阅读说明：本技术 用于蒸汽供应系统的加热器 (Heater for steam supply system ) 是由 帕特里克·莫洛尼 于 2020-03-11 设计创作，主要内容包括：一种加热器(110),用于在电子蒸汽供应系统中汽化可气雾化基质材料,该加热器具有细长形式并由具有长度、宽度和两对相对边缘的电阻材料的平面元件形成,该两对相对边缘包括基本上平行于长度的两个主边缘和基本上平行于宽度的两个次边缘,其中,该平面元件被弯曲以形成加热器的细长形式,使得所述相对边缘对中的一对边缘的边缘定位成彼此相邻并且弯曲的平面元件限定了容纳多孔材料(113)的容积(112),该多孔材料用于将可气雾化基质材料芯吸至加热器。(A heater (110) for vaporising an aerosolizable matrix material in an electronic vapour provision system, the heater having an elongate form and being formed from a planar element of electrically resistive material having a length, a width and two pairs of opposing edges comprising two major edges substantially parallel to the length and two minor edges substantially parallel to the width, wherein the planar element is curved to form the elongate form of the heater such that the edges of one of said pairs of opposing edges are positioned adjacent one another and the curved planar element defines a volume (112) containing porous material (113) for wicking the aerosolizable matrix material to the heater.)

1. A heater for vaporising an aerosolizable matrix material in an electronic vapour provision system, the heater having an elongate form and being formed from a planar element of electrically resistive material, the planar element having a length, a width and two pairs of opposing edges comprising two major edges substantially parallel to the length and two minor edges substantially parallel to the width, wherein the planar element is curved to form the elongate form of the heater such that the edges of one of the pairs of opposing edges are positioned adjacent to each other and the curved planar element defines a volume to contain a porous material for wicking the aerosolizable matrix material to the heater.

2. The heater of claim 1, wherein the planar element is curved about an axis substantially parallel to the length such that the two major edges are positioned adjacent one another to form the heater with a substantially tubular form.

3. The heater of claim 2, wherein the two major edges are positioned such that major edge portions of the planar element overlap one another to form the heater with a tubular form that is closed along the length of the heater.

4. The heater of claim 3, wherein the overlapping major edge portions are slidable relative to one another to vary the capacity of the volume.

5. A heater as claimed in claim 3 wherein the overlapping major edge portions are connected to one another to form a fixed volume.

6. The heater of claim 2 wherein the two major edges are positioned with a gap to form a heater having a tubular form opening along the length of the heater.

7. A heater as claimed in any of claims 2 to 6 wherein the tubular form has a substantially circular cross-section in a plane parallel to the minor edge.

8. The heater of any one of claims 2 to 7, wherein the planar element further comprises an end portion extending from one of the minor edges and folded relative thereto to at least partially cover an end of the tubular form of the heater.

9. The heater of claim 1, wherein the planar element is curved about an axis substantially parallel to the width and at or near a midpoint between the two minor edges such that the minor edges are positioned adjacent to each other to form the heater with a substantially folded form.

10. The heater of claim 9, wherein the planar element is curved about the axis with a radius of curvature substantially in the range of 0.25mm to 2.5 mm.

11. The heater of claim 9 or 10, wherein the planar element has at least one longitudinal fold formed therein, the longitudinal fold being substantially parallel to the two major edges and defining a concave surface of the volume.

12. The heater of claim 11, wherein the at least one longitudinal crease comprises two longitudinal creases, each longitudinal crease extending from the secondary edge toward a midpoint of the heater element.

13. A heater as claimed in any preceding claim wherein the length of the planar element is L1 and the width of the planar element is L2, and the ratio L1: L2 is substantially in the range of 4:1 to 12:1, or 2: pi to 6: within a range of pi.

14. A heater as claimed in any preceding claim wherein the elongate form of the heater has a length L_HAnd width W_HSo that the ratio L_H:W_HSubstantially in the range of 2:1 to 6: 1.

15. A heater as claimed in any preceding claim, wherein the resistive material is metallic.

16. The heater of claim 15, wherein the resistive material is one of low carbon steel, ferritic stainless steel, aluminum, nickel, nichrome, or alloys of these materials.

17. A heater as claimed in any preceding claim wherein the planar element has a plurality of perforations therein.

18. The heater of claim 17, wherein the plurality of perforations are for egress of vaporized aerosolizable matrix material from the volume.

19. The heater of claim 18, wherein the plurality of perforations are distributed over all or a substantial area of the planar element.

20. The heater of any of claims 17 to 19, wherein the plurality of perforations comprise one or more rows of perforations substantially parallel to a width of the planar element to reduce heat transfer in the material of the planar element through the one or more rows of perforations.

21. The heater of any one of claims 1 to 20, wherein the heater is a susceptor configured to be placed in an oscillating magnetic field to be heated by induction.

22. The heater as claimed in any one of claims 1 to 20 wherein the heater is configured as a resistive heating element for joule heating by the flow of electrical current.

23. An atomiser for an electronic vapour provision system comprising a heater according to any preceding claim, and a portion of porous material housed in the volume.

24. The nebulizer of claim 23, wherein the porous material comprises cotton or organic cotton.

25. The atomizer of claim 23, wherein the porous material comprises a porous ceramic rod.

26. An atomiser for an electronic vapour provision system according to any of claims 23 to 25, further comprising a support member having a support portion defining a slot into which one or both minor edges of the planar element are inserted such that the heater is supported at one end of the elongate form in a cantilevered arrangement only.

27. A cartridge for an electronic vapour provision system, comprising a heater according to any of claims 1 to 22 or a nebuliser according to any of claims 23 to 26; and a reservoir containing an aerosolizable matrix material for vaporization by the heater.

28. An electronic vapour provision system comprising a heater according to any of claims 1 to 22, or a nebuliser according to any of claims 23 to 26, or a cartridge according to claim 27.

Technical Field

The present disclosure relates to a heater for a steam supply system, and to an atomizer (atomiser), a cartomiser (cartomiser) or a cartidge (cartidge) and a steam supply system comprising such a heater.

Background

Many electronic vapour provision systems, such as e-cigarettes and other electronic nicotine delivery systems that deliver nicotine via a vapourised liquid, are made up of two main components or sections, namely a cartridge or cartomiser section and a control unit (battery section). A cartomizer typically includes a reservoir and an atomizer for vaporizing the liquid. These parts may be collectively referred to as an aerosol source. Nebulizers typically incorporate porosity or wicking and heating functions to transport liquid from a reservoir to a location where it is heated and vaporized. For example, it may be implemented as an electric heater, which may be a resistive wire formed into a coil or other shape for resistive (joule) heating, or a base for inductive heating, and a porous element with capillary or wicking capabilities that draws liquid from a reservoir and carries it to the heater, near the heater. The control unit typically includes a battery for operating the system to provide electrical power. Power from the battery is delivered to activate the heater, which heats up to vaporize a small amount of the liquid delivered from the reservoir. The user then inhales the vaporized liquid.

The components of the cartomizer are only intended for short-term use, and so the cartomizer is a disposable component of the system, also known as a consumable. In contrast, the control unit is typically intended for multiple uses with a series of cartomisers, which the user replaces each time they expire. A consumable cartomizer is provided to the consumer with a reservoir that is pre-filled with liquid and discarded when the reservoir is empty. For convenience and safety, the reservoir is sealed and designed to be not easily refillable, as the liquid may be difficult to handle. When a new supply of liquid is required, the user can replace the entire cartomizer more simply.

In this context, it is desirable that the cartomizer is easy to manufacture and comprises few parts. Thus, they can be efficiently manufactured in large quantities at low cost with minimal waste. Accordingly, there is considerable interest in designing simple cartomisers.

Disclosure of Invention

According to a first aspect of some embodiments described herein, there is provided a heater for vaporising an aerosolizable matrix material in an electronic vapour provision system, the heater having an elongate form and being formed from a planar element of electrically resistive material having a length, a width and two pairs of opposing edges comprising two major edges substantially parallel to the length and two minor edges substantially parallel to the width, wherein the planar element is curved to form the elongate form of the heater such that the edges of one of the pairs of opposing edges are positioned adjacent to each other and the curved planar element defines a volume containing a porous material for wicking the aerosolizable matrix material to the heater.

According to a second aspect of some embodiments described herein, there is provided an atomiser for an electronic vapour provision system comprising a heater according to the first aspect, and a portion of porous material housed in the volume.

According to a third aspect of some embodiments described herein, there is provided a cartridge for an electronic vapour provision system, comprising a heater according to the first aspect or a nebuliser according to the second aspect; and a reservoir containing an aerosolizable matrix material for vaporization by the heater.

According to a fourth aspect of some embodiments described herein, there is provided an electronic vapour provision system comprising a heater according to the first aspect or a nebuliser according to the second aspect or a cartridge according to the third aspect.

These and further aspects of certain embodiments are set out in the accompanying independent and dependent claims. It is to be understood that features of the dependent claims may be combined with each other and with features of the independent claims in combinations other than those explicitly set out in the claims. Furthermore, the methods described herein are not limited to a particular embodiment, such as the embodiments listed below, but include and contemplate any suitable combination of features presented herein. For example, a heater for or a steam supply system including a heater may be provided according to the methods described herein, including any one or more of the various features described as appropriate below.

Drawings

Various embodiments of the present invention will now be described in detail, by way of example only, with reference to the following drawings, in which:

figure 1 shows a cross-section of an example electronic cigarette that includes a cartomizer and a control unit;

FIG. 2 illustrates an external perspective exploded view of an example cartomizer in which aspects of the present disclosure may be implemented;

figure 3 shows a partially cut-away perspective view of the cartomizer of figure 2 in an assembled arrangement;

4, 4(A), 4(B), and 4(C) show simplified schematic cross-sectional views of another example cartomizer in which aspects of the present disclosure may be implemented;

FIG. 5 shows a highly schematic cross-sectional view of a first example steam supply system that may implement aspects of the present disclosure employing induction heating;

FIG. 6 shows a highly schematic cross-sectional view of a second example steam supply system that may implement aspects of the present disclosure employing induction heating;

fig. 7 shows a plan view of a planar element for forming a heater of an atomizer according to a first example;

fig. 8 shows a simplified schematic of a nebulizer supported in a socket according to an example;

fig. 9 shows a plan view of a planar element for forming a heater of an atomizer according to a second example;

FIG. 10 shows a perspective side view of a heater formed from the example planar element of FIG. 9;

FIG. 11 shows a cross-sectional side view of the heater of FIG. 10 supported in a socket;

FIG. 12 shows a perspective side view of an alternative heater formed from the example planar element of FIG. 9;

FIG. 13 shows a cross-sectional side view of an example atomizer including the heater of FIG. 10;

FIG. 14 illustrates a selected plan view of another example planar element for forming a heater;

FIG. 15 illustrates a plan view of a planar element for forming a heater with perforations that limit heat transfer according to an example;

FIG. 16 shows a perspective side view of a heater formed from the planar element of FIG. 15;

FIG. 17 shows a plan view of a planar element for forming a heater for an atomizer, according to another example;

FIG. 18A shows an end view of an example heater that may be formed from the planar element of FIG. 17;

FIG. 18B shows a perspective side view of the heater of FIG. 18A;

FIG. 19A shows an end view of another example heater that may be formed from the planar element of FIG. 18;

FIG. 19B shows a perspective side view of the heater of FIG. 19A;

FIG. 20 illustrates a plan view of an additional exemplary planar element for forming a heater;

FIG. 21 shows a perspective side view of an example atomizer including a heater such as the example of FIG. 18B;

FIG. 22 shows a perspective side view of an example heater with perforations for steam release; and

FIG. 23 shows a perspective side view of an example heater with perforations that limit heat transfer.

Detailed Description

Various aspects and features of certain examples and embodiments are discussed/described herein. Some aspects and features of certain examples and embodiments may be routinely implemented and, for the sake of brevity, are not discussed/described in detail. It will thus be appreciated that aspects and features of the apparatus and methods discussed herein, which have not been described in detail, may be implemented in accordance with any conventional technique for implementing such aspects and features.

As mentioned above, the present disclosure relates to (but is not limited to) electronic aerosol or vapour provision systems, such as e-cigarettes. In the following description, the terms "electronic cigarette" and "electronic cigarette" will sometimes be used; however, it should be understood that these terms may be used interchangeably with an aerosol (vapor) supply system or device. The system is intended to produce an inhalable aerosol by vaporising a substrate in liquid or gel form, which may or may not contain nicotine. Further, the mixing system may include a liquid or gel matrix plus a solid matrix that is also heated. The solid substrate may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. As used herein, the term "aerosolizable substrate material" is intended to refer to a substrate material that can form an aerosol by the application of heat or some other means. The term "aerosol" is used interchangeably with "vapor".

As used herein, the term "component" is used to refer to a part, section, unit, module, assembly, or the like of an e-cigarette or similar device that incorporates several smaller parts or elements that may be within a housing or wall. An e-cigarette may be formed or constructed from one or more such components, and these components may be removably or detachably connected to each other, or may be permanently joined together during manufacture to define the entire e-cigarette. The present disclosure is applicable to, but not limited to, a system comprising two components detachably connected to each other and configured as, for example, an aerosolizable matrix material carrier holding a liquid or another aerosolizable matrix material (cartridge, cartomizer, or consumable), and a control unit having a battery for providing electrical power to operate the elements for generating vapor from the matrix material. To provide one specific example, in the present disclosure, the aerosol cartridge is described as an example of an aerosolizable matrix material carrying portion or member, but the present disclosure is not so limited and applies to any configuration of an aerosolizable matrix material carrying portion or member. Moreover, such components may include more or less parts than those included in the examples.

The present disclosure is particularly directed to vapor supply systems and components thereof that utilize an aerosolizable matrix material in liquid or gel form that is retained in a reservoir, canister, container or other receptacle included in the system. Comprising an arrangement for transporting substrate material from a reservoir to provide substrate material for generating a vapour/aerosol. The terms "liquid," "gel," "fluid," "source liquid," "source gel," "source fluid," and the like may be used interchangeably with "aerosolizable matrix material" and "matrix material" to refer to aerosolizable matrix material in a form that is capable of being stored and delivered in accordance with examples of the present disclosure.

Figure 1 is a highly schematic (not to scale) view of a generic example aerosol/vapour provision system, such as an e-cigarette 10, for the purpose of illustrating the relationship between the various parts of a typical system and explaining the general principles of operation. In this example, the e-cigarette 10 has a generally elongate shape, extends along a longitudinal axis indicated by the dashed line, and includes two main components, namely a control or power supply component, section or unit 20, and a cartridge assembly (cartridge) or section 30 (sometimes referred to as a cartomizer or a clear cartomiser) that carries an aerosolizable matrix material and operates as a component to generate steam.

The cartomizer 30 comprises a reservoir 3 containing a source liquid or other aerosolizable matrix material comprising a formulation, such as a liquid or gel, from which an aerosol, e.g., a nicotine-containing aerosol, is generated. As an example, the source liquid may comprise about 1% to 3% nicotine and 50% glycerin, with the remainder comprising approximately equal amounts of water and propylene glycol, and possibly other ingredients such as flavoring agents. Nicotine-free source liquids, such as delivery flavors, may also be used. A solid substrate (not shown) may also be included, such as a portion of tobacco or other flavor, through which the liquid-generated vapor passes. The liquid reservoir 3 has the form of a storage tank, being a container or receptacle in which the source liquid can be stored such that the liquid can move and flow freely within the confines of the tank. For consumable cartomisers, the reservoir 3 can be sealed after filling during manufacture for disposal at will after source liquid is consumed, otherwise it can have an inlet or other opening through which a user can add new source liquid. The cartomizer 30 also includes an electrically powered heating element or heater 4 located outside the reservoir 3 for vaporizing the source liquid by heating to produce an aerosol. A liquid transfer or transport arrangement (liquid transfer element) such as a wick or other porous element 6 may be provided to transport the source liquid from the reservoir 3 to the heater 4. The wick 6 may have one or more portions located inside the reservoir 3 or otherwise in fluid communication with the liquid in the reservoir 3 so as to be able to absorb the source liquid and transfer it by wicking or capillary action to other portions of the wick 6 adjacent to or in contact with the heater 4. The liquid is thereby heated and vaporized to be replaced by fresh source liquid from the reservoir for transfer through the wick 6 to the heater 4. The wick may be considered to be a bridge, path or conduit between the reservoir 3 and the heater 4 which transports or transfers liquid from the reservoir to the heater. Terms including conduit, liquid transfer path, liquid transfer mechanism or element, and liquid transport mechanism or element may be used interchangeably herein to refer to a wick or corresponding component or structure.

The heater and wick (or similar) combination is sometimes referred to as an atomizer or atomizer assembly, and the reservoir with source liquid and atomizer may be collectively referred to as an aerosol source. Other terms may include a liquid delivery assembly or a liquid transfer assembly, where these terms are used interchangeably herein to refer to a vapor generating element (vapor generator) plus a wicking or similar component or structure (liquid transfer element) that delivers or transfers liquid obtained from a reservoir to the vapor generator to generate a vapor/aerosol. Various designs are possible, wherein the arrangement of the parts may be different compared to the highly schematic view of fig. 1. For example, the wick 6 may be an element completely separate from the heater 4, or the heater 4 may be constructed to be porous and capable of directly performing at least a portion of the wicking function (e.g., a metal mesh). In an electrical or electronic device, the steam generating element may be an electrical heating element operated by ohmic/resistive (joule) heating or by induction heating. Thus, in general, an atomizer may be considered to be one or more elements that perform the function of a vapor-generating or vaporizing element capable of generating vapor from a source liquid delivered thereto, as well as a liquid-transporting or delivery element capable of transporting or delivering liquid from a reservoir or similar liquid storage to a vapor generator by wicking/capillary forces. The atomizer is typically housed in the cartomizer component of the steam generation system. In some designs, the liquid may be dispensed from the reservoir directly onto the steam generator without the need for a significant wicking or capillary element. Embodiments of the present disclosure are applicable to all and any such configurations consistent with the examples and descriptions herein.

Returning to figure 1, the cartomizer 30 also includes a mouthpiece or mouthpiece portion 35 having an opening or air outlet through which a user can inhale the aerosol generated by the atomizer 4.

The power supply component or control unit 20 includes a battery cell or battery 5 (hereinafter referred to as a battery, and which may be rechargeable) to provide power to the electrical components of the e-cigarette 10, in particular to operate the heater 4. In addition, there is a controller 28, such as a printed circuit board and/or other electronics or circuitry typically used to control electronic cigarettes. When steam is required, the control electronics/circuitry 28 uses power from the battery 5 to operate the heater 4, for example in response to a signal from an air pressure sensor or air flow sensor (not shown) that detects inhalation on the system 10 during air ingress through one or more air inlets 26 in the wall of the control unit 20. When the heating element 4 is operated, the heating element 4 vaporizes the source liquid delivered by the liquid delivery element 6 from the reservoir 3 to produce an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. When a user inhales on the mouthpiece 35, aerosol is carried from the aerosol source to the mouthpiece 35 along one or more air channels (not shown) connecting the air inlet 26 to the aerosol source and the air outlet.

The control unit (power supply section) 20 and the cartomizer (cartridge assembly) 30 are separately connectable parts which are separable from each other by separation in a direction parallel to the longitudinal axis, as indicated by the double-ended arrow in fig. 1. When the device 10 is in use, the parts 20, 30 are joined together by cooperating engagement elements 21, 31 (e.g. screws or bayonet fittings), the engagement elements 21, 31 providing a mechanical and in some cases electrical connection between the power supply section 20 and the cartridge assembly 30. If the heater 4 operates by ohmic heating, an electrical connection is required so that current can pass through the heater 4 when the heater 4 is connected to the battery 5. In systems using induction heating, electrical connections may be omitted if no parts requiring power are located in the cartomizer 30. The induction work coil may be housed in the power supply section 20 and powered by the battery 5, and the cartomiser 30 and the power supply section 20 are shaped such that when they are connected, the heater 4 is suitably exposed to the flux generated by the coil for the purpose of generating an electrical current in the material of the heater. The induction heating arrangement is discussed further below. The design of fig. 1 is merely an example arrangement, and various parts and features may be variously distributed between the power supply section 20 and the cartridge assembly section 30, and may include other components and elements. The two sections may be connected together end-to-end in a longitudinal configuration as shown in fig. 1 or in a different configuration such as a parallel, side-by-side arrangement. The system may or may not be generally cylindrical and/or have a generally longitudinal shape. One or both of the segments or components may be intended to be discarded and replaced when depleted (e.g., the reservoir is empty or the battery is dead), or to be used multiple times through operations such as refilling the reservoir and recharging the battery. In other examples, the system 10 may be unitary in that the control unit 20 and the components of the cartomizer 30 are included in a single housing and cannot be separated. The embodiments and examples of the present disclosure are applicable to any of these configurations and others that will be known to those of skill.

Figure 2 illustrates an exterior perspective view of portions that may be assembled to form a cartomizer in accordance with examples of the present disclosure. The cartomizer 40 comprises only four parts and can be assembled by pushing or pressing together if the shape is appropriate. Thus, the manufacture can be very simple and straightforward.

The first part is a housing 42 defining a reservoir for holding an aerosolizable matrix material (hereinafter referred to simply as matrix or liquid for simplicity). The housing 42 has a generally tubular shape, in this example having a circular cross-section, and includes one or more walls shaped to define portions of the reservoir and other items. The cylindrical outer side wall 44 is open at an opening 46 at its lower end through which the reservoir can be filled with liquid and to which parts can be attached as described below to close/seal the reservoir and also to be able to transport liquid outwards for vaporisation. This defines the external or outer volume or size of the reservoir. References herein to an element or feature located at or outside of the reservoir are intended to indicate that the feature is outside or partially outside of the area bounded or defined by the outer wall 44 and its upper and lower extents and edges or surfaces.

A cylindrical inner wall 48 is concentrically disposed within the outer sidewall 44. This arrangement defines an annular volume 50 between the outer wall 44 and the inner wall 48, which is a receptacle, cavity, void or the like holding the liquid, in other words, a reservoir. The outer wall 44 and the inner wall 48 are connected together (e.g., by a top wall or by walls that taper toward each other) to close an upper edge of the accumulator volume 50. The inner wall 48 is open at an opening 52 at its lower end and also open at its upper end. The tubular interior space defined by the inner wall is an air flow channel or passage 54 which, in the assembled system, carries the generated aerosol from the atomizer to the nozzle outlet of the system for inhalation by the user. The opening 56 at the upper end of the inner wall 48 may be a nozzle outlet configured to be comfortably received in the mouth of a user, or a separate nozzle feature may be coupled on or around the housing 42 with a channel connecting the opening 56 to the nozzle outlet.

The housing 42 may be formed from a molded plastic material, such as by injection molding. In the example of fig. 2, it is formed of a transparent material; this allows the user to observe the level or amount of liquid in the reservoir 44. The housing may alternatively be opaque, or opaque with a transparent window through which the liquid level can be seen. In some examples, the plastic material may be rigid.

The second portion of the cartomizer 40 is a flow guide member 60, which in this example also has a circular cross-section, and is shaped and configured to engage the lower end of the housing 42. The flow directing member 60 is actually a plug and is configured to provide multiple functions. When inserted into the lower end of the housing 42, it couples with the opening 46 to close and seal the reservoir volume 50 and with the opening 52 to seal the air flow channel 54 from the reservoir volume 50. Furthermore, the flow guiding member 60 has at least one passage for liquid flow therethrough which carries liquid from the reservoir volume 50 to a space outside the reservoir which serves as an aerosol chamber in which a vapour/aerosol is generated by heating the liquid. Furthermore, the flow guide member 60 has at least one further passage therethrough for aerosol flow which carries the generated aerosol from the aerosol chamber space to the air flow passage 54 in the housing 42 for delivery to the mouthpiece opening for inhalation.

Also, the flow guide member 60 may be made of a flexible, resilient material, such as silicone, so that it may be easily engaged with the housing 46 via a friction fit. In addition, the flow directing member has a slot or similar shaped formation (not shown) on its lower surface 62 opposite the upper surface or surfaces 64 that engage the housing 42. The slot receives and supports an atomizer 70, the atomizer 70 being a third portion of the cartomizer 40.

Atomizer 70 has an elongated shape with a first end 72 and a second end 74 oppositely disposed with respect to its elongated length. In the assembled cartomizer, an atomizer is mounted at its first end 72, which atomizer is pushed into the slot of the flow guide member 60 in a direction towards the reservoir housing 42. Thus, the first end 72 is supported by the flow directing member 60, and the atomizer 70 extends longitudinally outward from the reservoir substantially along a longitudinal axis defined by the concentrically shaped portions of the housing 42. Second end 74 of atomizer 70 is not mounted and is free. Thus, the atomizer 70 is supported in a cantilever fashion extending outwardly from the outer boundary of the reservoir. The atomizer 70 performs a wicking function and a heating function to generate an aerosol, and may include a resistive heater portion configured to act as an inductive base and a porous portion configured to wick liquid from a reservoir to the vicinity of the heater.

The fourth portion of the cartomizer 40 is a housing or shroud 80. Also in this example, it has a circular cross-section. It includes a cylindrical side wall 81 closed by an optional bottom wall to define a central hollow space or void 82. The upper edge 84 of the sidewall 81 surrounding the opening 86 is shaped to enable the housing 80 to engage with a mutually shaped portion on the flow directing member 60 so that the housing 80 can be coupled to the flow directing member 60 once the atomizer 70 is installed in the socket on the flow directing member 60. Thus, the flow guiding member 60 acts as a cap closing the central space 82, and this space 82 forms an aerosol chamber in which the atomizer 70 is arranged. The openings 86 allow communication with the liquid flow passage and the aerosol flow passage in the flow directing member 60 so that liquid can be delivered to the atomizer and the resulting aerosol can be removed from the aerosol chamber. In order to pass the air flow through the aerosol chamber past the atomiser 70 and collect the vapour, entraining it in the air flow to form an aerosol, one or more walls 81 of the housing 80 have one or more openings or perforations allowing air to be drawn into the aerosol chamber when a user inhales through the mouthpiece opening of the atomised cartridge.

The housing 80 may be formed from a plastic material, such as by injection molding. It may be formed of a rigid material and then may be easily engaged with the flow directing member by pushing or pressing the two parts together.

As described above, the flow guide member may be made of a flexible elastic material, and may hold the parts coupled thereto, i.e., the housing 42, the atomizer 70, and the housing 80, by a friction fit. Since these parts may be more rigid, the flexibility of the flow directing member allows it to deform slightly when pressed against these other parts, thereby accommodating any minor tolerances in the dimensions of the manufactured parts. In this manner, the flow directing member can absorb manufacturing tolerances of all parts while still being able to assemble the parts together in high quality to form the cartomizer 40. Thus, the manufacturing requirements for manufacturing the housing 42, atomizer 70 and housing 80 may be somewhat relaxed, thereby reducing manufacturing costs.

Figure 3 shows a cut-away perspective view of the cartomizer of figure 1 in an assembled configuration. The flow guide member 60 is shaded for clarity. It can be seen how the flow directing member 60 is shaped on its upper surface to engage around the opening 52 defined by the lower edge of the inner wall 48 of the reservoir housing 42 and concentrically outwardly to engage in the opening 46 defined by the lower edge of the outer wall 44 of the housing 42 to seal the reservoir space 50 and the air flow channel 54.

The flow guide member 60 has a liquid flow channel 63 that allows liquid L to flow from the reservoir volume 50 through the flow guide member into a space or volume 65 below the flow guide member 60. Furthermore, there is an aerosol flow channel 66 which allows aerosol and air a to flow from the space 65 through the flow guiding member 60 to the air flow channel 54.

The outer shell 80 is shaped at its upper edge to engage with a correspondingly shaped portion in the lower surface of the flow directing member 60 to form an aerosol chamber 82 outside substantially the outer dimensions of the volume of the reservoir 50 according to the reservoir housing 42. In this example, the housing 80 has an aperture 87 at its upper end adjacent the flow directing member 60. This coincides with the space 65 through which the liquid flow passage 63 and the aerosol flow passage 66 communicate and thus allows liquid to enter the aerosol chamber 82 and aerosol to exit the aerosol chamber 82 via the passages in the flow guide member 60.

In this example, the aperture 87 also acts as a socket for mounting the first support end 74 of the atomiser 70 (recall that in the description of figure 2, the atomiser socket is mentioned as being formed in the flow directing member, either option may be used). Thus, liquid arriving through the liquid flow channel 63 is fed directly to the first end of the atomizer 70 for absorption and wicking, and air/aerosol can be drawn in and through the atomizer to enter the aerosol flow channel 66.

In this example, the atomiser 70 comprises a planar elongate portion 71 of metal which is folded or bent at its mid-point such that the two ends of the metal portion are adjacent one another at a first end of the atomiser 74. This acts as a heater component for the atomizer 70. A portion of cotton or other porous material 73 is sandwiched between the two folded sides of the metal portion. This acts as a wicking member for atomizer 70. Liquid that reaches the space 65 is collected by the absorbency of the porous wicking material 73 and carried down to the heater. Many other arrangements of elongated atomizers suitable for cantilever mounting are also possible and may be used instead.

The heater component is intended to be heated via induction, as will be described further below.

The examples of figures 2 and 3 have parts with substantially circular symmetry in a plane orthogonal to the longitudinal dimension of the assembled cartomizer. Thus, the parts do not have any desired orientation in the plane in which they are joined together, which makes manufacture easy. The parts can be assembled together in any orientation about the axis of the longitudinal dimension, and thus the parts need not be placed in a particular orientation prior to assembly. However, this is not essential and the parts may be shaped instead.

Figure 4 shows a cross-sectional view of a cartomizer assembled through another example, which cartomizer includes a reservoir housing, a flow guide member, an atomizer, and an outer shell, as previously described. However, in this example, in a plane orthogonal to the longitudinal axis of the cartomizer 40, at least some of the features have an elliptical shape rather than a circular shape and are arranged symmetrically along the major and minor axes of the elliptical shape. The features are reflected on either side of the major axis and on either side of the minor axis. This means that for assembly, the parts can have either of two orientations, rotated 180 ° from each other about the longitudinal axis. Also, assembly is simplified compared to systems containing asymmetric parts.

In this example, the housing 80 again comprises side walls 81 and a bottom wall 83, the side walls 81 being formed with varying cross-sections at different points along the longitudinal axis of the housing, the bottom wall 83 delimiting a space forming the aerosol chamber 82. Toward its upper end, the housing widens to a large cross-section to provide a space to accommodate the flow guide member 60. The large cross-sectional portion of the housing 80 has a generally elliptical cross-section (see fig. 4(B)), while the narrower cross-sectional portion of the housing has a generally circular cross-section (see fig. 4 (C)). An upper rim 84 of the housing surrounding the top opening 86 is shaped to engage a corresponding shape on the reservoir housing 42. This shape and engagement is shown in simplified form in fig. 4; in practice, it may be more complicated to provide a reasonably gas-and liquid-tight connection. The housing 80 has at least one opening 85, in this case in the bottom wall 83, to allow air to enter the aerosol chamber during inhalation by the user.

The shape of the reservoir housing 42 is different compared to the example of fig. 2 and 3. The outer wall 44 defines an interior space divided into three regions by two inner walls 48. These regions are arranged side by side. The central area between the two inner walls 48 is a reservoir volume 50 for holding liquid. This area is closed at the top by the top wall of the housing. An opening 46 at the bottom of the reservoir volume allows liquid to be transferred from the reservoir 50 to the aerosol chamber 82. The two side regions between the outer wall 44 and the inner wall 48 are air flow passages 54. Each having an opening 52 at its lower end for aerosol entry and a mouthpiece opening 56 at its upper end (a separate mouthpiece portion may be added to the exterior of the reservoir housing 42 as previously described).

A flow directing member 60 (shown shaded for clarity) is engaged via a shaped portion into the lower edge of the housing 42 to engage with the openings 46 and 52 in the housing 42 to close/seal the reservoir volume 50 and the air flow channel 54. The flow guide member 60 has a single centrally disposed liquid flow channel 63 aligned with the reservoir volume opening 46 to convey the liquid L from the reservoir to the aerosol chamber 82. Furthermore, there are two aerosol flow channels 66, each extending from an inlet at the aerosol chamber 82 to an outlet of the air flow channel 54 through which air entering the aerosol chamber through the perforations 83 and collecting vapour in the aerosol chamber 82 flows into the air flow channel 54 to the mouthpiece outlet 56.

The atomizer 70 is mounted by inserting its first end 72 into the liquid flow channel 63 of the flow directing member 60. Thus, in this example, the liquid flow channel 63 acts as a cantilever-mounted slot for the atomizer 70. Thus, the first end 72 of the atomizer 70 is directly supplied with liquid from the reservoir 50 into the liquid flow channel 60, and the liquid is absorbed via the porous nature of the atomizer 70 and drawn along the atomizer length to be heated by the heater portion (not shown) of the atomizer 70 located in the aerosol chamber 70.

Fig. 4(a), (B) and (C) show cross-sections through the cartomizer 40 at corresponding positions along the longitudinal axis of the cartomizer 40.

While aspects of the present disclosure are related to nebulizers in which the heating aspect is achieved via resistive heating, which requires electrical connection with a heating element to pass an electrical current, the design of the cartomizer is particularly relevant to the use of induction heating. This is a process by which an electrically conductive article, typically made of metal, is heated by electromagnetic induction, eddy currents flow in the article and generate heat. When a high-frequency alternating current from an oscillator passes through, an induction coil (work coil) works as an electromagnet; this generates a magnetic field. When an electrically conductive article is placed in a flux of a magnetic field, the magnetic field penetrates the article and induces eddy currents. The eddy current flows in the article and generates heat via joule heating according to the current flowing through the resistance of the article, in the same manner as heat is generated in the resistance electric heating element by directly supplying current. An attractive feature of induction heating is that no electrical connection to the conductive article is required; instead, the requirement is to generate sufficient magnetic flux density in the area occupied by the article. In the context of a vapour supply system, there is a need to generate heat in the vicinity of the liquid, which is advantageous in that the separation of liquid and current can be achieved more efficiently. Given that no other electrically powered items are placed in the cartomizer, no electrical connection is required between the cartomizer and its power supply section, the cartomizer wall can provide a more effective liquid barrier, thereby reducing the likelihood of leakage.

As mentioned above, induction heating is effective for directly heating electrically conductive articles, but can also be used for indirectly heating electrically non-conductive articles. In vapor supply systems, heat needs to be provided to the liquid in the porous wicking portion of the atomizer to cause vaporization. For indirect heating via induction, an electrically conductive article is placed in proximity to or in contact with the article to be heated and between the work coil and the article to be heated. The work coil directly heats the electrically conductive object by induction heating, and the heat is transferred to the negatively electrically conductive article by thermal radiation or conduction. In this arrangement, the conductive article is referred to as a base. Thus, in an atomizer, the heating member may be provided by an electrically conductive material (typically a metal) that acts as an inductive base to transfer thermal energy to the porous portion of the atomizer.

Fig. 5 shows a highly simplified schematic diagram of a steam supply system including an aerosol cartridge 40 according to an example of the present disclosure and a power supply component 20 configured for induction heating. The cartomizer 40 may be as shown in the examples of figures 2, 3 and 4 (although other arrangements are not excluded) and is only schematically illustrated for simplicity. The cartomizer 40 includes an atomizer 70 in which heating is achieved by induction heating, so that a heating function is provided by a base (not shown). The atomizer 70 is located in the lower portion of the cartomizer 40 and is surrounded by a housing 80, the housing 80 not only serving to define an aerosol chamber, but also providing a degree of protection for the atomizer 70, which atomizer 70 may be relatively vulnerable to damage due to its cantilevered mounting. However, the cantilever mounting of the atomizer 70 enables efficient induction heating, since the atomizer 70 can be inserted into the inner space of the coil 90, and in particular, the reservoir is located far away from the inner space of the work coil 90. Thus, the power supply component 20 includes a recess 22 in which the housing 80 of the cartomizer 40 is received (via, for example, a friction fit, a clamping action, threads, or magnetic capture) when the cartomizer 40 is coupled to the power supply component for use. An inductive work coil 90 is located in the power supply component 20 to surround the recess 22, the coil 90 having a longitudinal axis, each turn of the coil extending on the longitudinal axis and having a length substantially matching the length of the base such that when the cartomizer 40 and the power supply component 20 are engaged, the coil 90 and the base overlap. In other embodiments, the length of the coil may not substantially match the length of the base, for example, the length of the base may be shorter than the length of the coil, or the length of the base may be longer than the length of the coil. In this manner, the pedestal is located within the magnetic field generated by the coil 90. If the item is positioned such that the spacing of the susceptor from the surrounding coil is minimized, the flux experienced by the susceptor may be higher and the heating effect more efficient. However, the spacing is set at least in part by the width of the aerosol chamber formed by the housing 80, which needs to be dimensioned to allow sufficient air flow through the atomizer and avoid droplet entrapment. Therefore, there is a need to balance these two requirements in determining the size and location of various items.

The power supply unit 20 includes a battery 5 for supplying power to energize the coil 90 at a suitable AC frequency. In addition, a controller 28 is included to control the power supply when steam generation is required, and possibly to provide other control functions for the steam supply system not further considered herein. The power supply components may also include other parts not shown and not relevant to the present discussion.

The example of figure 5 is a system in a linear arrangement in which the power supply component 20 and the cartomizer 40 are connected end-to-end to achieve a pen-like shape.

Figure 6 shows a simplified schematic of an alternative design in which the cartomizer 40 provides a mouthpiece for a more box-like arrangement in which the battery 5 is provided in the power supply component 20 on one side of the cartomizer 40. Other arrangements are also possible.

As previously mentioned, the atomizer is elongated and includes a heater portion and a porous portion. Liquid from the reservoir is delivered to a porous section which absorbs the liquid and carries it by capillary action (also known as wicking) to the vicinity of the heater, from where it is delivered to vaporize it.

According to an example, the heater has an elongated form or shape and generally defines an exterior of the atomizer. By "elongated" is meant that the heater has a length and a width wherein the length significantly exceeds the width (e.g., a maximum width where the width varies along the length). For example, the length may be at least two times the width, or at least three times the width, or at least four times the width, or at least five times the width, or at least ten times the width. However, other values are not excluded.

The heater may usefully be formed from a planar element of suitable material which is resistive/conductive, in other words capable of carrying an electrical current. This enables the heater to raise its temperature by exposure to a magnetic field generated by a high frequency alternating current in the work coil, by an inductive effect as described above, wherein the magnetic flux induces eddy currents in the heater material. Alternatively, the current may be supplied directly to the heater to increase the temperature when the current experiences the resistivity of the heater material via the joule effect (ohmic or resistive heating). The planar element may be considered to be a piece of suitable material, suitably sized and shaped to form a heater. The planar elements are formed into heaters by bending or curving into a non-planar shape (the elements no longer occupy a single plane). According to various examples, bending may be considered rolling or folding. In all cases, at least a portion of the planar element is curved according to a suitable radius of curvature to form an elongate form of the heater.

Fig. 7 shows a plan view of a planar element of resistive material used to form a heater according to an example. Planar element 100 has a generally rectangular shape with a length L1 and a width L2. It has a pair of minor edges 102 that are opposite each other and substantially parallel to the width L2. Extending between the minor edges are a pair of major edges 101 that are opposite each other and substantially parallel to length L1. The portions of the planar element near the edges may be referred to as a major edge portion and a minor edge portion, respectively. Although the planar elements have a regular rectangular shape in this example, this is not essential and more complex shapes, for example lacking straight sides, may be used. In general, however, the edges along the longer dimension are generally major edges, while the edges along the shorter dimension are generally minor edges. The width may be taken as the largest dimension in a direction substantially parallel to the shorter dimension, and the length may be taken as the largest dimension in a direction substantially parallel to the longer dimension.

The planar element 100 is bent into a desired heater having an elongated form or shape. Examples of possible curvatures are described below.

Fig. 8 shows a highly simplified schematic of an elongated atomizer 70 comprising an elongated heater (not separately shown). A heater having such an elongated form extends between a first end 72 and a second end 74 of the atomizer. The heater/atomizer may be installed for use by inserting the first end 72 into a slot 103 formed in the support portion or support portion 104. For example, as in the examples of fig. 2-4, the support portion may be included in the housing 80 or the flow guide member 60 differently or designated as the housing 80 or the flow guide member 60. Other designs of support portions may alternatively be provided if desired. In any case, if the heater/atomizer 70 and the socket 103 are similarly sized, the heater/atomizer 70 may be held and supported by merely being inserted into the socket 103, such as by a friction fit. This provides a cantilevered arrangement for the atomizer. The first end 72 includes an inlet to a portion of the porous material contained in the cartomizer for wicking, as described further below, and is positioned to receive liquid L from the reservoir of the cartomizer, as shown in fig. 3 or 4.

The elongated form of the heater has a length L_HAnd width W_H. The ratio of these dimensions may be in L_H:W_HIn the range of 2:1 to 6:1, for example, or in the range of 3:1 to 5: 1. The length should not be too long as this may prevent liquid from reaching the lower part of the elongated atomizer. Furthermore, the width should not be too large, as this would increase the overall size of the cartomizer and the housing (which would require a corresponding increase in the size of the work coil). In one example, the length of the elongate form heater is 12mm and the width is 3 mm.

In some examples, planar element 100 is bent about an axis substantially parallel to minor edges 102 such that the minor edges are adjacent to each other.

Fig. 9 shows a plan view of an exemplary planar element 100 (or blank for forming a heater) having a length L1 and a width L2 as previously described. The planar element 100 has an aspect ratio typically in the range of, for example, 4:1 to 12:1 or 6:1 to 10:1, and is well suited for making heaters that in some examples are folded elongate forms. In one example, the length L1 is approximately 24mm and the width is approximately 3 mm. Planar element 100 has an axis 105 shown across its central portion parallel to the minor edges and in the direction of width L2 and substantially midway between minor edges 102. To make a heater from a planar element, the planar element 100 is bent or curved around or about axis 105 such that the two minor edges 102 are brought into proximity with each other; the minor edges 102 are made to lie adjacent to each other. Planar element 100 is actually folded along axis 105 such that portions of the planar element on either side of axis 105 are in facing relationship. However, the folds are not well defined or sharp, but take the form of the curvature of a planar element. This is to leave a space between the two portions of the planar element, which defines a volume or cavity for holding or containing the porous material required to manufacture the atomizer from the heater.

Fig. 10 shows a perspective side view of a heater 110 formed in this manner from a planar element, such as the planar element of fig. 9. The heater 110 has a folded shape formed as described, wherein the two minor edges 102 of the planar element are brought together by curvature at the midpoint axis of the planar element. The adjacent minor edges 102 form the first end 72 of the heater 110 and the folded or bent region forms the second end 74 of the heater 110. The two facing portions of the heater on either side of the fold or curve have a space between them which is a volume 112 for containing a porous material (not shown).

Fig. 11 shows a simplified schematic side view of a folding heater 110, as in the example of fig. 8, mounted by inserting two minor edges into slots 103. Since the heater 110 is formed by folding or bending or rolling a planar element, typically of sheet metal material, the folded shape may have some elasticity against the folded position, wherein the secondary edges have a bias to return to their pre-folded position (unfolding the planar element). When the heater 110 is inserted into the insertion slot 103 for cantilever mounting, the two minor edge portions will spring outward as shown by the arrows in fig. 11 and thus press against the side walls of the insertion slot 103. This will help to hold the heater 110 in place in the socket 103. If desired, tabs, notches, or the like may be cut or stamped in the minor edge portions to provide teeth, barbs, or other shaped surface features that may assist in engaging the heater end 102 with the interior of the socket 103. This may assist or replace any bias to retain the heater 110 in the socket 103.

The curved portion of the heater 110 at the second end 74 has a radius of curvature R (bending radius) about an axis parallel to the central axis 105 of the planar element 100 (see fig. 9). The radius of curvature is typically small, for example in the range 0.25mm to 2.5mm or 0.75mm to 1.0mm or 0.5mm to 1.5 mm. The curvature is preferably not less than 0.25mm because this makes the curved shape too brittle to easily break or break. Curvatures in excess of 2.5mm may be unsuitable because too much wicking (porous) material is required and often provides too much volume for the porous material and makes the overall heater size too large. The curvature within the given range brings the facing portions of the heater into close proximity so that the volume 112 for porous material has a moderate capacity and is able to hold a workable amount of porous material (not shown) in at least moderately restricted conditions so that it does not fall out of the volume 112. In practice, the porous material may be sandwiched between two halves of the heater 110.

It has been found that a heater shaped in this manner with a simple mid-point bend fold may have a tendency to bend laterally outward as the porous material in the volume 112 absorbs liquid from the reservoir and thus increases in size. The increased size of the porous material can increase the capacity of the volume 112 if the material of the heater is very thin and lacks any high degree of rigidity or structural integrity. This has a number of effects. The porous material may be held less firmly or less tightly by the heater and have a tendency to fall out, thereby disassembling the atomizer. In an induction heating arrangement (see fig. 5 and 6), the altered heater shape will alter the position of at least part of the heater within the magnetic field of the work coil. This, in turn, changes the level of magnetic flux to which the heater is exposed, changing the desired level of heating, thereby affecting the production of steam. Thus, it may be desirable to introduce features that increase the structural integrity or stiffness of the heater.

Referring back to fig. 9, two lines 106 are indicated, which are parallel to the major edges 101 and approximately midway between the major edges 101. They extend from the minor edge 102 to the fold axis 105 at an intermediate point, but do not extend all the way to the fold axis 105. These lines or similar lines may be used to form creases in a planar element by folding relatively sharp folds or creases at locations along line 106 prior to bending the planar element about midpoint fold axis 105. The folds are formed in the same direction and form an angled configuration in the planar member. This curvature is implemented such that the portions of the planar members on either side of the curve are in the desired facing relationship with the concave surfaces of the corrugated formations facing each other.

Fig. 12 shows a perspective view of a heater 110 formed with creases in this manner. The folds may be described as longitudinal because they are sized along the length of the heater 110. Fold 107 forms an outward facing angle. These have the effect of increasing the strength and rigidity of the heater 110 so that it can better resist outward bending under the force of the liquid absorbed by the porous material in the volume 112. In addition, the angled face provided by the folds allows the heater 110 to extend around more of the volume 112, thereby more securely holding the porous material in place.

The example of fig. 12 has a crease along line 106 depicted in fig. 9, such that the crease is not implemented in the region of the bend fold. This may make the formation of the curvature easier to achieve, since the planar element does not resist such a large bending in its central region. Alternatively, however, the two crease lines 106 may be replaced by a single crease line extending the full length of the planar element 100, across the central portion to be subjected to the bending folding. As a further alternative, more creases may be introduced. For example, each line 106 in fig. 9 may be replaced by two lines 106 each folded in the same direction. This would provide two angles and three angled faces for each half of the heater, providing a slightly hexagonal cross-section for the volume 112 instead of the slightly square cross-section illustrated in fig. 12. For example, additional creases may be used to add more structural rigidity to a heater made of a very thin and flexible material, although additional creases generally increase manufacturing complexity.

Fig. 13 shows a simple side view of a folding heater 110 configured as a nebulizer 70. Atomizer 70 includes a folded heater 110, such as the heater of fig. 10, and a portion of porous material 113 disposed within a volume 112 defined by the curvature of the planar element forming heater 110. The porous material may comprise any suitable wicking material. For example, it may be made of fibers grouped, bundled, filled, woven or non-woven into a fabric or fiber mass, with voids between adjacent fibers to provide capillary effect for absorption and wicking. Examples of fibrous materials include cotton (including organic cotton), ceramic fibers, and silica fibers. And does not exclude other suitable materials as will be apparent to the skilled person.

The planar element is not limited to a simple rectangular shape in the example of fig. 9. Fig. 14 shows a plan view of various alternative shapes. In this case, each planar element has a shaped end portion of smaller width. These are secondary edges that are folded together for insertion into a slot for mounting the atomizer, and the reduced width may allow a smaller slot to be used without reducing the amount of heater material available for heating and vaporizing liquid. Some examples include a narrow central portion having a reduced width compared to the width at the ends; this may make the fold curve easier to form because the amount of material that needs to be bent is reduced, allowing lower forces to be used.

It is also noted that many of the planar elements in fig. 14 include perforations, which are perforations cut or punched through the material of the planar element. Each aperture is small compared to the area of the planar element and the apertures are relatively closely packed and evenly distributed on the planar element, thereby comprising a plurality of apertures. For example, the perforations may be circular, or they may be elongated or slotted, as shown in the three examples on the right side of FIG. 14. The purpose of the perforations is to make it easier for the generated vapour to escape from the atomizer into the aerosol chamber to be collected by the airflow through the aerosol chamber. The liquid in the porous material in the atomizer is vaporized by the heat from the heater and can flow outwardly through the perforations into the free space of the aerosol chamber.

In designing the heater, it may be desirable to balance the increased convenience of steam flow provided by the additional perforations with the reduced amount of heater material available for heating. Thus, the optimal total area of perforations may be considered as compared to the area of heater material that generates heat and vaporizes it. For example, if we define the total heater material area without any perforations, the total area occupying the perforations may be in the range of about 5% to 30%, for example about 20% of the total heater material area. In any event, due to manufacturing limitations, it is useful that the total area of the perforations not exceed about 50%. Furthermore, if inductive heating is used, too large an open area (total area of perforations) may result in poor inductive coupling, while too small an open area makes it difficult for the generated steam to escape from the porous material.

Perforations, holes or openings may be provided for other purposes. Referring to fig. 11, it can be appreciated that the secondary end portion of the heater is inserted into a slot for mounting the atomizer. Although the heater material is part of a heater located in the aerosol chamber and is subject to temperature increases for heating purposes (in an inductive arrangement this unsupported portion of the heater is the portion disposed in the magnetic field of the work coil), the heat conducting properties of the heater material mean that heat will be conducted to the supported end within the socket. This may be acceptable if the socket is made of a heat resistant material, but in addition, or for other reasons, it is preferable to minimize the temperature rise at the support end of the heater. This may be achieved by providing one or more rows of perforations in the planar element parallel to the minor edge.

Fig. 15 shows a plan view of an exemplary planar element constructed in this manner. A row of perforations, eyelets, apertures, or openings 114 is cut through the material of planar element 100 toward each minor edge 102. The perforations are intended to be large enough (based on the total area of all perforations in the row) to remove enough material from the planar element to reduce heat transfer by conduction from one side of the row to the other. Thus, the planar element is divided by the perforation line 114 into a central portion 100A and two end portions 100B adjacent to the minor edges 102, a curved fold being formed in this central portion 100A and forming a portion generating heat. The perforations reduce heat transfer from the central portion 100A to the end portion 110B and thus reduce heat exposure to the remainder of the cartomizer via the connection of the heater to the cartomizer at the slot.

Fig. 16 shows a perspective view of the planar element of fig. 15 formed into a folded heater 100.

The perforations for steam escape and the perforations for inhibiting heat conduction may be combined in a single heater. For example, the two types of perforations may have different sizes or shapes.

Alternatively, the heater may be made from a planar element by bending the planar element about a different axis, which is orthogonal to the axis used in the folded embodiment.

Fig. 17 shows a plan view of an example planar element for making an alternative elongated heater. As previously mentioned, the planar element 100 has a rectangular shape delimited by two opposite major edges 101 and two opposite minor edges 102. The length parallel to the major edge, and therefore the longer dimension, is L1, and the width parallel to the minor edge, and therefore the shorter dimension, is L2. To form a properly scaled heater, the ratio of these dimensions L1: L2 may be in the range of, for example, 2: pi to 6: in the range of pi or in the range of 3: pi to 5: pi, but other ratios are not excluded. The area or portion of planar element 100 adjacent to major edge 101 may be considered major edge portion 101A.

To form a heater from a planar element 100, the planar element is forced into a curved shape, with the curvature about an axis parallel to the length of the planar element, in other words, parallel to the line shown at 114 in fig. 17. The bending action may be considered as a rolling of planar element 100, as indicated by the bending arrows in fig. 17, such that the planar element is rolled into a tube. Thus, the heater has a tubular form, length L_HIs greater than its width W_H(diameter in the case of a cylindrical tube) to provide the heater with the desired elongate form. For example, the tube may be formed to have a circular cross-section in a plane perpendicular to the length, but this is not required and other shapes may be used. For example, the cross-section may be elliptical.

Thus, in this example, the curvature of the planar element is over the entire extent of the planar element in the width direction. This is in contrast to the folded heater examples of fig. 9-13, where the bend is only over the central portion of the planar element in the length direction.

Fig. 18A shows an end view of an example heater 110 having a tubular form that may be formed from a planar element such as that of fig. 17. The planar elements have been given a curvature by rolling around a central axis x parallel to the length of the planar elements, so that the main edges 101 of the planar elements are adjacent to each other and form a cylindrical tube with a circular cross-section. This gives the heater 110 having a tubular form. In this example, the planar element has been rolled up such that two main edge portions 101A of the planar element near the main edge 101 overlap each other. The tubular shape enables the curved planar member to define a central cylindrical volume 112, i.e., a hollow space within the tube. This volume is used to contain a portion of the porous material to allow the heater 110 to be used in an atomizer.

Fig. 18B shows a perspective side view of the heater 110 of fig. 18A.

In such a configuration where the major edge portions 101A overlap, the tube is formed in a closed tubular form because of the length L along the heater 110_HThere are no openings. There are two options to achieve this. In a first alternative, the overlapping portions 101A may be separated from each other. Thus, they can slide freely between each other to reduce or enlarge the circumference of the tube and thus change the capacity of the volume 112. This may be useful when the porous material is installed into the volume when manufacturing the atomizer. The porous material must generally be tightly or tightly fitted within the tube so that it does not fall out when the atomizer is vertical, so it can be more easily fitted if the tube can expand. The tube may then be retracted back to its original circumference to more tightly grip the porous material. Further, if the porous material absorbs more or less liquid, the adjustment provided by the overlap may allow the heater to accommodate changes in the volume of the porous material.

In a second alternative, the overlapping portions 101A may be fixed or connected to each other to form a tube having a fixed circumference and a fixed volume capacity. The overlap may be secured, for example, by welding or crimping or any method capable of withstanding the temperature increase during operation of the heater. A fixed size heater may be preferred in designs where the width of the aerosol chamber around the heater is small, so that an increase in the volume of the atomizer may restrict the flow of air through the atomizer, or promote the formation of droplets in a reduced space.

In a further alternative, the planar element may be shaped by rolling up around the axis X in such a way that the main edges are adjacent to each other on either side of a small intermediate gap. The major edges do not touch and the major edge portions do not overlap.

Fig. 19A shows an end view of an example heater 110 formed in this manner. As with the previous examples, the tubular form of the heater 110 has a circular cross-section in a plane parallel to the width, with the planar element being curved around to define a central cylindrical volume 112 for containing the porous material. The two major edges 101 face each other on either side of the gap or space 116.

Fig. 19B shows a perspective side view of the heater of fig. 19A. The gap 116 between adjacent major edges 101 extends the entire length of the heater. Thus, the tubular form of the heater is open along the length of the heater. This configuration can be used to allow vapour formed by heating liquid in the porous material contained in the volume 112 to escape more easily into the aerosol chamber via the gap 116. Furthermore, if the planar element material is thin enough to allow some flexing of the tubular shape, the heater circumference may vary with the size of the porous material in the manner described by example for the overlapping edge portions, where the edge portions are free and not fixed to each other.

When a heater having the form of an elongated tube forms an atomizer by adding porous material to the volume 116 within the tube, there is a risk that the porous material may fall off the lower end of the tube when the atomizer is upright. The lower end of the tube is open and therefore the porous material may slide downwards, for example as it becomes heavier and the absorbed liquid is more lubricated. A tight fitting part of the porous material may avoid this effect.

An alternative approach is to form a tubular heater with a closed end.

Fig. 20 shows a plan view of a planar element configured to form an elongated heater in the form of a closed-end tube. The planar element 100 comprises a substantially rectangular portion as in the previous examples, which is delimited by two major edges 101 and two minor edges 102. An end portion is also provided in the form of a shaped portion 118, the size and shape of which corresponds to the desired cross-section of the tube into which the planar element 100 is to be bent. The shaped portion 118 is connected to one of the minor edges 102 at a junction 119 and extends outwardly from one of the minor edges 102. As previously described, the heater is formed by bending a planar element in a rolling action about an axis parallel to the length to form a tube open at both ends. The end portions 118 are then bent inwardly by folding across the joining zone 119. By moving the end portion 118 approximately 90 degrees, the end portion is moved to a position substantially covering the open end of the tube, thereby forming a tube that is closed at one end. In this example, the end portion is shown as having an elliptical shape and is adapted to close the end of a tube of elliptical cross-section.

Manufacture may preferably be carried out by inserting the desired porous material into the volume 112 defined by the curved planar element while the lower end of the tube is still open, and then bending the end portion into position to close the tube end. Alternatively, for open-ended and closed-ended tubes, the porous material may be placed on the planar element while the planar element is still flat, and the planar element rolled around the porous material to form a tubular form.

The end portion need not completely close the end of the tube. A gap or open space around some or all of the edges of the end portion may be advantageous to allow vapour to escape from the volume in the heater to the aerosol chamber around the heater. Thus, there is no need to form any seal or connection around the edges of the end portions. Furthermore, by providing potential support under the porous material while only partially closing the ends of the tube, the end portions may be specifically configured to enable steam to pass through the atomizer. For example, the end portion may have a size and/or shape that is smaller/less than the cross-section of the tube to increase the size of the gap around the end portion as it is bent into place. The end portion may be provided with apertures for the passage of steam. Thus, typically, the end portion at least partially closes or covers the lower end of the heater tube.

The porous material placed into the volume 112 to form the atomizer from the heater may be formed from fibers of various materials, as described above with respect to the folded heater form. In this case, a portion of the porous material may be used to fill or partially fill the volume 112 inside the heater tube. The tube may then be inserted into a slot configuration on the cartomizer component to support the heater in the desired cantilevered position.

An alternative to fibrous materials that are particularly compatible with tubular heater forms are porous elements in the form of rods or sticks of porous ceramic material. The porous ceramic includes a network of tiny pores or voids that can support capillary action and thus provide wicking capability to absorb liquid from the reservoir and transport it to the vicinity of the heater for vaporization. In this context, the porous ceramic rod may be inserted into the tubular heater after the heater is formed. The expandable circumference of the heater provided by the non-stationary main edge may contribute to this; the circumference can be opened for easier insertion of the rod and then the rolled up form will cause the heater to shrink again around the rod, thereby gripping it tightly for good contact between the heater and the ceramic. For this reason, the rod and tube ideally should have the same cross-sectional shape, although for unmatched shapes the overall effect is the same. However, the contact will be reduced, so that the heat transfer to the liquid can be reduced. However, some clearance between the outer surface of the ceramic rod and the inner surface of the heater may assist in the escape of vapour to the aerosol chamber. If the heater has a closed lower end as shown in fig. 20, a looser fit between the heater and the ceramic rod can be tolerated because the heater is not required to clamp the ceramic to hold the atomizer together.

Alternatively, the atomiser may be manufactured by providing a ceramic rod and then rolling up the planar element around the rod, preferably tightly or loosely.

The ceramic rod may be sized to be completely enclosed within the heater when the atomizer is assembled. For example, it may be the same length as the heater, or shorter than the heater. The heater is an external component of the cartomizer and then inserted into the slot of the cartomizer to mount the cartomizer.

Fig. 21 shows a perspective side view of an alternative configuration. The atomizer 70 includes a heater 110 in the form of a tube that is rolled around a porous element in the form of a ceramic rod 120. The ceramic rod 120 preferably coincides at its bottom with the lower edge 102A of the heater 110 to efficiently heat the liquid in the lower part of the rod without any waste of thermal energy. At the upper end, however, ceramic rods 120 protrude above the top edge 102B of heater 110. This allows the atomizer to be mounted into the socket only by the ceramic rod 120. The heater 110 need not be in contact with the socket so that potentially undesirable heat transfer from the heater to the socket material may be reduced or avoided.

To improve the release of the vapour from the nebuliser into the aerosol chamber, the tubular form heater may be provided with a plurality of perforations or apertures, as described for the folding heater with reference to figure 14. The perforations may be evenly distributed over the entire heater surface, or only over a portion of the heater surface, or may be provided at different densities (perforations per unit area) in different portions of the heater. As previously mentioned, the perforations may have any shape.

Fig. 22 shows a perspective side view of an elongated heater 110 in the form of a tube provided with perforations 122 evenly distributed over the heater surface. So that the steam can escape from all parts of the atomizer equally easily. As with the folded heater form, it may be desirable to balance the increased convenience of steam flow provided by the additional perforations with the reduced amount of heater material available for heating. Thus, the optimal total area of perforations may be considered as compared to the area of heater material that generates heat and delivers the heat for vaporization. For example, if we define the total heater material area without any perforations, the total area occupying the perforations may range from about 5% to 30%, such as about 20% of the total heater material area. In any event, due to manufacturing limitations, it is useful that the total area of the perforations not exceed about 50%. Furthermore, if inductive heating is used, too large an open area (total area of perforations) may result in poor inductive coupling, while too small an open area makes it difficult for the generated steam to escape from the porous material. Furthermore, since there is no open side configuration of the folded form, a larger opening area than for an elongated heater of the folded form may be used to allow sufficient vapor escape. For example, the total heater material area may be the total area of the planar element.

As described above, the example atomizer of fig. 21 can be mounted in a socket via a ceramic porous element. This prevents the socket from being directly exposed to the heat of the heater. In examples where the atomizer is installed via insertion of a heater into the socket, it may be beneficial to reduce the amount of heat that may be transferred from the heater to the socket material. The same method as for the folded heater can be used for the tubular form heater as described in fig. 15 and 16. One or more rows of perforations may be formed in the planar element substantially parallel to and closer to a minor edge intended to be the upper edge of the heater than to the opposite minor edge. In the case of induction heating, the portion of the planar element below the perforated row that is the main portion is intended to act as a pedestal and will therefore be the portion of the heater that generates thermal energy. The portion of the planar element above the row of perforations, i.e. the minor portion, is the portion to be inserted into the slot supporting the heater and will therefore be the portion requiring the least amount of heat. By reducing the amount of material available for heat conduction, the perforations will reduce the spread of heat from the base portion to the socket mounting portion, thus reducing the exposure of the socket to heat.

Fig. 23 shows a perspective side view of an elongated heater 110 in the form of a tube provided with a single row of perforations, holes or apertures 114 for reducing heat conduction to the socket mounting portion of the heater 110.

The coiled structure of the tubular form heater example may provide the heater with a sufficient degree of structural rigidity or integrity to maintain its desired shape and support the porous element therein regardless of the orientation of the steam supply system.

For a folded or tubular (rolled) heater, the planar element should be made of an electrically conductive material with sufficient electrical resistance to be able to be heated via the inductive effect of induced eddy currents or by direct supply of current through the heater. The planar element is a sheet and thus may be a sheet of metal material, wherein suitable metals include mild steel, ferritic stainless steel, aluminum, nickel-chromium alloys (nichrome) and alloys of these materials. Further, the sheet may be a laminate of two or more materials. The sheet thickness should be thin enough to allow the curved shape to be formed to make the heater without requiring excessive force, and thick enough to maintain the curved shape after formation without returning the planar element to the flat plate, and to maintain any induced bias, such as the tendency of a folded heater to bounce off at the secondary edge or the tendency of a rolled heater to return to its original circumference after a forced increase in its circumference. Furthermore, it may be desirable to balance the thickness of the sheet material that meets these requirements with the need to provide sufficient volume of resistive material to provide sufficient heating (recall that in some examples the amount of material is reduced by perforations). Thus, the planar elements may have a thickness in the range of about 10 μm to about 70 μm, such as about 20 μm to about 50 μm, or about 30 μm to about 40 μm. These values may be the total thickness of the sheet including any support elements or coatings. If the thickness is not sufficient, the heater may lack sufficient structural integrity, although this may be compensated for using additional material for the component. Suitable thicknesses may vary between different embodiments, for example for folded and tubular forms.

As described above, the heater according to the present disclosure may be a base for induction heating, as described with respect to the cartomizer shown in fig. 2-6. For induction heating, no electrical connection to the heater is required. Alternatively, the heater may be used as part of an atomizer operating via joule or ohmic heating, in which case an electrical connection to the heater is required to enable current to flow through the heater. In either case, the atomizer formed by the heater may be supported by mounting in a socket configuration as described above or by other means, and this mounting may or may not support the heater in a cantilevered manner.

In conclusion, the present disclosure shows by way of illustration various embodiments in which the claimed invention may be practiced, in order to solve various problems and to advance the art. The advantages and features of the present disclosure are merely representative of embodiments and are not exhaustive and/or exclusive. They are used only to aid in understanding and teaching the claimed invention. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claims. Various embodiments may suitably comprise or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc., in addition to those specifically described herein. The present disclosure may include other inventions not presently claimed, but which may be claimed in the future.