Aerosol generating device including a thermal insulation wall and associated assembly method

Abstract

The aerosol generating device (10) comprises a housing (12), the housing (12) defines an internal space (30), and the device (10) comprises at least one heat source (34) within the internal space (30); the housing (12) comprises at least one insulating wall (40) comprising an inner surface (41) facing the internal space (30) and an outer surface (42) opposite to the inner surface (41); the device (10) further comprises a thermal insulating layer (50) arranged on at least one heat-protected portion of the outer surface (42) of the insulating wall (40), the thermal insulating layer (50) comprises a mesh sublayer, and the mesh sublayer comprises an entangled structure.

Description

Technology Field

[0001] The present invention relates to an aerosol generating device comprising a thermal insulating wall.

[0002] The present invention also relates to a method for assembling such an aerosol generating device. Background Technology

[0003] Different types of aerosol generating devices are already known in the technology. Generally, such devices include a housing that defines an internal space. The internal space includes a storage portion for storing a vaporizable substance, which may be, for example, a liquid or a solid. Typically, the internal space also includes a heat source. For example, this heat source is a heating system consisting of one or more electrically activated resistive heating elements arranged to heat the vaporizable substance to generate an aerosol. The aerosol is discharged through a flow path extending between the inlet and outlet of the device. The outlet may be arranged as a mouthpiece that allows a user to inhale for delivery of the aerosol.

[0004] In the case of extensive vaping, the heat source can generate a significant amount of heat. This can lead to the housing heating up in a way that makes it uncomfortable for the user to hold the device. Consequently, the user may be compelled to stop vaping to allow the device to cool down.

[0005] One of the objectives of the present invention is to provide an aerosol generating device in which overheating is reduced.

[0006] For this purpose, the present invention relates to an aerosol generating device comprising a housing, wherein the housing defines an internal space, and the device comprises at least one heat source within the internal space;

[0007] The housing includes at least one insulating wall comprising an inner surface facing the internal space and an outer surface opposite the inner surface;

[0008] The device further comprises a thermal insulation layer arranged on at least one thermally protected portion of the outer surface of the insulating wall, the thermal insulation layer comprises a mesh sublayer, the mesh sublayer comprises an entangled structure, the entangled structure comprises a through hole that allows heat generated by a heat source to flow from the internal space to the outside of the device, and the through hole has a size of 20 μm to 100 μm.

[0009] The intertwined structure of the mesh sublayer forms perforations on the heat-protected portion of the outer surface. These perforations facilitate the flow of heat from the inside of the internal space toward the outside of the device.

[0010] According to some embodiments, the mesh layer is made of wood or fabric.

[0011] Wood and fabric are materials that are relatively excellent thermal insulators. Therefore, the mesh layer allows heat to flow through its mesh openings but conducts only a small amount of heat.

[0012] According to some embodiments, the thermal insulation layer further comprises a backer sublayer fixed to the thermally protected portion and an adhesive sublayer fixed to the backer sublayer, and the mesh sublayer is fixed to the adhesive sublayer.

[0013] Due to these characteristics, the mesh layer is firmly attached to the insulating wall.

[0014] According to some embodiments, the aerosol generating device further comprises a thermal diffusion layer arranged between at least one thermal diffusion portion of the inner surface of an insulating wall and the internal space of the device.

[0015] According to some embodiments, the thermal diffusion layer extends substantially parallel to the extension plane of the insulating wall.

[0016] According to some embodiments, the heat diffusion layer is a heat conduction plate.

[0017] According to some embodiments, the heat-conducting plate is made of copper.

[0018] Due to these characteristics, heat generated by the heat source diffuses through the housing. This makes it possible to prevent heat accumulation in the narrow space surrounding the heat source. This also expands the surface area for heat exchange with the heat-protected section. Heat flow through the mesh sublayer is increased.

[0019] According to some embodiments, the aerosol generating device further comprises a support attached to a housing and extending within an internal space, and at least one magnet arranged on the support to secure a thermal-diffusion layer to the support.

[0020] Due to these characteristics, the thermal diffusion layer is easily fixed to the device.

[0021] According to some embodiments, the aerosol generating device further includes a light source within the internal space of the device.

[0022] According to some embodiments, the thermal diffusion layer includes a light orifice arranged facing a light source.

[0023] Due to these characteristics, despite the presence of a thermal diffusion layer, the user can perceive whether the device is turned on or not thanks to the light emanating from the light source and passing through the optical orifice.

[0024] According to some embodiments, the insulating wall is a removable wall of the housing.

[0025] Due to these characteristics, the insulation wall is customizable. Users of the device can select a specific insulation wall based on its insulation properties or other characteristics such as its appearance or texture.

[0026] According to some embodiments, the heat source is a heating system configured to generate an aerosol from a vaporizable material.

[0027] The heating system of an aerosol generating device can generate a significant amount of heat. Due to this characteristic, the device can dissipate a significant amount of heat from its heating system.

[0028] The present invention also relates to a method for assembling an aerosol generating device as disclosed above, comprising the step of fixing a thermal insulation layer on a thermally protected portion of the outer surface of an insulating wall.

[0029] According to some embodiments, the thermal insulation layer further comprises a backer sublayer fixed to a thermally protected portion and an adhesive sublayer fixed to the backer sublayer, and the mesh sublayer is fixed to the adhesive sublayer, and the fixing step is,

[0030] - Fixing the adhesive layer onto the backer layer;

[0031] - Forming a thermal insulation layer by placing a mesh sublayer on an adhesive sublayer;

[0032] - Placing the thermal insulation layer in a heating press;

[0033] - Fixing the mesh sublayer to the adhesive sublayer by pressing and heating the thermal insulation layer;

[0034] - Cutting the thermal insulation layer to dimensions that match the dimensions of the aforementioned thermally protected part;

[0035] - Includes fixing a backer layer on the heat-protected portion. Brief explanation of the drawing

[0036] - FIG. 1 is a perspective view of an aerosol generating device according to the present invention; - FIG. 2 is a simplified cross-sectional view along the vertical plane (II-II) of the aerosol generating device of FIG. 1; - FIG. 3 is a simplified front view of the aerosol generating device of FIG. 1 with the insulating wall removed; - FIG. 4 is a simplified rear view of the insulating wall of the aerosol generating device of FIG. 1; - FIG. 5 is a cross-sectional view of the thermal insulation layer and the insulation wall of the device of FIG. 1, taken perpendicular to the extension plane of the insulation wall; Specific details for implementing the invention

[0037] Before describing the present invention, it is understood that the present invention is not limited to the details of the configurations presented in the following description. It will be apparent to those skilled in the art to benefit from the present disclosure that the present invention may be in other embodiments and may be practiced or performed in various ways.

[0038] As used in this specification, the term " Aerosol generating device " or " device "It may include a vaping device that delivers an aerosol to a user, including an aerosol for vaping, by means of an aerosol generating device (e.g., an aerosol generating element that generates vapor that condenses into an aerosol before delivery from the mouthpiece to the outlet of the device for inhalation by the user). The device may be portable. "Portable" may indicate that the device is used when held by the user. The device may be configured to generate a variable amount of aerosol by activating a heating system for a variable amount of time (as opposed to a metered dose of aerosol) which may be controlled, for example, by a trigger. A trigger, such as a vaping button and / or an inhalation sensor, may be activated by the user. The inhalation sensor may be sensitive to the intensity of the inhalation as well as the duration of the inhalation, so that a variable amount of vapor may be delivered (to mimic the effect of smoking a conventional combustible smoking item such as a cigarette, cigar, or pipe).

[0039] As used in this specification, the term " aerosol"It may include a suspension of a precursor as one or more of solid particles; liquid droplets; and gases. The suspension may be in a gas including air. The aerosol in this specification may generally represent and / or contain vapor. The aerosol may include one or more components of a precursor.

[0040] As used in this specification, the term " Vaporizable material " or " Aerosol formation Precursor " or Precursor or " Aerosol-forming substances " or " substance "It may represent one or more of a liquid; a solid; a gel; a mousse; a foam or other material. The precursor may be treatable by a heating system of the device to form an aerosol as defined herein. The precursor may include one or more of nicotine, caffeine, or other active ingredients. The active ingredient may be carried by a carrier which may be a liquid. The carrier may include propylene glycol or glycerin. A flavoring may also be present. The flavoring may include ethyl vanillin (vanilla), menthol, isoamyl acetate (banana oil), or similar. The solid aerosol-forming material may be in the form of a rod, including a treated tobacco material, a pleated sheet of reconstituted tobacco (RTB), or an oriented strip.

[0041] Referring to FIGS. 1 and 2, an aerosol generating device (10) according to the present invention comprises a housing (12). For example, as shown in FIG. 1, the housing (12) has a substantially parallelepiped shape with slightly rounded edges. The housing (12) comprises walls (20) that define an internal space (30) of the device (10). For example, the housing (12) comprises a front wall (21), a rear wall (22) on the opposite side, two transverse side walls (23), and two upper and lower side walls (24).

[0042] The device (10) further includes a support (32) attached to the housing (12) that extends within the internal space (30) and is configured to support a functional component of the device (10). The support (32) may be formed by a chassis configured to accommodate and secure such functional component within the housing (12). For example, such functional component includes an electronic component, a battery, or a power supply designed to power said electronic component. In some embodiments, the functional component may further include a storage portion (not shown) for storing a vaporizable material. Thus, in this embodiment, the storage portion is arranged inside the housing (12). This may be recharged in this case directly with a vaporizable material or using a removable cartridge designed to be inserted into this portion. In some other embodiments, the storage portion may be formed outside the housing (12), for example, by a removable cartridge. In this case, the housing (12) defines a fixing means configured to accommodate and secure the removable cartridge.

[0043] The device (10) further comprises at least one heat source (34) arranged within the internal space (30). For example, the heat source (34) is included in the heating system of the device (10), which is attached to the support (32) and configured to generate an aerosol by heating a vaporizable material. In this case, the heat source (34) may correspond to a heating element used to heat a vaporizable material contained in the storage portion, such as a heating plate, an electric resistor, or a heating element. According to another example, the heat source (34) is formed by the device's battery and / or power supply or any other electrical component of the device. In some examples, the heat source (34) is formed by some of the components mentioned above.

[0044] In the case of extensive use of the device (10), the heat source (34) can generate a significant amount of heat. This can lead to overheating of the device (10), particularly the walls (20) of the housing. Thus, the user of the device (10) may feel this unpleasant heat in their hands. In the case of severe overheating, the user may experience pain and the bearing of the device (10) may become impossible. Therefore, it may be necessary to stop the heat source (34) to prevent damage to the device (10).

[0045] For example, as illustrated in FIGS. 2 and 3, the device (10) further includes a light source (36) arranged within an internal space (30). For example, the light source (36) is attached to a support (20) and faces the front wall (21) of the housing. For example, the device (10) is configured to emit light when turned on, particularly when a battery or power supply supplies power to the electronic components or heating system of the device to generate an aerosol.

[0046] With reference to FIGS. 2 and FIGS. 4, the housing (12) includes at least one insulating wall (40). For example, the insulating wall (40) is one of the walls (20) of the housing (12), for example, the front wall (21). For example, the insulating wall (40) extends substantially along an extension plane (P). This includes an inner surface (41) facing the internal space (30) and an outer surface (42) opposite to the inner surface (41). The insulating wall (40) is a removable wall of the housing (12) that is movable between, for example, a mounting position (Fig. 1) where the insulating wall (40) is mounted on the housing (12) and a spaced position (Figs. 2, 3 and 4) where the insulating wall is spaced away from the housing (12). In the mounting position, the insulating wall (40) protects the internal space (30) from external elements, for example, dust or water. As described below, at the mounting position, the insulating wall (40) also regulates the heat flow from the heat source (34). At the separated position, the user may access the internal space (30), for example, to repair or maintain a functional element of the device (10). In some embodiments, the user may access the internal space (30) to directly refill the storage portion with a vaporizable material or a removable cartridge.

[0047] The insulating wall (40) may also be removed and replaced by another insulating wall (40) exhibiting different features, such as another aspect or another texture of the outer surface (42). For example, the insulating wall (40) is secured to another wall of the housing (12) or support (32) by a snap fit. For example, the transverse side wall (23) and the upper and lower side walls (24) include a peripheral snap fit box (not shown) at their front edges. The insulating wall (40) may include a snap fit pin at its edge designed to work with the peripheral snap fit box to attach the insulating wall (40) to the wall (23, 24) at a mounting position.

[0048] In some embodiments, for example, in the embodiment illustrated in FIG. 2, the insulating wall (40) includes a light orifice (43) designed to allow light emitted by a light source (36) to pass through the device (10) and reach the outside of the device. For example, the light orifice (43) of the insulating wall (40) is filled with a translucent material to allow the emitted light to pass through but prevent external elements from entering the internal space (30).

[0049] The outer surface (42) of the insulating wall (40) includes at least one thermally protected portion. The device (10) includes a thermal insulating layer (50) arranged on the thermally protected portion, for example, fixed to the thermally protected portion. As illustrated in the example of FIG. 2, the thermally protected portion corresponds to the entire outer surface (42). According to another embodiment of the invention, the thermally protected portion corresponds to a portion of the outer surface (42), for example, a portion of the outer surface (42) facing the heat source (34).

[0050] As illustrated in FIG. 5, the thermal insulation layer (50) includes a mesh sublayer (52). For example, the thermal insulation layer (50) further includes an adhesive sublayer (54) and a backer sublayer (56). For example, the backer sublayer (56) is fixed on the outer surface (42) of the insulation wall (40), the adhesive sublayer (54) is placed on the upper portion of the backer sublayer (56), and the mesh sublayer (52) is placed on the upper portion of the adhesive sublayer (54).

[0051] The mesh sublayer (52) comprises an entangled structure of a material such as, for example, wood or fabric. Thus, the mesh sublayer (52) is made of entangled fibers. For example, the mesh sublayer (52) is made of wood fibers or fabric fibers. Wood fibers are made of, for example, cellulose. For example, fabric fibers are made of cotton fabric, polyester, nylon, acrylic and / or polyurethane. The entangled structure may be a woven or non-woven structure of wood fibers or fabric fibers. Such an entangled structure includes through holes that allow heat generated by the heat source (34) to flow from the internal space (30) to the outside of the device (10). For example, the mesh sublayer (52) extends facing the entire outer surface (42) of the insulating wall (40). For example, the mesh sublayer (52) is fixed on an adhesive sublayer (54). The through holes in the mesh sublayer (52) also allow light emitted by the light source (36) to pass through the device (10) and reach the outside of the device. For example, the through holes have a size such as 20 μm to 100 μm, preferably 30 μm to 90 μm, more preferably 40 μm to 80 μm, even more preferably 50 μm to 70 μm, particularly substantially 60 μm. Of course, other value ranges are possible for the size of the through holes.

[0052] The backer sublayer (56) is fixed to the heat-protected portion. For example, the backer sublayer (56) is made of nonwoven fibers. For example, the nonwoven fibers are made of polyester.

[0053] An adhesive layer (54) is fixed to a backer layer. For example, the adhesive layer (54) is made of a thermoplastic resin glue that fluidly changes its shape. For example, the adhesive layer (54) is made of a hot-melted glue such as an acrylic resin glue. For example, a mesh layer (52) is fixed to the adhesive layer (54) and thus is fixed to the insulating wall (40) through the adhesive layer (54) and the backer layer (56). For example, the backer layer (56) and the adhesive layer (54) extend only in contact with the portion of the heat-protected portion and only the portion of the mesh layer (52). In this way, the backer layer (54) and the adhesive layer (56) do not obstruct the flow of heat from the heat source (34) to the outside of the device (10), but still firmly attach the mesh layer (52) to the insulating wall (40).

[0054] Referring to FIG. 2, the inner surface (41) of the insulating wall (40) includes at least one heat-diffusion portion. For example, the device (10) further includes a heat-diffusion layer (60) arranged between the heat-diffusion portion of the inner surface (41) of the insulating wall (40) and the inner space (30) of the device (10). The heat-diffusion layer (60) extends substantially parallel to the extension surface (P) of the insulating wall (40). For example, it is fixed to the inner surface (41) of the insulating wall (40). The heat-diffusion layer (60) is a heat-conducting plate made of, for example, copper or any other heat-diffusion material. The heat-diffusion layer (60) is configured to diffuse heat generated by the heat source (34) through its entirety, for example, through the extension surface (P). The heat-diffusion layer (60) diffuses the generated heat over an increased surface facing the heat-protected portion. Accordingly, the heat exchange surface between the internal space (30) and the outside of the device (10) is increased. For example, as shown in FIG. 2, the heat-diffusion layer (60) includes a light orifice (64) arranged facing the light source (36) when the insulating wall (40) is in the mounting position. When the insulating wall (40) is in the mounting position, light emitted by the light source (34) exits the housing (12) through the light orifice (64) of the heat-diffusion layer (60), the light orifice (43) of the insulating wall (40), and through the through hole of the mesh sublayer (52).

[0055] For example, as illustrated in FIGS. 2 and 3, the device (10) further includes at least one magnet (62) arranged on the support (32) to secure the heat-conducting plate to the support (32) when the heat-conducting plate is made of a ferromagnetic material such as copper. For example, as illustrated in FIGS. 2 and 3, the device (10) includes two magnets (62). The magnets (62) have additional securing means between the insulating wall (40) and the walls (23, 24).

[0056] It will be obvious to those skilled in the art that the thermal insulation layer (50) and the thermal diffusion layer (60) as described above may be arranged on any other wall (20) of the housing (12), particularly depending on the arrangement of the heat source (34) inside the housing. In some embodiments, these layers (50, 60) may be arranged on some of the walls (20) or on the intrinsic transverse wall (20), for example, when the housing (12) has a cylindrical shape.

[0057] The operation method of the aerosol generating device (10) will now be described. The user of the device (10) generates an aerosol by activating the vaping button or the inhalation sensor. By doing so, the heat source (34) is turned on and generates heat. For example, when the heat source (34) generates heat, the light source (36) emits light. Thus, the user of the device (10) can perceive that the heat source (34) is turned on by detecting the light emitted through the light orifices (64 and 43) and through the mesh sublayer (52). The heat-diffusion layer (60) diffuses the heat generated by the heat source (34) through its entirety. The heat diffuses, for example, over an extended surface parallel to the extended plane (P). The diffused heat then flows from inside the internal space (30) to the outside of the device (10) through the insulating wall (40) and through the through hole of the mesh sublayer (52). This results in efficient cooling of the internal space (30) and the housing (12). Even in the case of extensive vaping, overheating of the walls (20) is prevented.

[0058] If necessary, the user can remove the insulating wall (40) along with the thermal insulating layer (50) and the thermal diffusion layer (60) and, for example, replace it with a different insulating wall having a different layer (50, 60) or a different aspect or texture.

[0059] A method for assembling an aerosol generating device (10) will now be described. The assembly method includes the step of fixing a thermal insulation layer (50) onto a thermally protected portion of the outer surface (42) of an insulating wall (40). The fixing step includes fixing an adhesive portion (54) onto a backer portion (56). Then, a mesh portion (52) is placed on the adhesive portion (54) to form a thermal insulation layer (50). Then, the thermal insulation layer (50) is placed in a heating press. The thermal insulation layer (50) is pressed and heated within the heating press to fix the mesh portion (52) to the adhesive portion (54). Then, the thermal insulation layer is cut to a size that matches the dimensions of the thermally protected portion. Finally, a backer portion (56) is fixed onto the thermally protected portion. Thus, as illustrated, the implementation of a thermal insulation layer (50) on the wall (20) of the housing (12) of a conventional device is easily achieved.

Claims

Claim 1 An aerosol generating device (10) comprising a housing (12), wherein the housing (12) defines an internal space (30), and the device (10) comprises at least one heat source (34) within the internal space (30); the housing (12) comprises at least one insulating wall (40) comprising an inner surface (41) facing the internal space (30) and an outer surface (42) opposite to the inner surface (41); the device (10) further comprises a thermal insulating layer (50) arranged on at least one heat-protected portion of the outer surface (42) of the insulating wall (40), wherein the thermal insulating layer (50) comprises a mesh sublayer (52), wherein the mesh sublayer (52) comprises an entangled structure, and the entangled structure comprises a through hole that allows heat generated by the heat source (34) to flow from the internal space (30) to the outside of the device (10), and An aerosol generating device (10) having a through hole with a size of 20 μm to 100 μm. Claim 2 In claim 1, the mesh sublayer (52) is made of wood or fabric, an aerosol generating device (10). Claim 3 In claim 1 or 2, the thermal insulation layer (50) further comprises a backer sublayer (56) fixed to the thermally protected portion and an adhesive sublayer (54) fixed to the backer sublayer (56), and the mesh sublayer (52) is fixed to the adhesive sublayer (54), aerosol generating device (10). Claim 4 An aerosol generating device (10) further comprising, in claim 1 or 2, a heat-diffusion layer (60) arranged between at least one heat-diffusion portion of the inner surface (41) of the insulating wall (40) and the inner space (30) of the device (10). Claim 5 In paragraph 4, the heat-diffusion layer (60) is an aerosol generating device (10) that extends parallel to the extension surface (P) of the insulating wall (40). Claim 6 In paragraph 4, the heat-diffusion layer (60) is a heat-conducting plate, aerosol generating device (10). Claim 7 In claim 6, the heat-conducting plate is an aerosol generating device (10) made of copper. Claim 8 In claim 4, an aerosol generating device (10) further comprising a support member (32) attached to the housing (12) and extending within the internal space (30), and at least one magnet (62) arranged on the support member (32) to secure the heat-diffusion layer (60) to the support member (32). Claim 9 An aerosol generating device (10) according to claim 1 or 2, further comprising a light source (36) within the internal space (30) of the device (10). Claim 10 In claim 9, the aerosol generating device (10) further comprises a thermal diffusion layer (60) arranged between at least one thermal diffusion portion of the inner surface (41) of the insulating wall (40) and the inner space (30) of the device (10), wherein the thermal diffusion layer (60) comprises a light orifice (64) arranged facing the light source (36). Claim 11 In claim 1 or 2, the insulating wall (40) is a removable wall of the housing (12), an aerosol generating device (10). Claim 12 In claim 1 or 2, the heat source (34) is an aerosol generating device (10) configured to generate an aerosol from a vaporizable material. Claim 13 A method of assembling an aerosol generating device (10) according to claim 1 or 2, comprising the step of fixing the thermal insulation layer (50) on the thermally protected portion of the outer surface (42) of the insulating wall (40). Claim 14 In claim 13, the thermal insulation layer (50) further comprises a backer layer (56) fixed to the thermally protected portion and an adhesive layer (54) fixed to the backer layer (56), and the mesh layer (52) is fixed to the adhesive layer (54), and the fixing step comprises: fixing the adhesive layer (54) on the backer layer (56); forming the thermal insulation layer (50) by placing the mesh layer (52) on the adhesive layer (54); placing the thermal insulation layer (50) in a heating press; pressing and heating the thermal insulation layer (50) to fix the mesh layer (52) to the adhesive layer (54); cutting the thermal insulation layer (50) to a size that matches the size of the thermally protected portion; and fixing the backer layer (56) on the thermally protected portion.

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