Heater assembly, flavor inhaler, flavor inhalation system, and heater assembly manufacturing method

Abstract

A heater assembly according to the present invention comprises an inner tube accommodating a consumable, an outer tube surrounding the inner tube, and an electrode, wherein the outer tube comprises a tubular outer tube body and a first bottom portion formed on the inside of the outer tube body, the inner tube comprises a tubular inner tube body and a heating portion connected to the electrode, the first bottom portion comprises a bottom body and a sleeve traversing the bottom body, the electrode extends through the sleeve, and the space between the sleeve and the electrode on the inside of the sleeve is sealed.

Description

Heater Assembly, Scent Attractor, Scent Attraction System, and Method for Manufacturing Heater Assembly

[0001] The present invention relates to a heater assembly, a scent attractor, a scent attraction system, and a method for manufacturing a heater assembly.

[0002] Conventionally, a scent attractor for generating an aerosol or the like having a scent without burning a material is known. In such a scent attractor, a heater assembly having a tubular member surrounding a heating part such as a heater to suppress heat transfer has been proposed. In the heater module of Patent Document 1, it is disclosed that a lead wire for supplying electricity to the heater is pulled out to the outside of the sealing plug through the through hole of the sealing plug and then the through hole is completely sealed. In the heating device of Patent Document 2, it is disclosed that in an outer tube in which a glass connection part is laser welded to form a seal between glass and metal at the lower end of the outer tube, a wiring connected to the heater and the glass connection part are molded.

[0003] Japanese Patent Application Laid-Open No. 2022-540282 International Publication No. 2023 / 175144

[0004] From the viewpoint of providing a more robust heater assembly, it is desirable to stably attach an electrode connected to the heating part and extending outside the heater assembly to the heater assembly. In the heating device of Patent Document 2, when molding the wiring and the glass connection part, stress is applied to the wiring due to the volume change of the glass and the deformation of the outer tube, and there is a risk that appropriate connection cannot be made, such as the wiring detaching from the heating part. Also, even if a connection is formed, stress may remain on the wiring, which may adversely affect the robustness of the heater assembly.

[0005] One object of the present invention is to provide a heater assembly, a scent attractor, or a scent attraction system in which an electrode connected to the heating part and extending outside the heater assembly is stably attached to the heater assembly and the robustness is improved.

[0006] According to one embodiment, a heater assembly is provided. The heater assembly comprises an inner tube for housing a consumable material, an outer tube surrounding the inner tube, and electrodes, wherein the outer tube comprises a tubular outer tube body and a first bottom formed inside the outer tube body, the inner tube comprises a tubular inner tube body and a heating portion connected to the electrodes, the first bottom comprises a bottom body and a sleeve penetrating the bottom body, the electrodes extend through the sleeve, and the space between the sleeve and the electrodes is sealed inside the sleeve.

[0007] According to the above embodiment, there is no need to directly fix the electrodes to the bottom body, and displacement of the electrodes due to thermal expansion or contraction of the bottom body can be suppressed. The electrodes connected to the heating section and extending to the outside of the heater assembly are stably mounted, and a heater assembly with improved robustness can be provided.

[0008] The sleeve may protrude from the bottom body toward the inner tube.

[0009] In this case, it is possible to facilitate the alignment of the sleeve, enabling the manufacture of more efficient heater assemblies, and to prevent materials that make up the bottom body from flowing into the sleeve.

[0010] The sleeve has a first inner diameter at the end on the inner pipe side and a second inner diameter in the portion of the sleeve that penetrates the bottom body, and the first inner diameter may be larger than the second inner diameter.

[0011] In this case, the insertion of the electrode into the sleeve can be facilitated.

[0012] The sleeve may have at least one of a flared shape and a tapered shape.

[0013] In this case, the risk of the sleeve detaching from the bottom body during the manufacturing of the heater assembly can be suppressed, especially when the inside of the outer tube is under vacuum. Alternatively, the inner diameter of the end of the sleeve can be increased to facilitate the insertion of the electrode into the sleeve.

[0014] The electrode may be rod-shaped or strip-shaped and may have a curved portion inside the outer tube to relieve the stress caused by the electrode being fixed to the first bottom.

[0015] In this case, when sealing the space between the sleeve and the electrode, it is possible to reduce the risk of the electrode detaching from the inner tube due to stress caused by thermal expansion or contraction of the electrode, and to reduce the risk of the heater assembly's robustness decreasing due to stress after sealing.

[0016] The first bottom portion comprises a plurality of sleeves, and the heater assembly comprises a plurality of electrodes extending through each of the plurality of sleeves, wherein the plurality of electrodes may comprise a first electrode and a second electrode having a different length from the first electrode.

[0017] In this case, when inserting the electrodes into the sleeve, inserting one electrode into the sleeve first makes it easier to align the other electrode into the sleeve.

[0018] The outer pipe may have an outer flange portion extending in a second direction intersecting the first direction in which the consumable material is inserted into the inner pipe, and the inner pipe may have an inner flange portion extending in the second direction and joining with the outer flange portion.

[0019] In this case, the joining position is further from the heat source than when the outer surface of the outer tube body and the inner surface of the inner tube body are joined, which suppresses heat transfer from the heat source to the outside of the heater assembly, thereby improving heating efficiency and suppressing adverse effects caused by localized temperature increases.

[0020] The inner tube comprises a second bottom formed inside the inner tube body, and the inner circumferential surface of the outer tube body, the bottom body, the outer circumferential surface of the inner tube body, and the second bottom define the internal space of the heater assembly, and the internal space may be a vacuum.

[0021] In this case, heat transfer from the heat source to the outside of the heater assembly via air can be suppressed.

[0022] The bottom body may include glass.

[0023] In this case, because glass has relatively low thermal conductivity, heat transfer from the heat source to the outer tube via electrodes can be suppressed.

[0024] The thermal expansion coefficient of the material constituting the outer tube or the sleeve may be in the range of 50% to 150% of the thermal expansion coefficient of the glass contained in the bottom body.

[0025] In this case, the difference in thermal expansion or contraction between the bottom body and the outer tube body or sleeve can cause misalignment or other issues, preventing the seal from breaking.

[0026] The heater assembly includes a sealing material that seals the space between the sleeve and the electrode inside the sleeve, and the sealing material may include solder or brazing material.

[0027] In this case, a more reliable seal can be achieved by using the appropriate type of solder or brazing material that matches the materials of the sleeve and electrodes.

[0028] The heating unit may include a heater or an induction coil.

[0029] In this case, the heating element can be easily positioned between the outer and inner tube bodies, or on top of the inner tube body, making it easier to create an internal space with a uniform thickness in the circumferential direction to suppress heat transfer or to achieve a configuration that heats uniformly in the circumferential direction.

[0030] In another embodiment, a flavor aspirator is provided, which comprises the heater assembly described above.

[0031] In this case, the electrodes connected to the heating element and extending outside the heater assembly are stably mounted within the heater assembly, providing a flavor inhaler with improved robustness.

[0032] In another embodiment, a flavor suction system is provided, which comprises the flavor suction device described above and a consumable material including a flavor source.

[0033] In this case, the electrodes connected to the heating element and extending outside the heater assembly are stably mounted within the heater assembly, providing a flavor inhalation system with improved robustness.

[0034] In another embodiment, a method for manufacturing a heater assembly is provided, the method comprising: preparing a subassembly comprising an inner tube and electrodes, wherein the inner tube comprises a tubular inner tube body and a heating portion connected to the electrodes; preparing an outer tube comprising a tubular outer tube body and a bottom, wherein the bottom is formed inside the outer tube body and comprises a sleeve; inserting the subassembly into the outer tube such that the outer tube surrounds the inner tube and the electrodes extend through the sleeve; and sealing the space between the sleeve and the electrodes inside the sleeve.

[0035] In this case, there is no need to directly fix the electrodes to the bottom body, which can suppress electrode displacement due to thermal expansion or contraction of the bottom body, and the electrodes that are connected to the heating section and extend to the outside of the heater assembly can be stably attached, providing a heater assembly with improved robustness.

[0036] This is a schematic diagram showing a flavor suction system according to one embodiment. This is a side view showing a heater assembly according to one embodiment. This is a bottom view of the heater assembly. This is a schematic side cross-sectional view of the heater assembly at the line 4-4 shown in Figure 3. This is a schematic cross-sectional view of the heater assembly at the line 5-5 shown in Figure 4. This is a side view showing an outer tube according to one embodiment. This is a bottom view of the outer tube. This is a schematic side cross-sectional view of the outer tube at the line 8-8 shown in Figure 7. This is a schematic diagram showing a method for manufacturing a heater assembly according to one embodiment. This is a schematic diagram showing a method for manufacturing a heater assembly according to one embodiment. This is a schematic diagram showing a method for manufacturing a heater assembly according to one embodiment. This is a schematic diagram showing a method for manufacturing a heater assembly according to one embodiment. This is a schematic side cross-sectional view showing an outer tube according to modified example 1-1. This is a schematic side cross-sectional view showing an outer tube according to modified example 1-2. This is a schematic side cross-sectional view showing an outer tube according to modified example 1-3. This is a schematic enlarged side cross-sectional view showing a flange extension member according to modified example 2-1. This is a schematic bottom view showing a flange extension member. This is a schematic enlarged side cross-sectional view showing a flange extension member according to modified example 2-2.

[0037] Embodiments of the present invention will be described below with reference to the drawings. In the drawings described below, the same or corresponding components are denoted by the same reference numerals, and redundant descriptions are omitted. Figure 1 is a schematic diagram showing the flavor inhalation system 1000 according to this embodiment. As shown in Figure 1, the flavor inhalation system 1000 includes a non-combustion heating type consumable 100 and a flavor inhaler 200. The consumable 100 is a flavor generating article that has a flavor source and is configured to generate a flavored aerosol or the like when heated. The air inhaled by the user is guided into the user's oral cavity in the order of, for example, airflow A1, airflow A2, and airflow A3. That is, the flavor inhalation system 1000 shown in Figure 1 has a so-called counterflow type airflow path.

[0038] The consumable material 100 has, for example, a columnar shape extending along its longitudinal direction. The flavor source contained in the consumable material 100 is not particularly limited and may include at least one of natural materials such as plant materials and fragrances. The consumable material 100 may also contain a filler. Such a filler may include shredded plant material, a sheet obtained by processing plant material into a sheet, or something obtained by shredding such a sheet. If the plant material is tobacco, the material of shredded tobacco contained in the filler is not particularly limited and known materials such as laminas and backbones can be used. Furthermore, the sheet described above may be a homogenized sheet obtained by grinding dried tobacco leaves to an average particle size of 20 μm or more and 200 μm or less to obtain crushed tobacco, homogenizing this, and then processing it into a sheet. Such a filler may be wrapped in paper. The consumable material 100 may be, for example, a tobacco stick. The consumable material 100 may have a cylindrical shape, a columnar shape with a polygonal cross-section, a flattened shape, or a capsule shape.

[0039] The flavor inhaler 200 includes a battery 10, a control unit 20, and a heater assembly 30. The battery 10 stores the power used by the flavor inhaler 200. For example, the battery 10 is a lithium-ion battery. The battery 10 may be rechargeable by an external power source.

[0040] The control unit 20 consists of a CPU and memory, and controls the operation of the flavor inhaler 200. For example, the control unit 20 starts heating the consumable 100 in response to user operation on an input device such as a push button or a slide switch (not shown), and stops heating the consumable 100 after a certain period of time has elapsed. The control unit 20 may also stop heating the consumable 100 before a certain period of time has elapsed since the start of heating if the number of puffing operations by the user exceeds a certain value. For example, the puffing operation is detected by a sensor (not shown).

[0041] Alternatively, the control unit 20 may start heating the consumable material 100 in response to the start of the puffing operation and stop heating the consumable material 100 in response to the end of the puffing operation. The control unit 20 may also stop heating the consumable material 100 even before the end of the puffing operation if a certain amount of time has elapsed since the start of the puffing operation.

[0042] FIGS. 2 and 3 are a side view and a bottom view showing the heater assembly 30, respectively. FIG. 4 is a schematic side cross-sectional view of the heater assembly 30 in the arrow view 4-4 shown in FIG. 3. FIG. 5 is a schematic cross-sectional view of the heater assembly 30 in the arrow view 5-5 shown in FIG. 4. The heater assembly 30 can function as an atomizing unit that heats and atomizes a flavor source housed in the heater assembly 30.

[0043] As shown in FIG. 4, the heater assembly 30 has an insertion port 326 into which the consumable 100 is inserted. As shown in FIG. 4, it is preferable that the central axis AX of the heater assembly 30 extends in the insertion direction when the consumable 100 is inserted into the heater assembly 30. The heater assembly 30 can be arranged surrounded by a housing (not shown) of the flavor attractor 200 around the central axis AX.

[0044] As shown in FIGS. 2 to 4, the heater assembly 30 has an outer tube 31, an inner tube 32, and an electrode 33. The outer tube 31 surrounds the inner tube 32, and it is particularly preferable that it surrounds around the central axis AX. From the viewpoint of uniformly heating and insulating the consumable 100 in the circumferential direction, as shown in FIG. 5, it is preferable that the outer tube 31 and the inner tube 32 are coaxially arranged around the central axis AX. Hereinafter, the "radial direction" and the "circumferential direction" respectively refer to the radial direction and the circumferential direction of the cylindrical coordinate system based on the central axis AX of the heater assembly 30 or the inner tube central axis AX1 described later.

[0045] As shown in FIG. 4, the inner tube 32 has a tubular inner tube body 320 and a heating portion 321. The inner tube 32 is configured to accommodate the consumable 100. Here, "accommodating the consumable" includes accommodating all or part of the consumable 100. From the viewpoint of uniformly heating the consumable 100 in the circumferential direction, the inner tube body 320 is preferably a hollow cylindrical shape.

[0046] The inner tube body 320 is preferably extended along the central axis AX. The material constituting the inner tube body 320 is not particularly limited as long as it has the desired heat resistance and workability. The inner tube body 320 may include stainless steel, and its main component may be stainless steel. In the following, "main component" refers to a component that makes up 50% or more by weight. If the inner tube body 320 includes a conductive material such as metal, the inner tube body 320 may be insulated with glass or the like. Furthermore, the inner tube body 320 may include a ceramic with high emissivity to promote radiant heating of the contained consumable 100, and its main component may be ceramic. The inner tube body 320 may also be surface-treated to increase its emissivity.

[0047] In the following, the side where the insertion opening 326 is located along the central axis AX will be referred to as the insertion opening side, and the side opposite the insertion opening side will be referred to as the bottom side. As shown in Figure 4, the inner tube 32 may have an inner flange portion 325. The inner tube body 320 may be connected to the inner flange portion 325 on the insertion opening side. In the illustrated example, the inner tube body 320 and the inner flange portion 325 are integrally formed, but are not limited to this. The inner flange portion 325 may be located at the end of the inner tube body 320 on the insertion opening side. The inner flange portion 325 extends from the inner tube body 320 in a direction intersecting the central axis AX, and is particularly preferably extended in a direction perpendicular to the central axis AX. In other words, if the insertion direction of the consumable material 100 is the first direction, the inner flange portion 325 extends in a second direction intersecting the first direction. The inner flange portion 325 may have a boss 420, which will be described later (see Figure 17).

[0048] The heating unit 321 is configured to heat the fragrance source. The heating unit 321 is connected to the electrode 33 and is electrically connected to the battery 10 via the electrode 33. The heating unit 321 can be a heater disposed in the fragrance suction device 200. The heater can include a resistance heater such as a heating wire or a resistance track. The heater can heat the consumable 100 including the fragrance source from the outside. The heater can be flexible and formed in a sheet shape, and can be positioned to surround the inner tube body 320 around the central axis AX. The heater may be a film heater in which a heating wire formed in a sheet shape is covered with a film. As an example, the inner tube body 320 may be made of stainless steel with an insulating coating formed thereon, and a resistance track may be printed on the outer surface of the insulating coating. As shown in FIG. 4, the heating unit 321 may be located on the outer surface in the radial direction of the inner tube body 320. However, it is not limited thereto, and the heating unit 321 may be disposed at a distance from the inner tube body 320, and may be attached to the inner tube body 320 via, for example, other members.

[0049] In addition, the heating unit 321 may be an induction coil that inductively heats a susceptor included in the consumable 100, a susceptor installed on the inner or outer side in the radial direction of the inner tube body 320, or a susceptor that constitutes at least a part of the inner tube body 320. When the heating unit 321 is a heater or an induction coil disposed in the inner tube 32, the heating unit 321 can be easily disposed between the outer tube body 310 and the inner tube body 320 or on the inner tube body 320, etc., and a configuration for uniformly heating in the circumferential direction can be realized, or an internal space having a uniform thickness in the circumferential direction can be easily provided. Such an internal space can suppress heat transfer from a heat source such as the heating unit 321 or the susceptor. Therefore, it is possible to prevent the surface of the fragrance suction device 200 from getting hot and being difficult for the user to grip, or to suppress the adverse effects of heat on the components of the fragrance suction device 200.

[0050] The heating temperature when the heating unit 321 heats the consumable material 100 is not particularly limited, but is preferably 200°C or higher, and preferably 250°C or higher. It is also preferably 400°C or lower, and preferably 350°C or lower. The heating temperature is the temperature of the heat source that heats the flavor source when the consumable material 100 is inserted into the inner tube 32 and used, or the temperature of the flavor source, and may be the temperature of the heater or susceptor mentioned above.

[0051] As shown in Figure 4, the inner tube 32 may have an inner tube bottom 323 (corresponding to an example of a second bottom). The inner tube bottom 323 may be formed radially inward of the inner tube body 320. The inner tube bottom 323 may be formed integrally with the inner tube body 320, or it may be formed of a different material from the material constituting the inner tube body 320. As will be described later, from the viewpoint of creating a vacuum in the internal space SP, it is preferable that the inner tube bottom 323 closes one end of the inner tube body 320. The inner tube bottom 323 may have a step to facilitate the flow of air into the inner tube body 320 from the end face of the consumable material 100 into the consumable material 100.

[0052] Figures 6 and 7 are a side view and a bottom view of the outer tube 31, respectively. Figure 8 is a schematic cross-sectional view of the outer tube 31 in the direction of arrow 8-8 shown in Figure 7. As shown in Figures 4 and 7, the outer tube 31 has a tubular outer tube body 310 and an outer tube bottom 311 (corresponding to an example of a first bottom). As shown in Figure 5, from the viewpoint of providing uniform circumferential insulation to the consumable material 100, it is preferable that the outer tube body 310 is hollow and cylindrical.

[0053] The outer tube body 310 preferably extends along the central axis AX. The material constituting the outer tube body 310 is not particularly limited. As will be described later, if the bottom body 313 contains glass and the space between the outer tube body 310 and the bottom body 313 is sealed by a glass-metal seal, the material constituting the outer tube body 310 preferably has a thermal expansion coefficient in the range of 50% to 150% of the thermal expansion coefficient of the glass contained in the bottom body 313. This prevents the seal from breaking due to displacement or other issues caused by the difference in thermal expansion or contraction between the bottom body 313 and the outer tube body 310. From this viewpoint, the outer tube body 310 preferably contains Kovar, and more preferably its main component is Kovar. As will be described later, if the internal space SP (Figure 4) is evacuated, the outer tube body 310 preferably has a thickness of 0.1 mm or more, and more preferably 0.13 mm or more, from the viewpoint of increasing strength so as not to deform due to the pressure difference between the inside and outside of the outer tube 31. On the other hand, from the viewpoint of suppressing energy loss due to heat conduction in the outer tube body 310 and improving heating efficiency, the outer tube body 310 preferably has a thickness of 0.2 mm or less, and more preferably has a thickness of 0.18 mm or less. Therefore, the thickness of the outer tube body 310 is preferably 0.1 mm or more and 0.2 mm or less, and more preferably 0.13 mm or more and 0.18 mm or less.

[0054] As shown in Figures 6 and 8, the outer pipe 31 may have an outer flange portion 315. The outer flange portion 315 defines an opening 316. The outer pipe 31 is configured so that the consumable material 100 and the inner pipe 32 can be inserted through the opening 316. The outer pipe body 310 may be connected to the outer flange portion 315 at the insertion side. In the illustrated example, the outer pipe body 310 and the outer flange portion 315 are integrally formed, but are not limited thereto. The outer flange portion 315 may be located at the insertion end of the outer pipe body 310. The outer flange portion 315 extends from the outer pipe body 310 in a direction intersecting the central axis AX, and is particularly preferably in a direction perpendicular to the central axis AX. In other words, if the insertion direction of the consumable material 100 is the first direction, the outer flange portion 315 extends in a second direction intersecting the first direction.

[0055] As shown in Figure 4, the outer flange portion 315 is joined to the inner flange portion 325. By joining the outer pipe 31 and the inner pipe 32 via a flange, the distance from the heat source to the joining position becomes longer than when the outer circumferential surface of the outer pipe body 310 and the inner circumferential surface of the inner pipe body 320 are joined. Therefore, heat transfer from the heat source can be suppressed. Preferably, the outer flange portion 315 is joined to the inner flange portion 325 by welding such as projection welding.

[0056] As shown in Figure 4, the outer tube body 310 may have a neck portion 317. The neck portion 317 is connected to the outer flange portion 315, and the inner diameter of the neck portion 317 is smaller than the inner diameter of the outer tube body 310 on the bottom side of the neck portion 317. The neck portion 317 allows for a compact configuration of the insertion side of the heater assembly 30 while ensuring the area of ​​the outer flange portion 315. From the viewpoint of suppressing heat transfer from the heating source, it is preferable that a radial gap is formed between the outer tube body 310 and the inner tube body 320. As shown in Figure 4, when the outer tube body 310 has a neck portion 317, it is preferable that a gap C1 is formed between the neck portion 317 and the inner tube body 320.

[0057] The outer tube body 310 is connected to the outer tube bottom 311 at its bottom. The outer tube bottom 311 is located inside the outer tube body 310. In other words, the outer tube bottom 311 is located radially inward of the outer tube body 310. In the illustrated example, the outer tube bottom 311 is located at the bottom end of the outer tube body 310, but it is not limited to this; the outer tube bottom 311 can be located further down than the inner tube 32.

[0058] As shown in Figures 4 and 8, the bottom portion 311 of the outer tube has a sleeve 312 and a bottom body 313. The bottom body 313 preferably contains glass, and more preferably contains glass as its main component. Because glass has low thermal conductivity, it can suppress heat transfer from the heat source to the outer tube 31 via the electrode 33. The bottom body 313 may be attached to the inside of the outer tube body 310 by glass-metal sealing.

[0059] As shown in Figure 4, the inner circumferential surface S31 of the outer tube body 310, the bottom body 313, the outer circumferential surface S32 of the inner tube body 320, and the bottom of the inner tube 323 define the internal space SP of the heater assembly 30. The heat insulating effect of the internal space SP can suppress heat transfer from the heat source. It is preferable that the internal space SP is positioned so as to surround the inner tube 32 around the central axis AX. From the viewpoint of suppressing heat transfer from the heat source via air, it is preferable that the internal space SP be a vacuum. Here, vacuum refers to a pressure lower than atmospheric pressure. The pressure of the internal space SP is preferably 100 Pa or less, more preferably 10 Pa or less, and even more preferably 1 Pa or less.

[0060] As shown in Figures 3 and 4, the sleeve 312 penetrates the bottom body 313. The electrode 33 connected to the heating section 321 extends through the sleeve 312. Inside the sleeve 312, the space between the sleeve 312 and the electrode 33 is sealed. If the heater assembly does not have a sleeve, when fixing the electrode to the bottom body in direct contact, stress may be generated due to thermal expansion or contraction, which may cause the electrode to detach from the inner tube or reduce its robustness due to the stress. In the heating device of Patent Document 2, when molding the wiring and the glass connection part, it is conceivable to heat the glass powder that will be the raw material for the glass connection part to cause a phase transition, and then cool it together with the wiring and the outer tube. However, stress may be generated due to the volume change of the glass and the outer tube due to the temperature change. In this embodiment, it is not necessary to directly fix the electrode 33 to the bottom body 313, and the installation of the sleeve 312 to the bottom body 313 and the sealing of the electrode 33 inside the sleeve 312 can be performed sequentially. Therefore, displacement of the electrodes 33 due to thermal expansion or contraction of the bottom body 313 can be suppressed, and the risk of the above-mentioned stress occurring can be reduced.

[0061] As shown in Figure 8, it is preferable that the sleeve 312 protrudes from the bottom body 313 toward the inner tube 32 side (insertion side). This makes it easier to center the sleeve 312 during the manufacturing of the heater assembly 30 and prevents materials constituting the bottom body 313, such as glass, from flowing into the sleeve 312. It is preferable that the sleeve 312 protrudes 1 mm to 3 mm from the bottom body 313 toward the inner tube 32 side, and more preferably protrudes about 2 mm. It is preferable that the sleeve 312 extends along the central axis AX. As shown in Figures 4 and 8, the sleeve 312 may have a first end 351 that protrudes into the internal space SP and is on the inner tube 32 side, and a second end 352 that is outside the outer tube 31 and is on the opposite side of the first end 351. The sleeve 312 may also protrude from the bottom body 313 toward the side opposite the insertion side. The sleeve 312 does not protrude from the bottom body 313, and may be positioned to overlap with the bottom body 313 in the direction in which the central axis AX extends.

[0062] The material constituting the sleeve 312 is not particularly limited. When the bottom body 313 contains glass and the space between the sleeve 312 and the bottom body 313 is sealed by a glass-metal seal, it is preferable that the material constituting the sleeve 312 has a thermal expansion coefficient in the range of 50% to 150% of the thermal expansion coefficient of the glass contained in the bottom body 313. This prevents the seal from breaking due to displacement or other issues caused by differences in thermal expansion or contraction between the bottom body 313 and the sleeve 312. From this viewpoint, it is preferable that the sleeve 312 contains Kovar, and more preferably that its main component is Kovar. The thickness of the outer wall of the sleeve 312 is not particularly limited, but it is preferable that it has a thickness of 0.15 mm or more.

[0063] As shown in Figure 4, the heater assembly 30 may have a sealing material 34 that seals the space between the sleeve 312 and the electrode 33 inside the sleeve 312. The sealing material 34 may include solder or brazing material. This allows for more reliable sealing by using an appropriate type of solder or brazing material that matches the materials of the sleeve 312 and the electrode 33. When solder is used as the sealing material 34, the sleeve 312 may be plated before sealing to improve the flowability of the solder. For example, if the plating is performed before the sleeve 312 is installed on the bottom body 313, nickel plating can be performed. The thickness of the nickel plating is preferably 3 μm to 5 μm, and more preferably about 4 μm. If the plating is performed after the sleeve 312 is installed on the bottom body 313, gold plating may be performed together with the outer tube body 310. When brazing material is used as the sealing material 34, the type of brazing material is not particularly limited, but gold-tin (Au-Sn) brazing material containing an alloy of gold and tin can be used. The method of sealing the space between the sleeve 312 and the electrode 33 inside the sleeve 312 is not particularly limited. The sealing between the sleeve 312 and the electrode 33 may be performed by welding.

[0064] As shown in Figure 4, the electrode 33 is preferably rod-shaped or strip-shaped. This allows for easier manufacturing with a simpler configuration, such as making it easier to pass through the sleeve 312. The electrode 33 is preferably extended along the central axis AX. The material constituting the electrode 33 is not particularly limited, but can be nickel or copper, etc. When sealing the space between the copper electrode 33 and the sleeve 312 using solder, the electrode 33 may be nickel-plated and gold-plated so that flux treatment is not required.

[0065] As shown in Figure 4, the electrode 33 may have a first straight section 331, a second straight section 332, and a curved section 333. In the illustrated example, the first straight section 331 and the second straight section 332 extend parallel to each other, with the first straight section 331 connected to the insertion side of the curved section 333 and the second straight section 332 connected to the bottom side of the curved section 333. The curved section 333 is located inside the outer tube 31 and relieves the stress caused by the electrode 33 being fixed to the bottom 311 of the outer tube. For example, when the sealing material 34 hardens, if the electrode 33 shifts in a direction perpendicular to the central axis AX, the electrode 33 deforms, and stress is generated as it tries to return to its original shape. The higher the rigidity of the electrode, the higher this stress becomes. In this embodiment, the curved section 333 can relieve the stress by curving. The shape of the curved section 333 is not particularly limited as long as it can provide elasticity to relieve such stress, but it can be arched or bellows-shaped, etc. The presence of a curved portion 333 in the electrode 33 reduces the risk of the electrode 33 detaching from the inner tube 32 due to stress caused by thermal expansion or contraction when fixing the electrode 33 to the sleeve 312, and also reduces the risk of reduced robustness due to stress after fixing.

[0066] As shown in Figures 3 and 4, the bottom of the outer tube 311 may have a plurality of sleeves 312. The heater assembly 30 may have a plurality of electrodes 33 extending through each of the plurality of sleeves 312. In the example in Figure 4, electrode 33A extends through sleeve 312A and electrode 33B extends through sleeve 312B. This configuration allows for a simple configuration in which the plurality of electrodes 33 do not come into contact with each other. In the illustrated example, two sleeves 312 are arranged on the bottom of the outer tube 311, but the system is not limited to this, and three or more sleeves 312 can be arranged on the bottom of the outer tube 311.

[0067] As shown in Figure 4, electrode 33A is longer than electrode 33B. It is preferable that the multiple electrodes 33 consist of a first electrode and a second electrode having a different length from the first electrode. This makes it easier to align each of the multiple electrodes 33 with the multiple sleeves 312 when manufacturing the heater assembly 30, as will be described later. However, this is not limited to this configuration, and the multiple electrodes 33 may have the same length.

[0068] Manufacturing Method of Heater Assembly Figures 9 to 12 are conceptual diagrams illustrating the manufacturing method of the heater assembly 30. This manufacturing method can suppress displacement of the electrodes 33 due to thermal expansion or contraction of the bottom body 313. As a result, the electrodes 33 connected to the heating section 321 and extending to the outside of the heater assembly 30 are stably attached to the outer tube 31, providing a heater assembly 30 with improved robustness. As shown in Figure 9, the outer tube 31 and the sub-assembly 300 are prepared. In the step of preparing the outer tube 31, the outer tube 31 having an outer tube bottom 311 including a sleeve 312 and an outer tube body 310 is prepared. For example, the space between the sleeve 312 and the bottom body 313, and the space between the bottom body 313 and the outer tube bottom 311 may be sealed by glass-metal sealing.

[0069] The subassembly 300 has an inner tube 32 and an electrode 33. In the subassembly 300, the electrode 33 extends from the heating portion 321 of the inner tube 32 along the inner tube central axis AX1, which is the central axis of the inner tube 32, to the opposite side of the insertion opening, and beyond the inner tube bottom 323. In the process of preparing the subassembly 300, the electrode 33 can be attached to the heating portion 321 of the inner tube 32 using solder or welding. It is preferable that the inner tube 32 is attached to the outer tube 31 such that the inner tube central axis AX1 coincides with the central axis AX of the heater assembly 30. After the process of preparing the outer tube 31 and the process of preparing the subassembly 300 are carried out, the insertion process is performed.

[0070] Figure 9 shows the insertion process in which the inner tube 32 is inserted into the outer tube 31, and corresponds to a schematic side cross-sectional view of the inner tube 32 and the outer tube 31. Figure 10 corresponds to a schematic side cross-sectional view of the intermediate body 3000 when the insertion process is completed. As shown in Figure 9, in the insertion process, the sub-assembly 300 is inserted into the outer tube 31 such that the outer tube 31 surrounds the inner tube 32. In the insertion process, it is preferable that the end of the electrode 33 opposite to the insertion port side is inserted into the outer tube body 310 first. In the insertion process, the electrode 33 and the inner tube body 320 may be inserted into the outer tube body 310 in this order through the opening 316 in the direction in which the central axis AX1 of the inner tube extends. In the insertion process, the outer tube 31 may be moved so as to cover the electrode 33 as schematically shown by arrow A10 and attached to the sub-assembly 300, or the sub-assembly 300 may be moved toward the stationary outer tube 31.

[0071] In the insertion process, the subassembly 300 is inserted into the outer tube 31 such that the outer tube 31 surrounds the inner tube 32 and the electrode 33 extends through the sleeve 312. As shown in Figure 10, it is preferable that the electrode 33 penetrates the sleeve 312 between the time the subassembly 300 is inserted into the outer tube 31 and the inner flange portion 325 contacts the outer flange portion 315. The electrode 33 is inserted into the first end 351 of the sleeve 312 and moved to protrude from the second end 352 to the outside of the outer tube 31. The insertion process may be carried out in a high-temperature atmosphere or under far-infrared irradiation.

[0072] As shown in the example in Figure 10, if, in a plurality of electrodes 33, electrode 33A extends further away from the insertion port side than electrode 33B in the direction in which the inner tube central axis AX1 extends, then in the insertion process, electrode 33A is inserted into the sleeve 312 before electrode 33B. At this time, by rotating the subassembly 300 around the axis extending along electrode 33A with the end of electrode 33A inserted into the sleeve 312A, it becomes easier to align electrode 33B with the sleeve 312B. Thus, from the viewpoint of making it easier to align a plurality of electrodes 33 with the sleeve 312, it is preferable that the plurality of electrodes 33 include electrodes 33A and 33B of different lengths. Thus, the insertion process may include a step of rotating the subassembly 300 after inserting electrode 33A into the sleeve 312A to position electrode 33B at the first end 351 of the sleeve 312B. After the insertion process is performed, a sealing process is carried out.

[0073] Figure 11 is a conceptual diagram showing the sealing process, corresponding to an enlarged cross-sectional view schematically showing the outer tube 31 and the sub-assembly 300. In the sealing process, the space between the sleeve 312 and the electrode 33 is sealed inside the sleeve 312. This sealing may be performed by soldering, brazing, or welding. In the illustrated example, the point where solder is used as the sealing material 34 is schematically shown by a soldering iron SD. The sealing process may be performed at room temperature, but if soldering is difficult, it may be performed in a reducing atmosphere using a reduction furnace or the like. After the sealing process is completed, the joining process is performed.

[0074] Figure 12 is a conceptual diagram showing the joining process, and corresponds to an enlarged cross-sectional view schematically showing the outer pipe 31 and the sub-assembly 300. In the joining process, the outer pipe 31 and the inner pipe 32 are joined. Preferably, the space between the outer pipe 31 and the inner pipe 32 is hermetically sealed by the joining process, and more preferably, the space is sealed in such a way that the internal space SP can maintain a vacuum state. The joining process is preferably performed by welding, and more preferably by projection welding. In this embodiment, as described above, the space between the outer flange portion 315 and the inner flange portion 325 is welded from the viewpoint of suppressing heat transfer from the heat source. When the internal space SP is to be in a vacuum state, the joining process can be performed under vacuum. Preferably, the joining process is performed under a vacuum with a pressure of 1 Pa or less.

[0075] Modification 1-1 In the above embodiment, the inner diameter of the sleeve 312 does not have to be constant. Figure 13 is a schematic side cross-sectional view showing the outer tube 31A of this modification. The outer tube 31A of this modification has a sleeve 312C. The sleeve 312C has a through portion 350 which penetrates the bottom body 313 and a first end portion 351A. The first end portion 351A is the end of the sleeve 312C on the inner tube 32 side (the side where the opening 316 is located) of the heater assembly 30. The first inner diameter D1, which is the inner diameter of the first end portion 351A, is larger than the second inner diameter D2, which is the inner diameter of the through portion 350. This makes it easier to insert the electrode 33 into the sleeve 312C. As shown in Figure 13, it is preferable that the first end portion 351A has a flared shape in which the outer diameter increases towards the tip.

[0076] Modification 1-2 In the above embodiment, the second end 352 of the sleeve 312 may have a flared shape. Figure 14 is a schematic side cross-sectional view showing the outer pipe 31B of this modification. The outer pipe 31B of this modification has a sleeve 312D. The sleeve 312D has a through portion 350 and a second end 352A. The second end 352A is the end of the sleeve 312D opposite to the side where the opening 316 is located. The second end 352A may protrude from the bottom body 313 to the outside of the outer pipe 31. The second end 352A has a flared shape with an outer diameter that increases towards the tip. This prevents the sleeve 312D from moving toward the opening 316 and falling out of the bottom body 313. In particular, during the joining process described above, when the inside of the outer tube 31B is evacuated, air flows out from the gap between the outer flange portion 315 and the inner flange portion 325, creating negative pressure that pulls the sleeve 312D towards the opening 316. The flared shape of the second end portion 352A prevents the sleeve 312D from falling off during the joining process.

[0077] Modification 1-3 In the above embodiment, the sleeve 312 may have a tapered shape. Figure 15 is a schematic side cross-sectional view showing the outer tube 31C of this modification. The outer tube 31C of this modification has a sleeve 312E. The sleeve 312E has a through portion 350A that penetrates the bottom body 313, and the through portion 350A has a tapered shape in which the diameter decreases toward the opening 316 side. As shown in Figure 13, the sleeve 312E may have the outer diameter of a frustocone. In this modification as well, it is possible to prevent the sleeve 312E from moving toward the opening 316 and falling out of the bottom body 313. Note that at least one of modifications 1-1, 1-2, and 1-3 can be combined.

[0078] Modification 2-1 In the above embodiment, the inner pipe body 320 and the inner flange portion 325 may be made of different materials. Figure 16 is a schematic side cross-sectional view showing the inner pipe 32A of this modification. The inner pipe 32A has an inner pipe body 320A and a flange extension member 400. The flange extension member 400 has a connecting portion 410 connected to the inner pipe body 320A and an inner flange portion 325A.

[0079] Figure 17 is a schematic bottom view showing the flange extension member 400. As shown in Figures 16 and 17, in this modified example, the connecting portion 410 is formed in a cylindrical shape located radially inward of the inner pipe body 320A, and the outer circumferential surface of the connecting portion 410 and the inner circumferential surface of the inner pipe body 320A are connected by welding or the like. The inner flange portion 325A extends radially outward from the connecting portion 410. The flange extension member 400 can ensure an inner flange portion 325A of sufficient size and increase design flexibility. The thickness of the flange extension member 400 is not particularly limited, but can be 0.1 to 0.2 mm or about 0.15 mm. The inner pipe body 320A and the inner flange portion 325A may also be connected by welding or the like.

[0080] The material constituting the flange extension member 400 is not particularly limited as long as it can be joined with the outer flange portion 315, but it is preferable that it be the same material as that constituting the inner pipe body 320A. This prevents damage due to differences in thermal expansion or contraction between the inner pipe body 320A and the flange extension member 400. The flange extension member 400 may include stainless steel. The inner flange portion 325A of the flange extension member 400 may be nickel-plated. This allows for more reliable hermetically sealed connection between the inner flange portion 325A and the outer flange portion 315.

[0081] As shown in Figure 17, the inner flange portion 325A may have at least one boss 420. This allows for a stronger bond between the inner flange portion 325A and the outer flange portion 315 by welding. In the illustrated example, four bosses 420 are formed on the inner flange portion 325A, but the number of bosses 420 is not particularly limited and may be one to three, or five or more.

[0082] In this modified example, the flange extension member 400 may be attached to the inner pipe body 320A, and then the subassembly 300 including the inner pipe 32A and the electrode 33 may be inserted into the outer pipe 31. Alternatively, the subassembly 300 without the flange extension member 400 may be inserted into the outer pipe 31, and then the flange extension member 400, the inner pipe body 320A, and the outer pipe 31 may be joined together. In the latter case, the flange extension member 400, the inner pipe body 320A, and the outer pipe 31 can be joined together in a single welding process.

[0083] Modification 2-2 In the above-described modification 2-1, the flange extending member 400 may be located radially outward of the inner pipe body 320A. Figure 18 is a schematic side cross-sectional view showing the inner pipe 32B of this modification. The inner pipe 32B has an inner pipe body 320A and a flange extending member 400A. The flange extending member 400A has a connecting portion 410A connected to the inner pipe body 320A and an inner flange portion 325B. In this modification, the connecting portion 410A is formed in a cylindrical shape located radially outward of the inner pipe body 320A, and the inner circumferential surface of the connecting portion 410A and the outer circumferential surface of the inner pipe body 320A are connected by welding or the like. The inner flange portion 325B extends radially outward from the connecting portion 410A. In this modification, since there is no inner pipe body 320A between the inner flange portion 325B and the outer flange portion 315, it is easier to connect the inner flange portion 325B and the outer flange portion 315 more strongly. The inner pipe body 320A and the inner flange portion 325B may be connected by welding or other means.

[0084] Although embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and various modifications are possible within the scope of the claims, specification, and drawings. Furthermore, any shape or material not directly described in the specification and drawings is within the scope of the technical idea of ​​the present invention as long as it achieves the function and effect of the present invention.

[0085] (1) According to a first aspect of the present invention, the heater assembly comprises an inner tube for housing a consumable, an outer tube surrounding the inner tube, and an electrode, wherein the outer tube comprises a tubular outer tube body and a first bottom formed inside the outer tube body, the inner tube comprises a tubular inner tube body and a heating portion connected to the electrode, the first bottom comprises a bottom body and a sleeve penetrating the bottom body, the electrode extends through the sleeve, and the space between the sleeve and the electrode is sealed inside the sleeve. (2) According to a second aspect of the present invention, in the first aspect, the sleeve protrudes from the bottom body toward the inner tube. (3) According to a third aspect of the present invention, in the first or second aspect, the sleeve has a first inner diameter at the end toward the inner tube and a second inner diameter in the portion of the sleeve that penetrates the bottom body, wherein the first inner diameter is larger than the second inner diameter. (4) According to a fourth aspect of the present invention, in any of the first to third aspects, the sleeve has at least one of a flared shape and a tapered shape. (5) According to a fifth aspect of the present invention, in any of the first to fourth aspects, the electrode is rod-shaped or strip-shaped and has a curved portion inside the outer tube to relieve stress caused by the electrode being fixed to the first bottom. (6) According to a sixth aspect of the present invention, in any of the first to fifth aspects, the first bottom comprises a plurality of sleeves, the heater assembly comprises a plurality of electrodes extending through each of the plurality of sleeves, the plurality of electrodes comprising a first electrode and a second electrode having a different length from the first electrode. (7) According to a seventh aspect of the present invention, in any of the first to sixth aspects, the outer tube comprises an outer flange portion extending in a second direction intersecting a first direction into which the consumable is inserted into the inner tube, and the inner tube comprises an inner flange portion extending in the second direction and joining with the outer flange portion.(8) According to the eighth aspect of the present invention, in any of the first to seventh aspects, the inner tube comprises a second bottom formed inside the inner tube body, the inner circumferential surface of the outer tube body, the bottom body, the outer circumferential surface of the inner tube body, and the second bottom define the internal space of the heater assembly, the internal space being a vacuum. (9) According to the ninth aspect of the present invention, in any of the first to eighth aspects, the bottom body comprises glass. (10) According to the tenth aspect of the present invention, in the ninth aspect, the thermal expansion coefficient of the material constituting the outer tube or the sleeve is in the range of 50% to 150% of the thermal expansion coefficient of the glass contained in the bottom body. (11) According to the eleventh aspect of the present invention, in any of the first to tenth aspects, the sleeve comprises a sealing material that seals the space between the sleeve and the electrode inside the sleeve, the sealing material comprising solder or brazing material. (12) According to a twelfth aspect of the present invention, in any of the first to eleventh aspects, the heating unit comprises a heater or an induction coil. (13) According to a thirteenth aspect of the present invention, the flavor inhaler comprises a heater assembly according to any of the first to twelfth aspects. (14) According to a fourteenth aspect of the present invention, the flavor inhalation system comprises a flavor inhaler according to a thirteenth aspect and a consumable material including a flavor source. (15) According to a fifteenth aspect of the present invention, a method for manufacturing a heater assembly includes: preparing a subassembly comprising an inner tube and an electrode, wherein the inner tube comprises a tubular inner tube body and a heating unit connected to the electrode; preparing an outer tube comprising a tubular outer tube body and a bottom, wherein the bottom is formed inside the outer tube body and comprises a sleeve; inserting the subassembly into the outer tube such that the outer tube surrounds the inner tube and the electrode extends through the sleeve; and sealing the space between the sleeve and the electrode inside the sleeve.

[0086] 10: Battery 20: Control unit 30: Heater assembly 31, 31A, 31B, 31C: Outer tube 32, 32A, 32B: Inner tube 33, 33A, 33B: Electrode 34: Sealing part 100: Consumable 200: Flavoring inhaler 310: Outer tube body 311: Outer tube bottom 312, 312A, 312B, 312C, 312D, 312E: Sleeve 313: Bottom body 315: Outer flange part 320: Inner tube body 321: Heating part 323: Inner tube bottom 325, 325A, 325B: Inner flange part 326: Insertion port 333: Curved part 350, 350A: Through part 351, 351A: First end of sleeve 352, 352A: Second end of sleeve 400, 400A: Flange extension member 1000: Flavor suction system 2000: Housing AX: Central axis of heater assembly AX1: Central axis of inner tube D1: First inner diameter D2: Second inner diameter SP: Internal space S31: Inner circumferential surface of outer tube S32: Outer circumferential surface of inner tube

Claims

1. A heater assembly comprising an inner tube for containing a consumable material, an outer tube surrounding the inner tube, and an electrode, wherein the outer tube comprises a tubular outer tube body and a first bottom formed inside the outer tube body, the inner tube comprises a tubular inner tube body and a heating portion connected to the electrode, the first bottom comprises a bottom body and a sleeve penetrating the bottom body, the electrode extends through the sleeve, and the space between the sleeve and the electrode is sealed inside the sleeve.

2. The heater assembly according to claim 1, wherein the sleeve protrudes from the bottom body toward the inner tube.

3. The heater assembly according to claim 1 or 2, wherein the sleeve has a first inner diameter at the end on the inner tube side and a second inner diameter in the portion of the sleeve that penetrates the bottom body, and the first inner diameter is larger than the second inner diameter.

4. The heater assembly according to any one of claims 1 to 3, wherein the sleeve has at least one of a flared shape and a tapered shape.

5. The heater assembly according to any one of claims 1 to 4, wherein the electrode is rod-shaped or strip-shaped and has a curved portion inside the outer tube for relieving stress caused by the electrode being fixed to the first bottom.

6. The heater assembly according to any one of claims 1 to 5, wherein the first bottom comprises a plurality of sleeves, the heater assembly comprises a plurality of electrodes extending through each of the plurality of sleeves, and the plurality of electrodes comprises a first electrode and a second electrode having a different length from the first electrode.

7. The heater assembly according to any one of claims 1 to 6, wherein the outer tube has an outer flange portion extending in a second direction intersecting the first direction in which the consumable material is inserted into the inner tube, and the inner tube has an inner flange portion extending in the second direction and joining with the outer flange portion.

8. The heater assembly according to any one of claims 1 to 7, wherein the inner tube comprises a second bottom formed inside the inner tube body, the inner circumferential surface of the outer tube body, the bottom body, the outer circumferential surface of the inner tube body, and the second bottom define the internal space of the heater assembly, and the internal space is a vacuum.

9. The heater assembly according to any one of claims 1 to 8, wherein the bottom body includes glass.

10. The heater assembly according to claim 9, wherein the thermal expansion coefficient of the material constituting the outer tube or the sleeve is in the range of 50% to 150% of the thermal expansion coefficient of the glass contained in the bottom body.

11. The heater assembly according to any one of claims 1 to 10, comprising a sealing material that seals the space between the sleeve and the electrode inside the sleeve, wherein the sealing material includes solder or brazing material.

12. The heater assembly according to any one of claims 1 to 11, wherein the heating section comprises a heater or an induction coil.

13. A flavor inhaler comprising the heater assembly according to any one of claims 1 to 12.

14. A flavor inhalation system comprising the flavor inhaler described in claim 13 and a consumable material containing a flavor source.

15. A method for manufacturing a heater assembly, comprising: preparing a subassembly comprising an inner tube and an electrode, wherein the inner tube comprises a tubular inner tube body and a heating portion connected to the electrode; preparing an outer tube comprising a tubular outer tube body and a bottom, wherein the bottom is formed inside the outer tube body and comprises a sleeve; inserting the subassembly into the outer tube such that the outer tube surrounds the inner tube and the electrode extends through the sleeve; and sealing the space between the sleeve and the electrode inside the sleeve.

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