Abstract: A fluid permeable heater assembly for an aerosol-generating system includes a cap and a substantially flat electrically conductive and fluid permeable heating element. The cap includes a hollow body with a first cap opening and a second cap opening. The first cap opening is opposite to the second cap opening. The heating element is configured to vaporise aerosol-forming substrate. The heating element is mounted on the cap, such that the heating element extends across the first cap opening. A cartridge for an aerosol-generating system includes the heater assembly, a liquid storage portion, a mouth piece, and a retainer.

Abstract: An aerosol-generating system including a cartridge is provided, the cartridge including a liquid storage portion including a housing configured to hold a liquid aerosol-forming substrate, the housing having an opening; and a heater assembly including at least one heater element fixed to the housing and extending across an opening of the housing, wherein a width of the at least one heater element of the heater assembly is smaller than a width of the opening of the housing. The heater element may be spaced from a periphery of the opening, leading to more efficient heating and aerosol production.

Abstract: A split airflow system for an electrically heatable smoking system for generating aerosol is provided, the system having a downstream end, the system including: a first channel defining a first flow route; and a second Channel defining a second flow route, the first flow route directing ambient air from outside the split airflow system to the downstream end of the split airflow system, the second flow route directs ambient air from outside the split airflow system towards a substantially flat, fluid-permeable heating element before conveying the ambient air to the downstream end, and the first channel and the second channel define a total volume of ambient air passing through the split airflow system and the first channel provides at least 50 percent of the total volume of ambient air passing through the split airflow system.

Abstract: An aerosol-generating system including a cartridge is provided, the cartridge including a liquid storage portion including a housing configured to hold a liquid aerosol-forming substrate, the housing having an opening; and a heater assembly including at least one heater element fixed to the housing and extending across an opening of the housing, wherein a width of the at least one heater element of the heater assembly is smaller than a width of the opening of the housing. The heater element may be spaced from a periphery of the opening, leading to more efficient heating and aerosol production.

Abstract: A cartridge system is provided, including a liquid storage portion including a housing to hold a liquid aerosol-forming substrate; a mouthpiece having an outlet opening removably connected to a first end of the storage portion; and a heater assembly including an electrical heating element to heat the substrate to form an aerosol, and a porous capillary material having a first face contacting part of the heating element and to convey the substrate to the heating element by capillary action, the heating element disposed across the first face of the material, the liquid storage portion disposed at a first side of the heater assembly and a first airflow channel disposed at a second side of the assembly and defining an airflow path directed at a center of the heating element, and part of a second airflow channel extending to the outlet opening via a central channel of the housing.

Abstract: An aerosol-generating system comprises a liquid storage portion comprising a container holding a liquid aerosol-forming substrate and defining an opening, and a heater assembly which extends across the opening along a transverse plane. The heater assembly comprises at least one electrically operated heating element, and a first channel defines a first flow route which brings ambient air into impingement against the heater assembly. In an embodiment a portion of the first channel is arranged orthogonally to the transverse plane such that the at least a portion of the first channel directs ambient air from outside the system to impinge perpendicularly onto a surface portion of the heating element before conveying the ambient air to a downstream end.

Abstract: An aerosol-generating device is provided for heating an aerosol-forming substrate to form an inhalable aerosol, the aerosol-generating device including: a heating chamber configured to heat an aerosol-forming substrate, the heating chamber comprising a first end having an opening, a second end having a base, and a side wall extending between the opening and the base, in which a cavity is defined by inner surfaces of the base and side wall; a heating assembly; and a power supply, the heating assembly including a heater extending into the heating chamber through an inner portion of the base, and the inner portion of the base being contoured to provide a chamfered or filleted intersection between the base and the heater.

Abstract: An aerosol-generating system is provided, including: a liquid storage portion including a container to hold a liquid aerosol-forming substrate and defining an opening at an end thereof; a fluid-permeable heater assembly extending across a first pair of opposite side portions of the opening along a plane transverse to a longitudinal axis of the liquid storage portion and including an arrangement of one or more filaments, and a capillary material between the liquid storage portion and the arrangement and being configured to convey the substrate to the filaments; and conductive contacts in a main housing and making electrical contact with corresponding contacts of the heater assembly, the liquid storage portion being at a first side of the heater assembly, and a portion of a first airflow channel being at a second side of the heater assembly, and the first airflow channel including several channel portions upstream of the heater assembly.

Abstract: An aerosol-generating device configured to heat an aerosol-forming substrate to form an inhalable aerosol is provided, the aerosol-generating device including a heating chamber configured to heat the aerosol-forming substrate, the heating chamber including a first end having an opening, a second end having a base, and a side wall extending between the opening and the base, a cavity being defined by inner surfaces of the base and the side wall, and a peripheral portion of the base being contoured to provide a chamfered or filleted intersection between the inner surfaces of the base and the side wall; a heating assembly; and a power supply.

Abstract: A cartridge for an aerosol-generating system includes a storage container containing a supply of an aerosol-forming substrate, a fluid permeable heating element positioned across an opening in the storage container, a protective cover coupled to the storage container and covering the fluid permeable heating element, at least one air inlet, at least one air outlet, and an airflow path from the at least one air inlet to the at least one air outlet. The protective cover is configured such that a portion of the airflow path is between the protective cover and the fluid permeable heating element.

Abstract: An aerosol-generating article may include a base layer, at least one aerosol-forming substrate positioned on the base layer, and a cover layer overlying the at least one aerosol-forming substrate and secured to the base layer so that the at least one aerosol-forming substrate is sealed between the base layer and the cover layer. The cover layer includes a polymeric film comprising at least one of a plurality of micropores and a plurality of microperforations.

Abstract: A cartridge for an aerosol-generating system includes a storage container containing a supply of an aerosol-forming substrate, a fluid permeable heating element positioned across an opening in the storage container, a protective cover coupled to the storage container and covering the fluid permeable heating element, at least one air inlet, at least one air outlet, and an airflow path from the at least one air inlet to the at least one air outlet. The protective cover is configured such that a portion of the airflow path is between the protective cover and the fluid permeable heating element.

Abstract: An aerosol-generating article may include a base layer, at least one aerosol-forming substrate positioned on the base layer, and a cover layer overlying the at least one aerosol-forming substrate and secured to the base layer so that the at least one aerosol-forming substrate is sealed between the base layer and the cover layer. The cover layer includes a polymeric film comprising at least one of a plurality of micropores and a plurality of microperforations.

Abstract: An aerosol-generating system is provided, including: a liquid storage portion including a container to hold a liquid aerosol-forming substrate and defining an opening at an end thereof; a heater assembly extending across the opening along a plane transverse to a longitudinal axis of the storage portion and including electrically conductive filaments having a substantially flat orientation; a capillary material between the storage portion and the assembly; and conductive contacts in electrical contact with contacts of the assembly, the storage portion being at a first side of the assembly, and first and second portions of a first airflow channel at a second side of the assembly, the first portion to direct air from outside the system in a direction towards a surface of the capillary material, and the second portion to direct air from the outside in a direction away from the surface before such air enters the first portion.

Abstract: An aerosol-generating system is provided, including an air inlet and an air outlet; a liquid storage portion having a liquid outlet and being configured to hold a liquid aerosol-forming substrate; an air flow passage from the air inlet to the air outlet past the liquid outlet, wherein the air flow passage is shaped such that there is a pressure drop within the air flow passage at the liquid outlet when air flows from the air inlet to the air outlet through the air flow passage; and a heating element disposed within the air flow passage between the liquid outlet and the air outlet. There is also provide a cartridge for an aerosol-generating system and a method of generating aerosol from a liquid aerosol-forming substrate.

Abstract: A method for manufacturing a fluid permeable heater assembly includes providing a heating element, and over-molding a cap on edge areas of one side of the heating element. The cap includes a hollow body having a first cap opening and a second cap opening. The first cap opening is opposite to the second cap opening, and the heating element is mounted on the cap such that the heating element extends across the first cap opening.

Abstract: An aerosol-generating system is provided, including: an aerosol-generating device including a power source; and a cartridge removably coupled to the aerosol-generating device, the cartridge including: a liquid storage portion including a housing having an open end and containing a liquid aerosol-forming substrate, a heater assembly at the open end of the housing and including a planar electrical heating element to heat the liquid aerosol-forming substrate to form an aerosol, and a capillary material in contact with the planar electrical heating element and being configured to convey the liquid aerosol-forming substrate to the planar electrical heating element, the liquid storage portion being at a first side of the heater assembly and an airflow channel being at a second side of the heater assembly, and the power source of the aerosol-generating device is to supply power to the heater assembly.

Abstract: An aerosol-generating system is provided, including: an aerosol-generating device including a power source; and a cartridge removably coupled to the aerosol-generating device, the cartridge including: a liquid storage portion including a housing having an open end and containing a liquid aerosol-forming substrate, a heater assembly at the open end of the housing and including a planar electrical heating element to heat the liquid aerosol-forming substrate to form an aerosol, and a capillary material in contact with the planar electrical heating element and being configured to convey the liquid aerosol-forming substrate to the planar electrical heating element, the liquid storage portion being at a first side of the heater assembly and an airflow channel being at a second side of the heater assembly, and the power source of the aerosol-generating device is to supply power to the heater assembly.

Abstract: An aerosol-generating system is provided, including: a liquid storage portion including a container to hold a liquid aerosol-forming substrate and defining an opening at an end thereof; a heater assembly extending across the opening along a plane transverse to a longitudinal axis of the storage portion and including electrically conductive filaments having a substantially flat orientation; a capillary material between the storage portion and the assembly; and conductive contacts in electrical contact with contacts of the assembly, the storage portion being at a first side of the assembly, and first and second portions of a first airflow channel at a second side of the assembly, the first portion to direct air from outside the system in a direction towards a surface of the capillary material, and the second portion to direct air from the outside in a direction away from the surface before such air enters the first portion.

Abstract: An aerosol-generating system including a cartridge is provided, the cartridge including a liquid storage portion including a housing configured to hold a liquid aerosol-forming substrate, the housing having an opening; and a heater assembly including at least one heater element fixed to the housing and extending across an opening of the housing, wherein a width of the at least one heater element of the heater assembly is smaller than a width of the opening of the housing. The heater element may be spaced from a periphery of the opening, leading to more efficient heating and aerosol production.