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BR-112021008572-B1 - Atomizer for an electrically heated aerosol generation system, electrically heated aerosol generator system, and cartridge for an aerosol generator system.

BR112021008572B1BR 112021008572 B1BR112021008572 B1BR 112021008572B1BR-112021008572-B1

Abstract

ATOMIZER AND AEROSOL GENERATING SYSTEM COMPRISING AN ATOMIZER. The present invention relates to an atomizer for an electrically heated aerosol generating system, comprising: an atomizer housing (31) defining an air inlet (16) and an air outlet (28), a reservoir portion for containing an aerosol-forming substrate in a condensed form, an airflow passage (22) extending in a longitudinal direction between the air inlet and the air outlet, the atomizer housing defining the reservoir portion and the airflow passage, and a flat fluid-permeable heating element (32) positioned between the airflow passage and the reservoir such that one side of the flat fluid-permeable heating element is in fluidic communication with the airflow passage and an opposite side of the flat fluid-permeable heating element is in fluidic communication with liquid in the reservoir (45), wherein the flat fluid-permeable heating element extends in the longitudinal direction.

Inventors

  • ALI MURAT SAYGILI

Assignees

  • PHILIP MORRIS PRODUCTS S.A

Dates

Publication Date
20260310
Application Date
20191206
Priority Date
20181207

Claims (19)

  1. 1. Atomizer for an electrically heated aerosol generation system, comprising: an atomizer housing (31, 60) defining an air inlet (16, 67) and an air outlet (28, 68), a reservoir portion (45, 66) for containing a liquid aerosol forming substrate, an airflow passage (22, 63) extending in a longitudinal direction between the air inlet (16, 67) and the air outlet (28, 68), the atomizer housing (31, 60) defining the reservoir portion (45, 66) and the airflow passage (22, 63), a flat fluid-permeable heating element (32, 50) positioned between the airflow passage (22, 63) and the reservoir portion (45, 66) such that one side of the fluid-permeable heating element plane (32, 50) is in fluid communication with the air flow passage (22, 63) and an opposite side of the plane fluid permeable heating element (32, 50) is in fluid communication with liquid in the reservoir portion (45, 66), where the plane fluid permeable heating element (32, 50) extends in the longitudinal direction; a heater mounting portion (39, 52) in which the flat fluid-permeable heating element (32, 50) is supported, the heater mounting portion (39, 52) being received in the atomizer housing (31, 60) and positioned between the reservoir portion (45, 66) and the airflow passage (22, 63) so that the fluid can pass from the reservoir portion (45, 66) to the airflow passage through the flat fluid-permeable heating element (32, 50); characterized in that the heater mounting portion (39, 52) is press-fitted into the atomizer housing (31, 60) to separate the reservoir portion from the airflow passage.
  2. 2. Atomizer according to claim 1, characterized in that the heater mounting portion (39, 52) is press-fitted into the atomizer housing (31, 60) in a direction orthogonal to the longitudinal axis.
  3. 3. Atomizer according to claim 1, characterized in that the atomizer housing (31, 60) comprises an orifice (69) through which a mounting portion of the heater (51) may pass and a cap (65) configured to seal the orifice.
  4. 4. Atomizer, according to claim 3, characterized in that the cap (65) can be pressed to ensure the electrical connection of at least one electrical contact (64) with the fluid-permeable heating element (32, 50).
  5. 5. Atomizer, according to any of the preceding claims, characterized in that it comprises a plurality of electrical contacts (64) positioned at an air inlet end of the atomizer and accessible from an exterior of the atomizer housing (31, 60), the electrical contacts (64) being electrically connected or connectable to the flat fluid-permeable heating element (32, 50).
  6. 6. Atomizer, according to any of the preceding claims, characterized in that the atomizer housing (31, 60) is a one-piece component.
  7. 7. Atomizer, according to any of the preceding claims, characterized in that it comprises an outer housing (34, 62), wherein the atomizer housing (31, 60) is press-fitted or pressure-fitted into the outer housing (34, 62), the atomizer housing (31, 60) and the outer housing (34, 62) together enclosing a portion of the reservoir (45, 66) to contain the liquid aerosol forming substrate.
  8. 8. Atomizer, according to claim 7, characterized in that the atomizer housing (31, 60) is press-fitted or press-fitted into the outer housing (34, 62) in the longitudinal direction.
  9. 9. Atomizer, according to any one of claims 7 or 8, characterized in that the outer housing (34, 62) comprises a mouthpiece portion into which a user can inhale to aspirate the aerosol or vapor generated by the atomizer through the air outlet (28, 68).
  10. 10. Atomizer, according to any of the preceding claims, characterized in that the airflow passage (22, 63) extends in a straight line between the air inlet (16, 67) and the air outlet (28, 68).
  11. 11. Atomizer, according to any of the preceding claims, characterized in that the atomizer has a rectangular cross-section orthogonal to the longitudinal direction.
  12. 12. Atomizer, according to any of the preceding claims, characterized in that the flat fluid-permeable heating element (32, 50) is elongated and has a length and width and a thickness, the length being in the longitudinal direction and being greater than the width, and the width being greater than the thickness.
  13. 13. Electrically heated aerosol generating system, characterized in that it comprises: an atomizer, as defined in any of the preceding claims, and a portion of the device (10), wherein the portion of the device (10) comprises a power supply and a control circuit connected to the power supply and is coupled to the atomizer to allow a power supply from the power supply (12) to the flat fluid permeable heating element (32, 50).
  14. 14. Electrically heated aerosol generating system according to claim 13, characterized in that the device portion (10) has a longitudinal axis aligned with the longitudinal direction.
  15. 15. Electrically heated aerosol generating system, according to any one of claims 13 or 14, characterized in that the system comprises a mouthpiece into which a user can inhale to aspirate the aerosol or vapor generated by the atomizer through the air outlet (28, 68).
  16. 16. Electrically heated aerosol generating system according to claim 15, characterized in that the device portion (10) is configured to provide a non-zero initial energy to the heating element or to provide sufficient energy to maintain the heating element at an initial temperature or within an initial temperature range between puffs by the user.
  17. 17. Electrically heated aerosol generating system according to claim 16, characterized in that the device portion is configured to provide a second power to the heating element (32, 50) during the user's puffs, wherein the second power is greater than the first power.
  18. 18. Electrically heated aerosol generating system according to any one of claims 13 to 17, characterized in that the reservoir portion (45, 66) contains an aerosol-forming substrate comprising nicotine.
  19. 19. Cartridge for an aerosol generating system, characterized in that it comprises: a cartridge housing (34) defining an air inlet (16, 67) and an air outlet (28, 68), an aerosol forming substrate, an airflow passage (22, 63) extending in a longitudinal direction between the air inlet (16, 67) and the air outlet (28, 68), and a heater assembly comprising a flat fluid-permeable heating element (32, 50) positioned between the airflow passage (22, 63) and the aerosol forming substrate such that one side of the flat fluid-permeable heating element (32, 50) is in fluidic communication with the airflow passage (22, 63) and an opposite side of the flat fluid-permeable heating element (32, 50) is in fluidic communication with the aerosol forming substrate. aerosol; and a heater mounting portion (39, 52) in which the flat fluid-permeable heating element (32, 50) is supported, the heater mounting portion (32, 50) being received in the cartridge housing (34) and positioned between the reservoir portion (45, 66) and the airflow passage (22, 63) so that the fluid can pass from the reservoir portion (45, 66) to the airflow passage (22, 63) through the fluid-permeable heating element (32, 50); and wherein the cartridge housing (34) includes a wall extending in the longitudinal direction and includes an orifice (69) in the wall through which the heater assembly can be received.

Description

[001] The present invention relates to electrically heated aerosol generating systems. In particular, the invention relates to heated aerosol generating systems that produce an aerosol for inhalation by the user that are compact and simple to manufacture, but provide efficient aerosol production. [002] One type of aerosol generating system is an electrically heated smoking system that generates an aerosol for the user to inhale. Electrically heated smoking systems come in various forms. A popular type of electric smoking system is an electronic cigarette that vaporizes a liquid substrate to form an aerosol. Early electronic cigarette designs used a coil heater wrapped around a wick. A more recent design uses a mesh heating element, the mesh heating element allowing the vaporized substrate to pass through the mesh. [003] WO2015/117702A describes an aerosol generating system that heats a liquid substrate to form an aerosol. The heating is carried out using a mesh of heating filaments. The liquid is transported to the mesh from a liquid reservoir by a capillary material on one side of the mesh. An airflow channel is on the other side of the mesh. The vaporized liquid aerosol-forming substrate passes through the mesh into the airflow channel. [004] However, current mesh heating element designs are relatively bulky and complex to manufacture. Consumers have been found to prefer more compact devices, closer in size to a conventional cigarette. It would be desirable to provide a robust and compact aerosol generating device that is simple to manufacture, yet capable of producing a sufficient volume of aerosol to satisfy users. [005] In a first aspect, an atomizer is provided for an electrically heated aerosol generation system, comprising: an atomizer housing defining an air inlet and an air outlet, a reservoir portion for containing an aerosol-forming substrate in a condensed form, an airflow passage extending in a longitudinal direction between the air inlet and the air outlet, the atomizer housing defining the reservoir portion and the airflow passage, and a flat fluid-permeable heating element positioned between the airflow passage and the reservoir such that one side of the flat fluid-permeable heating element is in fluid communication with the airflow passage and an opposite side of the flat fluid-permeable heating element is in fluid communication with liquid in the reservoir, wherein the flat fluid-permeable heating element extends in the longitudinal direction. [006] At least a portion of the airflow passage may be defined between the flat fluid-permeable heating element and the atomizer housing. [007] In this context, a condensed form means a liquid, solid, gel or other non-gaseous form. In some embodiments, the aerosol-forming substrate comprises a liquid mixture. [008] In this context, planar means that it extends in two dimensions substantially more than in a third dimension. In particular, the planar fluid-permeable heating element extends in the length and width directions substantially more than in a thickness direction. The planar fluid-permeable heating element may have a length and width at least 5 times greater than its thickness. The length of the planar fluid-permeable heating element may be parallel to the longitudinal direction. The planar fluid-permeable heating element is preferably planar. [009] The atomizer housing may have a length, a width, and a thickness, and may have a thickness significantly less than its length and width. The direction of the thickness of the atomizer housing may be the same as the direction of the thickness of the heating element. [0010] The arrangement of this aspect of the invention has the advantage of allowing an atomizer with a small size to be made for a given size of heating element. In particular, the atomizer can be thin in one dimension, allowing the atomizer and potentially the entire aerosol generating system to fit easily in a user's pocket. This is popular among users. [0011] The aerosol-forming substrate can be a liquid at room temperature. The aerosol-forming substrate can be a solid at room temperature or it can be in another condensed form, such as a gel, at room temperature. [0012] Heating the aerosol-forming substrate by the heating element can release volatile compounds from the aerosol-forming substrate as a vapor. The vapor can then cool within the airflow passage to form an aerosol. [0013] The heating element can be configured to operate by resistive heating. In other words, the heating element can be configured to generate heat when an electric current passes through the heating element. [0014] The heating element can be configured to operate by inductive heating. In other words, the heating element may comprise a susceptor which, in operation, is heated by eddy currents induced in the susceptor. Hysteresis losses may also contribute to inductive heating. [0015] The heating element can be arranged to heat the aerosol-forming substrate by