Aerosol generating device and heating cavity thereof

Abstract

An aerosol generating device (100) has a heating chamber (108) for receiving a substrate carrier (114) containing an aerosol substrate (128). The heating chamber (108) includes a first open end (110); a base (112); and a sidewall (126) between the open end (110) and the base (112). The base (112) is connected to the sidewall (126) and provides structural support for the sidewall (126). The sidewall (126) has a first thickness, and the base (112) has a second thickness that is greater than the first thickness.

Description

Technical Field

[0001] The present disclosure relates to an aerosol-generating device and a heating chamber thereof. The disclosure is particularly applicable to a portable aerosol-generating device that can be self-contained and cryogenic. Such a device can generate an aerosol for inhalation by heating tobacco or other suitable materials through conduction, convection, and / or radiation, rather than burning them. Background Art

[0002] Over the past few years, there has been a rapid increase in the popularity and use of reduced-risk or modified-risk devices (also known as vaporizers) to help habitual smokers who want to quit traditional tobacco products such as cigarettes, cigars, cigarillos, and roll-on cigarettes. Instead of burning the tobacco in traditional tobacco products, various devices and systems are available that heat or warm an aerosolizable substance.

[0003] Commonly available risk-reduced or risk-modified devices are heated substrate aerosol-generating devices or heat-without-burn devices. This type of device generates an aerosol or vapor by heating an aerosol substrate, typically comprising moist tobacco leaves or other suitable aerosolizable material, to a temperature typically in the range of 150°C to 300°C. Heating, but not burning, or burning, the aerosol substrate releases an aerosol that includes the components sought by the user but without the toxic and carcinogenic byproducts of combustion and burning. Furthermore, the aerosol generated by heating tobacco or other aerosolizable material typically does not include the burnt or bitter taste that combustion and burning can produce, which may be unpleasant to the user. Thus, the substrate does not require sugars and other additives that are often added to such materials to make the smoke and / or vapor more palatable to the user.

[0004] In a general sense, it is desirable to quickly heat the aerosol substrate to a temperature at which the aerosol can be released and to maintain the aerosol substrate at that temperature. Obviously, the aerosol will only be released from the aerosol substrate and delivered to the user when there is airflow through the aerosol substrate.

[0005] This type of aerosol generating device is a portable device and therefore energy consumption is an important design consideration.The present invention aims to solve the problems of existing devices and to provide an improved aerosol generating device and a heating chamber thereof. Summary of the Invention

[0006] According to a first aspect of the present disclosure, there is provided a heating chamber for an aerosol-generating device, the heating chamber comprising:

[0007] a first open end;

[0008] base; and

[0009] a sidewall between the open end and the base;

[0010] wherein the base is connected to the sidewall and provides structural support to the sidewall; and

[0011] The side wall has a first thickness, and the base has a second thickness greater than the first thickness.

[0012] Optionally, the sidewall and the base are formed of the same material, preferably wherein the material is metal, more preferably wherein the sidewall and the base are stainless steel, even more preferably wherein the stainless steel is 300 series stainless steel, even more preferably selected from the group consisting of 304 stainless steel, 316 stainless steel and 321 stainless steel.

[0013] Optionally, the base and the side wall are formed as a single element, preferably forming a cup-shaped element.

[0014] Optionally, the first thickness is 100 μm or less.

[0015] Optionally, the second thickness is between 200 μm and 500 μm.

[0016] Optionally, the base seals a second end of the side wall opposite the open end, preferably wherein the side wall extends all the way around the base.

[0017] Optionally, the heating chamber comprises a flanged portion attached to the open end, the flanged portion extending radially outwardly at the open end of the heating chamber.

[0018] Optionally, the flanged portion extends all the way around the heating cavity.

[0019] Optionally, the flanged portion extends obliquely away from the side wall.

[0020] Optionally, the flanged portion comprises a first material and the sidewall comprises a second material, the first material having a lower thermal conductivity than the second material.

[0021] Optionally, the sidewall comprises a material having a thermal conductivity of 50 W / mK or less.

[0022] Optionally, the heating chamber further comprises a plurality of protrusions formed on the inner surface of the side wall.

[0023] Optionally, the protrusions are formed by indenting the outer surface of the side wall.

[0024] Optionally, the heating chamber further comprises a platform on the inner surface of the base.

[0025] Optionally, the platform is formed by indenting the outer surface of the base.

[0026] Optionally, the heating cavity is a product of deep drawing.

[0027] According to a second aspect of the present disclosure, there is provided an aerosol generating device, comprising:

[0028] power supply;

[0029] The above-mentioned heating cavity;

[0030] a heater arranged to provide heat to the heating cavity; and

[0031] Control circuitry is configured to control the supply of electrical power from the power source to the heater.

[0032] Optionally, the heater is provided on the outer surface of the side wall.

[0033] Optionally, the heater is positioned adjacent to the outer surface of the side wall.

[0034] Optionally, the heating chamber is removable from the aerosol-generating device. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a schematic perspective view of an aerosol-generating device according to a first embodiment of the present disclosure.

[0036] Figure 2 yes Figure 1 Schematic cross-sectional view of an aerosol-generating device from the side.

[0037] Figure 2 (a) Yes Figure 1 The top of the aerosol generating device along Figure 2 A schematic cross-sectional view taken along line XX is shown.

[0038] Figure 3 yes Figure 1 Schematic perspective view of an aerosol generating device, in which a substrate carrier of an aerosol substrate is shown being loaded into the aerosol generating device.

[0039] Figure 4 yes Figure 1 Schematic cross-sectional view of an aerosol-generating device from the side, showing a substrate carrier of an aerosol substrate being loaded into the aerosol-generating device.

[0040] Figure 5 yes Figure 1 Schematic perspective view of an aerosol generating device, in which a substrate carrier of an aerosol substrate is shown to have been loaded into the aerosol generating device.

[0041] Figure 6 yes Figure 1 Schematic cross-sectional view of an aerosol generating device from the side, showing that a substrate carrier of an aerosol substrate has been loaded into the aerosol generating device.

[0042] Figure 6 (a) Yes Figure 6 Detailed cross-sectional view of a portion of FIG, highlighting the interaction between the substrate carrier and the protrusions in the heating chamber and the corresponding effect on the airflow path.

[0043] Figure 7 It is a plan view of the heater separated from the heating cavity.

[0044] Figure 8 is a schematic cross-sectional view from the side of an aerosol-generating device with an alternative airflow arrangement according to a second embodiment of the present disclosure.

[0045] Figure 9 is a schematic cross-sectional view from the side of an aerosol-generating device according to a third embodiment of the present disclosure, the aerosol-generating device having a heating cavity, the base of the heating cavity being separate from the base of the side wall.

[0046] Figure 9 (a) is a perspective view from above of the heating chamber of an aerosol-generating device according to the third embodiment of the present disclosure.

[0047] Figure 9 (b) is a perspective view from below of the heating chamber of the aerosol-generating device according to the third embodiment of the present disclosure.

[0048] Figure 10 is a schematic perspective view of an aerosol-generating device according to a fourth embodiment of the present disclosure, the aerosol-generating device having a heating chamber without a flange.

[0049] Figure 10 (a) is a perspective view from above of the heating chamber of an aerosol-generating device according to the fourth embodiment of the present disclosure.

[0050] Figure 10 (b) is a perspective view from below of the heating chamber of the aerosol-generating device according to the fourth embodiment of the present disclosure.

[0051] Figure 11 is a schematic perspective view of an aerosol-generating device according to a fifth embodiment of the present disclosure, the aerosol-generating device having a heating cavity without protrusions on its side walls.

[0052] Figure 11 (a) is a perspective view from above of a heating chamber of an aerosol-generating device according to a fifth embodiment of the present disclosure.

[0053] Figure 11 (b) is a perspective view from below of the heating chamber of the aerosol-generating device according to the fifth embodiment of the present disclosure. DETAILED DESCRIPTION

[0054] First embodiment

[0055] See also Figure 1 and Figure 2 According to a first embodiment of the present disclosure, an aerosol-generating device 100 includes a housing 102 that houses the various components of the aerosol-generating device 100. In the first embodiment, the housing 102 is tubular. More specifically, the housing is cylindrical. It should be noted that the housing 102 need not have a tubular or cylindrical shape, but can be any shape, as long as its dimensions accommodate the components described in the various embodiments described herein. The housing 102 can be formed from any suitable material, or even layers of materials. For example, a metal inner layer can be surrounded by a plastic outer layer. This makes the housing 102 pleasant to hold for the user. Any heat that leaks from the aerosol-generating device 100 is distributed around the housing 102 by the metal layer, thereby preventing the formation of hot spots, while the plastic layer softens the feel of the housing 102. Additionally, the plastic layer can help protect the metal layer from rust or scratches, thereby improving the long-term appearance of the aerosol-generating device 100.

[0056] For convenience, the first end 104 of the aerosol generating device 100 (shown as facing Figures 1 to 6 The respective bottoms) are described as the bottom, base or lower end of the aerosol-generating device 100. The second end 106 of the aerosol-generating device 100 (shown as facing Figures 1 to 6 The top of each housing 102 is described as the top or upper end of the aerosol-generating device 100. In the first embodiment, the first end 104 is the lower end of the housing 102. In use, the user typically orients the aerosol-generating device 100 with the first end 104 facing downward and / or in a distal position relative to the user's mouth, and the second end 106 facing upward and / or in a proximal position relative to the user's mouth.

[0057] As shown, the aerosol-generating device 100 is held in place at the second end 106 by a pair of gaskets 107a, 107b via an interference fit with an interior portion of the housing 102 (at the Figure 1 、 Figure 3 and Figure 57a, 107b are formed from a thermally insulating material. In this embodiment, the thermally insulating material is suitable for use in medical devices, for example, polyetheretherketone (PEEK).

[0058] The aerosol-generating device 100 has a heating chamber 108 positioned toward the second end 106 of the aerosol-generating device 100. The heating chamber 108 is open toward the second end 106 of the aerosol-generating device 100. In other words, the heating chamber 108 has a first open end 110 that faces the second end 106 of the aerosol-generating device 100. The heating chamber 108 is maintained spaced from the inner surface of the housing 102 by a central aperture that fits through the gaskets 107a, 107b. This arrangement maintains the heating chamber 108 in a generally coaxial arrangement with the housing 102. The heating chamber 108 is suspended by a flange 138 of the heating chamber 108, which is located at the open end 110 of the heating chamber 108 and is sandwiched between the pair of gaskets 107a, 107b. This means that heat transfer from the heating chamber 108 to the housing 102 generally passes through the gaskets 107a, 107b and is therefore limited by the insulating properties of the gaskets 107a, 107b. Since there are air gaps elsewhere around the heating chamber 108, heat transfer from the heating chamber 108 to the housing 102, other than through the gaskets 107a, 107b, is also reduced. In the illustrated embodiment, the flange 138 extends outwardly away from the sidewall 126 of the heating chamber 108 by a distance of approximately 1 mm, forming an annular structure.

[0059] To further improve the thermal insulation of the heating chamber 108, the heating chamber 108 is also surrounded by insulation. In some embodiments, the insulation is a fibrous material or a foam material, such as cotton wool. In the illustrated embodiment, the insulation includes an insulating member 152 in the form of an insulating cup, which includes a double-walled tube 154 and a base 156. In some embodiments, the insulating member 152 may include a pair of nested cups with an inner cavity enclosed therebetween. The inner cavity 158 defined between the walls of the double-walled tube 154 may be filled with an insulating material, such as fiber, foam, gel, or gas (e.g., under low pressure). In some cases, the inner cavity 158 may include a vacuum. Advantageously, a vacuum requires a very small thickness to achieve high thermal insulation, and the walls of the double-walled tube 154 enclosing the inner cavity 158 can be as small as 100 μm thick, and the total thickness (the two walls and the inner cavity 158 between them) can be as low as 1 mm. The base 156 is an insulating material, such as silicone. Because silicone is flexible, the electrical connections 150 of the heater 124 can pass through the base 156 , forming a seal around the electrical connections 150 .

[0060] like Figures 1 to 6 As shown, the aerosol generating device 100 may include a housing 102 , a heating chamber 108 , and a thermally insulating member 152 , as described above. Figures 1 to 6 A resiliently deformable member 160 is shown positioned between the outward-facing surface of the insulating sidewall 154 and the inner surface of the housing 102 to hold the insulating member 152 in place. The resiliently deformable member 160 can provide sufficient friction to create an interference fit, keeping the insulating member 152 in place. The resiliently deformable member 160 can be a gasket or an O-ring, or other closed loop of material that conforms to the outward-facing surface of the insulating sidewall 154 and the inner surface of the housing 102. The resiliently deformable member 160 can be formed from a thermally insulating material, such as silicone. This can provide further insulation between the insulating member 152 and the housing 102. This can, therefore, reduce the amount of heat transferred to the housing 102, allowing the housing 102 to be more comfortably gripped by the user during use. The resiliently deformable material can be compressed and deformed, but then spring back to its original shape, such as an elastomeric or rubber material.

[0061] As an alternative to this arrangement, the insulating member 152 can be supported by struts extending between the insulating member 152 and the housing 102. The struts can provide added rigidity, allowing the heating chamber 108 to be centrally located within the housing 102, or to be located at a predetermined location. This can be designed to evenly distribute heat throughout the housing 102 so that hot spots do not form.

[0062] As a further alternative, the heating chamber 108 may be secured in the aerosol-generating device 100 by engaging portions on the housing 102, these engaging portions being used to engage the side wall 126 at the open end 110 of the heating chamber 108. As the open end 110 is exposed to the greatest cold airflow and therefore cools fastest, attaching the heating chamber 108 to the housing 102 near the open end 110 allows heat to be dissipated quickly to the environment and ensures a secure fit.

[0063] It should be noted that in some embodiments, the heating chamber 108 is removable from the aerosol-generating device 100. Thus, the heating chamber 108 can be easily cleaned or replaced. In such embodiments, the heater 124 and the electrical connections 150 may not be removable and may remain in place within the thermal insulation member 152.

[0064] In a first embodiment, the base 112 of the heating chamber 108 is closed. That is, the heating chamber 108 is cup-shaped. In other embodiments, the base 112 of the heating chamber 108 has one or more holes or is perforated, and the heating chamber 108 remains roughly cup-shaped but is not closed at the base 112. In yet other embodiments, the base 112 is closed, but the sidewall 126 has one or more holes or is perforated in an area near the base 112, for example, between the heater 124 (or metal layer 144) and the base 112. The heating chamber 108 also has a sidewall 126 between the base 112 and the open end 110. The sidewall 126 and the base 112 are connected to each other. In the first embodiment, the sidewall 126 is tubular. More specifically, the housing is cylindrical. However, in other embodiments, the sidewall 126 has other suitable shapes, such as a tube with an elliptical or polygonal cross-section. Typically, the cross-section is generally uniform over the length of the heating chamber 108 (not accounting for the protrusions 140), but in other embodiments the cross-section may vary, for example the cross-section may taper toward one end such that the tubular shape tapers or becomes frusto-conical.

[0065] In the illustrated embodiment, the heating chamber 108 is unitary, meaning that the sidewalls 126 and base 112 are formed from a single piece of material, such as by a deep-drawing process. This can result in a stronger overall heating chamber 108. Other embodiments may form the base 112 and / or flange 138 as separate parts and then attach them to the sidewalls 126. This, in turn, allows the flange 138 and / or base 112 to be made of a different material than the sidewalls 126. The sidewalls 126 themselves are designed to be thin-walled. In some embodiments, the sidewalls are up to 150 μm thick. Typically, the sidewalls 126 are less than 100 μm thick, such as approximately 90 μm thick, or even approximately 80 μm thick. In some cases, the sidewalls 126 can be approximately 50 μm thick, but as the thickness decreases, the failure rate during manufacturing increases. In general, a range of 50 μm to 100 μm is generally suitable, with a range of 70 μm to 90 μm being optimal. Manufacturing tolerances are approximately ±10 μm, but the parameters provided are intended to be accurate to approximately + / - 5 μm.

[0066] When the sidewall 126 is thin as defined above, the thermal characteristics of the heating chamber 108 change significantly. The resistance to heat transfer through the sidewall 126 is negligible because the sidewall 126 is so thin, whereas heat transfer along the sidewall 126 (i.e., parallel to the central axis of the sidewall 126 or around the circumference of the sidewall) has a small path along which conduction can occur, and thus the heat generated by the heater 124 located on the outer surface of the heating chamber 108 remains concentrated near the heater 124 at the open end in a direction radially outward from the sidewall 126, but quickly causes heating of the inner surface of the heating chamber 108. In addition, the thin sidewall 126 helps to reduce the thermal mass of the heating chamber 108, thereby improving the overall efficiency of the aerosol-generating device 100 because less energy is used to heat the sidewall 126.

[0067] The heating chamber 108, and in particular the sidewalls 126 of the heating chamber 108, comprise a material having a thermal conductivity of 50 W / mK or less. In a first embodiment, the heating chamber 108 is a metal, preferably stainless steel. The thermal conductivity of stainless steel is between approximately 15 and 40 W / mK, the exact value depending on the specific alloy. As another example, a 300 series stainless steel suitable for this application has a thermal conductivity of approximately 16 W / mK. Suitable examples include 304, 316, and 321 stainless steels, which have been approved for medical use, are strong, and have sufficiently low thermal conductivity to allow the heat focusing described herein.

[0068] Compared to materials with higher thermal conductivity, materials with this level of thermal conductivity reduce the ability of heat to be conducted away from the area where heat is applied. For example, heat remains concentrated near the heater 124. By inhibiting heat from moving to other parts of the aerosol-generating device 100, heating efficiency is improved by ensuring that only those parts of the aerosol-generating device 100 that are intended to be heated are actually heated, while those parts that are not intended to be heated are not heated.

[0069] Metals are suitable materials because they are strong, ductile, and easily shaped. Furthermore, the thermal properties of metals vary widely from one metal to another and can be adjusted, if necessary, by careful alloying. In this application, the term "metal" refers to elemental (i.e., pure) metals as well as alloys of several metals or other elements (e.g., carbon).

[0070] Thus, configuring the heating chamber 108 with thin sidewalls 126 and selecting a material having desirable thermal properties for forming the sidewalls 126 ensures that heat can be efficiently conducted through the sidewalls 126 and into the aerosol substrate 128. Advantageously, this also reduces the time it takes to raise the temperature from ambient temperature to a temperature at which aerosol can be released from the aerosol substrate 128 following initial activation of the heater.

[0071] The heating cavity 108 is formed by deep drawing. This is an effective method for forming the heating cavity 108 and can be used to provide very thin sidewalls 126. The deep drawing process involves pressing a sheet metal blank with a punching tool to force it into a forming die. By using a series of progressively smaller punching tools and dies, a tubular structure is formed with a base at one end, resulting in a tube that is deeper than the distance across the tube (this means that the length of the tube is relatively greater than its width, which leads to the term "deep drawing"). Because it is formed in this way, the sidewalls of the tube formed in this manner are the same thickness as the original metal sheet. Similarly, the base formed in this manner is the same thickness as the original sheet metal blank. A flange can be formed at the end of the tube by leaving an outwardly extending edge of the original sheet metal blank at the end of the tubular wall opposite the base (i.e., starting with more material in the blank than required to form the tube and base). Alternatively, the flange can be formed later in a separate step involving one or more of cutting, bending, rolling, die forging, etc.

[0072] As previously mentioned, the tubular sidewall 126 of the first embodiment is thinner than the base 112. This can be achieved by first deep drawing the tubular sidewall 126 and then ironing the wall. Ironing involves heating and stretching the tubular sidewall 126, thinning it in the process. In this way, the tubular sidewall 126 can be made into the dimensions described herein.

[0073] The thin sidewalls 126 may be fragile. This can be alleviated by providing additional structural support to the sidewalls 126 and by forming the sidewalls 126 into a tubular (preferably cylindrical) shape. In some cases, the additional structural support is provided as a separate feature, but it should be noted that the flange 138 and the base 112 also provide a certain degree of structural support. Considering the base 112 first, it should be noted that a tube with open ends is generally easy to break, while providing the heating chamber 108 of the present disclosure with a base 112 adds support. It should be noted that in the embodiment shown, the base 112 is thicker than the sidewalls 126, for example, 2 to 10 times the thickness of the sidewalls 126. In some cases, this may result in a base 112 with a thickness between 200 μm and 500 μm, for example, a thickness of about 400 μm. The base 112 also has another purpose, which is to prevent the substrate carrier 114 from being inserted too far into the aerosol generating device 100. In the event that a user accidentally uses too much force when inserting the substrate carrier 114, the increased thickness of the base 112 helps prevent damage to the heating chamber 108. Similarly, when a user is cleaning the heating chamber 108, the user may typically insert an object, such as an elongated brush, through the open end 110 of the heating chamber 108. This means that when the elongated object rests against the base 112 rather than against the sidewalls 126, the user may apply greater force to the base 112 of the heating chamber 108. Therefore, the thickness of the base 112 relative to the sidewalls 126 can help prevent damage to the heating chamber 108 during the cleaning process. In other embodiments, the base 112 and the sidewalls 126 are the same thickness, which provides some of the advantageous effects described above.

[0074] A flange 138 extends outward from the sidewall 126 and has an annular shape extending all the way around the edge of the sidewall 126 at the open end 110 of the heating chamber 108. The flange 138 resists bending and shear forces on the sidewall 126. For example, lateral deformation of the tube defined by the sidewall 126 may require the flange 138 to bend. It should be noted that while the flange 138 is shown as extending generally perpendicularly from the sidewall 126, the flange 138 can extend obliquely from the sidewall 126, for example, forming a funnel shape with the sidewall 126, while still retaining the advantageous features described above. In some embodiments, the flange 138 is positioned only around a portion of the edge of the sidewall 126, rather than being annular. In the illustrated embodiment, the flange 138 is the same thickness as the sidewall 126, but in other embodiments, the flange 138 is thicker than the sidewall 126 to improve resistance to deformation. Any added thickness to specific parts for strength is weighed against the increased thermal mass introduced so that the aerosol-generating device 100 as a whole remains robust and efficient.

[0075] A plurality of protrusions 140 are formed on the inner surface of the sidewall 126. The width of the protrusions 140 (around the circumference of the sidewall 126) is relatively small relative to their length (parallel to the central axis of the sidewall 126, or generally along the direction from the base 112 to the open end 110 of the heating chamber 108). In this example, there are four protrusions 140. Four is generally a suitable number of protrusions 140 for securing the substrate carrier 114 in a central position within the heating chamber 108, as will become clear from the following discussion. In some embodiments, three protrusions may be sufficient, for example spaced approximately 120 degrees apart (evenly) around the circumference of the sidewall 126. The protrusions 140 have a number of different purposes, and the exact form of the protrusions 140 (and the corresponding indentations on the outer surface of the sidewall 126) is selected based on the desired effect. In any case, the protrusions 140 extend toward the substrate carrier 114 and engage the substrate carrier, and are therefore sometimes referred to as engagement elements. Indeed, the terms "protrusion" and "engagement element" may be used interchangeably herein. Similarly, when the protrusions 140 are provided by extruding the sidewall 126 from the outside, such as by hydroforming or pressing, the term "indentation" may also be used interchangeably with the terms "protrusion" and "engagement element." Forming the protrusions 140 by indenting the sidewall 126 has the advantage that these protrusions are integral to the sidewall 126, thereby minimizing the impact on heat flow. Furthermore, the protrusions 140 do not add any thermal mass, as would be the case if additional elements were added to the inner surface of the sidewall 126 of the heating chamber 108. Indeed, because the protrusions 140 are formed by indenting the sidewall 126, the thickness of the sidewall 126 remains substantially constant in the circumferential and / or axial directions, even where the protrusions are provided. Finally, indenting the sidewall as described increases the strength of the sidewall 126 by introducing portions extending transversely to the sidewall 126, thereby providing resistance to bending of the sidewall 126.

[0076] The heating chamber 108 is arranged to receive a substrate carrier 114. Typically, the substrate carrier comprises an aerosol substrate 128, such as tobacco or another suitable aerosolizable material that can be heated to produce an aerosol for inhalation. In a first embodiment, the heating chamber 108 is sized to receive a single portion of the aerosol substrate 128 (also referred to as a "consumable") in the form of a substrate carrier 114, e.g. Figures 3 to 6 However, this is not required, and in other embodiments, the heating chamber 108 is arranged to receive other forms of aerosol substrate 128, such as loose tobacco or otherwise packaged tobacco.

[0077] The aerosol-generating device 100 operates in two ways: by conducting surface heat from the projections 140 that engage the outer layer 132 of the substrate carrier 114, and by heating the air in the air gap between the inner surface of the sidewall 126 and the outer surface of the substrate carrier 114. That is, when a user sucks on the aerosol-generating device 100, there is convective heating of the aerosol substrate 128 (as described in more detail below) as heated air is drawn through the aerosol substrate 128. The width and height (i.e., the distance that each projection 140 extends into the heating cavity 128) increase the surface area of ​​the sidewall 126 that transfers heat to the air, thereby allowing the aerosol-generating device 100 to reach an effective temperature more quickly.

[0078] The protrusions 140 on the inner surface of the side wall 126 extend toward the substrate carrier 114 and physically contact the substrate carrier when the substrate carrier is inserted into the heating chamber 108 (see, for example, FIG. Figure 6 ). This results in the aerosol substrate 128 also being heated conductively through the outer layer 132 of the substrate carrier 114.

[0079] 145 with the surface 145 of projection 140.Obviously, in order to conduct heat into the aerosol substrate 128, the surface 145 of projection 140 must interengage with the outer layer 132 of substrate carrier 114.Yet, manufacturing tolerance may cause the diameter of substrate carrier 114 to have slight variation.In addition, because substrate carrier 114 and the outer layer 132 of relatively soft and compressible character that remain on aerosol substrate 128 wherein, any damage to substrate carrier 114 or rough handling all may cause diameter to be reduced or shape-changed into oval or elliptical cross section in the zone that outer layer 132 is intended to interengage with the surface 145 of projection 140.Therefore, any variation of substrate carrier 114 diameter all may cause the thermal engagement between the outer layer 132 of substrate carrier 114 and the surface 145 of projection 140 to reduce, and this adversely affects the conduction that heat enters the aerosol substrate 128 through the outer layer 132 of substrate carrier 114 from the surface 145 of projection 140. To mitigate the effects of any diameter variations in the substrate carrier 114 due to manufacturing tolerances or damage, the protrusions 140 are preferably sized to extend far enough into the heating chamber 108 to cause compression of the substrate carrier 114 and thereby ensure an interference fit between the surface 145 of the protrusions 140 and the outer layer 132 of the substrate carrier 114. This compression of the outer layer 132 of the substrate carrier 114 may also cause longitudinal marking of the outer layer 132 of the substrate carrier 114 and provide a visual indication that the substrate carrier 114 has been used.

[0080] Figure 6(a) shows an enlarged view of the heating chamber 108 and substrate carrier 114. As can be seen, arrow B illustrates the airflow path that provides the above-mentioned convective heating. As described above, the heating chamber 108 can be cup-shaped with a sealed, airtight base 112, which means that air must flow downward from the side of the substrate carrier 114 to enter the first end 134 of the substrate carrier because airflow through the sealed, airtight base 112 is not possible. As described above, the protrusion 140 extends a sufficient distance into the heating chamber 108 to at least contact the outer surface of the substrate carrier 114 and generally cause at least some degree of compression to the substrate carrier. Therefore, due to Figure 6 The cross-sectional view of (a) cuts through the protrusion 140 on the left and right sides of the figure, so there are no air gaps all along the heating chamber 108 in the plane of the figure. Instead, the airflow path (arrow B) is shown in dashed lines in the area of ​​the protrusion 140, indicating that the airflow path is located in front of and behind the protrusion 140. In fact, Figure 2 Comparison of (a) shows that the airflow path occupies four equally spaced interstitial regions between the four protrusions 140. Of course in some cases there will be more or fewer than four protrusions 140, in which case the general idea that the airflow path exists in the interstitial regions between the protrusions remains correct.

[0081] Also in Figure 6 What emphasized among (a) is that when substrate carrier 114 was just being inserted into heating chamber 108, it was forced to pass through the deformation of the outer surface of substrate carrier 114 that protrusion 140 caused.As mentioned above, the distance that protrusion 140 extends into heating chamber can be advantageously selected as far enough away and any substrate carrier 114 is produced compression.This (sometimes being permanent) deformation during heating can help to provide the stability of substrate carrier 114 in the following sense: the deformation of the outer layer 132 of substrate carrier 114 creates the denser region of aerosol substrate 128 near the first end 134 of substrate carrier 114.In addition, the outer surface of the band profile of resulting substrate carrier 114 provides clamping action near the first end 134 of substrate carrier 114 on the edge of the denser region of aerosol substrate 128.Generally speaking, this reduces the possibility that any loose aerosol substrate will fall from the first end 134 of substrate carrier 114, which can cause heating chamber 108 to become dirty. This is a useful effect because, as described above, heating the aerosol substrate 128 may cause it to shrink, thereby increasing the likelihood that the loose aerosol substrate 128 will fall from the first end 134 of the substrate carrier 114. This undesirable effect is mitigated by the deformation effect described.

[0082] To ensure that the protrusions 140 contact the substrate carrier 114 (contact is necessary to cause conductive heating, compression, and deformation of the aerosol substrate), the manufacturing tolerances of each of the following are taken into account: the protrusions 140; the heating chamber 108; and the substrate carrier 114. For example, the inner diameter of the heating chamber 108 can be 7.6 ± 0.1 mm, the substrate 114 carrier can have an outer diameter of 7.0 ± 0.1 mm, and the protrusions 140 can have a manufacturing tolerance of ± 0.1 mm. In this example, assuming that the substrate carrier 114 is centered in the heating chamber 108 (i.e., leaving a uniform gap around the outside of the substrate carrier 114), the gap that each protrusion 140 must span to contact the substrate carrier 114 ranges from 0.2 mm to 0.4 mm. In other words, because each protrusion 140 spans a radial distance, the lowest possible value for this example is half the difference between the smallest possible heating cavity 108 diameter and the largest possible substrate carrier 114 diameter, or [(7.6 - 0.1) - (7.0 + 0.1)] / 2 = 0.2 mm. The upper end of the range for this example is (for similar reasons) half the difference between the largest possible heating cavity 108 diameter and the smallest possible substrate carrier 114 diameter, or [(7.6 + 0.1) - (7.0 - 0.1)] / 2 = 0.4 mm. To ensure that the protrusions 140 are in contact with the substrate carrier, it is clear that in this example, the protrusions must each extend at least 0.4 mm into the heating cavity. However, this does not take into account the manufacturing tolerances of the protrusions 140. When a 0.4 mm protrusion is desired, the actual range that results is 0.4 ± 0.1 mm, or a variation between 0.3 mm and 0.5 mm. Some of these protrusions will not span the maximum possible gap between the heating chamber 108 and the substrate carrier 114. Therefore, the protrusions 140 of this example should be produced with a nominal protrusion distance of 0.5 mm, which results in a range of values ​​between 0.4 mm and 0.6 mm. This is sufficient to ensure that the protrusions 140 will always be in contact with the substrate carrier.

[0083] Typically, the inner diameter of the heating chamber 108 is written as D±δ D , the outer diameter of the matrix carrier 114 is written as d±δ d , and the distance the protrusion 140 extends into the heating chamber 108 is written as L±δ L , the distance that the protrusion 140 is intended to extend into the heating cavity should be selected as:

[0084]

[0085] Among them, |δ D | refers to the manufacturing tolerance of the inner diameter of the heating chamber 108, |δ d | refers to the size of the manufacturing tolerance of the outer diameter of the substrate carrier 114, and |δ L| refers to the manufacturing tolerance of the distance that the protrusion 140 extends into the heating chamber 108. For the avoidance of doubt, when the inner diameter of the heating chamber 108 is D±δ D =7.6±0.1mm, then |δ D |=0.1mm.

[0086] Furthermore, manufacturing tolerances may cause slight variations in the density of the aerosol matrix 128 within the matrix carrier 114. Such variations in the density of the aerosol matrix 128 may exist within a single matrix carrier 114 in both the axial and radial directions, or between different matrix carriers 114 manufactured in the same batch. Therefore, it is also clear that to ensure relatively uniform heat transfer within the aerosol matrix 128 within a particular matrix carrier 114, it is important that the density of the aerosol matrix 128 is also relatively consistent. To mitigate the effects of any inconsistencies in the density of the aerosol matrix 128, the protrusions 140 can be sized to extend far enough into the heating chamber 108 to compress the aerosol matrix 128 within the matrix carrier 114. This can improve heat transfer through the aerosol matrix 128 by eliminating air gaps. In the illustrated embodiment, it is suitable for the protrusions 140 to extend approximately 0.4 mm into the heating chamber 108. In other examples, the distance the protrusions 140 extend into the heating chamber 108 can be defined as a percentage of the distance across the heating chamber 108. For example, the protrusions 140 may extend between 3% and 7%, such as approximately 5%, of the distance across the heating chamber 108. In another embodiment, the limited diameter circumscribed by the protrusions 140 within the heating chamber 108 is between 6.0 mm and 6.8 mm, more preferably between 6.2 mm and 6.5 mm, and particularly 6.2 mm (+ / - 0.5 mm). Each of the plurality of protrusions 140 spans a radial distance between 0.2 mm and 0.8 mm, most preferably between 0.2 mm and 0.4 mm.

[0087] With respect to the projection / indentation 140, the width corresponds to the distance around the perimeter of the sidewall 126. Similarly, its length direction extends transversely to this, generally extending from the base 112 of the heating chamber 108 to the open end or extending to the flange 138, and its height corresponds to the distance that the projection extends from the sidewall 126. It should be noted that the space between adjacent projections 140, sidewalls 126 and the outer layer 132 substrate carrier 114 defines the area that can be used for air flow. As a result, the smaller the distance between adjacent projections 140 and / or the height of projections 140 (that is, the distance that projections 140 extend into the heating chamber 108), the greater the difficulty of the user sucking to draw air through the aerosol generating device 100 (called increased resistance to draw). Obviously, (assuming that the projection 140 is contacting the outer layer 132 of the substrate carrier 114), it is the width of the projection 140 that limits the reduction of the airflow channel between the sidewall 126 and the substrate carrier 114. On the contrary, (assuming that projection 140 is contacting the outer layer 132 of substrate carrier 114 as well), increasing the height of projection 140 results in more compression of the aerosol matrix, which eliminates the air gap in aerosol matrix 128 and also increases the resistance to draw. These two parameters can be adjusted to provide a satisfactory resistance to draw, neither too low nor too high. The heating chamber 108 can also be made larger to increase the air flow path between sidewall 126 and substrate carrier 114, but there is a practical limit before heater 124 begins to lose effectiveness due to the gap being too large. Typically, a gap of 0.2mm to 0.4mm or 0.2mm to 0.3mm around the outer surface of substrate carrier 114 is a good compromise, which allows fine-tuning the resistance to draw within an acceptable value by changing the size of projection 140. The air gap around the outside of substrate carrier 114 can also be changed by changing the number of projections 140. Any number of protrusions 140 (from one upward) provides at least some of the advantages described herein (increasing the heating area, providing compression, providing conductive heating of the aerosol substrate 128, adjusting the air gap, etc.). Four is the minimum number to reliably maintain the substrate carrier 114 in central (i.e., coaxial) alignment with the heating chamber 108. In another possible design, there are only three protrusions spaced 120 degrees apart from each other. Designs with fewer than four protrusions 140 tend to allow the substrate carrier 114 to be pressed against a portion of the sidewall 126 between two protrusions 140. Obviously, for limited space, providing a very large number of protrusions (e.g., thirty or more) tends to result in minimal or no gaps between them, which can completely block the airflow path between the outer surface of the substrate carrier 114 and the inner surface of the sidewall 126, thereby significantly reducing the ability of the aerosol generating device to provide convective heating. However, in combination with the possibility of providing a hole in the center of the base 112 to define the airflow channel, such a design can still be used.Typically, the protrusions 140 are evenly spaced around the perimeter of the sidewall 126, which can help provide uniform compression and heating, but some variations may have asymmetrical placement, depending on the exact effect desired.

[0088] Obviously, the size and number of the protrusions 140 also allow the balance between conductive heating and convective heating to be adjusted. By increasing the width of the protrusions 140 that contact the substrate carrier 114 (the distance the protrusions 140 extend around the perimeter of the sidewall 126), the sidewall 126 acts as an airflow channel ( Figure 6 and Figure 6 The available perimeter of arrow B) in (a) is reduced, thereby reduced the convection heating that aerosol generating device 100 provides.Yet, because wider protrusion 140 contacts with substrate carrier 114 on the larger part of perimeter, therefore increased the conduction heating that aerosol generating device 100 provides.If add more protrusion 140, similar effect will be seen, because the available perimeter that is used for convection of sidewall 126 reduces, and by increasing the total contact surface area between protrusion 140 and substrate carrier 114, increase conduction path simultaneously.It should be noted that increasing the length of protrusion 140 also can reduce the air volume heated by heater 124 in heating chamber 108 and reduce convection heating, increase the contact surface area between protrusion 140 and substrate carrier simultaneously and increase conduction heating.Increasing the distance that each protrusion 140 extends in heating chamber 108 can improve conduction heating under the situation that does not significantly reduce convection heating.Therefore, aerosol generating device 100 can be designed to balance conduction heating type and convection heating type by changing the quantity and size of protrusion 140, as mentioned above. The heat concentration effect resulting from the relatively thin sidewalls 126 and the use of a relatively low thermal conductivity material (e.g., stainless steel) ensures that conductive heating is an appropriate means of transferring heat to the substrate carrier 114 and subsequently to the aerosol substrate 128, because the heated portion of the sidewalls 126 can generally correspond to the location of the protrusions 140, meaning that the generated heat is conducted by the protrusions 140 to the substrate carrier 114, rather than away from it. The heating of the sidewalls 126 at locations that are heated but not corresponding to the protrusions 140 produces the convective heating described above.

[0089] like Figures 1 to 6As shown, protrusion 140 is elongated, meaning that the protrusion extends longer than it is wide. In some cases, protrusion 140 may be five, ten, or even twenty-five times longer than it is wide. For example, as described above, protrusion 140 may extend 0.4 mm into heating chamber 108, and in one embodiment, may be further 0.5 mm wide and 12 mm long. These dimensions are suitable for heating chambers 108 between 30 mm and 40 mm in length. In this embodiment, protrusion 140 does not extend the full length of heating chamber 108 because, in the example shown, the protrusion is shorter than heating chamber 108. Therefore, each protrusion 140 has a top edge 142a and a bottom edge 142b. Top edge 142a is the portion of protrusion 140 located closest to open end 110 of heating chamber 108 and also closest to flange 138. Bottom edge 142b is the end of protrusion 140 located closest to base 112. Above top edge 142a (closer to the open end than top edge 142a) and below bottom edge 142b (closer to base 112 than bottom edge 142b), sidewall 126 is free of protrusions 140. That is, sidewall 126 lacks deformations or indentations in these portions. In some instances, protrusions 140 are longer and extend all the way to the top and / or bottom of sidewall 126, such that one or both of the following are true: top edge 142a is aligned with open end 110 (or flange 138) of heating chamber 108; and bottom edge 142b is aligned with base 112. In fact, in such instances, top edge 142a and / or bottom edge 142b may not even be present.

[0090] It may be advantageous for the protrusion 140 not to extend all the way along the length of the heating chamber 108 (e.g., from the base 112 to the flange 138). At the upper end, as will be described below, the top edge 142a of the protrusion 140 can serve as an indicator for the user to ensure they do not over-insert the substrate carrier 114 into the aerosol-generating device 100. However, it can be used to heat not only the area of ​​the substrate carrier 114 containing the aerosol substrate 128, but also other areas. This is because once the aerosol is generated, it is advantageous to keep its temperature high (above room temperature, but not so high as to burn the user) to prevent recondensation, which in turn would reduce the user experience. Therefore, the effective heating area of ​​the heating chamber 108 extends past (i.e., above the heating chamber 108 and closer to the open end) the intended location of the aerosol substrate 128. This means that the heating chamber 108 extends higher than the upper edge 142a of the protrusion 140, or equivalently, that the protrusion 140 does not extend all the way up to the open end of the heating chamber 108. Similarly, compression of the aerosol substrate 128 at the end 134 of the substrate carrier 114 that is inserted into the heating chamber 108 may cause some of the aerosol substrate 128 to fall out of the substrate carrier 114 and soil the heating chamber 108. Therefore, it may be advantageous to position the lower edge 142b of the projection 140 further from the base 112 than the intended location of the end 134 of the substrate carrier 114.

[0091] In some embodiments, the protrusions 140 are not elongated and have a width that is approximately the same as their length. For example, the width of the protrusions can be the same as their height (e.g., having a square or circular profile when viewed in the radial direction), or the length of the protrusions can be two to five times the width. It should be noted that the centering effect provided by the protrusions 140 can be achieved even when the protrusions 140 are not elongated. In some examples, there can be multiple groups of protrusions 140, for example, an upper group of protrusions near the open end of the heating chamber 108 and a lower group of protrusions spaced apart from the upper group of protrusions and positioned closer to the base 112. This can help ensure that the substrate carrier 114 remains in a coaxial arrangement while reducing the suction resistance introduced by a single group of protrusions 140 at the same distance. The two groups of protrusions 140 can be substantially identical, or their length or width, or the number or position of protrusions 140 arranged around the sidewall 126, can vary.

[0092] In the side view, the protrusions 140 are shown as having a trapezoidal profile. This means that the profile along the length of each protrusion 140 (e.g., a longitudinally centered cross-section of the protrusion 140) is generally trapezoidal. That is, the upper edge 142a is generally planar and tapers to merge with the sidewall 126 near the open end 110 of the heating chamber 108. In other words, the profile of the upper edge 142a is chamfered. Similarly, the protrusion 140 has a lower portion 142b that is generally planar and tapers to merge with the sidewall 126 near the base 112 of the heating chamber 108. That is, the profile of the lower edge 142b is chamfered. In other embodiments, the upper edge 142a and / or the lower edge 142b do not taper toward the sidewall 126, but instead extend from the sidewall 126 at an angle of approximately 90 degrees. In yet other embodiments, upper edge 142a and / or lower edge 142b have a curved or rounded shape. Bridging upper edge 142a and lower edge 142b is a generally planar region that contacts and / or compresses substrate carrier 114. The planar contact portion can help provide uniform compression and conductive heating. In other examples, the planar portion can instead be a curved portion that bends outward to contact substrate carrier 128, such as having a polygonal or curved profile (e.g., a portion of a circle).

[0093] In the case where the protrusion 140 has an upper edge 142a, the protrusion 140 also serves to prevent the substrate carrier 114 from being over-inserted. Figure 4 and Figure 6 As shown most clearly, the substrate carrier 114 has a lower portion that contains an aerosol substrate 128, which ends halfway along the substrate carrier 114 at the boundary of the aerosol substrate 128. The aerosol substrate 128 is typically more compressible than other regions 130 of the substrate carrier 114. Therefore, due to the reduced compressibility of other regions 130 of the substrate carrier 114, a user inserting the substrate carrier 114 will feel an increase in resistance when the upper edge 142a of the projection 140 is aligned with the boundary of the aerosol substrate 128. To achieve this, the portion of the base 112 that the substrate carrier 114 contacts and the top edge 142a of the projection 140 should be spaced apart by a distance identical to the length of the substrate carrier 114 occupied by the aerosol substrate 128. In some examples, the aerosol substrate 128 occupies about 20 mm of the substrate carrier 114 such that when the substrate carrier 114 is inserted into the heating chamber 108 , the spacing between the top edge 142a of the protrusion 140 and the portion of the base that contacts the substrate carrier is also about 20 mm.

[0094] As shown, base 112 also includes a platform 148. Platform 148 is formed by a single step of pressing base 112 from below (e.g., by hydroforming, mechanical pressing, as part of forming heating chamber 108), leaving an indentation on the outer surface (lower face) of base 112 and a platform 148 on the inner surface (upper face, inside heating chamber 108) of base 112. When platform 148 is formed in this manner, e.g., by corresponding indentations, these terms may be used interchangeably. In other cases, platform 148 may be formed from a separate part attached to base 112, or by milling away a portion of base 112, leaving platform 148; in either case, the presence of a corresponding indentation is unnecessary. The latter approach can provide greater achievable variety in the shape of platform 148 because it does not rely on deformation of base 112, which (although a convenient approach) limits the complexity of the shapes that can be chosen. While the shape shown is generally circular, there are of course a wide variety of shapes that will achieve the desired effects detailed herein, including but not limited to polygonal shapes, curved shapes, and a plurality of shapes comprising one or more of these types. In fact, while shown as a centrally located platform 148, in some cases there may be one or more platform elements spaced from the center, such as at the edge of the heating chamber 108. Typically, the platform 148 has a generally flat top, but hemispherical platforms or platforms having a rounded dome shape at the top are also contemplated.

[0095] As described above, the distance between the top edge 142a of the protrusion 140 and the portion of the base 112 that the substrate carrier 114 contacts can be carefully selected to match the length of the aerosol substrate 128 to indicate to the user that they have inserted the substrate carrier 114 as far into the aerosol-generating device 100 as they should. In the absence of a platform 148 on the base 112, this simply means that the distance from the base 112 to the top edge 142a of the protrusion 140 should match the length of the aerosol substrate 128. When the platform 148 is present, the length of the aerosol substrate 128 should correspond to the distance between the top edge 142a of the protrusion 140 and the uppermost portion of the platform 148 (i.e., in some examples, the portion closest to the open end 110 of the heating chamber 108). In another example, the distance between the top edge 142a of the protrusion 140 and the uppermost portion of the platform 148 is slightly less than the length of the aerosol substrate 128. 148, can be compressed.In addition, the aerosol substrate 128 of substrate carrier 114 can be compressed by the projection 140 that extends from sidewall 126.This means that the tip 134 of substrate carrier 114 must extend through the topmost part of platform 148 slightly, thus makes the aerosol substrate 128 at the end 134 places of substrate carrier 114 be compressed.In fact, even under the situation that does not have protrusion 140 on the inner surface of sidewall 126, this compression effect also can take place.This compression can help to prevent the aerosol substrate 128 at the end 134 places of substrate carrier 114 from falling out and falling in the heating chamber 108, has reduced the needs of cleaning heating chamber 108 thus, and cleaning may be a complicated and difficult task.In addition, this compression helps the end 134 of compressed substrate carrier 114, alleviates above-mentioned influence when using the projection 140 that extends from sidewall 126 to compress this zone inappropriately thus, because the projection tends to increase the possibility that aerosol substrate 128 falls out from substrate carrier 114.

[0096] The platform 148 also provides an area that can collect any aerosol substrate 128 that falls out of the substrate carrier 114 without obstructing the airflow path into the tip 134 of the substrate carrier 114. For example, the platform 148 divides the lower end of the heating chamber 108 (i.e., the portion closest to the base 112) into a raised portion that forms the platform 148 and a lower portion that forms the remainder of the base 112. The lower portion can accommodate loose, small amounts of aerosol substrate 128 that fall out of the substrate carrier 114, while air can still flow through these loose, small amounts of aerosol substrate 128 and into that end of the substrate carrier 114. To achieve this effect, the platform 148 can be about 1 mm higher than the remainder of the base 112. The diameter of the platform 148 can be smaller than the diameter of the substrate carrier 114 so that the platform does not prevent air from flowing through the aerosol substrate 128. Preferably, the platform 148 has a diameter between 0.5 mm and 0.2 mm, most preferably between 0.45 mm and 0.35 mm, for example 0.4 mm (+ / - 0.03 mm).

[0097] The aerosol-generating device 100 has a user-operable button 116. In a first embodiment, the user-operable button 116 is located on a side wall 118 of the housing 102. The user-operable button 116 is arranged so that once the user-operable button 116 is actuated, for example by pressing the user-operable button 116, the aerosol-generating device 100 is activated to heat the aerosol substrate 128 to generate an aerosol for inhalation. In some embodiments, the user-operable button 116 is further arranged to allow the user to activate other functions of the aerosol-generating device 100 and / or illuminate to indicate the status of the aerosol-generating device 100. In other examples, a single light or multiple lights (e.g., one or more LEDs or other suitable light sources) may be provided to indicate the status of the aerosol-generating device 100. In this context, status can refer to one or more of the following: remaining battery charge, heater status (e.g., on, off, fault, etc.), device status (e.g., ready to suck or not suck), or other status indications, such as error mode, an indication of the number of sucks used or remaining before the power runs out or the entire matrix carrier 114, etc.

[0098] In a first embodiment, the aerosol-generating device 100 is electrically powered. That is, the aerosol-generating device is configured to use electrical power to heat the aerosol substrate 128. To this end, the aerosol-generating device 100 includes a power source 120, such as a battery. The power source 120 is coupled to a control circuit system 122. The control circuit system 122, in turn, is coupled to a heater 124. A user-operable button 116 is configured to couple and disconnect the power source 120 from the heater 124 via the control circuit system 122. In this embodiment, the power source 120 is positioned toward the first end 104 of the aerosol-generating device 100. This allows the power source 120 to be spaced apart from the heater 124, which is positioned toward the second end 106 of the aerosol-generating device 100. In other embodiments, the heating chamber 108 is heated in other ways, such as by burning a combustible gas.

[0099] The heater 124 is attached to the outer surface of the heating chamber 108. The heater 124 is disposed on a metal layer 144, which itself is in contact with the outer surface of the sidewall 126. The metal layer 144 is formed into a band around the heating chamber 108, thereby conforming to the shape of the outer surface of the sidewall 126. The heater 124 is shown as being centrally mounted on the metal layer 144, wherein the metal layer 144 extends an equal distance upward and downward beyond the heater 124. As shown, the heater 124 is completely located on the metal layer 144, such that the area covered by the metal layer 144 is larger than the area covered by the heater 124. Figures 1 to 6The heater 124 is shown attached to the middle portion of the heating cavity 108, between the base 112 and the open end 110, and to the area of ​​the exterior surface covered by the metal layer 114. It should be noted that in other embodiments, the heater 124 may be attached to other portions of the heating cavity 108, or may be contained within the sidewalls 126 of the heating cavity 108, and that it is not necessary for the exterior of the heating cavity 108 to include the metal layer 144.

[0100] The heater 124 includes a heating element 164, an electrical connection track 150, and a backing film 166, as shown. Figure 7 As shown. Heating element 164 is configured so that when current passes through heating element 164, heating element 164 heats up and its temperature increases. Heating element 164 is shaped to not include sharp corners. Sharp corners can cause hot spots or melting points in heater 124. The width of heating element 164 is also uniform, and portions of element 164 that are close to each other are kept approximately equidistant. Figure 7 The heating element 164 of FIG. 1 shows two resistive paths 164a, 164b that each take a serpentine path across the area of ​​the heater 124, thereby covering as much area as possible while meeting the above criteria. These paths 164a, 164b are Figure 7 Paths 164a and 164b are arranged in electrical parallel with one another. It should be noted that other numbers of paths may be used, for example, three paths, one path, or a plurality of paths. Paths 164a and 164b do not cross, as this would create a short circuit. Heating element 164 is configured to have a resistance to create the correct power density for the desired heating level. In some examples, heating element 164 has a resistance between 0.4Ω and 2.0Ω, more preferably between 0.5Ω and 1.5Ω, and more preferably between 0.6Ω and 0.7Ω.

[0101] Electrical connection track 150 is shown as part of heater 124, but in some embodiments, it can be replaced by wires or other connection elements. Electrical connection 150 is used to provide power to heating element 164 and complete an electrical circuit with power source 120. Electrical connection track 150 is shown extending vertically downward from heating element 164. With heater 124 in place, electrical connection 150 extends through base 112 of heating chamber 108 and through base 156 of thermal insulation 152 to connect to control circuitry 122.

[0102] The backing film 166 can be a single sheet to which the heating element 164 is attached, or it can form an envelope that sandwiches the heating element between two sheets 166a, 166b. In some embodiments, the backing film 166 is formed from polyimide. In some embodiments, the thickness of the backing film 166 is minimized to reduce the thermal mass of the heater 124. For example, the thickness of the backing film 166 can be 50 μm, 40 μm, or 25 μm.

[0103] The heating element 164 is attached to the side wall 108. Figure 7 In the embodiment of the present invention, by carefully selecting the size of the heater 124, the heating element 164 is configured to wrap around the heating chamber 108. This ensures that the heat generated by the heater 124 is substantially evenly distributed around the surface covered by the heater 124. It should be noted that in some examples, the heater 124 may wrap around the heating chamber 108 an integer number of times, rather than a complete circle.

[0104] It should also be noted that the height of the heater 124 is approximately 14 mm to 15 mm. The circumference of the heater 124 (or length before being applied to the heating chamber 108) is approximately 24 mm to 25 mm. The height of the heating element 164 can be less than 14 mm. This allows the heating element 164 to be completely positioned within the backing film 166 of the heater 124, which has a border around the heating element 164. Therefore, in some embodiments, the area covered by the heater 124 can be approximately 3.75 cm 2 .

[0105] The power used by the heater 124 is provided by a power supply 120, which is in the form of a battery cell (or battery) in this embodiment. The voltage provided by the power supply 120 is a regulated voltage or a boosted voltage. For example, the power supply 120 can be configured to generate a voltage within the range of 2.8V to 4.2V. In one example, the power supply 120 is configured to generate a voltage of 3.7V. Taking the exemplary resistance of the heating element 164 in one embodiment as 0.6Ω and the exemplary voltage as 3.7V as an example, this will generate a power output of approximately 30W in the heating element 164. It should be noted that based on the exemplary resistance and voltage, the power output can be between 15W and 50W. The battery cell forming the power supply 120 can be a rechargeable battery cell, or alternatively can be a disposable battery cell 120. The power supply is generally configured to provide power for 20 or more thermal cycles. This allows the user to use a complete pack of 20 substrate carriers 114 on a single charge of the aerosol generating device 100. The battery cell can be a lithium-ion battery cell, or any other type of commercially available battery cell. For example, it can be an 18650 battery cell or an 18350 battery cell. If the battery cell is an 18350 battery cell, then the aerosol-generating device 100 can be configured to store enough power for 12 thermal cycles, or indeed 20 thermal cycles, to allow the user to consume 12 or even 20 substrate carriers 114.

[0106] An important value for heater 124 is the power per unit area it produces. This is a measure of how much heat the heater 124 can provide to the area it is in contact with (in this case, the heating chamber 108). For the example described, this ranges from 4 W / cm 2 to 13.5W / cm 2 Heaters are typically rated at 2W / cm 2 With 10W / cm 2 Therefore, for some of these embodiments, a copper or other conductive metal layer 144 may be provided on the heating cavity 108 to effectively conduct heat from the heater 124 and reduce the possibility of damaging the heater 124.

[0107] The power delivered by heater 124 can be constant in some embodiments, but may not be constant in other embodiments. For example, heater 124 can provide variable power through a duty cycle, or more specifically, a pulse width modulated cycle. This allows power to be delivered in pulses, and the time-averaged power output of heater 124 can be easily controlled by simply selecting the ratio of "on" time to "off" time. The power level output by heater 124 can also be controlled by additional control means, such as current or voltage manipulation.

[0108] like Figure 7 As shown, the aerosol-generating device 100 has a temperature sensor 170 for detecting the temperature of the heater 124 or the temperature of the environment surrounding the heater 124. The temperature sensor 170 can be, for example, a thermistor, a thermocouple, or any other thermometer. For example, the thermistor can be formed from a glass bead that encapsulates a resistive material connected to a voltmeter and has a known current flowing through the material. Therefore, when the temperature of the glass changes, the resistance of the resistive material changes in a predictable manner, and such temperature can be determined by the voltage drop across the resistive material under a constant current (a constant voltage mode is also possible). In some embodiments, the temperature sensor 170 is positioned on a surface of the heating chamber 108, for example, in an indentation formed in the outer surface of the heating chamber 108. The indentation can be one of those described elsewhere herein, for example as part of the protrusion 140, or the indentation can be specifically configured to accommodate the temperature sensor 170. In the illustrated embodiment, the temperature sensor 170 is disposed on the backing layer 166 of the heater 124. In other embodiments, the temperature sensor 170 is integral to the heating element 164 of the heater 124 in the sense that the temperature is detected by monitoring changes in the resistance of the heating element 164 .

[0109] In the aerosol-generating device 100 of the first embodiment, the time at which the first puff is taken after the aerosol-generating device 100 is activated is an important parameter. Users of the aerosol-generating device 100 will find it desirable to begin inhaling aerosol from the substrate carrier 128 as quickly as possible, with minimal lag time between activating the aerosol-generating device 100 and inhaling aerosol from the substrate carrier 128. Therefore, during the first stage of heating, the power supply 120 provides 100% of the available power to the heater 124, for example by setting the duty cycle to always on or manipulating the product of voltage and current to the maximum possible value. This can be done for a period of 30 seconds, or more preferably for a period of 20 seconds, or for any period until the temperature sensor 170 gives a reading corresponding to 240°C. Typically, the substrate carrier 114 operates optimally at 180°C, but it may be advantageous to heat the temperature sensor 170 above this temperature so that the user can extract aerosol from the substrate carrier 114 as quickly as possible. This is done because the temperature of the aerosol substrate 128 typically lags (i.e., is lower than) the temperature detected by the temperature sensor 170, as the aerosol substrate 128 is heated by convection of warm air passing through the aerosol substrate 128 and, to some extent, by conduction between the protrusions 140 and the outer surface of the substrate carrier 114. In contrast, the temperature sensor 170 maintains good thermal contact with the heater 124, and therefore measures a temperature closer to the temperature of the heater 124 than to the temperature of the aerosol substrate 128. In practice, accurately measuring the temperature of the aerosol substrate 128 can be difficult, so the heating cycle is typically determined empirically, where different heating profiles and heater temperatures are tried and the aerosol generated from the aerosol substrate 128 is monitored for the different aerosol components formed at those temperatures. The optimal cycle provides the aerosol as quickly as possible, but avoids the generation of combustion products due to overheating of the aerosol substrate 128.

[0110] The temperature detected by the temperature sensor 170 can be used to set the power level delivered by the battery cell 120, for example by forming a feedback loop in which the temperature detected by the temperature sensor 170 is used to control the heater power cycle. The heating cycle described below can be used when the user wants to consume a single substrate carrier 114.

[0111] In a first embodiment, the heater 124 extends around the heating chamber 108. That is, the heater 124 surrounds the heating chamber 108. More specifically, the heater 124 extends around the sidewall 126 of the heating chamber 108, but does not extend around the base 112 of the heating chamber 108. The heater 124 does not extend along the entire sidewall 126 of the heating chamber 108. Instead, the heater extends all the way around the sidewall 126, but only for a portion of the length of the sidewall 126, in this context, from the base 112 to the open end 110 of the heating chamber 108. In other embodiments, the heater 124 extends along the entire length of the sidewall 126. In still other embodiments, the heater 124 includes two heating portions separated by a gap, leaving a central portion of the heating chamber 108 uncovered, for example, a portion of the sidewall 126 midway between the base 112 and the open end 110 of the heating chamber 108. In other embodiments, because the heating chamber 108 is cup-shaped, the heater 110 is similarly cup-shaped, for example, the heater extends completely around the base 112 of the heating chamber 108. In yet other embodiments, the heater 124 includes a plurality of heating elements 164 distributed about the heating chamber 108. In some embodiments, there is space between the heating elements 164; in other embodiments, the heating elements overlap one another. In some embodiments, the heating elements 164 can be spaced apart around the circumference of the heating chamber 108 or the sidewall 126 (e.g., laterally); in other embodiments, the heating elements 164 can be spaced apart along the length of the heating chamber 108 or the sidewall 126 (e.g., longitudinally). It should be understood that the heater 124 of the first embodiment is disposed on the outer surface of the heating chamber 108, outside the heating chamber 108. The heater 124 is positioned in good thermal contact with the heating chamber 108 to allow for good heat transfer between the heater 124 and the heating chamber 108.

[0112] The metal layer 144 can be formed from copper or any other material with high thermal conductivity (e.g., a metal or alloy), such as gold or silver. In this context, high thermal conductivity can refer to a metal or alloy with a thermal conductivity of 150 W / mK or higher. The metal layer 144 can be applied using any suitable method, such as electroplating. Other methods of applying the layer 144 include attaching a metal tape to the heating chamber 108, chemical vapor deposition, physical vapor deposition, and the like. While electroplating is a convenient method for applying the layer 144, the portion to be plated with the layer 144 needs to be conductive. Other deposition methods are not, and these other methods offer the possibility of forming the heating chamber 108 from a non-conductive material (e.g., ceramic), which may have useful thermal properties. Similarly, when a layer is described as metallic, while this should generally be understood to mean "formed from a metal or alloy," in this context it refers to a material with a relatively high thermal conductivity (>150 W / mK). When metal layer 144 is electroplated onto sidewall 126, it may be necessary to first form a "pre-plating layer" to ensure that the electroplated layer adheres to the outer surface. For example, when metal layer 144 is copper and sidewall 126 is stainless steel, a nickel pre-plating layer is often used to ensure good adhesion. Electroplated and deposited layers have the advantage that there is direct contact between the metal layer 144 and the material of sidewall 126, thereby improving heat conduction between the two components.

[0113] Regardless of the method used to form the metal layer 144, the thickness of the layer 144 is typically slightly thinner than the thickness of the sidewalls 126. For example, the thickness of the metal layer may range from 10 μm to 50 μm, or from 10 μm to 30 μm, such as approximately 20 μm. When a pre-plating layer is used, the pre-plating layer may be even thinner than the metal layer 144, such as 10 μm or even 5 μm. As described in more detail below, the purpose of the metal layer 144 is to distribute the heat generated by the heater 124 over a larger area than the area occupied by the heater 124. Once this effect is satisfactorily achieved, there is little benefit in making the metal layer 144 thicker, as this simply increases thermal mass and reduces the efficiency of the aerosol-generating device 100.

[0114] from Figures 1 to 6It is apparent that the metal layer 144 extends over only a portion of the outer surface of the side wall 126. This not only reduces the thermal mass of the heating chamber 108, but also allows the heating area to be limited. Generally, the metal layer 144 has a higher thermal conductivity than the side wall 126, so the heat generated by the heater 124 is quickly spread over the area covered by the metal layer 144, but because the side wall 126 is thinner than the metal layer 144 and has a relatively lower thermal conductivity, the heat is still relatively concentrated in the area of ​​the side wall 126 covered by the metal layer 144. Selective electroplating is achieved by masking multiple portions of the heating chamber 108 with suitable tape (e.g., polyester or polyimide) or silicone rubber molds. Other plating methods may use different tapes or masking methods as appropriate.

[0115] like Figures 1 to 6 As shown, metal layer 144 overlaps the entire length of heating cavity 108 along which protrusions / indentations 140 extend. This means that protrusions 140 are heated by the thermal conductivity of metal layer 144, which in turn allows protrusions 140 to provide the conductive heating described above. The extent of metal layer 144 generally corresponds to the extent of the heated area; therefore, it is generally not necessary to extend the metal layer to the top and bottom of heating cavity 108 (i.e., proximate the open end and base 112). As described above, the area of ​​substrate carrier 114 to be heated begins just above the boundary of aerosol substrate 128 and extends toward, but in many cases excludes, the end 134 of substrate carrier 114. As described above, the function of metal layer 144 is to spread the heat generated by heater 124 over a larger area than the area occupied by heater 124 itself. This means that heater 124 can be supplied with a power rating greater than 10 W / cm2 based on the rated power of heater 124. 2 The effective area of ​​heater 124 is greater than the surface area actually occupied by heater 124 because the heat generated is spread over a larger area.

[0116] Because the heating zone can be defined by multiple portions of the sidewall 126 covered by the metal layer 144, the exact placement of the heater 124 on the outside of the heating chamber 108 is less critical. For example, the heater 124 does not need to be aligned at a specific distance from the top or bottom of the sidewall 126. Instead, the metal layer 144 can be formed in a very specific area and the heater 124 can be placed on top of the metal layer 144 to spread heat over the metal layer 144 area or heating zone, as described above. Standardizing the masking process for electroplating or deposition is often simpler than precisely aligning the heater 124.

[0117] Similarly, when protrusions 140 are present, formed by indenting sidewall 126, these indentations represent portions of sidewall 126 that are not in contact with heater 124 wrapped around heating chamber 108; instead, heater 124 tends to bridge over the indentations, leaving gaps. Metal layer 144 can help mitigate this effect, as even portions of sidewall 126 that do not directly contact heater 124 receive heat from heater 124 by conduction through metal layer 144. In some cases, heater element 164 can be arranged to minimize overlap between heater element 164 and the indentations on the outer surface of sidewall 126, for example by arranging heater element 164 to span the indentations rather than extending along them. In other cases, heater 124 is positioned on the outer surface of sidewall 126 so that the portions of heater 124 that overlap the indentations are the gaps between heater elements 164. Regardless of the method chosen to mitigate the effect of heater 124 overlapping the indentations, metal layer 144 mitigates this effect by conducting heat into the indentations. Additionally, metal layer 144 provides additional thickness to the indented areas of sidewalls 126, thereby providing additional structural support to these areas. In fact, the additional thickness provided by metal layer 126 strengthens thin sidewalls 126 in all portions covered by metal layer 144.

[0118] The metal layer 144 can be formed before or after the step of forming the indentations in the outer surface sidewalls 126 to provide the protrusions 140 extending into the heating cavity 108. It is preferred to form the indentations before the metal layer because once the metal layer 144 is formed, steps such as annealing tend to damage the metal layer 144, and stamping the sidewalls 126 to form the protrusions 140 becomes more difficult due to the increased thickness of the sidewalls 126 combined with the metal layer 144. However, when the indentations are formed before the metal layer 144 is formed on the sidewalls 126, it is easier to form the metal layer 144 so that it extends beyond the indentations (i.e., above and below) because it is difficult to mask the outer surface of the sidewalls 126 so that it extends into the indentations. Any gaps between the masking and the sidewalls 126 can allow the metal layer 144 to be deposited beneath the masking.

[0119] An insulating layer 146 is wrapped around the heater 124. This layer 146 is under tension, thereby providing a compressive force on the heater 124, pressing the heater 124 tightly against the outer surface of the sidewall 126. Advantageously, this insulating layer 146 is a heat shrink material. This allows the insulating layer 146 to be tightly wrapped around the heating chamber (above the heater 124, the metal layer 144, etc.) and then heated. Once heated, the insulating layer 146 shrinks and presses the heater 124 tightly against the outer surface of the sidewall 126 of the heating chamber 108. This eliminates any air gap between the heater 124 and the sidewall 126 and maintains very good thermal contact between the heater 124 and the sidewall. This, in turn, ensures good efficiency because the heat generated by the heater 124 causes the sidewall (and subsequently the aerosol substrate 128) to heat up and is not wasted heating air or leaking out in other ways.

[0120] Preferred embodiments use heat shrinkable materials that shrink in only one dimension, such as treated polyimide tape. For example, in the case of polyimide tape, the tape can be configured to shrink only in the length direction. This means that the tape can be wrapped around the heating chamber 108 and the heater 124 and, when heated, will shrink and press the heater 124 against the sidewalls 126. Because the insulation layer 146 shrinks in the length direction, the force generated in this way is consistent and directed inward. If the tape shrinks in the transverse (width) direction, this may cause the heater 124 or the tape itself to wrinkle. This, in turn, can introduce gaps and reduce the efficiency of the aerosol generating device 100.

[0121] See also Figures 3 to 6 , the substrate carrier 114 includes a prepackaged amount of aerosol substrate 128 and an aerosol collection area 130 wrapped in an outer layer 132. The aerosol substrate 128 is positioned toward a first end 134 of the substrate carrier 114. The aerosol substrate 128 extends across the entire width of the substrate carrier 114 within the outer layer 132. They also partially abut each other along the substrate carrier 114, meeting at a boundary. Overall, the substrate carrier 114 is generally cylindrical. The aerosol generating device 100 is Figure 1 and Figure 2 is shown without the matrix carrier 114. Figure 3 and Figure 4 , the substrate carrier 114 is shown above the aerosol generating device 100 but not loaded in the aerosol generating device 100. Figure 5 and Figure 6 , the substrate carrier 114 is shown loaded into the aerosol generating device 100 .

[0122] When a user wishes to use the aerosol generating device 100, the user first loads the aerosol generating device 100 with the substrate carrier 114. This involves inserting the substrate carrier 114 into the heating cavity 108. The substrate carrier 114 is inserted into the heating cavity 108 oriented so that the first end 134 of the substrate carrier 114 (the aerosol substrate 128 is positioned towards this end) enters the heating cavity 108. The substrate carrier 114 is inserted into the heating cavity 108 until the first end 134 of the substrate carrier 114 rests on a platform 148 extending inwardly from the base 112 of the heating cavity 108, i.e. until the substrate carrier 114 can no longer be inserted into the heating cavity 108. In the embodiment shown, as described above, the interaction between the upper edge 142a of the protrusion 140 and the boundary of the aerosol substrate 128 and the adjacent less compressible region of the substrate carrier 114 has the additional effect of alerting the user that the substrate carrier 114 has been inserted far enough into the aerosol generating device 100. From Figure 3 and Figure 4 108 , only a portion of the length of the substrate carrier 114 is within the heating cavity 108. The remaining length of the substrate carrier 114 protrudes from the heating cavity 108. At least a portion of the remaining length of the substrate carrier 114 also protrudes from the second end 106 of the aerosol-generating device 100. In a first embodiment, the entire remaining length of the substrate carrier 114 protrudes from the second end 106 of the aerosol-generating device 100. That is, the open end 110 of the heating cavity 108 coincides with the second end 106 of the aerosol-generating device 100. In other embodiments, the entire or substantially the entire substrate carrier 114 may be received in the aerosol-generating device 100, such that none or substantially none of the substrate carrier 114 protrudes from the aerosol-generating device 100.

[0123] With the substrate carrier 114 inserted into the heating chamber 108, the aerosol substrate 128 within the substrate carrier 114 is at least partially disposed within the heating chamber 108. In a first embodiment, the aerosol substrate 128 is entirely within the heating chamber 108. In fact, the prepackaged amount of aerosol substrate 128 in the substrate carrier 114 is disposed along the substrate carrier 114, extending from the first end 134 of the substrate carrier 114, a distance that is approximately (or even exactly) equal to the interior height of the heating chamber 108 from the base 112 of the heating chamber 108 to the open end 110. This is effectively the same as the length of the sidewall 126 of the heating chamber 108 within the interior of the heating chamber 108.

[0124] When the substrate carrier 114 is loaded in the aerosol generating device 100, the user uses the user-operable button 116 to turn on the aerosol generating device 100. This makes the electric power from the power supply 120 be provided to the heater 124 via the control circuit system 122 (and under its control). The heater 124 conducts heat to the aerosol substrate 128 via the protrusion 140, thereby heating the aerosol substrate 128 to a temperature at which it can begin to release vapor. Once heated to the temperature at which it can begin to release vapor, the user can inhale the vapor by sucking the vapor through the second end 136 of the substrate carrier 114. That is, vapor is generated from the aerosol substrate 128 at the first end 134 of the substrate carrier 114 in the heating chamber 108 and is drawn to the second end 136 of the substrate carrier along the length of the substrate carrier 114, through the vapor collection area 130 in the substrate carrier 114, where the vapor enters the user's mouth. Figure 6 Arrows A in FIG. 5 show this flow of vapor.

[0125] It should be understood that when the user follows Figure 6 When the vapor is sucked in the direction of arrow A, the vapor flows out from the vicinity of the aerosol matrix 128 in the heating chamber 108. This action draws ambient air from the environment surrounding the aerosol generating device 100 (via Figure 6 Indicated by arrow B, and Figure 6 (a) shows a flow path shown in more detail in FIG. ) drawn into the heating chamber 108. Ambient air is then heated by the heater 124, which in turn heats the aerosol substrate 128 to generate an aerosol. More specifically, in a first embodiment, air enters the heating chamber 108 through the space between the sidewalls 126 of the heating chamber 108 and the outer layer 132 of the substrate carrier 114. To this end, the outer diameter of the substrate carrier 114 is smaller than the inner diameter of the heating chamber 108. More specifically, in a first embodiment, the inner diameter of the heating chamber 108 (when no protrusions are provided, e.g., when no protrusions 140 are present or between the protrusions) is 10 mm or less, preferably 8 mm or less, and most preferably approximately 7.6 mm. This allows the diameter of the substrate carrier 114 to be approximately 7.0 mm (±0.1 mm) (when not compressed by the protrusions 140). This corresponds to an outer circumference of 21 to 22 mm, or more preferably 21.75 mm. In other words, the space between the substrate carrier 114 and the sidewalls 126 of the heating chamber 108 is most preferably about 0.1 mm. In other variations, the space is at least 0.2 mm, and in some instances up to 0.3 mm. Figure 6 Arrow B in FIG. 1 shows the direction in which air is drawn into the heating chamber 108 .

[0126] When a user activates the aerosol-generating device 100 by actuating the user-operable button 116, the aerosol-generating device 100 heats the aerosol substrate 128 to a temperature sufficient to vaporize a portion of the aerosol substrate 128. More specifically, the control circuitry 122 supplies electrical power from the power source 120 to the heater 124 to heat the aerosol substrate 128 to a first temperature. When the aerosol substrate 128 reaches the first temperature, the components 128 of the aerosol substrate begin to vaporize, i.e., the aerosol substrate generates vapor. Once the vapor is generated, the user can inhale the vapor through the second end 136 of the substrate carrier 114. In some scenarios, the user may be aware that the aerosol-generating device 100 requires a certain amount of time to heat the aerosol substrate 128 to the first temperature and begin generating vapor. This means that the user can determine when to begin inhaling the vapor. In other scenarios, the aerosol-generating device 100 is configured to indicate to the user that the vapor is ready for inhalation. Indeed, in a first embodiment, the control circuitry 122 illuminates the user-operable button 116 when the aerosol substrate 128 has been at the first temperature for an initial period of time. In other embodiments, the indication is provided by another indicator, such as by producing an audio sound or vibrating a vibrator. Similarly, in other embodiments, the indication is provided after a fixed time after the aerosol-generating device 100 is activated, once the heater 124 reaches the operating temperature, or after some other event occurs.

[0127] The user can continue to inhale vapor as long as the aerosol matrix 128 is able to continue generating vapor, for example, as long as the aerosol matrix 128 has vaporized any remaining vaporizable components into a suitable vapor. The control circuitry 122 adjusts the electrical power supplied to the heater 124 to ensure that the temperature of the aerosol matrix 128 does not exceed a threshold level. Specifically, at a certain temperature, which depends on the composition of the aerosol matrix 128, the aerosol matrix 128 will begin to burn. This is undesirable, and temperatures above and around this temperature should be avoided. To facilitate this, the aerosol-generating device 100 is provided with a temperature sensor 170. The control circuitry 122 is arranged to receive an indication of the temperature of the aerosol matrix 128 from the temperature sensor and use this indication to control the electrical power supplied to the heater 124. For example, in one scenario, the control circuitry 122 supplies maximum electrical power to the heater 124 during an initial period until the heater or chamber reaches a first temperature. Subsequently, once the aerosol substrate 128 reaches the first temperature, the control circuit system 122 stops supplying electrical power to the heater 124 for a second time period until the aerosol substrate 128 reaches a second temperature lower than the first temperature. Subsequently, once the heater 124 reaches the second temperature, the control circuit system 122 begins supplying electrical power to the heater 124 for a third time period until the heater 124 again reaches the first temperature. This may continue until the aerosol substrate 128 is depleted (i.e., all aerosol that can be generated by heating has been generated) or the user stops using the aerosol-generating device 100. In another scenario, once the first temperature is reached, the control circuit system 122 reduces the electrical power supplied to the heater 124 to maintain the aerosol substrate 128 at the first temperature without increasing the temperature of the aerosol substrate 128.

[0128] A single inhalation by a user is often referred to as a “puff.” In some scenarios, it is desirable to simulate the smoking experience, which means that the aerosol-generating device 100 is typically able to hold enough aerosol substrate 128 to provide ten to fifteen puffs.

[0129] In some embodiments, the control circuitry 122 is configured to count puffs and turn off the heater 124 after the user has taken ten to fifteen puffs. This puff counting is performed in one of several different ways. In some embodiments, the control circuitry 122 determines when the temperature drops during a puff, as fresh, cool air flows through the temperature sensor 170, causing the cooling detected by the temperature sensor. In other embodiments, a flow detector is used to directly detect airflow. Other suitable methods will be apparent to those skilled in the art. In other embodiments, the control circuitry additionally or alternatively turns off the heater 124 after a predetermined amount of time has elapsed since the first puff. This can help reduce power consumption and provide a backup for shutting off in the event that the puff counter fails to correctly record the predetermined number of puffs taken.

[0130] In some examples, the control circuit system 122 is configured to power the heater 124 so that it follows a predetermined heating cycle that requires a predetermined amount of time to complete. Once the cycle is complete, the heater 124 is completely turned off. In some cases, this cycle can utilize a feedback loop between the heater 124 and the temperature sensor 170. For example, the heating cycle can be parameterized with a series of temperatures to which the heater 124 (or more accurately, the temperature sensor) is heated or allowed to cool. The temperature and duration of such a heating cycle can be determined empirically to optimize the temperature of the aerosol substrate 128. This may be necessary because directly measuring the temperature of the aerosol substrate may be impractical or misleading, for example, when the outer layer of the aerosol substrate 128 has a different temperature than the core.

[0131] In the following example, the time to the first puff is 20 seconds. After this point, the power level provided to heater 124 is reduced from 100% so that the temperature remains constant at approximately 240°C for approximately 20 seconds. Then, the power provided to heater 124 can be further reduced so that the temperature reading recorded by temperature sensor 170 is approximately 200°C. This temperature can be maintained for approximately 60 seconds. The power level can then be further reduced so that the temperature measured by temperature sensor 170 drops to the operating temperature of substrate carrier 114, in this example, approximately 180°C. This temperature can be maintained for 140 seconds. This time interval can be determined by the length of time that substrate carrier 114 can be used. For example, substrate carrier 114 can stop generating aerosol after a set time period, and therefore can allow the heating cycle to continue for this duration within the time period when the temperature is set to 180°C. After this point, the power provided to heater 124 can be reduced to zero. Even when the heater 124 is turned off, the aerosol or vapor generated when the heater 124 is turned on can still be drawn out of the aerosol generating device 100 by the user sucking. Therefore, even when the heater 124 is turned off, the user can be alerted to this situation by the visual indicator remaining on, but the heater 124 has been turned off to prepare for the end of the aerosol inhalation process. In some embodiments, this set period can be 20 seconds. In some embodiments, the total duration of the heating cycle can be about 4 minutes.

[0132] Above-mentioned exemplary thermal cycle can be changed by the user using substrate carrier 114.When the user draws aerosol from substrate carrier 114, the user's breath encourages cold air to flow to the base 112 of heating chamber 108 through the open end of heating chamber 108, thereby flows downward through heater 124.Then, air can enter substrate carrier 114 through the tip 134 of substrate carrier 114.The cold air enters the inner cavity of heating chamber 108 and reduces the temperature measured by temperature sensor 170, because cold air replaces the hot air that existed previously.When temperature sensor 170 senses that temperature has decreased, this can be used to increase the power that battery cell provides to heater, so that temperature sensor 170 is heated back to the operating temperature of substrate carrier 114.This can be realized by providing maximum power amount to heater 124 or alternatively by providing power amount greater than the amount needed in order to keep temperature sensor 170 reading stable temperature.

[0133] The power source 120 is at least sufficient to bring the aerosol substrate 128 in the single substrate carrier 114 to a first temperature and maintain it at the first temperature to provide sufficient vapor for at least ten to fifteen puffs. More generally, consistent with the experience of simulating smoking, the power source 120 is typically sufficient to repeat this cycle (bringing the aerosol substrate 128 to the first temperature, maintaining the first temperature, and vapor generation for ten to fifteen puffs) ten or even twenty times before the power source 120 needs to be replaced or recharged, thereby simulating the user experience of smoking a pack of cigarettes.

[0134] In general, the efficiency of the aerosol-generating device 100 is improved when the heat generated by the heater 124 causes as much as possible to heat the aerosol substrate 128. To this end, the aerosol-generating device 100 is typically configured to provide heat to the aerosol substrate 128 in a controlled manner while reducing heat flow to other parts of the aerosol-generating device 100. In particular, heat flow to parts of the aerosol-generating device 100 that are operated by the user is kept to a minimum, thereby keeping these parts cool and comfortable to hold, for example, by means of insulation, as described in more detail herein.

[0135] from Figures 1 to 6 As will be appreciated from the accompanying description, according to a first embodiment, a heating chamber 108 for an aerosol-generating device 100 is provided, the heating chamber 108 comprising an open end 110, a base 112, and a sidewall 126 between the open end 110 and the base 112, wherein the sidewall 126 has a first thickness and the base 112 has a second thickness that is greater than the first thickness. The reduced thickness of the sidewall 126 can help reduce the power consumption of the aerosol-generating device 100 because less energy is required to heat the heating chamber 108 to a desired temperature.

[0136] Second embodiment

[0137] Now see Figure 8 The second embodiment is described. Except for the following explanation, the aerosol generating device 100 of the second embodiment is the same as that of FIG. Figures 1 to 6 The aerosol-generating device 100 of the first embodiment described is identical and like reference numerals are used to indicate similar features.The aerosol-generating device 100 of the second embodiment has a different arrangement to that of the first embodiment for allowing air to be drawn into the heating chamber 108 during use.

[0138] For more details, see Figure 8, a channel 113 is provided in the base 112 of the heating chamber 108. The channel 113 is located in the middle of the base 112. The channel extends through the base 112 so as to be in fluid communication with the environment outside the housing 102 of the aerosol-generating device 100. More specifically, the channel 113 is in fluid communication with an inlet 137 in the housing 102.

[0139] An inlet 137 extends through the housing 102. The inlet is positioned along a portion of the length of the housing 102 between the first end 104 and the second end 106 of the aerosol-generating device 100. In the second embodiment, the housing defines a gap 139 adjacent the control circuitry 122 and between the inlet 137 in the housing 102 and the channel 113 in the base 112 of the heating chamber 108. The gap 139 provides fluid communication between the inlet 137 and the channel 113 so that air can enter the heating chamber 108 from the environment external to the housing 102 via the inlet 137, the gap 139, and the channel 113.

[0140] In use, when a user inhales vapor at the second end 136 of the substrate carrier 114, air is drawn from the environment surrounding the aerosol-generating device 100 into the heating chamber 108. More specifically, air passes through the inlet 139 in the direction of arrow C and into the void 139. From the void 139, air passes through the passage 113 in the direction of arrow D and into the heating chamber 108. This allows first the vapor, and then the vapor mixed with the air, to be drawn through the substrate carrier 114 in the direction of arrow D for inhalation by the user at the second end 136 of the substrate carrier 114. The air is typically heated upon entering the heating chamber 108, so that the air assists in transferring heat to the aerosol substrate 128 by convection.

[0141] It will be appreciated that in the second embodiment, the airflow path through the heating chamber 108 is generally linear, that is, the path extends in a generally straight line from the base 112 of the heating chamber 108 to the open end 110 of the heating chamber 108. The arrangement of the second embodiment also allows for a reduced gap between the sidewalls 126 of the heating chamber 108 and the substrate carrier. In fact, in the second embodiment, the diameter of the heating chamber 108 is less than 7.6 mm, and the space between the 7.0 mm diameter substrate carrier 114 and the sidewalls 126 of the heating chamber 108 is less than 1 mm.

[0142] In variations of the second embodiment, the inlet 137 is located in different positions. In one particular embodiment, the inlet 137 is located at the first end 104 of the aerosol-generating device 100. This allows the air path through the entire aerosol-generating device 100 to be generally linear, for example, air enters the aerosol-generating device 100 at the first end 104, which is generally distal to the user during use, thereby flowing through (or over, past, etc.) the aerosol substrate 128 within the aerosol-generating device 100, and exits at the second end 136 of the substrate carrier 114 into the user's mouth, which is generally proximal to the user during use, for example, in the user's mouth.

[0143] Third embodiment

[0144] Now see Figure 9 、 Figure 9 (a) and Figure 9 (b) A third embodiment is described. The aerosol generating device 100 of the third embodiment is similar to that of the embodiment described in the preceding paragraph except for the following explanations. Figures 1 to 6 The aerosol-generating device 100 of the first embodiment described is identical and like reference numerals are used to indicate similar features. The heating chamber 108 of the third embodiment may correspond to the heating chamber 108 of the second embodiment, except as described below, for example the channel 113 is provided in the base 112 of the heating chamber 108, and this forms another embodiment of the present disclosure.

[0145] The aerosol-generating device 100 of the third embodiment has a heating chamber 108 in which the base 112 is formed as a separate element, rather than being integral with the side wall 126, as shown in FIG. Figures 1 to 6 shown.

[0146] Providing a heating chamber 108 with a separate base provides the structural support effect described about the first embodiment. Moreover, such a base 112 can be formed by a material different from the material forming the sidewall 126, for example, by a material having a lower thermal conductivity than the sidewall 126. The first end 134 of the heating substrate carrier 114 may be problematic because this may result in the generation of undesirable aerosol components. Providing a heat-insulating portion at the base 112 of the heating chamber 108 can reduce the heat conduction to the first end 134 of the substrate carrier 114, thereby alleviating the undesirable influence of the first end 134 of the heating substrate carrier 114. In fact, in the presence of a platform 148, the platform 148 can be provided as a separate component of the base 112. This separate platform 148 can include a heat-insulating (relative to the base 112 and / or the sidewall 126) component, thereby reducing the undesirable heating to the first end 134 of the substrate carrier 114. In this example, the base 112 can be attached by any suitable means, for example, using adhesive, thread, interference fit, etc.

[0147] Fourth embodiment

[0148] Now see Figure 10 、 Figure 10 (a) and Figure 10 (b) A fourth embodiment is described. The aerosol generating device 100 of the fourth embodiment is similar to that of the embodiment described in the preceding paragraph except for the following explanations. Figures 1 to 6 The aerosol-generating device 100 of the first embodiment described is identical and like reference numerals are used to indicate similar features. The heating chamber 108 of the fourth embodiment may correspond to the heating chamber 108 of the second embodiment, except as described below, for example the channel 113 is provided in the base 112 of the heating chamber 108, and this forms another embodiment of the present disclosure.

[0149] The aerosol-generating device 100 of the fourth (and further) embodiment has a heating chamber 108 in which the flange 138 is absent.

[0150] Providing a heating chamber 108 without a flange 138 reduces the thermal mass of the heating chamber 108 at the expense of reducing the structural strength provided by the flange 138. In this embodiment, the heating chamber 108 is mounted differently to the aerosol-generating device 100, as there is no flange 138 to clamp between the gasket 106. In more detail, the heating chamber 108 is sized to form an interference fit with the inner diameter of the gasket 107 and is retained in this manner. This has the advantage that the surface area of ​​the heating chamber 108 in contact with the gasket 107 is smaller, which in turn reduces heat transfer out of the heating chamber 108 and improves the overall efficiency of the aerosol-generating device 100.

[0151] Fifth embodiment

[0152] Now see Figure 11 、 Figure 11 (a) and Figure 11 (b) A fifth embodiment is described. The aerosol generating device 100 of the fifth embodiment is similar to that of the embodiment described in the preceding paragraph except for the following explanations. Figures 1 to 6 The aerosol-generating device 100 of the first embodiment described is identical and like reference numerals are used to indicate similar features. The heating chamber 108 of the fifth embodiment may correspond to the heating chamber 108 of the second embodiment, except as described below, for example the channel 113 is provided in the base 112 of the heating chamber 108, and this forms another embodiment of the present disclosure.

[0153] The aerosol-generating device 100 of the fifth (and further) embodiment has a heating chamber 108 in which the protrusion 140 is absent.

[0154] In the fifth embodiment, it will be appreciated that because the sidewalls 126 are relatively thin, the use of protrusions 140 to form the conductive heating pathways is not necessary because the relatively small volume of air within the heating cavity 108 is heated relatively quickly by the heater 124. Any deformation of the thin sidewalls 126 may risk damaging the sidewalls 126, or stated another way, manufacturing the walls without protrusions 140 may improve the efficiency of the manufacturing process by reducing the number of heating cavities 108 that need to be scrapped due to manufacturing errors.

[0155] Definitions and Alternative Embodiments

[0156] It will be appreciated from the above description that many features of these different embodiments are interchangeable with one another. The present disclosure extends to further embodiments that include features from different embodiments combined in a manner not specifically mentioned. For example, the third to fifth embodiments do not have Figures 1 to 6 The platform 148 is shown. This platform 148 may be included in the third through fifth embodiments, thereby providing the benefits of the platform 148 described with respect to these figures.

[0157] Figure 9 (a) Figure 9 (b) Figure 10 (a) Figure 10 (b) Figure 11 (a), and Figure 11 (b) shows the heating chamber 108 separated from the aerosol-generating device 100. This is to emphasize that the advantageous features described for the design of the heating chamber 108 are independent of the other features of the aerosol inhalation device 100. Specifically, the heating chamber 108 has many uses, not all of which are relevant to the vapor inhalation device 100 described herein. Such designs may benefit from a base 112 for providing support to the sidewalls 126, as described herein. Such uses are advantageously provided by the heating chamber described herein.

[0158] The term "heater" should be understood to refer to any device for outputting heat energy sufficient to form an aerosol from the aerosol substrate 128. The transfer of heat energy from the heater 124 to the aerosol substrate 128 can be conductive, convective, radiative, or any combination thereof. As non-limiting examples, conductive heaters can directly contact and press against the aerosol substrate 128, or the heaters can contact a separate component that itself causes the aerosol substrate 128 to heat up by conduction, convection, and / or radiation. Convective heating can include heating a liquid or gas, which thereby transfers heat energy (directly or indirectly) to the aerosol substrate.

[0159] Radiative heating includes, but is not limited to, transferring energy to the aerosol matrix 128 by emitting electromagnetic radiation within the ultraviolet, visible, infrared, microwave, or radio wave portions of the electromagnetic spectrum. Radiation emitted in this manner can be absorbed directly by the aerosol matrix 128 to cause heating, or the radiation can be absorbed by another material (such as a susceptor or fluorescent material) that causes the radiation to be re-emitted at a different wavelength or spectral weighting. In some cases, the radiation can be absorbed by a material that then transfers heat to the aerosol matrix 128 by any combination of conduction, convection, and / or radiation.

[0160] The heater can be electrically powered, combustion-driven, or powered in any other suitable manner. An electrically powered heater can include a resistive tracking element (optionally including an insulating package), an induction heating system (e.g., including an electromagnet and a high-frequency oscillator), etc. The heater 128 can be arranged around the outside of the aerosol matrix 128, the heater can partially or completely penetrate the aerosol matrix 128, or any combination thereof.

[0161] The term "temperature sensor" is used to describe an element that is capable of determining the absolute or relative temperature of a portion of the aerosol-generating device 100. This may include a thermocouple, a thermopile, a thermistor, etc. The temperature sensor may be provided as part of another component, or may be a separate component. In some examples, more than one temperature sensor may be provided, for example to monitor heating of different portions of the aerosol-generating device 100 in order to determine a thermal profile, for example.

[0162] The control circuit system 122 is always shown as having a single user-operable button 116 to trigger the aerosol-generating device 100 to turn on. This keeps the control simple and reduces the chances of a user misusing the aerosol-generating device 100 or failing to properly control the aerosol-generating device 100. In some cases, however, the input controls available to the user may be more complex than this, such as for controlling the temperature within predetermined limits, for changing the flavor balance of the vapor, or for switching between an energy-saving mode or a rapid heating mode, for example.

[0163] With reference to the above-described embodiments, the aerosol matrix 128 includes, for example, tobacco in dried or smoked form, in some cases with additional ingredients for flavoring or for producing a smoother or otherwise more pleasant experience. In some instances, an aerosol matrix 128, such as tobacco, may be treated with a vaporizer. The vaporizer can improve the vapor generated from the aerosol matrix. For example, the vaporizer can include a polyol such as glycerol, or an ethylene glycol such as propylene glycol. In some cases, the aerosol matrix may not contain tobacco or even nicotine, but may contain natural or artificially extracted ingredients for flavoring, volatilization, improving smoothness and / or providing other pleasant effects. The aerosol matrix 128 can be provided as a solid or paste-type material in pulverized, granulated, powdered, granular, strip or sheet form, optionally in a combination of these forms. Similarly, the aerosol matrix 128 can be a liquid or gel. In fact, some examples can include both a solid portion and a liquid / gel portion.

[0164] Thus, the aerosol-generating device 100 may also be referred to as a "heated tobacco device," a "heat-but-not-burn tobacco device," a "device for vaporizing tobacco products," and the like, and it is to be construed as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol substrate.

[0165] The embodiment of the aerosol-generating device 100 is described as being arranged to receive an aerosol substrate 128 in a prepackaged substrate carrier 114. The substrate carrier 114 can be generally similar to a cigarette, having a tubular region with the aerosol substrate arranged in a suitable manner. In some designs, a filter, a vapor collection region, a cooling region, and other structures may also be included. An outer layer of paper or other flexible planar material (such as foil) may also be provided, for example, to hold the aerosol substrate in place, to make it more like a cigarette, etc.

[0166] As used herein, the term "fluid" should be understood to broadly refer to non-solid materials capable of flowing, including but not limited to liquids, pastes, gels, powders, and the like. "Fluidized material" should accordingly be interpreted as a material that is inherently fluid, or a material that has been modified to behave as a fluid. Fluidization may include, but is not limited to, powderization, dissolution in a solvent, gelation, thickening, and dilution.

[0167] As used herein, the term "volatile" refers to a substance that can readily change from a solid or liquid state to a gaseous state. As a non-limiting example, a volatile substance can be a substance that boils or sublimates at a temperature close to room temperature at ambient pressure. Thus, "volatilize" or "volatilise" should be interpreted as meaning to volatilize (a material) and / or to cause it to evaporate or disperse in a vapor.

[0168] As used herein, the term "vapor" means: (i) the form to which a liquid naturally converts when exposed to sufficient heat; or (ii) liquid / water particles suspended in the atmosphere and visible as clouds of steam / mist; or (iii) a fluid that fills space like a gas but liquefies under pressure alone below its critical temperature.

[0169] Consistent with this definition, the terms "vaporize" or "vaporize" mean: (i) to change or cause to change into a vapor; and (ii) when a particle changes physical state (ie, from a liquid or solid to a gas).

[0170] As used herein, the term "atomize" or "atomize" shall mean: (i) reducing (a substance, especially a liquid) into very small particles or droplets; and (ii) leaving the particles in the same physical state (liquid or solid) as before atomization.

[0171] As used herein, the term "aerosol" shall refer to a system of particles dispersed in air or gas (such as mist, fog or smoke). Thus, the term "aerosolize" or "aerosolize" refers to making and / or dispersing into an aerosol. It should be noted that the meaning of aerosol / aerosolization is consistent with each of volatilization, atomization and vaporization as defined above. For the avoidance of doubt, aerosol is used to consistently describe a mist or droplets comprising atomized, volatilized or vaporized particles. Aerosols also include mists or droplets comprising any combination of atomized, volatilized or vaporized particles.

Claims

1. A heating chamber (108) for an aerosol-generating device (100), the heating chamber (108) comprising: a first open end (110); base (112); a sidewall (126) between the first open end (110) and the base (112); a plurality of protrusions (140) formed on the inner surface of the sidewall (126); and providing a heater (124) on an outer surface of the side wall (126), the heater (124) being in thermal contact with the outer surface; wherein the base (112) is connected to the side wall (126) and provides structural support to the side wall (126); wherein the sidewall (126) has a first thickness, and the base (112) has a second thickness greater than the first thickness; wherein the protrusions (140) are formed by making indentations on the outer surface of the side wall (126); wherein the heater (124) extends around the sidewall (126) but does not extend around the base (112); and The side wall (126) and the base (112) are formed of the same material.

2. The heating chamber (108) according to claim 1, wherein The material is metal.

3. The heating chamber (108) according to claim 1, wherein The base (112) and the sidewall (126) are formed as a single component.

4. The heating chamber (108) according to claim 3, wherein: The base (112) and the sidewall (126) form a cup-shaped member.

5. The heating chamber (108) according to claim 1, wherein The first thickness is 100 μm or less.

6. The heating chamber (108) according to claim 1, wherein The second thickness is between 200 μm and 500 μm.

7. The heating chamber (108) according to claim 1, wherein The base (112) seals a second end of the side wall (126) opposite the first open end (110), and wherein the side wall (126) extends all the way around the base (112).

8. The heating chamber (108) of claim 1, comprising a flanged portion (138) attached to the first open end (110), the flanged portion (138) extending radially outward at the first open end (110) of the heating chamber (108).

9. The heating chamber (108) according to claim 8, wherein The flanged portion (138) extends all the way around the heating chamber (108).

10. The heating chamber (108) according to claim 8, wherein The flanged portion (138) extends obliquely away from the side wall (126).

11. The heating chamber (108) according to claim 8, wherein The flanged portion (138) comprises a first material and the sidewall (126) comprises a second material, the first material having a lower thermal conductivity than the second material.

12. The heating chamber (108) of claim 1, wherein: The sidewall (126) comprises a material having a thermal conductivity of 50 W / mK or less.

13. The heating chamber (108) of claim 1, further comprising a platform (148) on an inner surface of the base (112).

14. The heating chamber (108) according to claim 13, wherein The platform (148) is formed by indenting the outer surface of the base (112).

15. The heating chamber (108) of claim 1, wherein: The heating cavity (108) is a product of deep drawing.

16. An aerosol generating device (100), comprising: Power supply (120); The heating chamber (108) according to claim 1; and Control circuitry (122) is configured to control the supply of electrical power from the power source (120) to the heater (124).

17. The aerosol generating device (100) according to claim 16, wherein: The heating chamber (108) is removable from the aerosol-generating device (100).

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