Patent Description:
Flavor inhalers for inhaling flavor without burning a material have been known. As such flavor inhalers, for example, electronic cigarettes are known. Such an electronic cigarette supplies aerosol generated by atomizing an aerosol-forming material containing a flavor such as nicotine to a mouth of a user, or causes aerosol generated by atomizing an aerosol-forming material that does not contain a flavor such as nicotine to pass through a flavor source (for example, a tobacco source) and then supplies the aerosol to the mouth of the user.

Some electronic cigarettes include a tank or reservoir that accommodates a liquid for generating aerosol, and a heater that atomizes the liquid. Some such electronic cigarettes include an atomizer assembly in which a coiled heater is wound around a wick that is fluidly connected to a tank (for example, see <CIT>). <CIT> discloses a vaporizer including a liquid storage part, a cap having grooves for supporting the liquid storage part, and a heating element for heating the liquid storage part to generate vapour.

An object of the present disclosure is to provide a cartridge for an inhaler having a novel structure, and the inhaler.

According to a first aspect, there is provided a cartridge according to claim <NUM>.

In one embodiment, the first surface of the liquid holding member has a convex shape. The support member has a first convex surface that supports the second surface of the liquid holding member.

In one embodiment, the support member further has a second concave surface opposite the first convex surface, a first side portion, and a second side portion facing the first side portion. A space is formed by the second concave surface, an inner surface of the first side portion, and an inner surface of the second side portion.

In one embodiment, the cartridge further includes a base member that holds at least a part of the support member and is harder than the support member.

In one embodiment, the base member has a base and holds the support member so that a space exists between the base and the support member.

In one embodiment, the base member has at least two first protrusions, and the at least two first protrusions contact an apex of the second concave surface.

In one embodiment, each of the at least two first protrusions also contacts the inner surface of the first side portion or the inner surface of the second side portion.

In one embodiment, the heater and the at least two first protrusions are arranged not to overlap each other when the heater unit is viewed from the base member side.

In one embodiment, the base member has at least two second protrusions, and the at least two second protrusions contact a portion below an apex of the second concave surface.

In one embodiment, the heater is a linear heater.

In one embodiment, the cartridge further includes a tank unit that is to be engaged with the heater unit. The tank unit is provided with a tank body that has a tank for storing the liquid, an aerosol flow path which is separated from the tank and through which the aerosol passes, and a chamber communicating with the aerosol flow path. A part of the liquid holding member and the heater are exposed to inside of the chamber, and another part of the liquid holding member is exposed to the inside of the tank.

In the drawings, the same or equivalent constituent elements are designated with the same reference numerals, and a repetitive description will be omitted.

<FIG> is an overall perspective view of an inhaler according to an embodiment of the present disclosure. As illustrated in <FIG>, an inhaler <NUM> includes a cartridge <NUM> (corresponding to an example of a cartridge for an inhaler), and a battery unit <NUM>. The cartridge <NUM> atomizes a liquid containing an aerosol-forming material such as glycerin or propylene glycol, and generates aerosol. The aerosol-forming material may contain, for example, a flavor source such as nicotine. The battery unit <NUM> supplies electric power to the cartridge <NUM>. The cartridge <NUM> is formed by engaging a tank unit <NUM> with a heater unit <NUM>. A cover member to be described later included in the tank unit <NUM> may have a function as a mouthpiece, or may be configured to guide the aerosol generated in the heater unit <NUM> to a mouth of a user. After the inhaler <NUM> is used over a predetermined period of time, the cartridge <NUM> can be changed.

As illustrated in <FIG>, the inhaler <NUM> may be configured so that a charging unit <NUM> can be coupled to an end of the battery unit <NUM>. The charging unit <NUM> may be, for example, a USB charger. In this case, the battery unit <NUM> can be connected to each USB port of various devices via the charging unit <NUM>, and a power source (not illustrated) in the battery unit <NUM> can be charged by power supply from the USB port.

Hereinafter, the cartridge <NUM> illustrated in <FIG> will be described in detail. <FIG> is an exploded perspective view of the cartridge <NUM> according to one embodiment of the present disclosure.

The cartridge <NUM> is formed by engaging the tank unit <NUM> with the heater unit <NUM>. The tank unit <NUM> may include a cover member <NUM>, a tank body <NUM>, and a cap member <NUM>. The tank body <NUM> has a plurality of air inlet ports (hereinafter, collectively referred to as "air inlet ports <NUM>") including a first air inlet port 35A for communicating with a chamber and an aerosol flow path to be described later. The heater unit <NUM> may include a base member <NUM>, a support member <NUM>, a liquid holding member <NUM>, an electrode holding member <NUM>, an electrode <NUM>, and a heater <NUM>. The electrode <NUM> may include a pair of electrodes 30A and 30B as described later.

Here, the outline of steps of manufacturing the cartridge <NUM> will be described. Firstly, in a first step, the electrodes 30A and 30B and the electrode holding member <NUM> are integrally formed. In a second step, the heater <NUM> is soldered between the electrode 30A and the electrode 30B. On the other hand, in a third step, the base member <NUM>, the support member <NUM>, and the liquid holding member <NUM> are combined. Next, in a fourth step, a structure made up of the base member <NUM>, the support member <NUM> and the liquid holding member <NUM> is press-fitted to a structure made up of the electrode holding member <NUM>, the electrodes 30A and 30B, and the heater <NUM>, to thereby form the heater unit <NUM>. Separately from the first to fourth steps, in a fifth step, the cap member <NUM> is press-fitted to the tank body <NUM>. Next, in a sixth step, the tank body <NUM> to which the cap member <NUM> is press-fitted and the cover member <NUM> are engaged by welding. Next, in a seventh step, the liquid (containing the aerosol-forming material) is injected into a tank in the tank body <NUM>, to thereby form the tank unit <NUM>. Finally, in an eighth step, the heater unit <NUM> and the tank unit <NUM> are engaged by welding.

<FIG> is a transparent view of the cartridge <NUM> with the cover member <NUM> and the electrode holding member <NUM> removed according to the embodiment of the present disclosure. <FIG> is a perspective view of the cartridge <NUM> illustrated in <FIG> in a position turned about a direction connecting a proximal end <NUM> and a distal end <NUM> as an axis. <FIG> is a cross-sectional view of the cartridge <NUM> with the electrode <NUM> and the heater <NUM> removed.

As illustrated in <FIG>, <FIG>, and <FIG>, the cartridge <NUM> has the proximal end <NUM> and the distal end <NUM>. The proximal end <NUM> is an end which is located close to the mouth of the user when the user is using the inhaler <NUM>. The distal end <NUM> is an end on the opposite side from the proximal end <NUM> or an end which is located close to the battery unit <NUM> and is away from the mouth of the user when the user is using the inhaler <NUM>. In the present embodiment, for convenience, a direction connecting the proximal end <NUM> and the distal end <NUM> (an up-down direction in <FIG>) is referred to as a first direction, and a direction perpendicular to this direction is referred to as a second direction. The first direction can be also referred to as a longitudinal direction, and the second direction can be also referred to as a transverse direction. Note that in <FIG>, <FIG>, <FIG>, and <FIG> to be described later, X, Y, and Z axes are shown. In these figures, the Z-axis direction coincides with the first direction, and the X-axis direction and the Y-axis direction coincide with the second direction.

The cartridge <NUM> (or the tank body <NUM> included in the cartridge <NUM>) includes an upper wall <NUM>, a side wall <NUM> having a substantially cylindrical shape, and an inner side wall <NUM> having a substantially cylindrical shape that is located inside the side wall <NUM>. A space is defined in a gap between the side wall <NUM> and the inner side wall <NUM>. This space serves as a tank <NUM> for storing the liquid containing the aerosol-forming material. A chamber-forming member <NUM> separating the tank <NUM> and the chamber <NUM> is provided on the distal end <NUM> side. An internal space of the inner side wall <NUM> forms an aerosol flow path <NUM> extending in the first direction. The chamber <NUM> communicates with the aerosol flow path <NUM>. The cap member <NUM> is arranged on the proximal end <NUM> side. The cap member <NUM> separates the tank <NUM> and the aerosol flow path <NUM>. The cap member <NUM> may also serve as a buffer for fitting the cover member <NUM> and the tank body <NUM> to form the tank unit <NUM>.

The tank body <NUM> may be configured to include the tank <NUM> for storing the liquid, the aerosol flow path <NUM> which is separated from the tank <NUM> and through which the aerosol passes, and the chamber <NUM> communicating with the aerosol flow path <NUM>.

The heater unit <NUM> is attached to the distal end <NUM> side of the cartridge <NUM>. The heater unit <NUM> is not only configured to atomize the liquid to generate the aerosol, and but also has a function of a bottom wall that closes the distal end <NUM> side of the cartridge <NUM>.

An aerosol discharge port <NUM> communicating with the aerosol flow path <NUM> via the cap member <NUM> is formed in a substantially center portion of the upper wall <NUM>. The heater <NUM> is exposed to the inside of the chamber <NUM> over the entire length thereof. The air having flowed into the chamber <NUM> through the air inlet ports <NUM> reaches the inside of the mouth of the user through the aerosol flow path <NUM> and the aerosol discharge port <NUM>. The aerosol generated in the chamber <NUM> passes through the aerosol flow path <NUM> while being mixed with the air, and reaches the inside of the mouth of the user from the aerosol discharge port <NUM>. In this way, the aerosol generated in the entire length of the heater <NUM> can be efficiently transported to the aerosol discharge port <NUM>. In other words, the aerosol can be prevented from accumulating in the chamber <NUM>, and the attachment of the aerosol to a wall surface of the chamber <NUM> can be reduced.

<FIG> is a perspective view of the heater unit <NUM> with the electrode holding member <NUM> removed. The heater unit <NUM> is configured to atomize the liquid to generate the aerosol. The heater unit <NUM> includes at least the support member <NUM>, the liquid holding member <NUM>, and the heater <NUM>. The liquid holding member <NUM> may be formed of any porous member configured to transport the liquid containing the aerosol-forming material from the tank <NUM> to the heater <NUM>. Since the liquid holding member <NUM> is in close contact with the heater <NUM>, it is preferable that the liquid holding member <NUM> is formed of a fibrous member having flexibility such as cotton or a glass fiber. By way of example, the liquid holding member <NUM> may be formed by stacking two or more sheets of cotton. The liquid holding member <NUM> has a first surface <NUM> and a second surface <NUM> facing the first surface. The first surface <NUM> may have a convex shape. In the illustrated example, the first surface <NUM> is a ridge-shaped surface <NUM> protruding in the Z-axis direction. The convex shape of the ridge-shaped surface <NUM> illustrated in the figure may have a single apex in the Z-axis direction (i.e., a direction toward the proximal end when incorporated into the cartridge <NUM>). The apex forms a straight line extending in the X-axis direction when viewed from the Y-axis direction. However, the convex shape of the first surface <NUM> is not limited thereto, and may have various a plurality of apexes in the Z-axis direction. The second surface <NUM> facing the first surface <NUM> is supported by the support member <NUM>. The ridge-shaped surface <NUM> extends along the X-axis direction perpendicular to the Z-axis direction. In addition, the pair of electrodes 30A and 30B (hereinafter, collectively referred to as "electrodes <NUM>") are arranged to be spaced from each other in the Y-axis direction perpendicular to both of the Z-axis direction which is a protruding direction of the ridge-shaped surface <NUM> and the X-axis direction which is an extending direction of the ridge-shaped surface <NUM>. When the cartridge <NUM> is coupled to the battery unit <NUM>, the electrodes <NUM> connect the heater <NUM> with a battery in the battery unit <NUM>.

A center portion in the Y-axis direction of the first surface <NUM> (here, the ridge-shaped surface <NUM>) of the liquid holding member <NUM> exists at a position different in the Z-axis direction from other portions in the Y-axis direction. Specifically, the center portion in the Y-axis direction of the liquid holding member <NUM> forms the apex of the ridge-shaped surface <NUM>. In addition, the liquid holding member <NUM> is formed by deforming a disc-shaped or flat-plate-shaped porous member into a ridge shape. In the flat-plate-shaped porous member, the surface (the ridge-shaped surface <NUM>) to be contacted by the heater <NUM> has a pair of long sides and a pair of short sides. When this flat-plate-shaped porous member is formed into a ridge shape, the liquid holding member <NUM> is deformed into a substantially U shape when viewed from the X-axis direction, as illustrated in <FIG>.

The heater <NUM> has an element which is connected to the electrodes <NUM> to extend in a direction intersecting the protruding direction (Z-axis direction) of the ridge-shaped surface <NUM>, and is arranged to intersect the apex of the ridge-shaped surface <NUM>. The heater <NUM> is configured so that at least a portion thereof contacts the ridge-shaped surface <NUM> of the liquid holding member <NUM>. Specifically, a predetermined-length portion of the heater <NUM> is arranged along the ridge-shaped surface <NUM> of the liquid holding member <NUM>. It is preferable that the heater <NUM> contacts the ridge-shaped surface <NUM> of the liquid holding member <NUM> over substantially the entire length of the heater <NUM>. In this case, the connection portion (for example, a welded portion) between each electrode <NUM> and the heater <NUM> may contact the ridge-shaped surface <NUM> of the liquid holding member <NUM>. This enables the heater <NUM> to contact the ridge-shaped surface <NUM> over the entire length of the heater <NUM>. In addition, a distance in the Y-axis direction between connection portions between the electrodes <NUM> and the heater <NUM> is shorter than a length of the heater <NUM> between the connection portions. That is, the heater <NUM> is arranged to deflect between the electrodes <NUM>.

In one embodiment, a position of one end of the heater <NUM> connected to the first electrode 30A and a position of the other end of the heater <NUM> connected to the second electrode 30B may be misaligned with each other in the X-axis direction. That is, the heater <NUM> may be formed to extend not parallel to the Y-axis direction but obliquely with respect to the Y-axis direction.

In the cartridge <NUM> of the present embodiment, the ridge-shaped surface <NUM> protrudes toward the aerosol discharge port <NUM> side. Thus, an evaporation direction of the aerosol when the heater <NUM> is energized coincides with an air flow when inhaling, whereby the frequency of contact between the generated aerosol and the wall surface forming the flow path can be reduced to reduce condensation of the aerosol on the wall surface of the chamber <NUM>.

As illustrated in <FIG>, it is preferable that the heater <NUM> is arranged to be pressed against the ridge-shaped surface <NUM> of the liquid holding member <NUM>. It is preferable that the liquid holding member <NUM> is made of a material (material having the flexibility) which can be deformed by pressing the heater <NUM> against the liquid holding member <NUM>. The heater <NUM> may be, for example, a single or a plurality of linear heaters, or may be formed into any shape such as a mesh shape or a plate shape. When the heater <NUM> is a single linear heater as in the present embodiment, for example, the thermal capacity thereof can be smaller than that of the mesh-shaped or plate-shaped heater, whereby the liquid can be efficiently atomized.

As illustrated in <FIG>, the support member <NUM> supports the second surface <NUM> facing the ridge-shaped surface <NUM> of the liquid holding member <NUM>. More specifically, the support member <NUM> may be configured to support a position of the second surface <NUM> facing a position of the ridge-shaped surface <NUM> contacted by the heater <NUM>. In this way, the ridge shape of the liquid holding member <NUM> can be maintained even when the heater <NUM> is arranged to be pressed against the ridge-shaped surface <NUM> of the liquid holding member <NUM> so that the liquid holding member <NUM> receives a predetermined force from the heater <NUM>. In addition, the second surface <NUM> of the liquid holding member <NUM> contacts the support member <NUM>, and nothing is provided between the second surface <NUM> and the support member <NUM>. That is, the heater <NUM> is provided only on the ridge-shaped surface <NUM>. Accordingly, when the heater <NUM> atomizes the liquid held in the liquid holding member <NUM>, the aerosol becomes unlikely to be generated from the second surface <NUM>, and is preferentially generated from the ridge-shaped surface <NUM>. The support member <NUM> is formed as a member separate from the base member <NUM>. The length (width) in the Y-axis direction and the length in the X-axis direction of the support member <NUM> are arbitrary, and the support member <NUM> is designed to form a desired ridge-shaped surface <NUM>.

If the contact between the heater <NUM> and the liquid holding member <NUM> is too thin, the heater <NUM> is deformed at the time of heat generation, causing separation from the liquid holding member <NUM>, which may make it difficult to efficiently generate the aerosol. If the contact between the heater <NUM> and the liquid holding member <NUM> is too thick, the heater <NUM> is excessively embedded in the liquid holding member <NUM>, which may cause the bumping of the liquid held in the liquid holding member <NUM>. The support member <NUM> is formed to be softer than the liquid holding member <NUM>. The term "softness" means the ease of deformation of each member when the heater <NUM> is in contact with the liquid holding member <NUM>. That is, when the heater <NUM> is in contact with the liquid holding member <NUM> in a state in which the support member <NUM> and the liquid holding member <NUM> are stacked, the support member <NUM> is deformed before the liquid holding member <NUM> is deformed. By way of example, when the liquid holding member <NUM> is formed of cotton, the support member <NUM> may contain silicone rubber. When the heater <NUM> is pressed against the liquid holding member <NUM>, the support member <NUM> is deformed before the liquid holding member <NUM> is deformed, which can reduce the embedding of the heater <NUM> in the liquid holding member <NUM> and can fix the heater <NUM> so that the heater <NUM> is not detached from the liquid holding member <NUM> in use.

The base member <NUM> may be configured to be harder than the support member <NUM>. However, it is preferable that the base member <NUM> is made of a resin material such as PET or PP. In addition, the base member <NUM> may be configured to be harder than the liquid holding member <NUM>. In this case, among the base member <NUM>, the support member <NUM>, and the liquid holding member <NUM>, the support member <NUM> is the softest, the liquid holding member <NUM> is the next softest, and the base member <NUM> is the hardest.

For example, as the softness (hardness), the hardness measured by a durometer or the like can be used. For example, the hardness of the support member <NUM> is preferably <NUM> to <NUM>, and the hardness of the base member <NUM> is preferably <NUM> or more.

When the cartridge <NUM> is formed by engaging the tank unit <NUM> with the heater unit <NUM>, the liquid holding member <NUM> is compressed by the base member <NUM>, the electrode holding member <NUM>, the chamber-forming member <NUM>, and the like. The liquid holding member <NUM> is sandwiched between the chamber-forming member <NUM> and the support member <NUM>. Then, a part of the liquid holding member <NUM> and the heater <NUM> are exposed to the inside of the chamber <NUM>, and another part of the liquid holding member <NUM> is exposed to the inside of the tank <NUM>. The liquid in the tank <NUM> is supplied from the part of the liquid holding member <NUM> which is exposed to the inside of the tank <NUM> to the part of the liquid holding member <NUM> which is exposed to the inside of the chamber <NUM> utilizing capillary force.

The part of the liquid holding member <NUM> which is exposed to the inside of the tank <NUM> may be impregnated and spread in the liquid stored in the tank <NUM>. The part of the liquid holding member <NUM> which is exposed to the inside of the chamber <NUM> may absorb the liquid supplied from the tank <NUM> and expand. Accordingly, it should be noted that the liquid holding member <NUM> in the completed cartridge <NUM> may have a shape deformed more than the above-described basic shape.

<FIG> is a perspective view of an exemplary support member <NUM>. It should be noted that in <FIG>, the support member <NUM> is illustrated upside down with respect to that illustrated in <FIG> to illustrate the internal structure of the support member <NUM>. The support member <NUM> has a first convex surface <NUM> that supports the second surface <NUM> of the liquid holding member <NUM>. The support member <NUM> also has a second convex surface <NUM> facing the first convex surface <NUM>, a first side portion <NUM>, and a second side portion <NUM> facing the first side portion <NUM>. As will be understood from <FIG>, a space is formed by the second convex surface <NUM>, an inner surface of the first side portion <NUM>, and an inner surface of the second side portion <NUM>.

The first convex surface <NUM> of the support member <NUM> may have a single apex in a direction (Z-axis direction) toward the proximal end, when incorporated into the cartridge <NUM>. However, the shape of the first convex surface <NUM> is not limited thereto, and may have various a plurality of apexes in the Z-axis direction. The second convex surface <NUM> may have a similar shape to the first convex surface <NUM> or a different shape from the first convex surface <NUM>.

As illustrated in <FIG>, the first side portion <NUM> and the second side portion <NUM> may be arranged to be coupled to the ends of the first convex surface <NUM> in the X-axis direction, respectively, or may be flat plates having a shape (substantially semicircular shape in an example in <FIG>) conforming to the shape of the end of the first convex surface <NUM>.

The base member <NUM> holds at least a part of the support member <NUM>. The base member <NUM> may have a base <NUM> and hold the support member <NUM> so that a space exists between the base <NUM> and the support member <NUM>. The base member <NUM> may have one or a plurality of protrusions. For example, as illustrated in <FIG>, the base member <NUM> may have at least two first protrusions <NUM>. The at least two first protrusions <NUM> may contact the apex of the second convex surface <NUM>. In this case, the protrusions <NUM> of the base member <NUM> mainly contact an inner surface of the support member <NUM>, whereby a space is generated between the base member <NUM> and the support member <NUM>. With such a configuration, the degree of freedom of deformation of the support member <NUM> is increased when the heater <NUM> is pressed against the liquid holding member <NUM>.

Furthermore, each of the at least two first protrusions <NUM> of the base member <NUM> may contact the inner surface of the first side portion <NUM> of the support member <NUM> or the inner surface of the second side portion <NUM> of the support member <NUM>. In this case, the heater <NUM>, the liquid holding member <NUM>, the support member <NUM>, the space generated by existence of the protrusions <NUM>, and the base member <NUM> are located in the direction from the chamber <NUM> toward the distal end <NUM>.

The base member <NUM> may have at least two second protrusions <NUM>. The at least two second protrusions <NUM> may contact a portion below the apex of the second convex surface <NUM> of the support member <NUM>. Two of the at least two first protrusions <NUM> may be arranged to face each other along a particular direction (for example, the X-axis direction). Two of the at least two second protrusions <NUM> may be arranged to face each other along a direction (for example, the Y-axis direction) different from the above-described direction.

<FIG> is a perspective view of the heater unit <NUM> with the support member <NUM> and the liquid holding member <NUM> removed. The heater <NUM> has ends <NUM> including a first end part 33A and a second end part 33B that are to be connected to the electrodes <NUM> including the first electrode 30A and the second electrode 30B, respectively. The heater <NUM> may a linear heater, or may be configured to include one or a plurality of linear heater portions. The heater <NUM> and the at least two first protrusions <NUM> of the base member <NUM> may be arranged not to overlap each other when the heater unit <NUM> is viewed from the base member <NUM> side. Alternatively, the heater <NUM> may be arranged to intersect a line connecting the at least two first protrusions <NUM>.

In an example in <FIG>, the first end part 33A of the heater <NUM> is connected to the first electrode 30A, and the second end part 33B is connected to the second electrode 30B. The first electrode 30A and the second electrode 30B may have substantially the same shape. The first electrode 30A and the second electrode 30B may be arranged to be substantially symmetrical with each other about the X-axis direction. Furthermore, the first electrode 30A and the second electrode 30B may be arranged to be substantially symmetrical with each other about the Y-axis direction. Accordingly, in one example, as illustrated in <FIG>, the heater <NUM> may be arranged not parallel to the Y-axis direction but obliquely with respect to the Y-axis direction. According to this configuration, the length of the heater <NUM> is increased as compared with a case where the pair of ends <NUM> are connected to the pair of electrodes <NUM> at the same positions in the X-axis direction. Accordingly, a contact area between the heater <NUM> and the ridge-shaped surface <NUM> of the liquid holding member <NUM> can be increased. Note that in another example, the pair of electrodes <NUM> may be arranged at the same positions in the X-axis direction. In this case, the pair of ends <NUM> may be also connected to the pair of electrodes <NUM> at the same positions in the X-axis direction. In addition, it will be understood that the electrode <NUM> and the end 33A may be arranged at various positions.

The ends <NUM> are located on the distal end <NUM> side of the apex of the ridge-shaped surface <NUM> of the liquid holding member <NUM>. That is, the heater <NUM> curves along the ridge-shaped surface <NUM> of the liquid holding member <NUM> to contact the ridge-shaped surface <NUM>. This can sufficiently ensure the contact area between the heater <NUM> and the ridge-shaped surface <NUM> of the liquid holding member <NUM>.

As illustrated in <FIG> and <FIG>, the electrode holding member <NUM> forms, together with the base member <NUM>, a bottom wall forming the distal end <NUM> of the cartridge <NUM>. When the cartridge <NUM> is coupled to the battery unit <NUM> as illustrated in <FIG>, portions of the electrodes <NUM> extending to the outside of the bottom wall are configured to be connected to a battery terminal (not illustrated) of the battery unit <NUM>. This enables the battery unit <NUM> to supply the electric power to the heater <NUM> through the electrodes <NUM>.

In one embodiment, at least one electrode of the first electrode 30A and the second electrode 30B has a first portion to which one of the first end part 33A and the second end part 33B is to be connected and a second portion extending from an end on the proximal end <NUM> side of the first portion in the direction toward the proximal end <NUM>. For example, as illustrated in <FIG>, the first electrode 30A may have a first portion 31A-<NUM> to which the first end part 33A is to be connected and a second portion 31A-<NUM> extending from the end on the proximal end <NUM> side of the first portion 31A-<NUM> in the direction toward the proximal end <NUM>. Instead of the above-described configuration or in addition to the above-described configuration, the second electrode 30B may have a first portion 31B-<NUM> to which the second end part 33B is to be connected and a second portion 31B-<NUM> extending from an end on the proximal end <NUM> side of the first portion 31B-<NUM> in the direction toward the proximal end <NUM>.

In <FIG>, a dotted line drawn between the first portion 31A-<NUM> and the second portion 31A-<NUM> of the first electrode 30A indicates a boundary therebetween. A dotted line drawn between the first portion 31B-<NUM> and the second portion 31B-<NUM> of the second electrode 30B indicates a boundary therebetween. In one example, as illustrated in the figure, in the boundary between the first portion and the second portion, the width of the first portion is wider than the width of the second portion. In an example in <FIG>, the first portion and the second portion each have a rectangular shape. However, it will be understood that the shapes of the first portion and the second portion are not limited to the rectangular shape, and may have various shapes such as a shape tapering toward the proximal end <NUM>.

As illustrated in <FIG>, the first end part 33A of the heater <NUM> may be connected to a portion which does not contact the second portion 31A-<NUM> in the end on the proximal end <NUM> side of the first portion 31A-<NUM>. The second end part 33B of the heater <NUM> may be connected to a portion which does not contact the second portion 31B-<NUM> in the end on the proximal end <NUM> side of the first portion 31B-<NUM>.

As indicated by hatched lines in <FIG>, the first portion 31A-<NUM> and the second portion 31A-<NUM> of the first electrode 30A may form an L shape. Similarly, the first portion 31B-<NUM> and the second portion 31B-<NUM> of the second electrode 30B may form an L shape.

As illustrated in the figure, the second electrode 30B may include a third portion 31B-<NUM> extending from the first portion 31B-<NUM> in a direction toward the distal end <NUM>, in addition to the first portion 31B-<NUM> and the second portion 31B-<NUM>. In one example, the third portion 31B-<NUM> extends from a lower end of the first portion 31B-<NUM> along an inner side surface and an inner bottom surface of the electrode holding member <NUM>. The third portion 31B-<NUM> further includes an electrical contact 39B with the battery unit <NUM>. Similarly, the first electrode 30A may also include a third portion 31A-<NUM> extending from the first portion 31A-<NUM> in a direction toward the distal end <NUM>, in addition to the first portion 31A-<NUM> and the second portion 31A-<NUM>. In one example, the third portion 31A-<NUM> extends from a lower end of the first portion 31A-<NUM> along an inner side surface and an inner bottom surface of the electrode holding member <NUM>. Although not illustrated, the third portion 31A-<NUM> further includes an electrical contact 39A with the battery unit <NUM>.

<FIG> schematically illustrates the first air inlet port 35A illustrated in <FIG> and the second air inlet port 35B provided on the opposite side of the cartridge <NUM>. At least one air inlet port of the first air inlet port 35A and the second air inlet port 35B may have a substantially circle shape or other various shapes. When the user inhales using the inhaler <NUM>, air outside of the inhaler <NUM> flows into the chamber <NUM> through the first air inlet port 35A and the second air inlet port 35B, is mixed with the aerosol generated upon heat generation of the heater <NUM>, and reaches the inside of the mouth of the user through the aerosol flow path <NUM> and the aerosol discharge port <NUM>. According to the present embodiment, the electrodes <NUM> are arranged at positions so that air having flowed in through the air inlet ports <NUM> contacts the second portions of the electrodes <NUM>. For example, the electrodes <NUM> may be configured so that their second portions are arranged along an air flow path. In this case, the air having flowed in through the air inlet ports <NUM> passes through while contacting the second portions, whereby the cooling effect of the electrodes <NUM> can be increased, which can provide an efficient heat dissipation function. That is, in the present embodiment, the second portion is a part of the electrode <NUM> and can also serve as a heat dissipation portion that effectively releases heat.

<FIG> each illustrate an arrangement relationship between the first and second portions of the electrode and the air inlet port. <FIG> each illustrate the arrangement relationship between the first electrode 30A and the first air inlet port 35A which is an air inlet port located closest to the first electrode 30A. However, it will be understood by those skilled in the art that the second electrode 30B and the second air inlet port 35B which is an air inlet port located closest to the second electrode 30B may be arranged in the same manner.

In one example, at least a part of at least one air inlet port of the first air inlet port 35A and the second air inlet port 35B may be located on the distal end side from the uppermost top of the second portion of the electrode closest to the air inlet port. <FIG> illustrates an example of such a structure. In <FIG>, a part (indicated by the hatched lines) of the first air inlet port 35A is located on the distal end <NUM> side from the uppermost top (indicated by a dotted line <NUM>) of the second portion 31A-<NUM> of the electrode (first electrode 30A) closest to the first air inlet port 35A.

In one example, at least a part of at least one air inlet port of the first air inlet port 35A and the second air inlet port 35B may be located on the second portion side from an end of a portion which does not contact the second portion in the end on the proximal end side of the first portion of the electrode closest to the air inlet port. <FIG> illustrates an example of such a structure. In <FIG>, a part (indicated by the hatched lines) of the first air inlet port 35A is located on the second portion side from an end (indicated by a dotted line <NUM>) of a portion <NUM> which does not contact the second portion in the end on the proximal end <NUM> side of the first portion 31A-<NUM> of the electrode (first electrode 30A) closest to the first air inlet port 35A.

In one example, a center of a substantial circle of at least one air inlet port of the first air inlet port 35A and the second air inlet port 35B may be located on the distal end side from the uppermost top of the second portion of the electrode closest to the air inlet port. <FIG> illustrates an example of such a structure. In <FIG>, a center <NUM> of the first air inlet port 35A is located on the distal end <NUM> side from the uppermost top (indicated by a dotted line <NUM>) of the second portion 31A-<NUM> of the electrode (first electrode 30A) closest to the first air inlet port 35A.

In one example, a center of a substantial circle of at least one air inlet port of the first air inlet port 35A and the second air inlet port 35B may be located on the second portion side from an end of a portion which does not contact the second portion in the end on the proximal end side of the first portion of the electrode closest to the air inlet port. <FIG> illustrates an example of such a structure. In <FIG>, a center <NUM> of the first air inlet port 35A is located on the second portion side from an end (indicated by a dotted line <NUM>) of a portion <NUM> which does not contact the second portion in the end on the proximal end <NUM> side of the first portion 31A-<NUM> of the electrode (first electrode 30A) closest to the first air inlet port 35A.

In one example, when the first portion and the second portion of at least one electrode of the first electrode 30A and the second electrode 30B form an L shape, a predetermined percentage or more of an area of an air inlet port closest to the electrode out of the first air inlet port 35A and the second air inlet port 35B may be located in a notch formed by the L-shape of the electrode. <FIG> illustrates an example of such a structure. In <FIG>, the first portion 31A-<NUM> and 31A-<NUM> of the first electrode 30A form an L shape. A portion (indicated by hatched lines) greater than or equal to a predetermined percentage or more of an area of an air inlet port (first air inlet port 35A) closest to the first electrode 30A is located in a notch <NUM> formed by the L-shape of the first electrode 30A. The above-described predetermined percentage may be, for example, <NUM>%, or other various percentages.

At least one air inlet port of the first air inlet port 35A and the second air inlet port 35B and the first portion and second portion of the electrode closest to the air inlet port may be arranged not to overlap each other when viewed in the Y-axis direction.

As illustrated in <FIG>, the heater <NUM> may have a convex shape. At least a part of the second portion 31A-<NUM> of the first electrode 30A may be located on the proximal end side from the uppermost top of the convex shape of the heater <NUM>. In addition, at least a part of the second portion 31B-<NUM> of the second electrode 30B may be located on the proximal end side from the uppermost top of the convex shape of the heater <NUM>.

Note that the second portion of the electrode <NUM> can also serve as a guide when the heater unit <NUM> is combined with the other members to assemble the cartridge <NUM>. The first electrode 30A and the second electrode 30B have the second portion 31A-<NUM> and the second portion 31B-<NUM>, respectively, and these second portions are located above the heater <NUM> in the Z-axis direction, whereby the heater <NUM> can be prevented from being damaged due to unintended contact with the other members when the cartridge <NUM> is assembled.

The shape of a side surface of the cap member <NUM> will be understood from examples illustrated in <FIG>, <FIG>, and <FIG>. The tank body <NUM> and the cover member <NUM> are fitted with each other to define the tank <NUM> for storing the liquid and the aerosol flow path <NUM> extending in a direction connecting the proximal end <NUM> and the distal end <NUM>. The cap member <NUM> is arranged between the tank body <NUM> and the cover member <NUM>, and has a hole communicating with the aerosol flow path <NUM>. The hole may form a substantial circle. The cap member <NUM> may be formed of a flexible material. As can be seen from <FIG>, the cap member <NUM> is provided with a flat-plate portion having the hole, and a side wall portion extending from an edge of the flat-plate portion in the direction toward the distal end <NUM> and surrounding an end on the proximal end <NUM> side of the inner side wall <NUM>. The tank body <NUM> includes the inner side wall <NUM> forming the aerosol flow path <NUM>. As illustrated in <FIG>, the cap member <NUM> may be engaged, in a U-shape, with a forward end of a tube structure formed by the inner side wall <NUM> forming the aerosol flow path <NUM>. The tank <NUM> is separated from the aerosol flow path <NUM> by the cap member <NUM> and the inner side wall <NUM>. Using such a cap member <NUM> can surely separate the tank <NUM> and the aerosol flow path <NUM>.

<FIG> illustrates a cross-sectional view of an exemplary cap member <NUM> when viewed from the proximal end <NUM>. That is, <FIG> illustrates a shape of the flat-plate portion of the cap member <NUM>. In <FIG>, X, Y, and Z axes corresponding to the X, Y, and Z axes shown in <FIG> and <FIG> are shown. The Z-axis direction coincides with the first direction, and the X-axis direction and the Y-axis direction coincide with the second direction.

The flat-plate portion of the cap member <NUM> has a hole <NUM> communicating the aerosol flow path <NUM> and the aerosol discharge port <NUM>. The shape of the flat-plate portion of the cap member <NUM> includes a first side 54A and a second side 54B that are substantially parallel to each other, a third side 54C that connects one end of the first side 54A and one end of the second side 54B, and a fourth side 54D that connects the other end of the first side 54A and the other end of the second side 54B. A distance L1 between the first side 54A and the second side 54B is shorter than a maximum distance L2 between the third side 54C and the fourth side 54D. The first side 54A and the second side 54B may be substantially linear. The third side 54C and the fourth side 54D may be substantially arcuate. This shape is merely an example of a shape of the flat-plate portion. The flat-plate portion may have various shapes such as a polygonal shape, which satisfy a relationship of L1 < L2.

When L2/L1, which is the ratio of L2 to L1, is X, the relation of <NUM> < X < <NUM> may be preferably satisfied.

<FIG> illustrates a shape formed by the inside of the side wall of the tank body <NUM> when viewed from the proximal end <NUM>. In <FIG>, X, Y, and Z axes corresponding to the X, Y, and Z axes shown in <FIG> are shown. In addition, <FIG> illustrates a cross section of the aerosol flow path <NUM>. The aerosol flow path <NUM> communicates with the aerosol discharge port <NUM> provided in the cover member <NUM>, through the hole <NUM> provided in the flat-plate portion of the cap member <NUM>.

The shape formed by the inside of the side wall of the tank body <NUM> when viewed from the proximal end <NUM> includes a fifth side 56A that is substantially parallel to the first side 54A illustrated in <FIG>, a sixth side 56B that is substantially parallel to the second side 54B illustrated in <FIG>, a seventh side 56C that connects one end of the fifth side 56A and one end of the sixth side 56B, and an eighth side 56D that connects the other end of the fifth side 56A and the other end of the sixth side 56B. A distance L3 between the fifth side 56A and the sixth side 56B is shorter than a maximum distance L4 between the seventh side 56C and the eighth side 56D. The shape illustrated in <FIG> is merely an example, and may be various shapes, which satisfy a relationship of L3 < L4.

When L4/L3, which is the ratio of L4 to L3, is Y, the relation of <NUM> < Y < <NUM> may be preferably satisfied.

<FIG> illustrates an example of an arrangement relationship between the tank body <NUM> and the cap member <NUM> when viewed from the proximal end <NUM>, in the completed cartridge <NUM>. A cross-sectional area of the hole <NUM> of the cap member <NUM> is smaller than the cross-sectional area of the aerosol flow path <NUM>. The cap member <NUM> is arranged so that the first side 54A and the second side 54B illustrated in <FIG> face the fifth side 56A and the sixth side 56B illustrated in <FIG>, respectively. The third side 54C and the fourth side 54D illustrated in <FIG> face the seventh side 56C and the eighth side 56D illustrated in <FIG>, respectively.

As described above, the cap member <NUM> according to the present embodiment has a characteristic shape as illustrated in <FIG>. When the flat-plate portion of the cap member <NUM> has a simple circle shape unlike in the present embodiment, the deformation of the cap member <NUM> caused when the cover member <NUM> and the tank body <NUM> are fitted with each other causes deformation of the shape of the hole in the cap member <NUM>, which may cause inhibition of air flow communication between the aerosol flow path <NUM> and the aerosol discharge port <NUM> or leakage of the liquid from the tank <NUM> to the aerosol flow path <NUM>. In contrast, using the cap member <NUM> according to the present embodiment makes it difficult to deform the shape of the cap member <NUM> even when the cover member <NUM> and the tank body <NUM> are fitted with each other, whereby the above-described problem can be prevented.

Hereinafter an operation of the inhaler <NUM> provided with the cartridge <NUM> of the present disclosure will be described. The liquid stored in the tank <NUM> contacts the end of the liquid holding member <NUM> which is exposed to the inside of the tank <NUM> and is absorbed by the liquid holding member <NUM>. The absorbed liquid is transported to the part of the liquid holding member <NUM> which is exposed to the inside of the chamber <NUM> and is transported to the vicinity of the heater <NUM>, utilizing capillary force. When the user inhales air through the aerosol discharge port <NUM>, an air pressure sensor (not illustrated) provided in the battery unit <NUM> detects the inhalation, for example. In response to such detection, the electric power is supplied from the battery unit <NUM> to the heater <NUM>. Therefore, the liquid held in the liquid holding member <NUM> is heated by the heater <NUM>, and the liquid is atomized to generate the aerosol. The air having flowed into the cartridge <NUM> through the air inlet ports <NUM> in response to the user's inhalation passes through the aerosol flow path <NUM> and the aerosol discharge port <NUM>, along with the aerosol generated in the chamber <NUM>, and reaches the inside of the mouth of the user.

In the cartridge <NUM> according to the embodiment of the present disclosure, the heater <NUM> is mounted only on the first surface <NUM> of the liquid holding member <NUM>. Thus, when the heater <NUM> is energized, the aerosol is generated preferentially on the aerosol discharge port <NUM> side. Accordingly, since the direction of generating the aerosol when the heater <NUM> is energized coincides with the direction of air flow caused by the inhalation, the frequency of contact between the generated aerosol and the wall surface forming the flow path can be reduced to thereby reduce condensation of the aerosol on the wall surface of the chamber <NUM>.

When the liquid holding member <NUM> is formed of a fibrous member having flexibility, the liquid holding member <NUM> expands when holding the liquid. In the cartridge <NUM> of the present embodiment, the first surface <NUM> of the liquid holding member <NUM> may have a ridge shape. When the liquid holding member <NUM> has the ridge-shaped surface <NUM>, an expansion amount of the ridge-shaped surface <NUM> in the protruding direction (Z-axis direction) is smaller than that when the liquid holding member <NUM> is flat. In other words, when the liquid holding member <NUM> is flat, the contact with the heater <NUM> may become unstable due to the expansion amount in the Z-axis direction when the liquid holding member <NUM> holds the liquid. In this case, the atomization efficiency of the liquid may be reduced. In contrast, in the cartridge <NUM> of the present embodiment in which the liquid holding member <NUM> has the ridge-shaped surface <NUM>, a positional relationship between the liquid holding member <NUM> and the heater <NUM> is hardly changed between before and after the liquid is held. Accordingly, according to the cartridge <NUM> of the present embodiment, the positional relationship between the liquid holding member <NUM> and the heater <NUM> can be maintained at a desired degree as compared with the case where the liquid holding member <NUM> is flat. As a result, the liquid held in the liquid holding member <NUM> can be appropriately atomized.

When being energized, the heater <NUM> thermally expands due to an increase in temperature. In the cartridge <NUM> of the present embodiment, the heater <NUM> is curved along the ridge-shaped surface <NUM> of the liquid holding member <NUM> to thereby contact the ridge-shaped surface <NUM>. When the heater <NUM> is curved, the position of the heater <NUM> in the protruding direction of the ridge-shaped surface <NUM> is hardly changed when the heater <NUM> thermally expands, as compared with the case where the heater <NUM> is substantially linear. Since the heater <NUM> of the present embodiment is curved, the position of the heater <NUM> in the protruding direction of the ridge-shaped surface <NUM> is hardly changed even when the heater <NUM> thermally expands, whereby the contact between the liquid holding member <NUM> and the heater <NUM> can be maintained.

Claim 1:
A cartridge (<NUM>) for an inhaler (<NUM>), comprising:
a heater unit (<NUM>) configured to atomize a liquid to generate aerosol,
wherein the heater unit includes:
a liquid holding member (<NUM>) that has a first surface (<NUM>), and a second surface (<NUM>) opposite the first surface;
a heater (<NUM>) that contacts the first surface of the liquid holding member; and
a support member (<NUM>) that supports the second surface of the liquid holding member and is softer than the liquid holding member;
wherein the heater (<NUM>) is arranged to press the liquid holding member (<NUM>) against the support member (<NUM>).