Aerosol generator with heated coating

Abstract

To provide an aerosol generation device for generating inhalable aerosol.SOLUTION: A device includes a heating chamber (10) constituted so as to receive an aerosol generating article (12) containing an aerosol generating substrate. The heating chamber (10) includes a heating element. The heating element is an electrically resistive coating (16).SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an aerosol generating device for generating an inhalable aerosol. Aerosol generating devices that heat an aerosol generating substrate such as tobacco but do not burn it are well known. These devices heat the aerosol generating substrate to a temperature high enough to create an aerosol for inhalation by the user.

Background Art

[0002] These aerosol generating devices typically comprise a heating chamber, and a relatively complex heating element is disposed within the heating chamber or surrounds the heating chamber. An aerosol generating article comprising an aerosol generating substrate can be inserted into the heating chamber and heated by the heating element. The heating element is typically configured as a heating blade and penetrates into the aerosol generating substrate of the aerosol generating article when the aerosol generating article is inserted into the heating chamber. Conventional heating elements mainly heat the center of the aerosol generating substrate.

Summary of the Invention

Problems to be Solved by the Invention

[0003] As a result, there is a need to provide a heating element that enables inexpensive and uniform heating.

Means for Solving the Problems

[0004] To solve this and for further purposes, the present invention proposes an aerosol generating device for generating an inhalable aerosol. The device comprises a heating chamber configured to receive an aerosol generating article containing an aerosol generating substrate. The heating chamber comprises a heating element. The heating element is an electrically resistive coating.

[0005] Using an electrical resistive coating as a heating element offers several advantages. The coating can heat a relatively large area of ​​the inserted aerosol-generating article, thus achieving a more uniform heat distribution. This more uniform heat distribution also has the effect of potentially resulting in higher energy efficiency of heating, as the heater may operate at a slightly lower temperature.

[0006] When a heating element is configured as an electrical resistive coating, the possible shapes of the heating element can be diverse. Therefore, the shape of the heating element is not limited to conventional heater shapes such as cylindrical or conical shapes that are bent in a single direction. Using an electrical resistive coating allows for irregular shapes (e.g., dome-shaped surfaces, parabolic surfaces, or irregularly shaped surfaces).

[0007] Conventional coil-shaped heaters can induce electromagnetic fields that may cause electromagnetic interference. Electromagnetic interference requires an additional layer of metallic material to shield and block the electromagnetic field. In the present invention, such additional components are unnecessary because the electrically resistive coating does not generate an electromagnetic field that causes electromagnetic interference.

[0008] The electrical resistance coating (or film) may be formed by atmospheric pressure chemical vapor deposition (APCVD), vacuum evaporation, sputtering, conventional CVD, plasma CVD, or flame decomposition. Alternatively, the material may be applied using other conventional coating methods such as wet spraying, powder coating, or dipping coating. In some embodiments, the coating may be applied by powder sintering. Depending on the selected material composition and the coating method, the coating may require drying, curing, or fixing steps.

[0009] The electrical resistance coating may be applied to the side walls of the heating chamber, particularly to the inner walls of the side walls facing the inside of the heating chamber.

[0010] The covering provided on the side walls of the heating chamber may allow direct heating of the aerosol-generating substrate contained in the aerosol-generating article inserted into the heating chamber. Preferably, the side walls of the heating chamber include walls surrounding the long axis of the heating chamber, as well as the base of the heating chamber. The heating chamber has an opening for inserting the aerosol-generating article, which does not form part of the side wall. The heating chamber may have a hollow tubular shape for inserting an aerosol-generating article having a cylindrical shape similar to a conventional cigarette. The opening of the heating chamber for inserting the article may be circular.

[0011] In addition to further heating elements such as a heating blade positioned in the center of the heating chamber, an electrical resistance coating may be provided. Next, the aerosol generating substrate may be heated uniformly not only from the inside but also from the outside.

[0012] The electrical-resistant coating may include electrical-resistant particles and a binder.

[0013] Resistive particles provide the coating with resistive heating properties. Suitable electrical resistant materials include, but are not limited to, semiconductors such as doped ceramics, conductive ceramics (e.g., molybdenum disilide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic and metal materials. Such composite materials may include doped or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-based, iron-based, cobalt-based, and stainless steel-based superalloys, Timetal, and iron-manganese-aluminum alloys. In composite materials, the electrical resistive material may optionally be embedded in, sealed in, or coated with an insulating material, depending on the required energy transfer dynamics and external physicochemical properties.

[0014] In another embodiment, the electrically resistive coating material comprises a thin film of molecularly bonded material, such as tin oxide, or doped tin oxide produced from independent precursors such as tin chloride, methyl alcohol, H2O, and dopant DFE (such as difluoroethane (DFE) and antimony pentachloride).

[0015] The binder binds the resistant material particles together, and the binder can be a polymer, ceramic material, or enamel frit. Suitable polymers include, but are not limited to, fluoropolymers, acrylics, and acrylates.

[0016] The binder may be configured to adhere to the side walls of the heating chamber. The binder may be made of a material resistant to mechanical damage so that the electrical resistance coating is not damaged during insertion and removal of aerosol generating articles and during operation of the aerosol generator.

[0017] The substrate may be placed between the electrical resistance coating and the heating chamber.

[0018] The substrate to which the coating material is applied may be configured to withstand the operating temperature of the electrical resistance coating and is preferably not conductive. Suitable materials include, but are not limited to, ceramic materials, beryllium oxide (BeO), glass ceramics, glass-based materials, aluminum nitride, quartz, and enamel-coated metals. The substrate may be configured to optimize the bonding between the electrical resistance coating and the sidewall of the heating chamber.

[0019] The substrate may be configured to be thermally insulating. Using thermal insulating material for the substrate inhibits heat transfer through the side walls of the heating chamber and directs the generated heat towards the inside of the heating chamber, and thus towards the inserted aerosol-generating article. This improves the energy efficiency and performance of the device.

[0020] The device may further include a controller, a power supply, and contacts, the contacts of which make electrical contact with the resistive sheath, and the controller may be configured to control the supply of power from the power supply to the resistive sheath via the contacts.

[0021] The power source is preferably configured as a battery. The contacts are preferably arranged at a distance from each other at both ends of the resistive coating so that the power supplied to the resistive coating passes uniformly through the coating, thereby creating a uniform heat distribution across the surface of the coating. One contact may be located at the base of the side wall of the heating chamber, while the second contact may be in the form of a ring arranged radially around the side wall of the heating chamber. In other words, one contact may be located at the base of the heating chamber, while the other contact may be located near the opening of the heating chamber.

[0022] The electrical resistance coating may be applied to the entire sidewall of the heating chamber. Applying the coating to the entire sidewall of the heating chamber may facilitate uniform heating of the aerosol-generating article inserted into the heating chamber.

[0023] The electrical resistance coating may be applied to sections of the side wall of the heating chamber adjacent to the opening of the heating chamber.

[0024] In this embodiment, the electrical resistance coating is not provided at the base of the heating chamber. Therefore, the aerosol-generating article is heated primarily adjacent to the opening of the heating chamber. This has the beneficial effect of reducing the amount of residue leaking from the aerosol-generating article near the base of the heating chamber. Thus, contamination of the heating chamber after the removal of the aerosol-generating article can be reduced. In this regard, a typical aerosol-generating article has an outer wrapper arranged around its outer circumference, while the portion of the aerosol-generating article facing the base of the heating chamber during and after insertion into the heating chamber is not covered by the wrapper. Therefore, residue of the aerosol-generating substrate mainly exits the aerosol-generating article through this portion of the article. By not providing an electrical resistance coating at the base of the heating chamber, heating of the substrate in this area is reduced, thereby reducing the amount of substrate leaking out of the article adjacent to the base of the heating chamber in solid or gaseous form. Thus, contamination of the heating chamber can be efficiently reduced.

[0025] The electrical resistance coating may be applied to multiple separate sections of the heating chamber, and each section of the electrical resistance coating may be configured to be independently controllable and operable.

[0026] Providing a plurality of sections of an electrically resistive coating has the effect of creating a plurality of heating elements. These plurality of heating elements can be separately controlled to heat separated portions of an aerosol generating substrate in an aerosol generating article inserted into a heating chamber. During operation of the device, for example when a user is smoking the device, a first portion of the aerosol generating substrate is preferably heated for aerosol generation by operating a first section of the electrically resistive coating. After the user has smoked, or after depletion of the aerosol generating substrate after a predetermined time, a second section of the electrically resistive coating may be activated and the first section may be deactivated. In this way, a plurality of portions of the aerosol generating substrate may be subsequently heated for aerosol generation by a plurality of subsequently operating sections of the electrically resistive coating. Separate contacts are provided as a result for different sections of the electrically resistive coating. Also, the controller may comprise a plurality of controller sections for controlling a plurality of sections of the electrically resistive coating.

[0027] The thickness of the electrically resistive coating may be configured to vary at different positions.

[0028] By varying the thickness of the electrically resistive coating at different positions, different electrical resistances are achieved at different positions of the electrically resistive coating. Thus, different heating temperatures are achieved using the same voltage at these different sections or positions of the electrically resistive coating. This may be utilized to volatilize different portions of the aerosol generating substrate in different ways. The plurality of independently controllable sections of the electrically resistive coating as described above may be combined with different thicknesses of these different sections.

[0029] The electrically resistive coating may be applied to the outside of the side wall of the heating chamber, and the side wall may be configured to be thermally conductive.

[0030] This embodiment is particularly advantageous when the electrical resistive coating is fragile, difficult to clean, or susceptible to organic contamination. As a result, the electrical resistive coating may be applied to the outer surface of the heating chamber sidewall between the housing of the aerosol generator and the sidewall of the heating chamber. Thus, not only the housing of the aerosol generator, but also the sidewall of the heating chamber prevents the electrical resistive coating from coming into contact with aerosol generating articles, aerosol generating substrates, or other external elements that could damage the electrical resistive coating. In all embodiments described in the context of the present invention, the electrical resistive coating may be applied directly to the heating chamber sidewall facing the inside of the heating chamber, or to the outside of the heating chamber sidewall as described in the previous embodiment. Preferably, the coating is applied to the inside of the sidewall facing the inside of the heating chamber, but not to the outside of the heating chamber.

[0031] The base of the heating chamber may have a hemispherical shape. In this embodiment, the thermal energy generated at the base of the heating chamber within the hemisphere is directed toward the central point of a protruding sphere. Thus, the aerosol-generating substrate of the aerosol-generating article positioned at this point is rapidly heated to produce aerosols very quickly. In this embodiment, the aerosol-generating coating provided at the base of the heating chamber shaped as a hemisphere may be provided as a section of electrically resistive coating that can be controlled separately. This section may be operated first to produce aerosols very quickly, while further sections of the electrically resistive coating may be operated for longer periods to produce aerosols over a longer period.

[0032] The present invention further relates to a method for manufacturing an aerosol generator for generating inhalable aerosols, the method being: i) A step of providing a heating chamber configured to receive an aerosol generating article containing an aerosol generating substrate, ii) The step of covering the heating chamber with an electrical resistance coating that acts as a heating element.

[0033] The invention will be described in more detail below with reference to the attached drawings. [Brief explanation of the drawing]

[0034] [Figure 1] Figure 1 shows an aerosol generator according to the present invention. [Figure 2] Figure 2 shows embodiments of a heating element of an aerosol generator provided on the inside of the side wall of the heating chamber, and a heating element of an aerosol generator provided on the outside of the side wall of the heating chamber. [Figure 3] Figure 3 shows an embodiment of the positioning of the heating element and an embodiment of the heating element section. [Figure 4] Figure 4 shows an embodiment of the base of a heating chamber having a hemispherical shape. [Modes for carrying out the invention]

[0035] Figure 1 shows an aerosol generating device according to the present invention. The device comprises a heating chamber 10. An aerosol generating article 12 may be inserted into the heating chamber 10. The heating chamber 10 comprises side walls 14. An electrical resistive coating 16 is provided on the side walls 14 of the heating chamber 10 to facilitate the heating element.

[0036] The electrical resistive coating 16 may be provided in addition to further heating elements, such as heating pins or heating blades aligned and centrally positioned along the longitudinal axis of the heating chamber 10, or heating coils arranged around the heating chamber 10. However, it is preferable that the electrical resistive coating 16 is the sole heating element of the aerosol generator for heating the aerosol generating substrate contained in the aerosol generating article 12.

[0037] In Figure 1, the electrical resistive coating 16 is applied to the inner surface of the side wall 14 of the heating chamber 10. Therefore, the electrical resistive coating 16 directly radiates heat toward the aerosol generating article 12 inserted into the heating chamber 10.

[0038] Figure 1 further shows contacts 18 and 20 electrically connected to the resistive coating 16 so that current can be supplied to and pass through the resistive coating 16. As can be seen in Figure 1, the first contact 18 is located at the base of the heating chamber 10, while the second contact 20 is located near the opening of the heating chamber 10. In this way, the current that passes through the resistive coating 16 and is supplied to the resistive coating 16 by the contacts 18 and 20 passes uniformly through the resistive coating 16. Preferably, the second electrode 20 is provided as a ring-shaped electrode adjacent to the opening of the heating chamber 10.

[0039] A controller 22 is provided, which is in contact with a power supply 24, to supply electrical energy toward and through the electrical resistive coating 16. The power supply 24 is configured as a battery.

[0040] Figure 2 shows two embodiments of the electrical resistance coating 16. In Figure 2A, the electrical resistance coating 16 is applied directly to the inner surface of the side wall 14 of the heating chamber 10. The electrical resistance coating 16 includes not only electrical resistance particles 26 but also a binder 28. The electrical resistance particles 26 are embedded in the binder 28. Therefore, the binder 28 functions as a carrier.

[0041] In Figure 2B, the electrical resistive coating 16 is applied to the outside of the side wall 14 of the heating chamber 10. In this embodiment and all other embodiments, the electrical resistive coating 16 may be configured as shown in Figure 2A, i.e., as an electrical resistive coating 16 consisting of electrical resistive particles 26 and a binder 28. In all embodiments, a single layer of material as shown in Figure 2B may also be used for the electrical resistive coating 16. Providing the electrical resistive coating 16 on the outside of the side wall 14 of the heating chamber 10 as shown in Figure 2B has the advantage that the electrical resistive coating 16 is protected from contamination or damage by the side wall 14 of the heating chamber 10. In the embodiment shown in Figure 2B, it is preferable that the side wall 14 of the heating chamber 10 is made of a thermally conductive material so that, upon insertion of the aerosol generating article 12, the heat released by the electrical resistive coating 16 is transferred to the inside of the heating chamber 10 and into the aerosol generating substrate disposed within the heating chamber 10.

[0042] Figure 3 shows several embodiments of the arrangement of the electrical resistive coating 16. In Figure 3A, the electrical resistive coating 16 is not provided over the entire side wall 14 of the heating chamber 10, as depicted in Figures 1 and 2. In the embodiment shown in Figure 3A, the electrical resistive coating 16 is provided only over the section of the heating chamber 10 adjacent to the opening of the heating chamber 10. In this embodiment, the aerosol generating article 12 inserted into the heating chamber 10 is not heated uniformly by the electrical resistive coating 16, but is heated selectively depending on the positioning of the electrical resistive coating 16. As shown in Figure 3A, it is preferable that the electrical resistive coating 16 heats the portion of the aerosol generating article 12 positioned adjacent to the opening of the heating chamber 10. In this way, heating of the aerosol generating substrate near the electrical resistive coating 16 is primarily performed. This reduces contamination of the heating chamber 10 by residue of the aerosol generating substrate leaking from the portion of the aerosol generating article 12 facing the base of the heating chamber 10.

[0043] In the embodiment shown in Figure 3B, multiple sections of the electrical resistive coating 16 are provided, which are individually and independently controllable and operable. These different sections of the electrical resistive coating 16 can be used to heat different sections of the aerosol generating substrate.

[0044] In Figure 3C, one embodiment is shown, in which different sections of an electrical resistive coating 16 are provided, each of which has a different thickness. These different thicknesses result in different electrical resistances for each section, and therefore different heating temperatures. The sections depicted in Figure 3C may be individually controllable and operable, or they may constitute a single coating layer.

[0045] Figure 4 shows an embodiment of the heating chamber 10 in which the base of the heating chamber 10 is formed as a hemisphere. As a result, the electrical resistive coating 16 applied to the hemispherical area has a hemispherical shape. The heat released from the coating in this area is therefore focused on the central point of the aerosol generating article 12, thereby resulting in rapid heating and aerosol generation in this portion of the aerosol generating substrate of the aerosol generating article 12.

Claims

1. A portable battery-powered aerosol generator for generating inhalable aerosols, wherein the aerosol generator comprises a heating element, the heating element comprises electrically resistive particles and a polymer binder, and the electrically resistive particles are embedded in the binder. The apparatus is configured to receive an aerosol generating article containing an aerosol generating substrate, and the apparatus comprises a controller, a power supply, and contacts, the power supply being configured as a battery. The contacts are arranged at a distance from each other at opposing ends of the heating element. At least one contact point is ring-shaped, An aerosol generator in which at least one ring-shaped contact is arranged on the radial periphery of the heating element.

2. The aerosol generating apparatus according to claim 1, wherein the heating element has a cylindrical shape.

3. The aerosol generating apparatus according to claim 2, wherein the heating element has a hollow tube shape.

4. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the heating element is configured to electrically contact the contacts of the apparatus.

5. The aerosol generating apparatus according to any one of claims 1 to 4, wherein the heating element comprises a plurality of separate sections.

6. The aerosol generating apparatus according to any one of claims 1 to 5, wherein the particles include metal or graphite.

7. The aerosol generating apparatus according to claim 6, wherein the particles consist of metal or graphite.

8. The aerosol generator according to any one of claims 1 to 7, wherein the contacts electrically contact the heating element, and the controller is configured to control the supply of power from the power source to the heating element via the contacts.

9. The aerosol generating device according to any one of claims 1 to 8, wherein the second contact is located at the base of the heating element.

10. The aerosol generating device according to any one of claims 1 to 9, wherein the heating element is configured to heat the aerosol generating substrate to a sufficiently high temperature in order to produce an aerosol for the user to inhale.

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