JP2024536567A - Multi-liquid cartridge assembly for induction heated aerosol generators - Google Patents

Abstract

The present invention relates to a cartridge assembly for an aerosol generating device. The cartridge assembly comprises an airflow channel. The cartridge assembly further comprises a first tubular liquid storage portion and a second tubular liquid storage portion. The first tubular liquid storage portion is disposed upstream of the second tubular liquid storage portion. The airflow channel is generally surrounded by the first and second tubular liquid storage portions. The present invention further relates to an aerosol generating system comprising an aerosol generating device and the cartridge assembly. The present invention further relates to a method for manufacturing the cartridge assembly.Selected Figures:

Description

The present disclosure relates to a cartridge assembly for an aerosol generating device. The present disclosure further relates to an aerosol generating device. The present disclosure further relates to an aerosol generating system comprising an aerosol generating device and a cartridge assembly. The present disclosure further relates to a method for manufacturing the cartridge assembly.

It is known to provide an aerosol generating device for generating an inhalable vapour. Such a device may heat an aerosol-forming substrate contained in a cartridge or aerosol-generating article without combusting the aerosol-forming substrate. The heating arrangement may be an induction heating arrangement and may comprise an induction coil and a susceptor. The susceptor may be part of the device or may be part of the article or cartridge.

When heated to a target temperature, the aerosol-forming substrate vaporizes to form an aerosol. The aerosol-forming substrate may be present in solid or liquid form. The liquid aerosol-forming substrate may be contained within a liquid reservoir and delivered to the heating element via a capillary component. The liquid reservoir may form part of a replaceable or refillable cartridge assembly.

It is desirable to have a cartridge for generating a customizable aerosol. It is desirable to have a cartridge for aerosolizing multiple liquid aerosol-forming substrates. It is desirable to have a cartridge for aerosolizing multiple liquid aerosol-forming substrates simultaneously. It is desirable to have a cartridge for aerosolizing multiple liquid aerosol-forming substrates individually. It is desirable to provide a cartridge that can be used within an existing inductively heated aerosol generator cavity. It is desirable to have a cartridge that can be used within an existing inductively heated aerosol generator cavity without requiring associated modifications. It is desirable to have a cartridge that can be used within an existing inductively heated aerosol generator cavity without requiring associated modifications. It is desirable to provide a cartridge with a compact design. It is desirable to provide a cartridge with improved air management in a compact design. It is desirable to provide a cartridge with a simplified design. It is desirable to provide a cartridge with only a small number of parts.

According to one embodiment of the present invention, a cartridge assembly for an aerosol generating device is provided. The cartridge assembly may include an airflow channel. The cartridge assembly may further include a first tubular liquid storage portion and a second tubular liquid storage portion. The first tubular liquid storage portion may be disposed upstream of the second tubular liquid storage portion. The airflow channel may be generally circumscribed by the first and second tubular liquid storage portions.

According to one embodiment of the present invention, a cartridge assembly for an aerosol generating device is provided. The cartridge assembly includes an airflow channel. The cartridge assembly further includes a first tubular liquid storage portion and a second tubular liquid storage portion. The first tubular liquid storage portion is disposed upstream of the second tubular liquid storage portion. The airflow channel is generally circumscribed by the first and second tubular liquid storage portions.

By providing a cartridge assembly with two tubular liquid storage portions, aerosolization can be improved. By providing a cartridge assembly with two tubular liquid storage portions, two different liquid aerosol-forming substrates, sensory media, or mixtures thereof can be aerosolized individually. By providing a cartridge assembly with two tubular liquid storage portions, two different liquid aerosol-forming substrates, sensory media, or mixtures thereof can be aerosolized simultaneously. By providing a cartridge assembly with two tubular liquid storage portions, a variation of the flavor of the aerosol can be made. By providing a cartridge assembly with two tubular liquid storage portions, the amount of nicotine contained in the aerosol can be adjusted. By providing a cartridge assembly with two tubular liquid storage portions, a flexible variation of the aerosol can be made. By providing a cartridge assembly with two tubular liquid storage portions, a compact design can be made. By providing a cartridge assembly with two tubular liquid storage portions, a compact design can be made, but flexible variation of the aerosol can be made.

Aerosol generating devices are known that have a cylindrical cavity for inserting an aerosol generating article or cartridge. The cylindrical cavity may include multiple inductor coils for heating the aerosol generating article or cartridge. The multiple inductor coils may be individually powered. The cavity may have limited space. Users desire variety and improvement in the aerosol generated. Variety in aerosols may enhance a customized experience. However, customization is difficult in devices with cavities that have limited space. By providing a cartridge assembly with two tubular liquid storage portions, the aerosol generated in an existing aerosol generating device may be customized.

There must be no direct fluid communication between the first and second tubular liquid storage portions.

The first and second tubular liquid storage portions may include the same liquid aerosol-forming substrate. The first and second tubular liquid storage portions may include different liquid aerosol-forming substrates. The aerosol-forming substrate may include a liquid sensory medium. The aerosol-forming substrate may be a liquid sensory medium. The first and second tubular liquid storage portions of the cartridge assembly may include one or both of a liquid aerosol-forming substrate and a liquid sensory medium, or a mixture thereof, independently of each other. The liquid sensory medium may include a flavoring agent. The liquid sensory medium may include nicotine. The liquid aerosol-forming substrate or liquid sensory medium may include a flavoring agent, such as menthol or an herbal compound. The liquid aerosol-forming substrate or liquid sensory medium may include nicotine. The liquid aerosol-forming substrate or liquid sensory medium may include a botanical content, such as CBD. By using different liquid aerosol-forming substrates, sensory media, or mixtures thereof in the first and second tubular liquid storage portions, the user can vary the amount of flavoring agent, nicotine, or CBD. For example, one of the first and second tubular liquid storage portions contains a flavorant and the other of the tubular liquid storage portions contains nicotine, whereby the user can vary the generation of two aerosols containing either the flavorant or the nicotine, or can decide to mix these two aerosols. Alternatively, the first and second tubular liquid storage portions may contain the same aerosol-forming substrate, sensory medium, or mixtures thereof, whereby the user can modify the strength of the aerosol generated. Thereby, the user can change, for example, the amount of nicotine or flavorant.

The first and second tubular liquid storage portions may have the same volume. The first tubular liquid storage portion may have a larger volume than the second tubular liquid storage portion, or vice versa. The first and second tubular liquid storage portions may have a length extending in a longitudinal direction of the cartridge assembly. The first and second tubular liquid storage portions may have the same length. The first and second tubular liquid storage portions may have different lengths. One or both of the first and second tubular liquid storage portions may be circular in cross section. One or both of the first and second tubular liquid storage portions may be elliptical, rectangular, or polygonal in cross section. The cross-sectional diameter may be the same along the length of the first and second tubular liquid storage portions. The cross-sectional diameter may vary along the length of the first and second tubular liquid storage portions. One or both of the first and second tubular liquid storage portions may be elongated in shape. One or both of the first and second tubular liquid storage portions may be cylindrical in shape. The length of the first and second tubular liquid storage portions may be greater than the cross-sectional diameter.

The first and second tubular liquid storage portions may include an outer tubular wall. The outer tubular wall may extend radially relative to a longitudinal axis of the cartridge assembly. The outer tubular wall may be divided into a first outer tubular wall and a second outer tubular wall. The first outer tubular wall may confine the first tubular liquid storage portion and the second outer tubular wall may confine the second tubular liquid storage portion. Alternatively, the first and second tubular liquid storage portions may share one single outer tubular wall.

One or both of the first and second tubular liquid storage portions may have the same outer diameter, thereby allowing for a compact design. The outer diameter of the outer tubular wall or the first and second outer tubular walls of the first and second tubular liquid storage portions may be measured in a direction perpendicular to the longitudinal axis of the cartridge assembly.

The airflow channel may be a straight airflow channel. The airflow channel may extend along a longitudinal axis of the cartridge assembly. The airflow channel may be coaxially surrounded by the first and second tubular liquid storage portions. The airflow channel may be a central airflow channel. The airflow channel may have the same longitudinal axis as the first and second tubular liquid storage portions. The airflow channel may have the same longitudinal axis as the cartridge assembly.

The first tubular liquid storage portion may comprise a first inner tubular core element. The first inner tubular core element may extend along a longitudinal axis of the first tubular liquid storage portion. The second tubular liquid storage portion may comprise a second inner tubular core element. The second inner tubular core element may extend along a longitudinal axis of the second tubular liquid storage portion. The first and second inner tubular core elements may be coaxially circumscribed by the first and second tubular liquid storage portions.

The first and second inner tubular core elements may have a length extending longitudinally of the cartridge assembly. The length of the first and second inner tubular core elements may be the same as the length of the first and second tubular liquid storage portions, respectively.

The first and second inner tubular core elements may be hollow. The first and second inner tubular core elements may be circular in cross section. The first and second inner tubular core elements may have the same cross-sectional shape as the first and second tubular liquid storage portions, respectively.

The cross-sectional diameter of the first and second inner tubular core elements may be smaller than the diameter of the first and second tubular liquid storage portions. The diameter of the first and second inner tubular core elements may be about half the diameter of the first and second tubular liquid storage portions. The diameter of the first and second inner tubular core elements may be about one-third or about one-quarter the diameter of the first and second tubular liquid storage portions.

The first inner tubular core element can include a first inner tubular wall. The second inner tubular core element can include a second inner tubular wall. The first and second inner tubular walls can confine the airflow channel. The first and second inner tubular core elements can be one single element. The first and second inner tubular core elements can be two different elements.

The first and second tubular liquid storage portions may be separated by a transverse wall. The transverse wall may be oriented perpendicular to the longitudinal axis of the cartridge assembly. The transverse wall may separate the liquid aerosol-forming substrate, sensory medium, or mixture thereof contained within the first and second tubular liquid storage portions. The transverse wall may be liquid impermeable. The transverse wall may prevent liquid exchange of the liquid aerosol-forming substrate, sensory medium, or mixture thereof contained within the first and second tubular liquid storage portions.

The transverse wall may have the same cross-sectional shape as the first and second tubular liquid storage portions. The transverse wall may have the same outer circumference as the inner circumference of the outer tubular wall or the inner circumference of the first and second outer tubular walls of the first and second tubular liquid storage portions.

The transverse wall may have a diameter measured perpendicular to the longitudinal axis of the cartridge assembly. The diameter of the transverse wall may be the same as the inner diameter of the outer tubular wall or the inner diameter of the first and second outer tubular walls of the first and second tubular liquid storage portions.

The transverse wall may comprise an opening. The opening may be a central opening. The opening may be a central hole. The airflow channel may extend through the opening. The first and second inner tubular core elements may be coupled to the transverse wall. The transverse wall may position the first and second inner tubular core elements within the first and second tubular liquid storage portions. The transverse wall may stabilize the outer tubular wall. Alternatively, the first and second tubular liquid storage portions may be two separate elements each comprising two of the transverse walls.

The cartridge assembly may include a distal air inlet and a proximal air outlet. The airflow channel may fluidly connect the distal air inlet with the proximal air outlet. The airflow channel may include a Venturi element. The Venturi element may connect the first inner tubular core element with the second inner tubular core element.

The venturi element may be disposed between the first and second inner tubular core elements. The venturi element may be in fluid communication with the first and second inner tubular core elements. The venturi element may provide a mixture of aerosols generated within the first and second inner tubular core elements. The airflow channel may be disposed within the venturi element. The venturi element may include a converging inlet portion and an expanding outlet portion. The first and second inner tubular core elements may be one single element with the venturi element at a central position between the first and second tubular liquid storage portions. The venturi element may be aligned with the transverse wall.

The first inner tubular wall may comprise a first tubular fluid permeable portion. The second inner tubular wall may comprise a second tubular fluid permeable portion. The first and second fluid permeable portions may be liquid permeable. The first and second fluid permeable portions may have the same permeability. The first and second fluid permeable portions may have different permeabilities. The permeability of the first and second fluid permeable portions may depend on the sensory medium or mixtures thereof of the liquid aerosol-forming substrate contained in the first and second tubular liquid storage portions.

The first tubular fluid permeable portion may be disposed at a distal end of the first tubular liquid storage portion. The second tubular fluid permeable portion may be disposed at a distal end of the second tubular liquid storage portion. A portion of the first and second inner tubular walls may be the first and second tubular fluid permeable portions. For example, 20 percent of the surface area of the first inner tubular wall may be the first tubular fluid permeable portion, preferably 25 percent. For example, 20 percent of the surface area of the second inner tubular wall may be the second tubular fluid permeable portion, preferably 25 percent.

The first and second tubular liquid storage portions may comprise a high retention and release material. During use of the cartridge assembly, the liquid aerosol-forming substrate, the sensory medium, or a mixture thereof may not contact the first and second tubular fluid-permeable portions. The high retention and release material may keep the first and second tubular fluid-permeable portions moist. The high retention and release material may uniformly disperse the liquid aerosol-forming substrate, the sensory medium, or a mixture thereof contained in the first and second tubular liquid storage portions. The high retention and release material may generate a more uniform aerosol.

The first tubular fluid permeable portion may be at least partially surrounded by a first high retention and release material. The second tubular fluid permeable portion may be at least partially surrounded by a second high retention and release material. The first and second high retention and release materials may be configured to prevent liquid aerosol-forming substrates stored in the first and second tubular liquid storage portions from coming into direct contact with the first and second tubular fluid permeable portions. The first and second high retention and release materials may control the supply of aerosol-forming substrates.

The high retention and release material may have a fibrous or spongy structure. Preferably, the high retention and release material comprises a web, mat, or bundle of fibers. The fibers may be generally aligned and transport the liquid in an aligned direction. Alternatively, the high retention and release material may comprise a porous or foam-like material. The high retention and release material may comprise any suitable material or combination of materials. Examples of suitable materials include spongy or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, fibrous materials made of spun or extruded fibers, or ceramic or glass.

The first and second tubular fluid-permeable portions may be porous. The porosity of the first and second fluid-permeable portions may be between 35 percent and 80 percent, preferably between 45 percent and 65 percent, and most preferably between 50 percent and 60 percent.

As used herein, "porosity" is defined as the fraction of a material that is void, per unit volume. Porosity is derived using standard methods and equations, which give a decimal value for porosity. Knowing the pore volume (Vp) of a defined volume of material and its total volume (Vt), the porosity (Pt) is given by the ratio Vp/Vt. To express porosity as a percentage, simply multiply the decimal by 100%. For example, Pt = 0.51, so 0.51 x 100% = 51%.

The first and second tubular porous portions may have a porosity suitable to allow controlled flow of the liquid aerosol-forming substrate, sensory medium, or mixture thereof contained in the first and second tubular liquid storage portions. The first and second tubular porous portions may have the same porosity. The first and second tubular porous portions may have different porosities. The porosity may depend on the viscosity of the liquid aerosol-forming substrate, sensory medium, or mixture thereof contained in the first and second tubular liquid storage portions.

The first and second tubular liquid storage portions and the airflow channel may be integrally formed. The first and second tubular liquid storage portions and the airflow channel may be contained within a single cartridge assembly element. The single cartridge element may comprise an outer tubular wall, a transverse wall, and first and second inner tubular core elements, and may comprise first and second tubular fluid permeable portions. The single cartridge element may further comprise a Venturi element.

The cartridge assembly may further comprise a first heating element and a second heating element. The airflow channel may comprise the first and second heating elements. The first and second heating elements may be disposed along a longitudinal axis of the cartridge assembly. Thereby, the first and second heating elements may be disposed at an interior position of the cartridge assembly. Overheating of the outer wall of the aerosol generating device during use of the aerosol generating device can be prevented. The first inner tubular core element may comprise a first heating element. The first heating element may be disposed in the first tubular fluid permeable portion. The second inner tubular core element may comprise a second heating element. The second heating element may be disposed in the second tubular fluid permeable portion.

The first and second heating elements may be independently inductively heated elements. The first and second heating elements may comprise a susceptor material. The first heating element may comprise a first susceptor. Preferably, the first susceptor may be a first hollow tubular susceptor. More preferably, the first hollow tubular susceptor may be in direct contact with a coaxially surrounded first hollow tubular wick. The second heating element may comprise a second susceptor. Preferably, the second susceptor may be a second hollow tubular susceptor. More preferably, the second hollow tubular susceptor may be in direct contact with a coaxially surrounded second hollow tubular wick.

The first and second heating elements may be the same. Alternatively, the first and second heating elements may be different. For example, the first heating element may comprise more susceptor material than the second heating element, or vice versa. The first heating element may comprise a different susceptor material than the second heating element, or vice versa. Heating elements with different susceptor materials may have different heating profiles. It may be advantageous to provide a cartridge assembly with different heating elements. The first heating element may be a heating element that generates a higher temperature than the second heating element. The liquid aerosol-forming substrate, sensory medium, or mixture thereof contained within the second tubular liquid storage portion may be exposed to a lower temperature than the liquid aerosol-forming substrate, sensory medium, or mixture thereof contained within the first tubular liquid storage portion.

The first tubular fluid permeable portion can be in fluid communication from the first tubular liquid storage portion to the first hollow tubular susceptor by capillary action of the first hollow tubular wick. The second tubular fluid permeable portion can be in fluid communication from the second tubular liquid storage portion to the second tubular susceptor by capillary action of the second hollow tubular wick. The first hollow tubular susceptor, the first hollow tubular wick, the first fluid permeable portion, and the first tubular liquid storage portion may have the same longitudinal axis. The second hollow tubular susceptor, the second hollow tubular wick, the second porous portion, and the second tubular liquid storage portion may have the same longitudinal axis.

The first and second tubular liquid storage portions may include a polymeric compound. Preferably, the polymeric compound may be an antistatic compound. The first and second tubular liquid storage portions may include a material that reduces adhesion of the liquid aerosol-forming substrate, the sensory medium, or a mixture thereof to the inner walls of the first and second liquid storage portions. Thereby, undesirable capillary effects of the inner walls of the first and second tubular liquid storage portions may be reduced. The liquid aerosol-forming substrate, the sensory medium, or a mixture thereof may be retained at a distal position within the first and second liquid storage portions even when the liquid aerosol-forming substrate, the sensory medium, or a mixture thereof is nearly depleted. The liquid aerosol-forming substrate, the sensory medium, or a mixture thereof may be retained at a distal position of the first and second tubular liquid storage portions when the cartridge assembly is in an upright position. The liquid aerosol-forming substrate, the sensory medium, or a mixture thereof may be retained near the first and second tubular fluid-permeable portions, respectively.

The cartridge assembly may further comprise a mouthpiece. The mouthpiece may be attached to a proximal end of the second tubular liquid storage portion. The mouthpiece may be a tubular mouthpiece. Alternatively, the mouthpiece may have a tubular distal portion and a tapered proximal portion. The mouthpiece may be hollow. The mouthpiece may comprise a tubular outer wall. The outer tubular wall may have an outer diameter and an inner diameter measured in a direction perpendicular to the longitudinal axis of the cartridge assembly. The outer diameter of the outer tubular wall of the mouthpiece may be the same as the outer diameter of the outer wall of the second tubular liquid storage portion.

The mouthpiece may comprise a tubular core element. The tubular core element may be configured to reduce the formation of condensation. The hollow tubular core element may comprise a tubular wall. The tubular core element may be disposed at the center of the mouthpiece. The tubular core element may be disposed on a longitudinal axis of the cartridge assembly. The tubular core element may be aligned with the first and second inner tubular core elements of the first and second tubular liquid storage portions. The tubular core element may have an inner diameter measured in a direction perpendicular to the longitudinal axis of the cartridge assembly. The inner diameter of the tubular core element of the mouthpiece may be larger than the inner diameter of the second inner tubular core element. The inner diameter of the tubular core element of the mouthpiece may be smaller than the inner diameter of the outer tubular wall of the mouthpiece. The inner diameter of the tubular core element may be about one-third the diameter of the mouthpiece. The tubular core element of the mouthpiece may have a length measured in a direction along the longitudinal axis of the cartridge assembly. The length of the tubular core element may be less than the length of the mouthpiece measured in the same direction. The length of the tubular core element may be about half the length of the mouthpiece. After exiting the tubular core element, the velocity of the aerosol flow may decrease. The aerosol may be further homogenized after exiting the tubular core element. The inside of the tubular wall of the tubular core element may be exposed to a higher temperature than the outside of the tubular wall. The tubular core element may prevent or reduce the formation of condensation. Condensation and droplet formation of the aerosol on the inside of the tubular wall of the tubular core element may be prevented or reduced. During use, the tubular wall of the tubular core element may have a higher temperature than the outer tubular wall of the mouthpiece. Thereby, the formation of condensation may be prevented or reduced.

The mouthpiece may be constructed of a high retention material configured to prevent condensation. As used herein, a "high retention material" is a material that can absorb and/or store liquid (e.g., aqueous liquid) and transport the liquid (e.g., by capillary action). For example, the liquid may be transported away from the inside of the outer tubular wall of the mouthpiece. The liquid aerosol-forming substrate or liquid residue of the aerosol-forming substrate may condense on the inside of the outer tubular wall. The high retention material may surround a tubular core element of the mouthpiece. The high retention material may surround a distal portion of the tubular core element of the mouthpiece, such that condensation may be absorbed when the cartridge assembly is in an upright position with the distal end pointing toward the center of gravity. The high retention material may be, for example, cotton.

The mouthpiece may comprise a distal wall. The distal wall is configured to seal the second liquid storage portion. The distal wall may seal the proximal opening of the second tubular liquid storage portion. By providing the distal wall of the mouthpiece as a sealing element for the second tubular liquid storage portion, a separate sealing element is not required.

The distal wall may have a diameter measured perpendicular to the longitudinal axis of the cartridge assembly. The diameter of the distal wall may be smaller than the outer diameter of the outer tubular wall of the mouthpiece. The distal wall may have a diameter the same as the inner diameter of the outer tubular wall of the mouthpiece. The distal wall may have an outer diameter the same as the inner diameter of the outer tubular wall of the second tubular liquid storage portion or the second outer tubular wall.

The distal wall of the mouthpiece may provide a fluid-tight seal to the second tubular liquid storage portion. The distal wall may be connectable to the second tubular liquid storage portion by a press-fit connection, a mating connection, a snap-fit, or a bayonet-type connection.

The distal wall may include an opening. The opening may be a central opening. The opening may have a diameter the same as the outer diameter of the second inner tubular core element. The opening may be configured to receive a proximal portion of the second inner tubular core element. The opening may position the second inner tubular core element within the second tubular liquid storage portion.

The distal wall may be configured to distally receive a proximal portion of the second inner tubular core element. The mouthpiece tubular core element may be coupled to the distal wall proximal to the distal wall.

The cartridge assembly may further include a distal sealing element. The distal sealing element may be configured to seal a distal opening of the first tubular liquid storage portion. The distal sealing element may have a diameter measured perpendicular to the longitudinal direction of the cartridge assembly. The distal sealing element may have an outer diameter equal to the inner diameter of the outer tubular wall or the first tubular wall of the first tubular liquid storage portion.

The distal sealing element may provide a fluid-tight seal to the first tubular liquid storage portion. The distal sealing element may be connected to the first tubular liquid storage portion by a press-fit connection, a mating connection, a snap-fit, or a bayonet-type connection.

The distal sealing element may include an opening. The opening may be a central opening. The opening may have an inner diameter the same as the outer diameter of the first inner tubular core element. The opening may be configured to receive a distal portion of the first inner tubular core element. The opening may position the first inner tubular core element within the first tubular liquid storage portion.

The distal sealing element may be configured to receive a distal portion of the first inner tubular core element from the proximal side. The distal sealing element may include a distal air inlet. The opening of the distal sealing element may be the distal air inlet.

The cartridge assembly may further include a first tubular core air management element and a second core air management element.

The cartridge assembly may have a cylindrical shape with an outer diameter measured perpendicular to the longitudinal axis of the cartridge assembly. The diameter may be between 5 millimeters and 10 millimeters, and preferably between 6 millimeters and 8 millimeters.

The cartridge assembly may have a length measured in a direction along the longitudinal axis of the cartridge assembly. The length may be between 35 millimeters and 75 millimeters, and preferably between 45 millimeters and 60 millimeters.

The outer wall of the cartridge assembly may be 0.1 millimeters to 0.9 millimeters, preferably 0.3 millimeters to 0.5 millimeters thick. The first and second outer walls of the cartridge assembly may be 0.1 millimeters to 0.9 millimeters, preferably 0.3 millimeters to 0.5 millimeters thick.

The length of the first and second tubular liquid storage portions may be between 8 mm and 20 mm, preferably between 10 mm and 15 mm.

The cartridge assembly may further comprise a third tubular liquid storage portion. The third liquid storage portion may be disposed downstream of the second tubular liquid storage portion. Another transverse wall may seal the proximal opening of the second tubular liquid storage portion. The another transverse wall may have the same characteristics as the transverse wall described above. The proximal end of the third tubular liquid storage portion may be sealed by the distal wall of the mouthpiece. The third liquid storage portion may comprise a third inner tubular core element having the same characteristics as the first and second inner tubular core elements. There may be another venturi element connecting the second and third inner tubular core elements. The third liquid storage portion may include a third liquid aerosol-forming substrate different from the first and second aerosol-forming substrates. This may allow further customization of the generated aerosol.

The present invention further relates to an aerosol generation system comprising a cartridge assembly as described herein and an aerosol generation device. The aerosol generation device may comprise a heating chamber for receiving the cartridge assembly. The aerosol generation device may further comprise at least one inductor coil. The aerosol generation device may be configured to inductively heat the cartridge assembly. The inductor coil may at least partially surround a periphery of the heating chamber.

The present invention further relates to an aerosol generation system comprising a cartridge assembly and an aerosol generation device as described herein. The aerosol generation device comprises a heating chamber for receiving the cartridge assembly. The aerosol generation device further comprises at least one inductor coil. The aerosol generation device is configured to inductively heat the cartridge assembly. The inductor coil at least partially surrounds the periphery of the heating chamber.

The aerosol generator of the aerosol generation system may include a first inductor coil and a second inductor coil. The first inductor coil may be disposed upstream of the second inductor coil. The first and second inductor coils may be simultaneously powered. The first and second inductor coils may be separately powered. The first inductor coil may be disposed at a distal end of the first tubular liquid storage portion. The second inductor coil may be disposed at a distal end of the second tubular liquid storage portion. The first inductor coil may be configured to inductively heat the first susceptor. The second inductor coil may be configured to inductively heat the second susceptor. The first and second inductor coils may be the same. Alternatively, the first and second inductor coils may be different. For example, one of the two inductor coils may include more turns than the other.

The heating chamber of the aerosol generator of the aerosol generating system may not include a susceptor material.

The present invention further relates to a method of manufacturing a cartridge assembly for an aerosol generating device. The method may include providing a cartridge assembly component comprising an airflow channel, a first tubular liquid storage portion and a second tubular liquid storage portion. The airflow channel of the provided cartridge assembly may be coaxially surrounded by the first and second tubular liquid storage portions. The first tubular liquid storage portion of the provided cartridge assembly may be upstream of the second tubular liquid storage portion. The first tubular liquid storage portion of the provided cartridge assembly may comprise a first internal tubular wall and the second tubular liquid storage portion may comprise a second internal tubular wall. The first internal tubular wall of the provided cartridge assembly may comprise a first fluid permeable portion and the second internal tubular wall may comprise a second fluid permeable portion. The method may further include inserting a first susceptor and wick element into the first fluid permeable portion from a distal end of the cartridge assembly, and inserting a second susceptor and wick element into the second fluid permeable portion from a proximal end of the cartridge assembly. The method may further include inserting a liquid aerosol-forming substrate into the first tubular liquid storage portion from a distal end of the cartridge assembly. The method may further include sealing the distal end of the cartridge assembly with a distal sealing element. The method may further include rotating the cartridge assembly by about 180 degrees. The method may further include inserting a liquid aerosol-forming substrate into the second tubular liquid storage portion from a proximal end of the cartridge assembly. The method may further include sealing the second tubular liquid storage portion with a distal end of the mouthpiece.

The present invention further relates to a method of manufacturing a cartridge assembly for an aerosol generating device. The method includes providing a cartridge assembly component including an airflow channel, a first tubular liquid storage portion, and a second tubular liquid storage portion. The airflow channel of the provided cartridge assembly is coaxially surrounded by the first and second tubular liquid storage portions. The first tubular liquid storage portion of the provided cartridge assembly is upstream of the second tubular liquid storage portion. The first tubular liquid storage portion of the provided cartridge assembly includes a first internal tubular wall, and the second tubular liquid storage portion includes a second internal tubular wall. The first internal tubular wall of the provided cartridge assembly includes a first fluid permeable portion, and the second internal tubular wall includes a second fluid permeable portion. The method further includes inserting a first susceptor and wick element into the first fluid permeable portion from a distal end of the cartridge assembly, and inserting a second susceptor and wick element into the second fluid permeable portion from a proximal end of the cartridge assembly. The method further includes inserting the liquid aerosol-forming substrate into the first tubular liquid storage portion from the distal end of the cartridge assembly. The method further includes sealing the distal end of the cartridge assembly with a distal sealing element. The method further includes rotating the cartridge assembly by approximately 180 degrees. The method further includes inserting the liquid aerosol-forming substrate into the second tubular liquid storage portion from the proximal end of the cartridge assembly. The method further includes sealing the second tubular liquid storage portion with the distal end of the mouthpiece.

The hollow tubular wick may include cotton. The hollow tubular wick may be made of cotton.

The hollow tubular wick may be a porous element. The hollow tubular wick may have the ability to absorb liquid from the airflow. The hollow tubular wick may be composed of a capillary material. The capillary material may have a fibrous or cavernous structure. The capillary material preferably comprises a bundle of capillaries. For example, the capillary material may comprise a plurality of fibers or threads, or other fine tubes. The fibers or threads may be generally aligned to transport liquid from a distal portion of the hollow tubular wick to a proximal portion of the hollow tubular wick. Alternatively, the capillary material may comprise a cavernous or foam-like material. The structure of the capillary material may form a plurality of small holes or tubes through which liquid can be transported by capillary action. The capillary material may comprise any suitable material or combination of materials. Examples of suitable materials are sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metal or plastic materials, fibrous materials, such as fibrous materials made of spun or extruded fibers (such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, ethylene or polypropylene fibers, nylon fibers or ceramics). The capillary material may have any suitable capillary action and porosity to be used with different liquid physical properties. The liquid has physical properties including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure that allow the liquid to be moved through the capillary material by capillary action. The capillary material may be configured to transport the aerosol-forming substrate to the proximal portion of the wick element and to the susceptor element. The capillary material may extend into the gaps in the susceptor element.

As used herein, the term "liquid sensory medium" refers to a liquid composition capable of modifying an airflow that comes into contact with the liquid sensory medium. The modification of the airflow may be one or more of forming an aerosol or vapor, cooling the airflow, and filtering the airflow. For example, the liquid sensory medium may include an aerosol-forming substrate capable of releasing a volatile compound capable of forming an aerosol or vapor. Preferably, the aerosol-forming substrate in the liquid sensory medium is or includes a flavoring agent. Alternatively, or additionally, the liquid sensory medium may include one or both of a cooling material for cooling the airflow passing through the liquid sensory medium, and a filtering material for capturing undesirable constituents in the airflow. Water may be used as a cooling material. Water may be used as a filtering material for capturing particles, such as dust particles, from the airflow. The liquid sensory medium may function as one or more of a nicotine-delivering liquid, a flavoring, and a bulking agent.

As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds capable of forming an aerosol or vapor. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be in solid or liquid form. The terms "aerosol" and "vapor" are used interchangeably.

The aerosol-forming substrate may be a portion of the liquid held in the liquid storage portion of the cartridge assembly. The aerosol-forming substrate may be a portion of the liquid sensory medium held in the liquid storage portion of the cartridge assembly. The liquid storage portion may contain a liquid aerosol-forming substrate. Alternatively, or in addition, the liquid storage portion may contain a solid aerosol-forming substrate. For example, the liquid storage portion may contain a suspension of a solid aerosol-forming substrate and a liquid. Preferably, the liquid storage portion may contain a liquid aerosol-forming substrate.

Preferably, a liquid nicotine or flavour/flavour-containing aerosol-forming substrate can be used in the liquid storage portion of the cartridge assembly.

The aerosol-forming substrate may comprise nicotine. The nicotine-containing aerosol-forming substrate may be a nicotine salt matrix.

The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material comprising volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise a homogenised plant-derived material. The aerosol-forming substrate may comprise a homogenised tobacco material. The homogenised tobacco material may be formed by agglomerating particulate tobacco.

The aerosol-forming substrate may include at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol in use and is substantially resistant to thermal decomposition at the operating temperature of the device. Suitable aerosol formers are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). A preferred aerosol former is a polyhydric alcohol or mixture thereof (such as triethylene glycol, 1,3-butanediol, etc.). Preferably, the aerosol former is glycerin. When present, the homogenized tobacco material may have an aerosol former content of 5 weight percent or more on a dry weight basis, and preferably has an aerosol former content of 5 weight percent to 30 weight percent on a dry weight basis. The aerosol-forming substrate may contain other additives and ingredients such as flavorings.

As used herein, the term "aerosol generating device" refers to a device that interacts with the cartridge assembly to generate an aerosol.

As used herein, the term "aerosol generation system" refers to the combination of an aerosol generation device and a cartridge assembly. In the system, the aerosol generation device and the cartridge assembly work together to generate a respirable aerosol.

The aerosol generating device is preferably portable. The aerosol generating device may have a size comparable to a conventional cigar or cigarette. The device may be an electrically operated smoking device. The device may be a handheld aerosol generating device. The aerosol generating device may have an overall length of between 30 millimeters and 150 millimeters. The aerosol generating device may have an outer diameter of between 5 millimeters and 30 millimeters.

The aerosol generating device may comprise a housing. The housing may be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), polyethylene. Preferably, the material is light and not brittle.

The housing may include at least one air inlet. The housing may include multiple air inlets.

The aerosol generating device may include a heating element. The heating element may include at least one inductor coil for inductively heating one or more susceptors.

Operation of the heating element may be triggered by a puff detection system. Alternatively, the heating element may be triggered by pressing an on-off button and held for the duration of the user's puff. The puff detection system may be provided as a sensor, which may be configured as an airflow sensor for measuring airflow velocity. Airflow velocity is a parameter characterizing the amount of air per time drawn by the user through the airflow path of the aerosol generating device. The start of a puff may be detected by the airflow sensor when the airflow exceeds a predefined threshold. The start may also be detected after the user activates the button. The sensor may also be configured as a pressure sensor.

The aerosol generating device may include a user interface for activating the aerosol generating device, such as a button to initiate heating of the aerosol generating device, or a display to indicate the status of the aerosol generating device or the aerosol-forming substrate.

The aerosol generating device may include additional components, such as, for example, an electrically operated or charging unit for recharging an on-board power supply within the electric aerosol generating device.

As used herein, the term "proximal" refers to the user or mouth end of the cartridge assembly, aerosol generating device or system, or a portion or part thereof, and the term "distal" refers to the end opposite the proximal end. When referring to the heating chamber, the term "proximal" refers to the area closest to the open end of the cavity, and the term "distal" refers to the area closest to the closed end.

As used herein, the terms "upstream" and "downstream" are used to describe the relative location of a component or portion of a component of a cartridge assembly with respect to the direction in which a user draws during use of the cartridge assembly in an aerosol generating device.

As used herein, the term "airflow path" means a channel suitable for transporting a gaseous medium. The airflow path may be used to transport ambient air. The airflow path may be used to transport an aerosol. The airflow path may be used to transport a mixture of air and an aerosol.

As used herein, "susceptor" or "susceptor element" means an element that heats up when subjected to an alternating magnetic field. This may be the result of eddy currents induced in the susceptor element, or hysteresis losses, or both eddy currents and hysteresis losses. In use, the susceptor element is placed in thermal contact or thermal proximity with an aerosol-forming substrate contained within the aerosol generator or cartridge assembly. In this manner, the aerosol-forming substrate is heated by the susceptor, thereby forming an aerosol.

The susceptor material may be any material that can be inductively heated to a temperature sufficient to aerosolize the aerosol-forming substrate. The following examples and features of the susceptor may apply to one or both of the susceptor element of the cartridge assembly, the susceptor of the aerosol generating device, and the susceptor of the aerosol generating article. Suitable materials for the susceptor material include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptor materials include metals or carbon. Advantageously, the susceptor material may include or consist of ferromagnetic or ferrimagnetic materials, such as, for example, ferritic iron, ferromagnetic alloys (such as ferromagnetic steel or stainless steel), ferromagnetic particles, ferrites, etc. A suitable susceptor material may be or include aluminum. The susceptor material may contain more than 5 percent, preferably more than 20 percent, more preferably more than 50 percent or more than 90 percent ferromagnetic, ferrimagnetic, or paramagnetic material. Preferred susceptor materials may be heated to temperatures in excess of 250 degrees Celsius without degradation.

The susceptor material may be formed from a single layer of material. The single layer of material may be a steel layer.

The susceptor material may comprise a non-metallic core having a metallic layer disposed thereon. For example, the susceptor material may comprise a ceramic core or a metallic track formed on the outer surface of the substrate.

The susceptor material may be formed from a layer of austenitic steel. One or more layers of stainless steel may be disposed on the layer of austenitic steel. For example, the susceptor material may be formed from a layer of austenitic steel having a layer of stainless steel on each of its upper and lower surfaces. The susceptor element may include a single susceptor material. The susceptor element may include a first susceptor material and a second susceptor material. The first susceptor material may be disposed in intimate physical contact with the second susceptor material. The first susceptor material and the second susceptor material may be in intimate contact to form a single susceptor that cannot be disassembled. In certain embodiments, the first susceptor material is stainless steel and the second susceptor material is nickel. The susceptor element may have a bi-layer structure. The susceptor element may be formed from a stainless steel layer and a nickel layer.

The intimate contact between the first susceptor material and the second susceptor material may be by any suitable means. For example, the second susceptor material may be plated, deposited, coated, clad, or welded onto the first susceptor material. Preferred methods include electroplating, galvanizing, and cladding.

The aerosol generating device may include a power source for powering the heating element. The power source may include a battery. The power source may be a lithium-ion battery. Alternatively, the power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery (e.g., a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery). The power source may require recharging and may have a capacity that allows for storage of sufficient energy for one or more use experiences. For example, the power source may have a capacity sufficient to continuously generate aerosol for about six minutes, or a multiple of six minutes. In another embodiment, the power source may have a capacity sufficient to provide a predetermined number of puffs, or discontinuous activation of the heating element.

The power source may be a direct current (DC) power source. In one embodiment, the power source is a DC power source having a DC supply voltage in the range of 2.5 volts to 4.5 volts and a DC supply current in the range of 1 amp to 10 amps (corresponding to a DC power source in the range of 2.5 watts to 45 watts). The aerosol generating device may advantageously comprise a direct current to alternating current (DC/AC) inverter for converting the DC current provided by the DC power source to an alternating current. The DC/AC converter may comprise a class D, class C, or class E power amplifier. The AC power output of the DC/AC converter is provided to the induction coil.

The power source may be adapted to supply power to the inductor coil and may be configured to operate at high frequencies. For high frequency operation, a class E power amplifier is preferred. As used herein, the term "high frequency oscillating current" means an oscillating current having a frequency between 500 kilohertz and 30 megahertz. The high frequency oscillating current may have a frequency between 1 megahertz and 30 megahertz, preferably between 1 megahertz and 10 megahertz, and more preferably between 5 megahertz and 8 megahertz.

In another embodiment, the switching frequency of the power amplifier may be in the lower kHz range, for example 100 kHz to 400 KHz. In embodiments where a class D or class C power amplifier is used, a switching frequency in the lower kHz range is particularly advantageous.

The aerosol generating device may comprise a controller. The controller may be electrically connected to the inductor coil. The controller may be electrically connected to the first induction coil and to the second induction coil. The controller may be configured to control the current supplied to the induction coil(s) and thus the magnetic field strength generated by the induction coil(s).

A power source and a controller may be connected to the inductor coil. A power source and a controller may be connected to the first and second inductor coils. A power source and a controller may be connected to the first and second inductor coils individually.

The controller may be configured to chop the current supply on the input side of the DC/AC converter. In this manner, the power supplied to the inductor coils may be controlled by conventional methods of duty cycle management. The first and second inductor coils may be controlled individually by the controller.

The controller may be configured to control the inductor coils to facilitate heating management. The heating management may be customizable by a user. For example, the heating management may stagger start times of the first and second inductor coils. The aerosol generating device may include an interface for customizing the heating management. The aerosol generating device may be customized by an external device, for example a smartphone. The aerosol generating device may include a connection port configured to be connected to a smartphone.

The following provides a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

Example A:
1. A cartridge assembly for an aerosol generating device, comprising:
An airflow channel;
a first tubular liquid storage portion;
a second tubular liquid storage portion, wherein the first tubular liquid storage portion is disposed upstream of the second tubular liquid storage portion, and the airflow channel is generally circumscribed by the first and second tubular liquid storage portions, a cartridge assembly comprising:
Example B:
The cartridge assembly of embodiment A, wherein the airflow channel is coaxially surrounded by first and second tubular liquid storage portions.
Example C:
A cartridge assembly as described in Example A or B, wherein the first tubular liquid storage portion has a first inner tubular core element extending along a longitudinal axis of the first tubular liquid storage portion, and the second tubular liquid storage portion has a second inner tubular core element extending along a longitudinal axis of the second tubular liquid storage portion.
Example D:
The cartridge assembly of example C, wherein the first inner tubular core element comprises a first inner tubular wall and the second inner tubular core element comprises a second inner tubular wall, the first and second inner tubular walls enclosing an airflow channel.
Example E:
The cartridge assembly of any one of embodiments AD, wherein the airflow channel is a central airflow channel.
Example F:
The cartridge assembly of any one of embodiments A to E, wherein the first and second tubular liquid storage portions are separated by a transverse wall, the transverse wall being oriented perpendicular to a longitudinal axis of the cartridge assembly.
Example G:
The cartridge assembly of any one of claims A to F, further comprising a distal air inlet and a proximal air outlet.
Example H:
The cartridge assembly of example G, wherein the airflow channel fluidly connects the distal air inlet with the proximal air outlet.
Example I:
The cartridge assembly of any one of embodiments AH, wherein the first and second tubular liquid storage portions comprise the same liquid aerosol-forming substrate or different liquid aerosol-forming substrates.
Example J:
The cartridge assembly of any one of Examples A-I, wherein the airflow channel comprises a Venturi element, preferably a Venturi element connecting the first inner tubular core element of Example C with the second inner tubular core element of Example C.
Example K:
The cartridge assembly of any one of embodiments A-J, wherein the first inner tubular wall of embodiment D comprises a first tubular fluid-permeable portion and the second inner tubular wall of embodiment D comprises a second tubular fluid-permeable portion.
Example L:
The cartridge assembly of embodiment K, wherein the first tubular fluid-permeable portion is disposed at a distal end of the first tubular liquid storage portion and the second tubular fluid-permeable portion is disposed at a distal end of the second tubular liquid storage portion.
Example M:
A cartridge assembly as described in Example K or L, wherein 20 percent of the surface area of the first inner tubular wall is the first tubular fluid-permeable portion, preferably 25 percent, and 20 percent of the surface area of the second inner tubular wall is the second tubular fluid-permeable portion, preferably 25 percent.
Example N:
The cartridge assembly of any one of claims K-M, wherein the first tubular fluid permeable portion is at least partially surrounded by a first high retention and release material and the second tubular fluid permeable portion is at least partially surrounded by a second high retention and release material, the first and second high retention and release materials being configured to prevent a liquid aerosol-forming substrate stored in the first and second tubular liquid storage portions from direct contact with the first and second tubular fluid permeable portions.
Example O:
The cartridge assembly of any one of embodiments KN, wherein the first and second tubular fluid-permeable portions are porous.
Example P:
The cartridge assembly of embodiment O, wherein the porosity of the first and second fluid-permeable portions is between 35 percent and 80 percent, preferably between 45 percent and 65 percent, and most preferably between 50 percent and 60 percent.
Example Q:
The cartridge assembly of any one of embodiments AP, wherein the first and second tubular liquid storage portions and the airflow channel are integrally formed.
Example R:
The cartridge assembly of any one of embodiments A-Q, further comprising a first heating element and a second heating element.
Example S:
The cartridge assembly of embodiment R, wherein the airflow channel comprises first and second heating elements.
Example T:
The cartridge assembly of any one of embodiments R and S, wherein the first inner tubular core element of embodiment C comprises a first heating element disposed in the first tubular fluid-permeable portion, and the second inner tubular core element of embodiment C comprises a second heating element disposed in the second tubular fluid-permeable portion.
Example U:
A cartridge assembly described in any one of Examples R to T, wherein the first heating element comprises a first susceptor, preferably a first hollow tubular susceptor, more preferably the first hollow tubular susceptor is in direct contact with a coaxially surrounded first hollow tubular wick, and the second heating element comprises a second susceptor, preferably a second hollow tubular susceptor, more preferably the second hollow tubular susceptor is in direct contact with a coaxially surrounded second hollow tubular wick.
Example V:
A cartridge assembly as described in Example U, wherein the first tubular fluid-permeable portion of Example K is fluidly connected from the first tubular liquid storage portion to the first hollow tubular susceptor by capillary action of the first hollow tubular wick, and the second tubular fluid-permeable portion of Example K is fluidly connected from the second tubular liquid storage portion to the second tubular susceptor by capillary action of the second hollow tubular wick.
Example W:
A cartridge assembly as described in Example U or V, wherein the first hollow tubular susceptor, the first hollow tubular wick, the first fluid-permeable portion of Example K, and the first tubular liquid storage portion have the same longitudinal axis, and the second hollow tubular susceptor, the second hollow tubular wick, the second fluid-permeable portion of Example K, and the second tubular liquid storage portion have the same longitudinal axis.
Example X:
The cartridge assembly of any one of embodiments A through W, wherein the first and second tubular liquid storage portions comprise a polymeric compound, preferably an antistatic compound.
Example Y:
The cartridge assembly of any one of claims AX, further comprising a mouthpiece.
Example Z:
The cartridge assembly of example Y, wherein the mouthpiece comprises a tubular core element configured to reduce the formation of condensation.
Example AA:
The cartridge assembly of example Y or Z, wherein the mouthpiece comprises a high retention material configured to prevent condensation.
Example AB:
The cartridge assembly of any one of claims Y-AA, wherein the mouthpiece comprises a distal wall, the distal wall configured to seal the second liquid storage portion.
Example AC:
The cartridge assembly of any one of embodiments A-AB, further comprising a distal sealing element configured to seal a distal opening of the first tubular liquid storage portion.
Example AD:
The cartridge assembly of any one of claims A-AC, further comprising a first tubular core air management element and a second core air management element.
Example AE:
The cartridge assembly of any one of embodiments A-AD, wherein the cartridge assembly has a cylindrical shape and an outer diameter of the cartridge assembly is between 5 millimeters and 10 millimeters, preferably between 6 millimeters and 8 millimeters.
Example AF:
The cartridge assembly of any one of embodiments A-AE, wherein the cartridge assembly has a length of 35 millimeters to 75 millimeters, preferably 45 millimeters to 60 millimeters.
Example AG:
The cartridge assembly of any one of embodiments A-AF, wherein the outer wall of the cartridge assembly has a thickness of 0.1 millimeters to 0.9 millimeters, preferably 0.3 millimeters to 0.5 millimeters.
Example AH:
The cartridge assembly of any one of embodiments A-AG, wherein the length of each of the first and second tubular liquid storage portions is between 8 millimeters and 20 millimeters, preferably between 10 millimeters and 15 millimeters.
Example AI:
The cartridge assembly of any one of embodiments A-AH, further comprising a third tubular liquid reservoir.
Example AJ:
1. An aerosol generation system comprising:
A cartridge assembly according to any one of Examples A-AI;
An aerosol generation system comprising: an aerosol generating device comprising a heating chamber for inserting a cartridge assembly therein; and at least one inductor coil at least partially surrounding the heating chamber for inductively heating the cartridge assembly.
Example AK:
The aerosol generation system of Example AJ, wherein the aerosol generating device comprises a first inductor coil and a second inductor coil, the first inductor coil being disposed upstream of the second inductor coil, and the first and second inductor coils can be powered simultaneously or separately.
Example AL:
The aerosol generation system of embodiment AK, wherein a first inductor coil is disposed at a distal end of the first tubular liquid storage portion and a second inductor coil is disposed at a distal end of the second tubular liquid storage portion.
Example A M:
The aerosol generating system of any one of Examples AJ-AL, wherein the heating chamber of the aerosol generating device does not include a susceptor material.
Example AN:
1. A method of manufacturing a cartridge assembly for an aerosol generating device, comprising the steps of:
(i) providing a cartridge component, the cartridge component comprising:
An airflow channel;
a first tubular liquid storage portion;
a second tubular liquid storage portion, the airflow channel being coaxially surrounded by the first and second tubular liquid storage portions, the first tubular liquid storage portion being upstream of the second tubular liquid storage portion, the first tubular liquid storage portion comprising a first internal tubular wall, the second tubular liquid storage portion comprising a second internal tubular wall, the first internal tubular wall comprising a first fluid permeable portion, and the second internal tubular wall comprising a second fluid permeable portion;
(ii) inserting a first susceptor and wick element into the first fluid-permeable portion from a distal end of the cartridge and inserting a second susceptor and wick element into the second fluid-permeable portion from a proximal end of the cartridge;
(iii) inserting a liquid aerosol-forming substrate into the first tubular liquid storage portion from a distal end of the cartridge;
(iv) sealing the distal end of the cartridge with a distal sealing element;
(v) rotating the cartridge approximately 180 degrees;
(vi) inserting a liquid aerosol-forming substrate into the second tubular liquid storage portion from the proximal end of the cartridge;
(vii) sealing the second tubular liquid storage portion with a distal end of a mouthpiece.

Features described with respect to one embodiment may equally be applied to other embodiments of the invention.

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

1A and 1B show a cartridge assembly with an aerosol generating device. FIG. 2 shows the cartridge assembly. 3A and 3B show a method for manufacturing a cartridge assembly for an aerosol generating device.

FIG. 1A shows a perspective view of a cartridge assembly 10. The cartridge assembly 10 includes an airflow channel 12. The airflow channel is coaxially surrounded by a first tubular liquid storage portion 14 and a second tubular liquid storage portion 16.

The cartridge assembly 10 further comprises a mouthpiece 18 having a proximal air outlet 20. Adjacent to the airflow channel 12 are disposed a first susceptor and wick element 22 and a second susceptor and wick element 24. The first and second susceptor and wick elements 22 and 24 each comprise a hollow tubular shaped susceptor (not shown). Each hollow tubular shaped susceptor is in direct contact with a coaxially surrounding hollow tubular wick (not shown).

FIG. 1B shows an aerosol generating device 26 comprising a cartridge assembly 10. The cartridge assembly 10 can be housed within a heating chamber 28 of the aerosol generating device 26. The aerosol generating device 26 comprises a first inductor coil 30 and a second inductor coil 32. The two inductor coils 30 and 32 at least partially surround the heating chamber 28. When the cartridge assembly 10 is fully inserted into the heating chamber 28, the first and second susceptor and wick elements 22 and 24 are aligned with the inductor coils 30 and 32, respectively.

The aerosol generating device 26 includes a base 34. The base 34 may include a battery and a controller. Alternatively or additionally, the base may include a connection element for connecting to a body including the battery and controller.

2 shows a cross-section of the cartridge assembly 10. The first tubular liquid storage portion 14 includes a first inner tubular core element 36. The second tubular liquid storage portion 16 includes a second inner tubular core element 38. The first and second inner tubular core elements 36 and 38 include first and second inner tubular walls 40 and 42, respectively. The first and second inner tubular walls 40 and 42 confine the airflow channel 12. The first and second tubular liquid storage portions 14 and 16 surround the first and second inner tubular core elements 36 and 38. The first and second inner tubular walls 40 and 42 include first and second tubular fluid permeable portions 44 and 46, respectively, at their distal ends. The first and second inner tubular core elements 36 and 38 include first and second susceptor and wick elements 22 and 24, respectively, surrounded by the first and second tubular fluid permeable portions 44 and 46. The first and second tubular fluid permeable portions 44 and 46 can be porous. The first and second tubular fluid permeable portions 44 and 46 are in fluid communication with the first and second tubular liquid storage portions 14 and 16 to the first and second susceptor and wick elements 22 and 24, respectively.

The cartridge assembly further comprises a distal air inlet 48. The airflow channel 12 fluidly connects the distal air inlet to the proximal air outlet 20. The airflow channel 12 may comprise a venturi element 50. The venturi element 50 is disposed between the first inner tubular core element 36 and the second inner tubular core element 38. The venturi element connects the first inner tubular core element to the second inner tubular core element. Alternatively, the airflow channel 12 is a single element comprising the first and second inner tubular core elements 36 and 38 and the venturi element 50.

When the cartridge assembly 10 is inserted into the aerosol generating device 26 and a user inhales through the mouthpiece, air flows from the proximal opening of the heating chamber 28 along its inner wall to the distal end of the heating chamber 28. The air then enters the cartridge assembly 10 through the distal air inlet 48 and exits the cartridge assembly at the proximal air outlet as an aerosol.

The hollow mouthpiece 18 comprises a tubular core element 52. The tubular core element 52 has a length shorter than the mouthpiece 18. For example, half the length of the mouthpiece 18. The tubular core element 52 can have a diameter larger than the first and second inner tubular core elements 36 and 38. The tubular core element can be surrounded by a high retention material 54. The mouthpiece further comprises a distal wall 56. The distal wall is configured to seal the proximal opening of the second tubular liquid storage portion 16. The distal wall 56 has a diameter the same as the diameter of the proximal opening of the second tubular liquid storage portion 16. The distal wall comprises a central opening 58. The central opening can receive the proximal portion of the second inner tubular core element 38. The diameter of the central opening 58 is approximately the same as the outer diameter of the second inner tubular core element 38. The tubular core element 52 is connected to the distal wall 56 on the proximal side of the distal wall 56.

The first and second tubular liquid storage portions are separated by a transverse wall 60. The transverse wall is connected to an outer tubular wall 62. The first and second tubular liquid storage portions can have separate first and second outer tubular walls and transverse walls, respectively.

The cartridge assembly 10 further includes a distal sealing element 64. The distal sealing element 64 has a proximal portion having the same diameter as the distal opening of the first tubular liquid storage portion 14. The distal portion of the sealing element 64 may be the same in diameter as the outer tubular wall 62.

3A and 3B show a method for manufacturing the cartridge assembly shown in FIG. 2. In a first step (i) of the method, a cartridge component is provided. The cartridge component comprises an airflow channel and first and second tubular liquid storage portions. The first and second tubular liquid storage portions comprise first and second internal tubular walls with first and second fluid permeable portions, respectively. In a next step (ii), a first and second susceptor and wick element are inserted into the first and second fluid permeable portions, respectively. The first susceptor and wick element is inserted from the distal end of the cartridge. The second susceptor and wick element is inserted from the proximal end of the cartridge. The two susceptor and wick elements can be added simultaneously or sequentially. In step (iii), a liquid aerosol-forming substrate, a sensory medium, or a mixture thereof is added into the first tubular liquid storage portion from the distal end of the cartridge. Then, in step (iv), the distal end of the cartridge is sealed with a distal sealing element. In step (v), the cartridge is rotated about 180 degrees about the sagittal axis of the cartridge. The sagittal axis is an axis perpendicular to the longitudinal and transverse axes of the cartridge. In step (vi), the liquid aerosol-forming substrate, sensory medium, or mixture thereof is added from the proximal end of the cartridge into the second tubular liquid storage portion. In the next step (vii), the second tubular liquid storage portion is sealed by the distal end of the mouthpiece. The distal end of the mouthpiece can be the distal wall described above.

Claims (15)

1. A cartridge assembly for an aerosol generating device, comprising:
An airflow channel;
a first tubular liquid storage portion, the first tubular liquid storage portion comprising a first inner tubular core element extending along a longitudinal axis of the first tubular liquid storage portion;
a second tubular liquid storage portion, the second tubular liquid storage portion having a second inner tubular core element extending along the longitudinal axis of the second tubular liquid storage portion, the first tubular liquid storage portion being disposed upstream of the second tubular liquid storage portion, and the air flow channel being generally circumscribed by the first and second tubular liquid storage portions. The cartridge assembly of claim 1, wherein the airflow channel is coaxially surrounded by the first and second tubular liquid storage portions. The cartridge assembly of claim 1 or 2, wherein the first inner tubular core element comprises a first inner tubular wall, the second inner tubular core element comprises a second inner tubular wall, and the first and second inner tubular walls confine the airflow channel. The cartridge assembly of any one of claims 1 to 3, wherein the first and second tubular liquid storage portions are separated by a transverse wall, the transverse wall being oriented perpendicular to the longitudinal axis of the cartridge assembly. A cartridge assembly according to any one of claims 1 to 4, wherein the first and second tubular liquid storage portions comprise the same liquid aerosol-forming substrate or different liquid aerosol-forming substrates. A cartridge assembly according to any one of claims 1 to 5, wherein the airflow channel comprises a venturi element, preferably the venturi element connecting the first inner tubular core element with the second inner tubular core element. A cartridge assembly according to any one of claims 1 to 6, wherein the first inner tubular wall comprises a first tubular fluid permeable portion and the second inner tubular wall comprises a second tubular fluid permeable portion, preferably the first tubular fluid permeable portion is disposed at a distal end of the first tubular liquid storage portion and the second tubular fluid permeable portion is disposed at a distal end of the second tubular liquid storage portion, more preferably the first and second tubular fluid permeable portions are porous. The cartridge assembly of any one of claims 1 to 7, wherein the first and second tubular liquid storage portions and the airflow channel are integrally formed. The cartridge assembly according to any one of claims 1 to 8, further comprising a first heating element and a second heating element, preferably the airflow channel comprises the first and second heating elements, more preferably the first inner tubular core element comprises the first heating element disposed in the first tubular fluid permeable portion, and the second inner tubular core element comprises the second heating element disposed in the second tubular fluid permeable portion. The cartridge assembly of claim 9, wherein the first heating element comprises a first susceptor, preferably a first hollow tubular shaped susceptor, more preferably the first hollow tubular shaped susceptor is in direct contact with a coaxially surrounded first hollow tubular wick, and the second heating element comprises a second susceptor, preferably a second hollow tubular shaped susceptor, more preferably the second hollow tubular shaped susceptor is in direct contact with a coaxially surrounded second hollow tubular wick. The cartridge assembly of any one of claims 1 to 10, further comprising a mouthpiece. The cartridge assembly of claim 11, wherein the mouthpiece comprises a distal wall, the distal wall configured to seal the second liquid storage portion. A cartridge assembly according to any one of claims 1 to 12, wherein the cartridge assembly has a cylindrical shape, the outer diameter of the cartridge assembly is between 5 mm and 10 mm, preferably between 6 mm and 8 mm, the cartridge assembly has a length of between 35 mm and 75 mm, preferably between 45 mm and 60 mm, the outer wall of the cartridge assembly has a thickness of between 0.1 mm and 0.9 mm, preferably between 0.3 mm and 0.5 mm, and the length of each of the first and second tubular liquid storage portions is between 8 mm and 20 mm, preferably between 10 mm and 15 mm. 1. An aerosol generation system comprising:
A cartridge assembly according to any one of claims 1 to 13;
An aerosol generation system comprising: an aerosol generation device comprising a heating chamber for inserting the cartridge assembly; and at least one inductor coil at least partially surrounding the heating chamber for inductively heating the cartridge assembly, preferably the aerosol generation device comprises a first inductor coil and a second inductor coil, the first inductor coil being disposed upstream of the second inductor coil, the first and second inductor coils being capable of being powered simultaneously or separately, more preferably the first inductor coil being disposed at the distal end of the first tubular liquid storage portion and the second inductor coil being disposed at the distal end of the second tubular liquid storage portion. 1. A method of manufacturing a cartridge assembly for an aerosol generating device, comprising:
(i) providing a cartridge component, said cartridge component comprising:
An airflow channel;
a first tubular liquid storage portion;
a second tubular liquid storage portion, said airflow channel being coaxially surrounded by said first and second tubular liquid storage portions, said first tubular liquid storage portion being upstream of said second tubular liquid storage portion, said first tubular liquid storage portion comprising a first internal tubular wall, said second tubular liquid storage portion comprising a second internal tubular wall, said first internal tubular wall comprising a first fluid permeable portion, and said second internal tubular wall comprising a second fluid permeable portion;
(ii) inserting a first susceptor and wick element into the first fluid-permeable portion from a distal end of the cartridge and inserting the second susceptor and wick element into the second fluid-permeable portion from a proximal end of the cartridge;
(iii) inserting a liquid aerosol-forming substrate into the first tubular liquid storage portion from the distal end of the cartridge;
(iv) sealing the distal end of the cartridge with a distal sealing element;
(v) rotating the cartridge approximately 180 degrees;
(vi) inserting a liquid aerosol-forming substrate into the second tubular liquid storage portion from the proximal end of the cartridge;
(vii) sealing the second tubular liquid storage portion with a distal end of a mouthpiece.

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