Aerosol generating device having a heat conductive assembly
Patent Information
- Application Number
- BR112021021691
- Authority / Receiving Office
- BR · BR
- Patent Type
- Patents
- Current Assignee / Owner
- Publication Date
- 2026-09-15
Smart Images
Figure 00000034_0000 
Figure 00000034_0001 
Figure 00000035_0000
Abstract
Description
1 / 29 “AEROSOL GENERATING DEVICE HAVING A HEAT-CONDUCTIVE ASSEMBLY”
[001] The present invention relates to an aerosol generating device comprising a heat-conducting assembly.
[002] Aerosol generating systems in which an aerosol-forming substrate, such as a tobacco-containing substrate, is heated rather than burned, are known in the art. The purpose of such aerosol generating systems is to reduce the known harmful constituents of smoke produced by the combustion and pyrolytic degradation of tobacco in conventional cigarettes. Typically, in such aerosol generating systems, an aerosol is generated by the transfer of energy from an aerosol generator device to an aerosol-forming substrate or material in an aerosol generating article that is physically separate from the aerosol generating device. For example, the aerosol generator may be an electric heater, and an aerosol may be generated by the transfer of heat from the electric heater to an aerosol-forming substrate. The aerosol generating article may be located within, around, or downstream of the electric heater.During use, volatile compounds are released from the aerosol-forming substrate by heat transfer from the electric heater to the aerosol-forming substrate and carried in the drawn air through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol that can be inhaled by a consumer.
[003] During the use of such aerosol generating devices, the control circuit for controlling the power supply to the electric heater typically generates a significant amount of heat. Dissipation of the heat generated by the control electronics is necessary to prevent damage to the control circuit. However, the Petition 870260040515, dated 04 / 30 / 2026, page 5 / 79 2 / 29 The small size of typical aerosol generating devices, combined with the need for a user to hold the device during use, makes it difficult to dissipate excess heat.
[004] It would be describable to provide an aerosol generating device comprising an aerosol generator and a control circuit that facilitates the dissipation of excess heat generated by the control circuit.
[005] According to the present invention, an aerosol generating device is provided. The aerosol generating device may comprise an aerosol generator. The aerosol generator may be for generating an aerosol from an aerosol-forming substrate. The aerosol generating device may comprise a power supply. The aerosol generating device may comprise a circuit board. The circuit board may comprise a control circuit. The control circuit may be for controlling a power supply from the power supply to the aerosol generator. The circuit board and the power supply may be arranged for heat transfer from the circuit board to the power supply.
[006] According to the present invention, an aerosol generating device is provided comprising an aerosol generator for generating an aerosol from an aerosol-forming substrate, a power supply and a circuit board comprising a control circuit for controlling a power supply from the power supply to the aerosol generator. The circuit board and the power supply are arranged for heat transfer from the circuit board to the power supply.
[007] Preferably, the circuit board and the power supply are arranged for conductive heat transfer from the circuit board to the power supply.
[008] The circuit board can come into direct contact with the power supply. Petition 870260040515, dated 04 / 30 / 2026, page 6 / 79 3 / 29 power supply. Advantageously, direct contact between the circuit board and the power supply can facilitate direct conductive heat transfer from the circuit board to the power supply.
[009] The circuit board and the power supply may be arranged for indirect conductive heat transfer from the circuit board to the power supply. In other words, the aerosol generating device may comprise at least one additional element arranged for conductive heat transfer from the circuit board to the power supply by at least one additional element. Advantageously, the at least one additional element may provide conductive heat transfer from the circuit board to the power supply while also facilitating a desired orientation and position of the circuit board relative to the power supply. The desired orientation and position of the circuit board relative to the power supply may accommodate at least one of a desired size and a desired shape of the aerosol generating device.
[0010] At least one additional element may comprise a heat-conducting assembly. The heat-conducting assembly may comprise a first end in thermal contact with the circuit board. The heat-conducting assembly may comprise a second end away from the circuit board.
[0011] According to the present invention, an aerosol generating device is provided. The aerosol generating device may comprise an aerosol generator. The aerosol generator may be for generating an aerosol from an aerosol-forming substrate. The aerosol generating device may comprise a power supply. The aerosol generating device may comprise a circuit board. The circuit board may comprise a control circuit. The control circuit may be Petition 870260040515, dated 04 / 30 / 2026, page 7 / 79 4 / 29 to control a power supply from the power source to the aerosol generator. The aerosol generator device may comprise a heat-conducting assembly. The heat-conducting assembly may comprise a first end in thermal contact with the circuit board. The heat-conducting assembly may comprise a second end away from the circuit board.
[0012] According to the present invention, an aerosol generation device is provided comprising an aerosol generator for generating an aerosol from an aerosol-forming substrate, a power supply, and a circuit board comprising a control circuit for controlling a power supply from the power supply to the aerosol generator. The aerosol generation device also comprises a heat-conducting assembly comprising a first end in thermal contact with the circuit board and a second end away from the circuit board.
[0013] Advantageously, the heat-conducting assembly conducts excess heat away from the circuit board and toward the second end of the heat-conducting assembly. Advantageously, the heat-conducting assembly provides at least some control over the location to which excess heat from the circuit board is transferred. Advantageously, the second end of the heat-conducting assembly can be positioned in a location where it is desirable to dissipate excess heat generated by the control circuit.
[0014] As used herein, the term aerosol generating device refers to a device that interacts with an aerosol-forming substrate to generate an aerosol.
[0015] As used in this document, the term aerosol-forming substrate refers to a substrate capable of releasing volatile compounds that can form an aerosol. Such compounds Petition 870260040515, dated 04 / 30 / 2026, page 8 / 79 5 / 29 volatile compounds can be released by heating the aerosol-forming substrate. An aerosol-forming substrate can be part of an aerosol-generating article.
[0016] As used in this document, the term aerosol-generating article refers to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. For example, an aerosol-generating article may be an article that generates an aerosol that is directly inhalable by the user by inhaling or blowing into a mouthpiece at a proximal or user end of the system. An aerosol-generating article may be disposable. An article comprising an aerosol-forming substrate comprising tobacco may be referred to as a tobacco stick.
[0017] As used herein, the term aerosol generating system refers to the combination of an aerosol generating device and an aerosol generating article. In the aerosol generating system, the aerosol generating article and the aerosol generating device cooperate to generate an aerosol.
[0018] Preferably, the second end of the heat-conducting assembly is in thermal contact with the power supply.
[0019] Advantageously, during use, there may be a high thermal gradient between the circuit board and the power supply. Advantageously, the high thermal gradient and the thermal contact between the second end of the heat-conducting assembly and the power supply can increase or maximize the rate of heat transfer away from the circuit board by the heat-conducting assembly.
[0020] Advantageously, the heat transfer from the circuit board to the power supply can facilitate the use of the aerosol generator device in cold ambient temperatures. For example, at temperatures of about 5 degrees Celsius and less, the performance of Petition 870260040515, dated 04 / 30 / 2026, page 9 / 79 6 / 29 Some power supplies may be reduced. Therefore, the heat transfer from the circuit board to the power supply can advantageously increase the power supply temperature above ambient temperature. Advantageously, increasing the power supply temperature above ambient temperature can maintain or improve the power supply performance.
[0021] Preferably, the heat-conducting assembly comprises a heat-conducting structure that defines the second end of the heat-conducting assembly. Preferably, the power source is positioned at least partially within the heat-conducting structure.
[0022] Advantageously, providing the heat-conducting assembly with a heat-conducting structure can facilitate the positioning of the power supply and the heat-conducting assembly relative to each other during the assembly of the aerosol generating device.
[0023] Advantageously, positioning the power supply inside the heat-conducting structure can facilitate heat transfer from the other end of the heat-conducting assembly to the power supply.
[0024] Aerosol generating device, according to any of the preceding claims, characterized in that the heat-conducting assembly comprises at least one cross element at the first end of the heat-conducting assembly and in that a portion of at least one cross element is positioned within a slot defined by the circuit board.
[0025] Advantageously, providing the heat-conducting assembly with at least one cross element positioned within a slot defined by the circuit board can facilitate thermal contact between the circuit board and the first end of the heat-conducting assembly.
[0026] Advantageously, provide the heat-conducting assembly with Petition 870260040515, dated 04 / 30 / 2026, page 10 / 79 7 / 29 At least one cross element positioned within a slot defined by the circuit board can help retain the first end of the heat-conducting assembly in thermal contact with the circuit board. Advantageously, the combination of at least one cross element and the slot can eliminate the need to solder or adhere the first end of the heat-conducting assembly to the circuit board. Advantageously, eliminating the need to solder or adhere the first end of the heat-conducting assembly to the circuit board can simplify at least one of the manufacturing and repair steps of the aerosol generating device.
[0027] Advantageously, providing the heat-conducting assembly with at least one cross element positioned within a slot defined by the circuit board can facilitate the positioning of the circuit board and the heat-conducting assembly relative to each other during the assembly of the aerosol generating device.
[0028] Preferably, at least one cross element is received within the slot by an interference fit. Advantageously, the interference fit may facilitate thermal contact between at least one cross element and the circuit board. Advantageously, the interference fit may facilitate the retention of at least one cross element within the slot.
[0029] At least one cross element may comprise a plurality of cross elements. The circuit board may define a plurality of slots, where each of the cross elements is received within a different slot defined by the circuit board.
[0030] Advantageously, providing a plurality of cross elements can increase the rate of heat transfer from the circuit board to the first end of the heat-conducting assembly.
[0031] Advantageously, provide a plurality of elements Petition 870260040515, dated 04 / 30 / 2026, page 11 / 79 8 / 29 crossbars can facilitate thermal contact between the first end of the heat-conducting assembly and a plurality of locations on the circuit board. Advantageously, the plurality of locations can be selected to provide a desired heat transfer profile from the circuit board to the first end of the heat-conducting assembly. For example, where the heat generated by the control circuit results in a non-uniform temperature distribution along at least a portion of the circuit board during use, the plurality of crossbars can be positioned to accommodate the non-uniform temperature profile.
[0032] Advantageously, providing a plurality of cross elements can further facilitate the positioning of the circuit board and the heat-conducting assembly relative to each other during the assembly of the aerosol generating device.
[0033] The slot defined by the circuit board may be a first slot and the circuit board may define a second slot. At least one cross element may comprise a first cross element having a first portion positioned within the first slot and a second cross element having a second portion positioned within the second slot.
[0034] The gap defined by the circuit board may extend through the circuit board from a first side of the circuit board to a second side of the circuit board. At least one cross element may extend through the gap such that at least one cross element projects from the first side of the circuit board and from the second side of the circuit board. In other words, at least one cross element may extend entirely through a thickness of the circuit board.
[0035] Advantageously, a cross element that extends entirely through a circuit board thickness can Petition 870260040515, dated 04 / 30 / 2026, page 12 / 79 9 / 29 increase or maximize the thermal contact area between at least one cross-sectional element and the circuit board.
[0036] The heat-conducting assembly may comprise at least one longitudinal arm extending between at least one transverse element and the heat-conducting structure.
[0037] Advantageously, at least one longitudinal arm can facilitate heat transfer from at least one transverse element at the first end of the heat-conducting assembly to the heat-conducting structure at the second end of the heat-conducting assembly.
[0038] Advantageously, at least one longitudinal arm may be flexible. Advantageously, at least one flexible longitudinal arm may facilitate the positioning of at least one transverse element in the slot during the assembly of the aerosol generating device.
[0039] In embodiments where the heat-conducting assembly comprises a plurality of transverse elements, preferably the heat-conducting assembly comprises a plurality of longitudinal arms. Preferably, each longitudinal arm extends between one of the transverse elements and the heat-conducting frame.
[0040] In embodiments where the heat-conducting assembly comprises a first transverse element and a second transverse element, preferably at least one longitudinal arm comprises a first longitudinal arm extending between the first transverse element and the heat-conducting structure, and a second longitudinal arm extending between the second transverse element and the heat-conducting structure.
[0041] The circuit board may be a first circuit board and the aerosol generating device may further comprise a second circuit board. Preferably, the first end Petition 870260040515, dated 04 / 30 / 2026, page 13 / 79 10 / 29 of the heat-conducting assembly is in thermal contact with the first circuit board and the second circuit board.
[0042] Advantageously, the first and second circuit boards can facilitate the provision of the aerosol generating device with at least one of a desired size and a desired shape. For example, the first and second circuit boards can facilitate an aerosol generating device with a shorter length when compared to an aerosol generating device comprising a single circuit board.
[0043] Advantageously, the first and second circuit boards can facilitate the separation of two or more electrical components of the aerosol generating device. Advantageously, providing a first set of electrical components on the first circuit board and a second set of electrical components on the second circuit board can facilitate the thermal separation of the first and second sets of electrical components.
[0044] Preferably, the second circuit board overlaps, at least partially, the first circuit board. Advantageously, at least partially overlapping the first and second circuit boards may facilitate thermal contact of the first end of the heat-conducting assembly with the first and second circuit boards.
[0045] Preferably, the first circuit board is set away from the second circuit board. Preferably, the first end of the heat-conducting assembly is positioned between the first circuit board and the second circuit board. Advantageously, positioning the first end of the heat-conducting assembly between the first and second circuit boards can facilitate thermal contact of the first end of the heat-conducting assembly with the first and second circuit boards. Petition 870260040515, dated 04 / 30 / 2026, page 14 / 79 11 / 29
[0046] Preferably, the control circuit for controlling the power supply from the power source to the aerosol generator is provided on the first circuit board. Preferably, the aerosol generator is electrically connected to the first circuit board.
[0047] As used in this document, the term electrically connected refers to a connection via an electrically conductive path.
[0048] Preferably, the power supply is electrically connected to at least one of the first circuit board and the second circuit board. The power supply may be electrically connected to the first circuit board and the second circuit board.
[0049] Preferably, the aerosol generating device comprises one or more additional electrical components. Preferably, one or more additional electrical components comprise at least one of a charging connector, a feedback device, a user input device, and an airflow sensor. Preferably, at least one of the one or more additional electrical components is positioned on the second circuit board or electrically connected to the second circuit board.
[0050] Preferably, the aerosol generating device comprises a device controller configured to control the operation of the aerosol generating device. Preferably, the device controller is provided on the second circuit board. Preferably, the device controller is in electrical communication with one or more additional electrical components. Preferably, the device controller is electrically connected to the power supply. Preferably, the device controller is in electrical communication with the control circuit to control the power supply from the power supply to Petition 870260040515, dated 04 / 30 / 2026, page 15 / 79 12 / 29 the aerosol generator. Preferably, the first circuit board is electrically connected to the second circuit board. Preferably, the electrical connection between the first circuit board and the second circuit board provides electrical communication between the device controller and the control circuit to control the power supply from the power source to the aerosol generator.
[0051] In embodiments where the heat-conducting assembly comprises at least one cross element, preferably at least a portion of the at least one cross element is positioned within a slot defined by the second circuit board. Advantageously, positioning the at least one cross element within the slots defined by the first and second circuit boards can facilitate heat transfer away from the first and second circuit boards by the heat-conducting assembly.
[0052] In embodiments where at least one cross element comprises a plurality of cross elements, at least one of the cross elements may be received within the slot defined by the first circuit board and the slot defined by the second circuit board. At least one of the cross elements may comprise a first end received within the slot defined by the first circuit board and a second end received within the slot defined by the second circuit board.
[0053] Advantageously, providing at least one cross element that is received within the slots defined by the first and second circuit boards can reduce or minimize the number of cross elements needed to provide a desired thermal contact between the first end of the heat-conducting assembly and each of the first and second circuit boards. Petition 870260040515, dated 04 / 30 / 2026, page 16 / 79 13 / 29
[0054] Preferably, at least one of the cross elements is in thermal contact with the first circuit board only. Advantageously, providing a cross element that is in thermal contact with the first circuit board only can facilitate a higher rate of heat transfer away from the first circuit board by the heat-conducting assembly compared to a rate of heat transfer away from the second circuit board by the heat-conducting assembly. Advantageously, a higher rate of heat transfer away from the first circuit board by the heat-conducting assembly can accommodate the significant amount of heat generated by the control circuit to control a power supply from the power source to the aerosol generator.
[0055] As described in this document, the heat-conducting assembly may comprise a first cross-sectional element positioned within a first slot defined by the first circuit board and a second cross-sectional element positioned within a second slot defined by the first circuit board. Preferably, the second circuit board defines a third slot, wherein the second cross-sectional element has a third portion positioned within the third slot. Preferably, the first cross-sectional element is in thermal contact with the first circuit board only.
[0056] The heat-conducting assembly is made of a thermally conductive material. Preferably, the thermally conductive material has a thermal conductivity of at least about 190 watts per meter kelvin at 23 degrees Celsius and a relative humidity of 50 percent measured using the modified transient plane source method (MTPS).
[0057] Suitable thermally conductive materials can Petition 870260040515, dated 04 / 30 / 2026, page 17 / 79 14 / 29 understand a metal. The heat-conducting assembly may be metallic. Suitable metals include aluminum, copper, iron, gold, zinc, or any suitable alloy of such metals. Suitable alloys include some stainless steels and some copper alloys such as brass, copper-nickel alloys, copper-beryllium alloys, and phosphor bronze.
[0058] Preferably, the heat-conducting assembly is made of brass. Advantageously, the brass may be sufficiently malleable to facilitate the shaping of the heat-conducting assembly into the required form. Advantageously, a heat-conducting assembly made of brass may be sufficiently resilient to facilitate the retention of one or more components of the aerosol generating device by the heat-conducting assembly. For example, in embodiments where the heat-conducting assembly comprises a heat-conducting structure, a brass heat-conducting assembly may be sufficiently resilient to facilitate the retention of the power supply within the heat-conducting structure.
[0059] The aerosol generating device may comprise an internal housing. Advantageously, the internal housing may support one or more components of the aerosol generating device.
[0060] The circuit board can be attached to the inner housing. The circuit board can be attached to the housing by an interference fit between a part of the circuit board and the inner housing. In embodiments where the aerosol generating device comprises a first circuit board and a second circuit board, the first and second circuit boards can be attached to the inner housing.
[0061] Preferably, the power supply is positioned inside the internal housing.
[0062] Preferably, the second end of the heat-conducting assembly is in thermal contact with the inner housing. Petition 870260040515, dated 04 / 30 / 2026, page 18 / 79 15 / 29 Advantageously, thermal contact between the heat-conducting assembly and the inner housing can facilitate heat dissipation from the circuit board to the inner housing by the heat-conducting assembly.
[0063] In embodiments where the heat-conducting assembly comprises a heat-conducting structure, preferably, the heat-conducting structure is in thermal contact with the inner housing.
[0064] At least part of the second end of the heat-conducting assembly may cover a portion of the inner housing.
[0065] Preferably, a portion of the inner housing is overmolded over at least a portion of the second end of the heat-conducting assembly. Advantageously, overmolding a portion of the inner housing over at least a portion of the second end of the heat-conducting assembly may incorporate at least a portion of the second end of the heat-conducting assembly within the material forming the inner housing. Advantageously, incorporating at least a portion of the heat-conducting assembly within the material forming the inner housing may facilitate heat transfer from the second end of the heat-conducting assembly to the inner housing.
[0066] In embodiments in which the second end of the heat-conducting assembly comprises a heat-conducting structure, preferably a portion of the inner housing is overmolded over at least a portion of the heat-conducting structure.
[0067] Preferably, the inner housing is made of a material that is suitable for molding onto the heat-conducting assembly. The inner housing may be made from a polymeric material. The inner housing may be made from a moldable polymer. Preferably, the inner housing is made of a material that is suitable for use in a process of Petition 870260040515, dated 04 / 30 / 2026, page 19 / 79 16 / 29 molding, such as injection molding. Suitable polymeric materials include thermoplastic materials and thermosetting polymers. Suitable polymeric materials include: polyphthalamide (PPA), polycarbonate (PC), a mixture of polycarbonate and acrylonitrile butadiene styrene (PC-ABS), polyphenylsulfone (PPSU), polyetheretherketone (PEEK), polypropylene (PP), polyethylene (PE), polyimide (PI), thermoplastic polyimide (TPI), polyamide (PAI), and polyetherimide (PEI). The polymeric material may be a composite polymeric material. The composite polymeric material may comprise other materials. The composite polymeric material may comprise at least one fibrous filler material. At least one fibrous filler material may comprise at least one of carbon fibers and glass fibers.
[0068] The control circuit for controlling a power supply from the power source to the aerosol generator may comprise at least one of a microprocessor, a microcontroller, and an application-specific integrated chip (ASIC).
[0069] In embodiments where the aerosol generating device comprises a device controller, the device controller may comprise at least one of a microprocessor, a microcontroller, and an application-specific integrated chip (ASIC).
[0070] The power supply can be a power supply In preferred embodiments, the power supply is a battery. The power supply may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, for example, lithium-cobalt, lithium-iron-phosphate, or lithium-polymer battery. The power supply may be another form of charge storage device, such as a capacitor. The power supply may require recharging and may have capacity that allows for the storage of sufficient energy for one or more... Petition 870260040515, dated 04 / 30 / 2026, p. 20 / 79 17 / 29 user experiences, for example, one or more aerosol generation experiences. For example, the power supply may have sufficient capacity to allow continuous heating of an aerosol-forming substrate for a period of about six minutes, corresponding to the typical time spent smoking a conventional cigarette, or for a period that is a multiple of six minutes. In another example, the power supply may have sufficient capacity to allow a predetermined number of puffs or discrete activations of the heater.
[0071] Preferably, the aerosol generating device comprises a cavity for receiving an aerosol-forming substrate. In embodiments where the aerosol generating device comprises an internal housing, the internal housing may define at least partially the cavity.
[0072] Preferably, the aerosol generating device comprises an external housing. In embodiments where the aerosol generating device comprises a cavity for receiving an aerosol-forming substrate, the external housing may define at least partially the cavity.
[0073] The housing may be elongated. The housing may have a cylindrical shape. The housing may comprise any suitable material or combination of suitable materials. Suitable materials include metals, alloys, plastics, and composite materials containing at least one of a metal, an alloy, and a plastic. Suitable materials include thermoplastics that are suitable for food or pharmaceutical applications. Suitable thermoplastics include polypropylene, polyetheretherketone (PEEK), and polyethylene.
[0074] Preferably, the aerosol generating device is portable. The aerosol generating device may have a length between approximately 70 millimeters and approximately 120 millimeters. Petition 870260040515, dated 04 / 30 / 2026, page 21 / 79 18 / 29 Ideally, the aerosol generating device is a portable device. In other words, the aerosol generating device can be sized and shaped to be held in a user's hand.
[0075] The aerosol generator may comprise an electric heater.
[0076] The electric heater may comprise at least one internal heating element. As used in this document, the term internal heating element refers to a heating element configured to be inserted into an aerosol-forming substrate. The internal heating element may have the form of at least one of a blade, a pin, and a cone. The internal heating element is preferably configured to be inserted into an aerosol-forming substrate. In embodiments where the aerosol-generating device comprises a cavity for receiving an aerosol-forming substrate, preferably at least one internal heating element extends into the cavity.
[0077] The electric heater may comprise at least one external heating element. As used in this document, the term external heating element refers to a heating element configured to heat an external surface of an aerosol-forming substrate. At least one external heating element is preferably configured to at least partially enclose an aerosol-forming substrate received by the aerosol-generating device. In embodiments where the aerosol-generating device comprises a cavity for receiving an aerosol-forming substrate, preferably at least one external heating element at least partially encloses the cavity.
[0078] The electric heater may comprise at least one Petition 870260040515, dated 04 / 30 / 2026, page 22 / 79 19 / 29 internal heating element and at least one external heating element.
[0079] In some preferred embodiments, the heater comprises at least one resistive heating element.
[0080] The electric heater may comprise a resistive heating element. The resistive heating element may comprise an electrically insulating substrate and one or more electrically conductive rails or wires provided on the surface of the electrically insulating substrate. The size and shape of the electrically insulating substrate may facilitate the insertion of the electric heater into an aerosol-forming substrate. Preferably, the electrically insulating substrate is rigid. The aerosol-generating device may comprise only one resistive heating element. The aerosol-generating device may comprise a plurality of resistive heating elements.
[0081] The aerosol generator may comprise a transfer element. The transfer element may be arranged to transfer a liquid aerosol-forming substrate to the electric heater. The transfer element may comprise a capillary wick. Preferably, the electric heater contacts the transfer element. The electric heater may comprise a resistive heating wire. At least a portion of the resistive heating wire may be wound around the transfer element. The electric heater may comprise a resistive heating mesh.
[0082] The aerosol generator may comprise an inductive heating arrangement. The inductive heating arrangement may comprise an inductor coil. Preferably, the control circuit for controlling a power supply from the power source to the aerosol generator is configured to provide Petition 870260040515, dated 04 / 30 / 2026, p. 23 / 79 20 / 29 a high-frequency oscillating current for the inductor coil of the power supply. As used in this document, the term high-frequency oscillating current refers to an oscillating current with a frequency between 500 kilohertz and 30 megahertz. The aerosol generating device may comprise a DC / AC inverter to convert a DC current supplied by a DC power supply to the oscillating current. The inductor coil may be arranged to generate a high-frequency oscillating electromagnetic field upon receiving the high-frequency oscillating current from the power supply. The inductor coil may be arranged to generate a high-frequency oscillating electromagnetic field in a device cavity configured to receive an aerosol forming substrate.In embodiments where the aerosol generating device comprises a cavity for receiving an aerosol-forming substrate, the induction coil may substantially encircle the cavity. The induction coil may extend at least partially along a length of the cavity.
[0083] In embodiments where the aerosol generator comprises an inductive heating arrangement, the aerosol generator may comprise an inductive heating element. The inductive heating element may be a susceptor element. As used in this document, the term susceptor element refers to an element comprising a material that is capable of converting electromagnetic energy into heat. When a susceptor element is located in an oscillating electromagnetic field, the susceptor is heated. The heating of the susceptor element may be the result of at least one of the hysteresis losses and eddy currents induced in the susceptor element, depending on the electrical and magnetic properties of the susceptor material. In embodiments where the aerosol generating device comprises a cavity for Petition 870260040515, dated 04 / 30 / 2026, page 24 / 79 21 / 29 To receive an aerosol-forming substrate, a susceptor element may be arranged such that, when an aerosol-forming substrate is received in the cavity, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element, causing the susceptor element to heat the aerosol-forming substrate. The susceptor element may be positioned inside the cavity. The aerosol generating device may comprise only one susceptor element. The aerosol generating device may comprise a plurality of susceptor elements.
[0084] A susceptor element may comprise any suitable material. The susceptor element may be formed from any material that can be inductively heated to a temperature sufficient to release volatile compounds from an aerosol-forming substrate. The susceptor element may comprise a metal or carbon. Suitable materials for the susceptor element include graphite, molybdenum, silicon carbide, stainless steels, niobium, aluminum, nickel, nickel-containing compounds, titanium, and compounds of metallic materials. The susceptor element may comprise a ferromagnetic material, for example, ferritic iron, a ferromagnetic alloy such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite.
[0085] In embodiments where the aerosol generator comprises an inductive heating arrangement, the aerosol generator may comprise only an inductor coil. In other words, the aerosol generating device may not comprise any susceptor element. The aerosol generating device may receive an aerosol generating article comprising an aerosol-forming substrate and at least one susceptor element. During use, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element of the aerosol generating article, causing Petition 870260040515, dated 04 / 30 / 2026, page 25 / 79 22 / 29 with which the susceptor element heats the aerosol-forming substrate.
[0086] The aerosol generator may comprise an element arranged to oscillate when powered from the power supply. The aerosol generator may comprise a piezoelectric element. The aerosol generator may comprise at least one nozzle. The piezoelectric element may be arranged to eject droplets from a liquid aerosol-forming substrate through at least one nozzle. The aerosol generator may comprise a mesh, wherein the mesh defines at least one nozzle.
[0087] The mesh can be arranged to oscillate during the use of the aerosol generating device. An oscillating mesh can be called an active mesh. The mesh can be formed of a piezoelectric material. The mesh can be the piezoelectric element. The piezoelectric element can be formed separately from the mesh and arranged to oscillate the mesh during use.
[0088] The mesh may be arranged to remain substantially stationary relative to the oscillating piezoelectric element during use of the aerosol generating device. A stationary mesh may be termed a passive mesh. The aerosol generator may comprise a reservoir positioned between the mesh and the piezoelectric element. The reservoir may be arranged to receive a liquid aerosol forming substrate.
[0089] Embodiments of the present invention are described below by way of example only, with reference to the accompanying drawings, in which:
[0090] Figure 1 shows a schematic cross-sectional view of an aerosol generating device according to a first embodiment of the present invention;
[0091] Figure 2 illustrates the electrical connection between the components. Petition 870260040515, dated 04 / 30 / 2026, page 26 / 79 23 / 29 electrical components of the aerosol generating device in Figure 1;
[0092] Figure 3 shows a top perspective view of the aerosol generating device of Figure 1 with the outer housing removed;
[0093] Figure 4 shows a bottom perspective view of the aerosol generating device of Figure 1 with the outer housing removed;
[0094] Figure 5 shows a perspective view of the heat-conducting assembly of the aerosol generating device in Figure 1;
[0095] Figure 6 shows an alternative arrangement of the heat-conducting assembly in relation to the internal housing of the aerosol generating device of Figure 1;
[0096] Figure 7 shows a schematic cross-sectional view of an aerosol generating device according to a second embodiment of the present invention; and
[0097] Figure 8 shows a schematic cross-sectional view of an aerosol generating device according to a third embodiment of the present invention.
[0098] Figure 1 shows a schematic cross-sectional view of an aerosol generating device 10 according to a first embodiment of the present invention. The aerosol generating device 10 comprises an inner housing 12 defining a cavity 14 for receiving an aerosol-forming substrate at a first end of the aerosol generating device 10. The aerosol generating device 10 also comprises an outer housing 16 that extends around the inner housing 12.
[0099] The aerosol generating device 10 also comprises an aerosol generator 18 comprising an inductive heating arrangement. The inductive heating arrangement comprises an induction coil 20 surrounding the cavity 14. During use, an aerosol-forming article comprising an aerosol-forming substrate Petition 870260040515, dated 04 / 30 / 2026, page 27 / 79 24 / 29 aerosol and a susceptor element is inserted into cavity 14.
[00100] A power supply 24 is positioned inside the inner housing 12 at one end of the aerosol generator device 10. The power supply 24 is a rechargeable battery.
[00101] The aerosol generating device 10 also comprises a series of control components generally illustrated by box 26 in Figure 1. The control components and their functional connectivity to each other (illustrated by connection arrows) are shown in more detail in the schematic illustration in Figure 2.
[00102] The aerosol generating device 10 comprises a first circuit board 28 on which a control circuit 30 is provided. The control circuit 30 is configured to control a power supply from the power source 24 to the aerosol generator 18. In particular, the control circuit 30 comprises a DC / AC inverter to convert a DC power supply from the power source 24 into an oscillating electric current that is supplied to the inductor coil 20. During use, the oscillating electric current in the inductor coil 20 generates a high-frequency oscillating electromagnetic field within the cavity 14. The high-frequency oscillating electromagnetic field inductively heats the susceptor element of an received aerosol generating article within the cavity 14, which heats the aerosol-forming substrate of the aerosol generating article.
[00103] A breath sensor 32 is disposed within or in communication with cavity 14. The breath sensor is disposed to detect when a user is drawing air through cavity 14 to inhale an aerosol generated by an aerosol-forming substrate received within cavity 14. The breath sensor 32 comprises a pressure sensor. The breath sensor 32 is electrically connected to the first circuit board 28 to communicate Petition 870260040515, dated 04 / 30 / 2026, page 28 / 79 25 / 29 the data generated by the drag sensor 32 for the control circuit 30.
[00104] The aerosol generator device 10 also comprises a second circuit board 34 on which a device controller 36 is provided. The device controller 36 communicates with the control circuit 30 to command the control circuit 30 to control the power supply from the power source 24 to the aerosol generator 18 or to interrupt the power supply from the power source 24 to the aerosol generator 18. The device controller 36 can also receive data generated by the puff sensor 32 via the control circuit 30.
[00105] A charging connector 38 is positioned at the second end of the aerosol generator device 10 and is electrically connected to the second circuit board 34. The charging connector 38 is configured to receive a power source from an external device, such as a main charger or a universal serial bus (USB) charger. The device controller 36 controls the power supply received by the charging connector 38 to recharge the power supply 24.
[00106] Two feedback devices comprising a light-emitting diode (LED) module 40 and a vibration motor 42 are electrically connected to the second circuit board 34. The device controller 36 is configured to provide feedback to a user using the two feedback devices. For example, the device controller 36 can control the LED module 40 to provide a power supply status 24 to a user. The device controller 36 can control the vibration motor 42 to indicate at least the beginning of a heating cycle and the end of a heating cycle.
[00107] A user input device comprising a Petition 870260040515, dated 04 / 30 / 2026, page 29 / 79 Pushbutton 44 is electrically connected to the second circuit board 34. Pushbutton 44 allows a user to operate the aerosol generator device by providing one or more signals to the device controller 36. For example, the device controller 36 can be configured to allow a user to use a single pushbutton, or a combination of pushbuttons, to start a heating cycle, to end a heating cycle, to generate feedback using at least one of the LED module 40 and the vibration motor 42, and to modify a setting of the aerosol generator device 10.
[00108] Figures 3 and 4 show a top perspective view and a bottom perspective view of the aerosol generating device 10 with the outer housing 16 removed to show the arrangement of the first and second circuit boards 28, 34 inside the aerosol generating device 10. The first circuit board 28 overlaps the second circuit board 34.
[00109] During the use of the aerosol generating device 10, the electrical components provided on the first and second circuit boards 28, 34, including the control circuit 30 and the device controller 36, generate heat. To dissipate the heat generated from the first and second circuit boards 28, 34 and to prevent thermal damage to the control circuit 30 and the device controller 36, the aerosol generating device comprises a heat-conducting assembly 46. The integration of the heat-conducting assembly 46 into the aerosol generating device 10 is shown in Figures 3 and 4. The heat-conducting assembly 46 is shown in detail, separated from the aerosol generating device 10, in Figure 5.
[00110] The heat-conducting assembly 46 comprises a first end 48 positioned between the first circuit board 28 and the second circuit board 34 and a second end 50 spaced Petition 870260040515, dated 04 / 30 / 2026, page 30 / 79 27 / 29 of the first and second circuit boards 28, 34.
[00111] The second end 50 of the heat-conducting assembly 46 is defined by a heat-conducting structure 52 arranged to partially enclose the power source 24 to provide thermal contact between the second end 50 of the heat-conducting assembly 46 and the power source 24. In the assembled aerosol generator article 10 shown in Figure 3, the heat-conducting structure 52 is partially incorporated within the inner housing 12 by overmolding a portion of the inner housing 12 over the heat-conducting structure 52 during the manufacture of the aerosol generator device 10.
[00112] The first end 48 of the heat-conducting assembly 46 comprises a first transverse element 54, a first longitudinal arm 56 extending between the first transverse element 54 and the heat-conducting frame 52, a second transverse element 58 and a second longitudinal arm 60 extending between the second transverse element 58 and the heat-conducting frame 52.
[00113] The first and second cross elements 54, 58 are positioned within the slots defined by the first and second circuit plates 28, 34 to provide thermal contact between the first end 48 of the heat-conducting assembly 46 and each of the first and second circuit plates 28, 34. The first cross element 54 comprises a first portion 62 positioned within a first slot 64 defined by the first circuit plate 28. The secondary cross element 58 comprises a second portion 66 positioned within a second slot 68 defined by the first circuit plate 28. The secondary cross element 58 also comprises a third part 70 positioned within a third slot 72 defined by the second circuit plate 34.
[00114] Thermal contact between the first and second elements Petition 870260040515, dated 04 / 30 / 2026, page 31 / 79 The 28 / 29 crossbars 54, 58 and the first and second circuit boards 28, 34 facilitate heat transfer from the first and second circuit boards 28, 34 to the first end 48 of the heat-conducting assembly 46. The heat transferred to the first end 48 of the heat-conducting assembly 46 is conducted along the first and second longitudinal arms 56, 60 and to the heat-conducting structure 52 where it is dissipated in the power supply 24 and the internal housing 12. The thermal contact between the first and second crossbars 54, 58 and the first circuit board 28 provides a higher rate of heat transfer than the thermal contact between the second circuit board 34 and the second crossbar alone. The higher rate of heat transfer accommodates the higher rate of heat generation by the control circuit 30 compared to the device controller 36.
[00115] Figure 6 shows an alternative arrangement of the heat-conducting structure 52 in relation to the inner housing 12. In the embodiment shown in Figure 6, the heat-conducting structure 52 completely overlaps the inner housing 12 and the power supply 24. In other words, the heat-conducting structure 52 is not partially incorporated within the inner housing 12. Although this arrangement simplifies the assembly of the aerosol generating device 10, since it does not require the overmolding of the inner housing 12 over the heat-conducting structure 52, the rate of heat transfer from the heat-conducting frame 52 to the inner housing 12 may be reduced.
[00116] Figure 7 shows an aerosol generating device 100 according to a second embodiment of the present invention. The aerosol generating device 100 is substantially the same as the aerosol generating device of Figure 1 and similar reference numbers are used to designate similar parts. Petition 870260040515, dated 04 / 30 / 2026, page 32 / 79 29 / 29
[00117] The aerosol generating device 100 differs from the aerosol generating device 10 by the aerosol generator. Although the aerosol generating device 100 includes an aerosol generator 118 comprising an inductor coil 20, the aerosol generator 118 also comprises a susceptor element 222 that extends into the cavity 14. During use, an aerosol-forming substrate is inserted into the cavity 14 so that the susceptor element 222 is received within the aerosol-forming substrate.
[00118] The remainder of the aerosol generating device 100, including the main conductor assembly 46, is identical to the aerosol generating device 10 in Figure 1.
[00119] Figure 8 shows an aerosol generating device 200 according to a third embodiment of the present invention. The aerosol generating device 200 is substantially the same as the aerosol generating device of Figure 1 and similar reference numbers are used to designate similar parts.
[00120] The aerosol generating device 200 differs from the aerosol generating device 10 by the aerosol generator. Instead of an inductor coil, the aerosol generator 218 of the aerosol generating device 200 comprises an electric heater 220 comprising a resistive heating element extending into the cavity 14. During use, an aerosol-forming substrate is inserted into the cavity 14 so that the electric heater 220 is received within the aerosol-forming substrate.
[00121] The remainder of the aerosol generation device 200, including the main conductor assembly 46, is identical to the aerosol generation device 10 in Figure 1. Petition 870260040515, dated 04 / 30 / 2026, page 33 / 79
Claims
1 / 4 CLAIMS 1. Aerosol generating device (100), comprising: an aerosol generator (118) for generating an aerosol from an aerosol-forming substrate; a power supply (24); a circuit board (28, 34) including a control circuit (30) for controlling a power supply from the power supply (24) to the aerosol generator (118);and a heat-conducting assembly (46) including a first end (48) in thermal contact with the circuit board (28, 34) and a second end (50) spaced from the circuit board (28, 34), wherein the circuit board (28, 34) is a first circuit board (28), wherein the aerosol generating device further includes a second circuit board (34) and wherein the first end (48) of the heat-conducting assembly (46) is in thermal contact with the second circuit board (34), and characterized in that the second circuit board (34) overlaps at least partially the first circuit board (28), wherein the second circuit board (34) is spaced from the first circuit board (28), and wherein the first end (48) of the heat-conducting assembly (46) is positioned between the first circuit board (28) and the second circuit board (34).
2. Aerosol generating device (100), according to claim 1, characterized in that the second end (50) of the heat-conducting assembly (46) is in thermal contact with the power source (24).
3. Aerosol generating device (100), according to claim 1 or 2, characterized in that the heat-conducting assembly (46) comprises a heat-conducting structure (52) defining the second end (50) of the heat-conducting assembly (46), Petition 870260040515, dated 04 / 30 / 2026, page 34 / 79 2 / 4 and in which the power supply (24) is positioned at least partially within the heat-conducting structure (52).
4. Aerosol generating device (100), according to any of the preceding claims, characterized in that the heat-conducting assembly (46) comprises at least one cross-sectional element (54, 58) at the first end (48) of the heat-conducting assembly (46), and in that a portion of at least one cross-sectional element (54, 58) is positioned within a slot defined by the circuit board (28, 34).
5. Aerosol generating device (100), according to claim 3 or 4, characterized in that the heat-conducting assembly (46) comprises at least one longitudinal arm (56) extending between at least one transverse element (54, 58) and the heat-conducting structure (52).
6. Aerosol generating device (100), according to claim 4 or 5, characterized in that the slot defined by the circuit board (28, 34) is a first slot (64), wherein the circuit board (28, 34) further defines a second slot (68), wherein at least one cross element (54, 58) comprises a first cross element (54) with a first portion (62) positioned within the first slot (64), and wherein at least one cross element (54, 58) further comprises a second cross element (58) with a second portion (66) positioned within the second slot (68).
7. Aerosol generating device (100), according to claim 3, characterized in that at least a portion of at least one cross element (54, 58) is positioned within a slot defined by the second circuit board (34).
8. Aerosol generating device (100), according to claim 6, characterized in that the second circuit board (34) defines a third slot, and in that the second cross element (58) has a third portion (70) positioned within the third slot (72).
9. Aerosol generating device (100), according to claim 8, characterized in that the first cross element (54) is in thermal contact only with the first circuit board (28).
10. Aerosol generating device (100), according to any of the preceding claims, characterized in that the aerosol generating device (100) comprises at least one additional electrical component, wherein at least one additional electrical component comprises at least one of a charging connector (38), a user input device and a feedback device, and wherein at least one additional electrical component is electrically connected to the second circuit board (34).
11. Aerosol generating device (100), according to any of the preceding claims, characterized in that the aerosol generating device (100) comprises an inner housing (12), in which the power supply (24) is positioned within the inner housing, and in which a portion of the inner housing (12) is overmolded over at least part of the second end (50) of the heat-conducting assembly (46).
12. Aerosol generating device (100), according to any of the preceding claims, characterized in that the aerosol generating device (100) comprises an inner housing (12), in which the power supply (24) is positioned inside the inner housing (12), and in which at least a portion of the second end (50) of the heat-conducting assembly (46) overlaps a portion of the inner housing (12).
13. Aerosol generating device (100), according to Petition 870260040515, dated 04 / 30 / 2026, p. 36 / 79 4 / 4 any of the preceding claims, characterized in that the aerosol generator (118) comprises an inductive heating arrangement. Petition 870260040515, dated 04 / 30 / 2026, p. 37 / 79