig. 4), the electrical resistance of the filament section 142 is greater than that of the electrode contacts, the filament section 142 is heated to a higher temperature than the electrode contacts on passing a current through the heating element 140 and is therefore provides the majority of the heat for heating and vaporising the aerosol precursor liquid. The heating element 140 in Fig. 4 is substantially planar, that is, its thickness (i.e. the vertical direction in Fig. 4) is substantially less than both its length and width.
[0140] In Fig. 4, the heating element 140 is mounted within the pocket (i.e. is at least partially contained within the pocket 111) through the opening 112 such that the length of the heating element 140 is aligned with the depth direction of the pocket 111 into the wicking body 110. The length, width, and thickness of the heating element 140 relative to the depth, width, and height, respectively, of the pocket 111 in Fig. 4 are such that the heating element 140 is capable of being (and is, in the case of Fig. 4) mounted in the pocket 111 such that the heating element 140 is completely received within the pocket 111 (i.e. all the dimensions of the heating element 140 are less than the respective dimensions of the pocket 111). The upper and lower planar heating element surfaces are covered by the upper and lower surfaces of the wicking body 110, respectively. Because the length of the heating element 140 (i.e. the longest dimension of the heating element along a principal axis thereof) is parallel to the depth direction of the pocket 111 away from the opening 112 through which the heating element 140 is inserted to mount it within the pocket 111, the distance that the heating element 140 would need to move to become dislodged from the pocket 111 (i.e. for no portion of the heating element 140 to be left contained within the pocket 111) is maximised. Accordingly, the likelihood of the heating element 140 becoming dislodged from the pocket 111 is low compared to configurations where the longest dimension of the heating element 140 is not aligned with the depth direction of the pocket 111 from the opening 112.
[0141] Because the heating element 140 is mounted in the pocket 111 such that the likelihood of the heating element 140 becoming dislodged from the pocket 111 is low, it is possible not to (directly or indirectly) attach the heating element 140 to the wicking body 110 and still position them in contact with one another. That is, the heating element 140 is mounted in the pocket such that it is not joined, bonded, affixed, adhered or fastened to the wicking body 110 (i.e. the heating element 140 is movable relative to the wicking body 110. The lack of (direct) attachment of the heating element 140 to the wicking body 110 means that where the coefficients of thermal expansion of these components differ (as is typical, since they are normally manufactured from different materials / have different compositions), the differential expansion of these components does not give rise to interfacial stresses between these components, since there is no fixed interface between them. Thus, the cracking, breaking and/or lifting of the heating element 140 that may occur where the heating element 140 is bonded to the wicking body 110 can be avoided.
[0142] Fig. 5 illustrates a kit of parts for forming a heater assembly 100, which may then be implemented in any of the preceding examples. The kit comprises a wicking body 110 comprising a pocket 111 configured to have a heating element 140, 240 mounted therein, and a plurality of heating elements 140, 240, each heating element configured to be mountable within the pocket 111.
[0143] The wicking body 110 in Fig. 5 is the same as that illustrated in, and described above in relation to, Fig. 4. Accordingly, reference can be made back to that preceding description of the wicking body 111.
[0144] The kit of parts in Fig. 5 comprises a first heating element 140 and a second heating element 240. The first heating element 140 in Fig. 5 is the same as that illustrated in, and described above in relation to, Fig. 4. Accordingly, reference can be made back that preceding description of the heating element 140. The second heating element 240 in Fig. 5 is similar to the first heating element 140 but differs in the geometry of the filament section 242. Alike features are annotated with equivalent reference numbers (e.g. 141 and 241). Reference may be made back to the description of Fig. 4 for alike features.
[0145] In the first heating element 140, the filament section 142 is substantially linear between the first and second electrode contacts 141a-b, whereas in the second heating element 240, the filament section 242 is contorted such that the length of the filament section 242 is greater than the straight-line distance between the first and second electrode contacts 242a-b. Accordingly, where the resistivity of the material used in the first and second heating elements 140, 240 is the same, the resistance of the filament section 242 in the second heating element 240 is greater than the resistance of the filament section 142 in the first heating element 140. The surface area of the filament section 242 is also increased compared to that of the first heating element 140. Additionally, the portion of the wicking body 110 that is adjacent a portion of the heating element 240 is increased with the second heating element 240 compared to the first heating element 140, such that in use, more uniform heating of the wicking body 140, and the liquid aerosol precursor it contains, is provided. Specifically, a greater proportion of the upper and lower pocket surfaces are adjacent the heating element 240. Thus, the different heating elements 140, 240 provided within the kit have different performance characteristics and thus provide the resulting heater assemblies with different performance characteristics.
[0146] The differing geometries of the two heating elements 140, 240 in Fig. 5 is just one example of how the plurality of heating elements contained within kits of parts according to the present disclosure can differ from each other in order to provide the heater assembly 100 with different performance characteristics. By way of example, the plurality of heating elements 140, 240 may also differ from each other in their compositions, electrical resistances, thickness, number of filament sections, filament section lengths, and/or filament section cross-sectional areas. The different performance characteristic provided by such heating elements 140, 240 may include different vapour generation characteristics, different power consumption characteristics and/or different aerosol-precursor residue generation characteristics.
[0147] By mounting the heating elements 140, 240 in the pocket 111 such that they are not attached to the wicking body 110 (i.e. not directly and/or indirectly joined, bonded, affixed, adhered, or fastened to the wicking body), one heating element 140, 240, mounted in the pocket 111 can be dismounted and replaced with a different heating element 140, 240. This facilitates the easy and quick interchanging of heating elements 140, 240 within the heater assembly 100, thereby allowing for efficient testing and use of different heating elements 140, 240 to obtain different performance characteristics. Moreover, replacement of a heating element 140, 240, for example, in the instance that it malfunctions, is made easier since no detachment and reattachment processes are required.
[0148] Figs. 6A - 6C illustrate a second wicking body 211 that is similar to the wicking body 110 illustrated in, and discussed in relation to, Fig. 4. Alike features are annotated with equivalent reference numbers (e.g. 110 and 210). Reference may be made back to the description of Fig. 4 for alike features.
[0149] Fig. 6A provides a perspective schematic of the second wicking body 210. Fig. 6B provides a cross-sectional schematic along a vertical plane through the wicking body 210 that lies on the longitudinal axis of the wicking body 210. Fig. 6C provides a plan view of the wicking body 210.
[0150] The second wicking body 210 differs from that in Fig. 4 in that the wicking body 210 further comprises two through holes 213a-b extending therethrough. As illustrated in Figs. 6A - 6C, the first through hole 213a extends from the lower external surface of the wicking body 210to the lower pocket surface. That is, the first through hole 213a provides a passage between the lower external surface of the wicking body 210 and the pocket 211. The second through hole 213b in Figs. 6A - 6B similarly extends from the lower external surface (first surface) of the wicking body 210 to the lower pocket surface. First and second apertures 214a-b are provided on the lower pocket surface where the first and second through holes 213a-b coincide with the pocket 211.
[0151] In the case of the wicking body 210 in Figs. 6A - 6C, the through-holes 213a-b are cylindrical in form, and accordingly have linear longitudinal axes that extend vertically in Fig. 6A and are perpendicular to the lower external surface that the through holes 213a-b extend from. The pocket 211 in the second wicking body 210 extends from an opening 212 that is provided on a second external surface of the wicking body, the second external surface being a sidewall of the wicking body 210. The second external surface lies at an angle of approximately 90 degrees to the lower external surface and accordingly, the longitudinal axes of the through holes 213a-b are at an angle of 90 degrees to the depth direction of the pocket 211. It can also be appreciated that the through holes 213a-b are sized such that a heating element such as those illustrated in Figs. 4 and 5 cannot be dislodged from the pocket 211 via either of the through holes 213a-b.
[0152] The first through hole 213a and second through hole 213b are spaced apart from each other in a direction parallel to the depth direction of the pocket 211, with the first through hole 213a disposed further from the opening 212 than the second through hole 213b.
[0153] Fig. 7 illustrates a schematic of a heater assembly according to the present disclosure. The heater assembly in Fig. 7 comprises the second wicking body 210 discussed in relation to Figs. 6A - 6C, the first heating element 140 discussed in relation to Fig. 4, two electrodes 180a-b and retaining means in the form of a plug 160.
[0154] Firstly, from Fig. 7 it can be appreciated that when the heating element 140 is mounted within the pocket 211, the geometry of the heating element 140 and the positioning of the through holes 213a-b on the lower external surface of the wicking body 210 are such that the first and second electrode contacts 141a-b of the heating element 140 can be simultaneously aligned with the first and second through holes 213a-b, respectively. Here, "simultaneously aligned" may be understood to mean that the first electrode contact 141a of the heating element 140 is coincident with the first aperture 214a along the longitudinal axis of the first through hole 213a, and also that the second electrode contact 141b of the heating element 140 is coincident with the second aperture 214b along the longitudinal axis of the second through hole 213b.
[0155] This arrangement then means that first and second electrodes 180a-b of the heater assembly can be inserted into the pocket 211 through the first and second through holes 213a-b, respectively, such that the electrodes 180a-b then contact the first and second electrode contacts 141a, 141b of the heating element 140. Accordingly, an electrical connection can be provided between portions of the first and second electrodes 180a, 180b that reside outside the wicking body 210 and the heating element 140 mounted completely inside the pocket 211 of the wicking body 210. This electrical connection then allows power to be delivered to the heating element 140 via the electrodes 180a-b in order to generate the heat required to vaporise the liquid aerosol precursor.
[0156] Moreover, the contact between the first and second electrodes 180a-b and the heating element 140 allows the electrodes 180a-b to exert a force on the heating element 140 (in the case of the heater assembly in Fig. 7, in the vertical direction) that moves the heating element 140 within the pocket 211 such that the upper heating element surface is in contact with the upper pocket surface. The electrodes 180a-b exert a biasing force on the heating element 140 when the upper heating element surface is in contact with the upper pocket surface such that friction between said surfaces of the heating element 140 and the pocket 211 resists movement of the heating element 140 within the pocket 211. Accordingly, the likelihood of the heating element 140 dislodging from the pocket 211 is reduced. This biasing force between the electrodes 180a-b and the heating element 140 (specifically the electrode contacts 141a-b of the heating element 140) and the friction between the upper heating element surface and the upper pocket surface also provides a secure electrical connection between the electrodes 180a-b and the respective electrode contacts 141a-b because this acts to resist the heating element 140 moving such as to break the electrical contact between these components.
[0157] In order to further reduce the likelihood of the heating element 140 being inadvertently dislodged from the pocket (e.g. due to movement of an aerosol generating apparatus containing the heater assembly), the heater assembly in Fig. 7 further comprises a plug 160 that is partially received in the opening 212 of the pocket 211. The plug 160 forms an interference fit with the opening 212 such as to be securely, but detachably, mounted to the wicking body 210 and by closing the opening 212, prevents the heating element 140 from moving out of the pocket 211 even if the heating element 140 were to move within the pocket 211. In the case that the heating element 140 needs to be removed from the pocket 211 (e.g. for replacement with a different heating element 140 or for cleaning), the plug 160 is detachably mounted to the wicking body 210 and thus can be removed from the opening 212 to allow the heating element 140 to be removed (provided, in the case of Fig. 7, that the biasing force of the electrodes 180a-b on the heating element 140 is also released).
[0158] Fig. 8 illustrates a schematic of a heater assembly according to the present disclosure that is a modification of the heater assembly in Fig. 7. The heating element 140, electrodes 180a-b, and plug 160 in Fig. 8 are the same as those illustrated in Fig. 7 and so reference can be made back to the preceding description of Fig. 7 in relation to these components. The wicking body 310 in Fig. 8 is similar to the wicking body 210 illustrated in Fig. 7 and so reference can be made back to the preceding description of Fig. 7 in relation to the wicking body 210; however, the wicking body 310 in Fig. 8 also includes a plurality of further through holes 315, 316 in addition to the through holes 313a-b that are also present in the wicking body 210 of Fig. 7. Alike features of the wicking body 310 are annotated with equivalent reference numbers (e.g. 211 and 311).
[0159] In addition to the first and second through holes 313a-b through the wicking body 310 through which the first and second electrodes 180a-b respectively extend into the pocket 311, the wicking body 310 in Fig. 8 further comprises two through holes 315 extending from an external surface of the wicking body 310 to another external surface of the wicking body 310. Specifically, in the example in Fig. 8, through holes 315 are provided in the wicking body 310 above the filament section 142 of the heating element 140 and extend between opposite sidewalls of the wicking body 310, i.e. extending horizontally (i.e. in the width direction of the wicking body through the wicking body 310 in Fig. 8. Through holes 315 can modify the airflow through the heater assembly 300 and the saturation of the wicking body 310 with liquid. In particular, through holes 315 may allow liquid above the heating element 140 within the wicking body 310, which is heated by heat rising from the heating element 140, to be vaporised at the surface provided inside through holes 315. This vapour can subsequently flow out from the wicking body 310 through holes 315. It can be appreciated that controlling the position of these through holes 315 in the wicking body 310 allows the vaporisation and saturation characteristics of the heater assembly to be controlled.
[0160] Furthermore, the wicking body 310 in Fig. 8 further comprises an additional through hole 316 extending from an external lower surface of the wicking body 310 to the lower surface of the pocket 311. This additional through hole 316 to the pocket 311 does not receive an electrode 180a-b, but instead allows the flowrate of air to the heating element 140 within the pocket 311 to be increased compared to the heater assembly in Fig. 7. Increasing the airflow to the heating element 140 in this manner may change the vapor generation characteristics of the heater assembly. In Fig. 8 the additional through hole 316 is provided vertically below the filament section 142 of the heating element 140, however it can be appreciated that different positions could be employed in order to provide heater assemblies with differing vaporisation and saturation characteristics.
[0161] Fig. 9 is a schematic view of an example of the component 430 described above. The component 430 comprises a tank 406 for storing e-liquid, a mouthpiece portion 436 and a conduit 440 extending along a longitudinal axis of the component 404. In the illustrated embodiment the conduit 440 is in the form of a tube having a substantially circular transverse cross-section (i.e. transverse to the longitudinal axis). The tank 406 surrounds the conduit 440, such that the conduit 440 extends centrally through the tank 406.
[0162] A component housing 442 defines an outer casing of the component 404. The component housing 442 extends from a lower shell 458 at the lower end 411 of the component 404 to the mouthpiece portion 436 at the upper end 409 of the component 404. The component housing may define a lip or shoulder which acts as a stop feature when the component 404 is inserted into the device 10 (i.e. by contact with an upper edge of the device 10).
[0163] The tank 406, the conduit 440 and the mouthpiece portion 436 are integrally formed with each other so as to form a single unitary component and may e.g. be formed by way of an injection moulding process. Such a component may be formed of a thermoplastic material.
[0164] The mouthpiece portion 436 comprises a mouthpiece aperture 448 defining an outlet of the conduit 440. The heater assembly 432 is downstream of the inlet 434 of the component 404 and is fluidly connected to the mouthpiece aperture 448 (i.e. outlet) by the conduit 440.
[0166] The heater assembly 432 forms the base of the tank 406 so that the aerosol precursor is in contact with the wicking and liquid aerosol precursor can move axially into the wicking body.
[0167] The aerosol precursor is heated by the heating element (when activated e.g. by detection of inhalation), which causes the aerosol precursor to be vaporised and to be entrained in air flowing past the wicking body. This vaporised liquid may cool to form an aerosol in the conduit 440, which may then be inhaled by a user.
[0168] The lower shell 458 of the component housing 442 has an opening that accommodates the electrical interface 419 of the consumable component 402 comprising two electrical contacts 436a, 436b that are electrically connected to the heater track. In this way, when the consumable component 404 is engaged with the device 402, power can be supplied from the power source 418 of the device to the heating element.
[0169] Fig. 10 is a flowchart illustrating a method of assembling a heater assembly for an aerosol generating apparatus, for example, one of the heater assemblies illustrated in Figs. 1, 7 and 8. The method may use a kit of parts such as that illustrated in Fig. 2.
[0170] Step S100 comprises providing a wicking body, that wicking body comprising a pocket. The pocket is configured to have a heating element mounted therein, e.g. by having an opening on an external surface of the wicking body through which a heating element can be inserted into the pocket. Typically, the wicking body is formed from a sintered ceramic material such that the wicking body provided at step S100 can be formed in a single sintering step by using a mould for the sintering process that provides the defines the shape of both the wicking body and the pocket . Alternatively, the pocket may be provided after initially forming the wicking body, e.g. by a machining step.
[0171] Step S200 comprises providing a heating element. The heating element is configured to be mountable within the pocket of the wicking body. Typically, the heating element comprises two electrode contacts to facilitate the connection of the heating element to a power source and a filament section extending between the electrode contacts. In order for the heating element to be mountable within the pocket, it typically has smaller width and thickness dimensions than the width and height of the pocket (assuming the heating element is to be inserted into the depth of the pocket along its longitudinal axis).
[0172] Although in Figure 10 step S200 is shown sequentially after step S100, it can be appreciated that the ordering of these two steps may be inverted, or that they may be conducted in parallel with one another.
[0173] At Step S300, the heating element is mounted within the pocket of the wicking body. As discussed above in relation to step S200, it is typical for the length of the heating element to be parallel to the depth direction of the pocket when mounted in the pocket. Accordingly, the heating element can be mounted in the pocket of the wicking body by inserting it lengthways through the pocket opening. The step of mounting the heating element within the pocket may allow a step of attaching the heating element to the wicking body to be omitted from the method of providing a heater assembly. However, where the heating element is not attached to the wicking body, then the step of mounting the heating element within the pocket may further comprise retaining the heating element in the pocket, for example by the heating element forming an interference fit with the pocket or applying retaining means to the wicking body or heating element. The mounting of the heating element may be such that that the heating element is completely received within the pocket (i.e. having no portion of the heating element protruding out of the pocket).
[0174] Although not illustrated in Figure 10, the method can further comprise retaining the heating element in the pocket, for example, by retaining means and/or by the heating element forming an interference fit with the pocket. In the case of the heater assemblies in Figs. 7 and 8, the retaining means is a plug and the method of assembling such heater assemblies comprises partially inserting the plug into the opening such as to close the pocket. The plugs are be received by, and retained in, the opening by forming an interference fit with the wicking body.
[0175] The method may further comprise electrically connecting the heating element to one or more electrodes. In the heater assemblies in Figs. 7 and 8, the respective wicking bodies each comprise two through holes extending from an external surface of the wicking body into the pocket, and thus the step of electrically connecting the heating element to the two electrodes comprises inserting respective electrodes through the two through holes to contact the heating element mounted in the pocket. In Figs. 7 and 8, the upper heating element surface is being biased against the upper pocket surface using the electrodes.
1. A heater assembly (34, 100, 200, 300 ,432) for an aerosol-generating apparatus (1),
the heater assembly (34, 100, 200, 300 ,432) comprising:
a wicking body (110, 210, 310) comprising a pocket (111, 211, 311); and
a heating element (140, 240) mounted within said pocket (111, 211, 311).
2. The heater assembly (34, 100, 200, 300 ,432) according to claim 1, wherein:
the heating element (140, 240) comprises one or more surfaces; and
a major portion of the surface area of each surface of the heating element (140, 240) is unattached to the wicking body (110, 210, 310).
3. The heater assembly (34, 100, 200, 300 ,432) according to any preceding claim, wherein
the heating element (140, 240) is not exposed externally of the wicking body (110,
210, 310).
4. The heater assembly (34, 100, 200, 300 ,432) according to any preceding claim, wherein
the pocket (111, 211, 311) extends from an opening (112, 212, 312) on an external
surface of the wicking body (110, 210, 310).
5. The heater assembly (34, 100, 200, 300 ,432) according to claim 4, wherein:
the pocket (111, 211, 311) extends to a depth away from the opening (112, 212, 312); and
the depth is greater than any dimension of the opening (112, 212, 312).
6. The heater assembly (34, 100, 200, 300 ,432) according to claim 5, wherein the heating
element (140, 240) is mounted within the pocket (111, 211, 311) such that the longest
dimension along a principal axis of the heating element (140, 240) is substantially
parallel to the depth direction of the pocket (111, 211, 311) into the wicking body
(110, 210, 310).
7. The heater assembly (34, 100, 200, 300 ,432) according to any preceding claim, wherein
the wicking body (110, 210, 310) comprises one or more through holes (213a, 213b,
313a, 313b, 315, 316) extending from an external surface of the wicking body (110,
210, 310) into the pocket (111, 211, 311).
8. The heater assembly (34, 100, 200, 300 ,432) according to claim 7, wherein:
the heating element (140, 240) comprises an electrode contact (141a, 141b, 241a, 241b);
the or each through hole (213a, 213b, 313a, 313b, 315, 316) opens into the pocket (111, 211, 311) coincident with the electrode contact (141a, 141b, 241a, 241b).
9. The heater assembly (34, 100, 200, 300 ,432) according to claim 8, further comprising
an electrode (180a, 180b) extending through the or each through hole (213a, 213b,
313a, 313b, 315, 316) to contact the electrode contact (141a, 141b, 241a, 241b).
10. The heater assembly (34, 100, 200, 300 ,432) according to any one of the preceding
claims, wherein the coefficient of thermal expansion of the heating element (140,
240) is 50% or more greater than the coefficient of thermal expansion of the wicking
body (110, 210, 310).
11. A kit of parts for forming a heater assembly (34, 100, 200, 300 ,432) for an aerosol
generating apparatus, the kit of parts comprising:
a wicking body (110, 210, 310) comprising a pocket (111, 211, 311); and
one or more heating elements (140, 240),
the pocket (111, 211, 311) being configured to house any one of the one or more heating elements (140, 240).12. A method of assembling a heater assembly (34, 100, 200, 300 ,432) for an aerosol generating
apparatus, the method comprising the steps of:
providing a wicking body (110, 210, 310) comprising a pocket (111, 211, 311);
providing a heating element (140, 240); and
mounting the heating element (140, 240) within the pocket (111, 211, 311).
13. A method according to claim 12, comprising inserting an electrode (180a, 180b) through
a through hole (213a, 213b, 313a, 313b, 315, 316) in the wicking body (110, 210, 310)
to contact an electrode contact (141a, 141b, 241a, 241b) of the heating element (140,
240).
14. An aerosol-generating component (430) comprising a heater assembly (34, 100, 200,
300 ,432) according to any of claims 1 to 10 and a liquid storage portion.
15. An aerosol-generating apparatus (1) comprising a component (430) according to claim
14 and a housing (442) for receipt of at least a portion of the component (430).