Heater module, method of manufacturing a heater module, and aerosol-generating device

Abstract

The disclosure provides a heater module, a method of manufacturing a heater module for an aerosol generating device, and an aerosol generating device. The method includes preparing a heat transfer pipe having a hollow shape and including a heat conductive material; forming an assembly of the heat transfer pipe and a cover by insert molding such that one end portion of the cover is integrally coupled to an end portion of the heat transfer pipe while a side wall of the cover is spaced apart from an outer surface of the heat transfer pipe and surrounds the heat transfer pipe, in the insert molding, the heat transfer pipe is placed in a mold and a resin is injected into the mold; arranging a heater on the outer surface of the heat transfer pipe; and sealing a space between the heat transfer pipe and the cover with a sealing stopper such that an internal pressure of the space is lower than an atmospheric pressure.

Description

TECHNICAL FIELD

[0001] One or more embodiments relate to a heater module, a method of manufacturing a heater module, and an aerosol generating device including the same, and more particularly, to a heater module having improved heating performance and safety, a method of manufacturing a heater module, and an aerosol generating device including the same. BACKGROUND

[0002] A heater module that heats an object to a desired temperature by generating heat by means of electricity is used for various purposes such as household use or industrial use. In order to rapidly heat an object, a heater module generates high-temperature heat, in which case stability and energy efficiency can be reduced due to heat emitted to the outside and lost. SUMMARY

[0003] TECHNICAL PROBLEM

[0004] One or more embodiments provide a heater module, a method of manufacturing a heater module, and an aerosol generating device including the same, which can rapidly and stably heat an object by blocking lost heat and which has improved energy efficiency.

[0005] TECHNICAL SOLUTION TO THE PROBLEM

[0006] The method of manufacturing a heater module according to an embodiment includes preparing a heat transfer pipe including a material for transferring heat and having a hollow shape; forming an assembly of the heat transfer pipe and a cover by molding the cover by means of an insert molding process, the cover having one end coupled to an end of the heat transfer pipe and the cover being spaced apart from an outer surface of the heat transfer pipe to surround the outer surface of the heat transfer pipe, in the insert molding process, the heat transfer pipe is placed in a mold and resin is injected into the mold; arranging a heater on the outer surface of the heat transfer pipe; and sealing a space between the heat transfer pipe and the cover with a sealing stopper such that the space between the heat transfer pipe and the cover is in a vacuum state in which an internal pressure of the space is lower than an atmospheric pressure.

[0007] ADVANTAGEOUS EFFECTS OF THE INVENTION

[0008] According to the above-described embodiment, according to the heater module, the method of manufacturing a heater module, and the aerosol generating device including the same, an object can be rapidly and stably heated by blocking lost heat.

[0009] In addition, heat loss can be reduced by maintaining a portion of an inside of the heater module in a vacuum state having a pressure lower than an atmospheric pressure, thereby improving heating performance and stability. BRIEF DESCRIPTION OF DRAWINGS

[0010] Figure 1 is a flowchart illustrating operations of a method of manufacturing a heater module according to an embodiment.

[0011] Figure 2 is a flowchart illustrating an example of operations of a method of manufacturing a heater module according to an embodiment. Figure 1

[0012] Figures 3 to 12 is a flowchart illustrating an example of operations of a method of manufacturing a heater module according to an embodiment. Figure 1 Figure 2

[0013] Figure 13A is a perspective view illustrating individual components of a heater module manufactured by a method of manufacturing a heater module according to another embodiment.

[0014] Figure 13B is a flowchart illustrating an example of operations of a method of manufacturing a heater module according to an embodiment. Figure 13A

[0015] Figure 14 is a cross-sectional view illustrating an aerosol-generating device including a heater module according to an embodiment.

[0016] Figure 15 is an enlarged cross-sectional view illustrating a portion including a heater module of an aerosol-generating device according to another embodiment.

[0017] Figure 16 is a perspective view illustrating some components of a heater module according to an embodiment.

[0018] Figure 17 is a cross-sectional view illustrating a coupling relationship between some components of a heater module according to an embodiment. Figure 16

[0019] Figure 18 is a cross-sectional view illustrating a coupling relationship between some components of a heater module according to another embodiment.

[0020] Figure 19 illustrates a method of arranging a heater on an outer surface of a heat transfer tube according to another embodiment. DETAILED DESCRIPTION

[0021] Best modes for carrying out the invention

[0022] ​​​​​A method of manufacturing a heater module according to an embodiment includes preparing a heat transfer pipe having a hollow shape and including a heat conductive material; forming an assembly of the heat transfer pipe and a cover by insert molding such that one end portion of the cover is integrally coupled to an end portion of the heat transfer pipe while a side wall of the cover is spaced apart from an outer surface of the heat transfer pipe and surrounds the heat transfer pipe, in the insert molding, the heat transfer pipe is disposed in a mold and a resin is injected into the mold; disposing a heater on the outer surface of the heat transfer pipe; and sealing a space between the heat transfer pipe and the cover with a sealing stopper such that an internal pressure of the space is lower than an atmospheric pressure.

[0023] A heater module according to an embodiment includes a heat transfer pipe having a hollow shape and including a heat conductive material; a cover having a side wall and one end portion integrally coupled to an end portion of the heat transfer pipe, the side wall being spaced apart from the heat transfer pipe and surrounding the heat transfer pipe; a heater disposed on an outer surface of the heat transfer pipe and configured to generate heat; and a sealing stopper sealing a space between the heat transfer pipe and the cover such that an internal pressure of the space is lower than an atmospheric pressure.

[0024] An aerosol-generating device according to an embodiment includes a heater module including a heat transfer pipe having a hollow shape and including a heat conductive material, a cover having a side wall and one end portion integrally coupled to an end portion of the heat transfer pipe, the side wall being spaced apart from the heat transfer pipe and surrounding the heat transfer pipe, a heater disposed on an outer surface of the heat transfer pipe and configured to generate heat, and a sealing stopper sealing a space between the heat transfer pipe and the cover such that an internal pressure of the space is lower than an atmospheric pressure; and a controller electrically connected to the heater module and configured to control an operation of the heater module.

[0025] The present invention

[0026] The present disclosure will now be described more fully with reference to the accompanying drawings, in which various embodiments of the present disclosure are illustrated. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the present disclosure to those skilled in the art, and the present disclosure will only be limited by the appended claims. The terminology used herein is for the purpose of describing various embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "includes", "including", "has", "have", "having", and / or "comprises" and / or "comprising", when used herein, specify the presence of stated components, steps, operations, and / or elements, but do not preclude the presence or addition of one or more other components, steps, operations, and / or elements. Although such terms as "first", "second", and the like can be used herein to describe various components, such components must not be limited to the above terms. The above terms are used only to distinguish one component from another.

[0027] Figure 1 FIG. 1 is a flowchart illustrating operations of a method of manufacturing a heater module according to an embodiment.

[0028] According to Figure 1 The method of manufacturing a heater module according to the embodiment shown in FIG. 1 includes an operation S100 of preparing a heat transfer pipe including a material for transferring heat, an operation S110 of molding an assembly of the heat transfer pipe and a cover by integrally coupling the cover to the heat transfer pipe using an insert molding process, an operation S120 of arranging a heater on an outer surface of the heat transfer pipe, an operation S130 of forming a heat reflector, and an operation S140 of sealing a space between the heat transfer pipe and the cover.

[0029] Although the method of manufacturing a heater module includes the operation S130 of forming a heat reflector, embodiments are not limited thereto, and the operation S130 of forming a heat reflector can be omitted. For example, in the case where the cover is made of a material having excellent heat reflecting performance, or in the case where the cover is made of plastic or metal and an inner side portion of the cover is pre-coated with a material having excellent heat reflecting performance, the operation S130 of forming a heat reflector can be omitted after the operation S110 of molding an assembly of the heat transfer pipe and the cover.

[0030] In the operation S110, the assembly of the heat transfer pipe and the cover can be molded by an insert molding process in which the heat transfer pipe is placed in a mold and resin is injected into the mold. Accordingly, one end portion of the cover can be integrally coupled to an end portion of the heat transfer pipe, and a side wall of the cover can be spaced apart from and surround an outer surface of the heat transfer pipe.

[0031] In operation S140, the space between the heat transfer pipe and the cover is sealed with the sealing stopper, so that the space between the heat transfer pipe and the cover is in a vacuum state lower than atmospheric pressure.

[0032] Figure 2 is a flowchart illustrating an example of operations of a method of manufacturing a heater module according to the embodiment shown in Figure 1 is a flowchart illustrating an example of operations of a method of manufacturing a heater module according to the embodiment shown in

[0033] Referring to Figure 2 The operation S140 of sealing the space between the heat transfer pipe and the cover includes an operation S141 of placing the assembly of the heat transfer pipe and the cover in a high-temperature environment, an operation S142 of arranging the sealing stopper for sealing the space between the heat transfer pipe and the cover in the assembly of the heat transfer pipe and the cover, and an operation S143 of cooling the assembled heater module.

[0034] In the method of manufacturing a heater module, in order to maintain the space between the heat transfer pipe and the cover in a vacuum state during the process of manufacturing the heater module, the process of coupling the sealing stopper to the assembly of the heat transfer pipe and the cover can be performed in a high-temperature environment, and by performing the operation S143 of cooling the heater module, a vacuum state can be naturally formed inside the heater module. That is, since the air inside the heater module expands in the high-temperature environment and then the air is again cooled and shrinks by the operation S143 of cooling the heater module, a vacuum state is formed inside the heater module.

[0035] According to the above-described embodiment, a vacuum state of the inside of the heater module is achieved without the need to perform a separate process of extracting air from the heater module after the heater module is assembled, and thus the process of manufacturing the heater module can be simplified.

[0036] In some existing methods of assembling a heater module, in order to avoid a complex process of achieving a vacuum state, a vacuum pipe module is separately purchased and connected to the heater module. However, in this case, the design and size of the heater module must be determined according to the design of the vacuum pipe module, and thus it is difficult to freely design the heater module and the manufacturing cost of the heater module can increase.

[0037] According to the embodiment, since a vacuum state inside the heater module can be naturally formed during the process of manufacturing the heater module, the manufacturing cost can be reduced and the manufacturing process can be simplified.

[0038] In this context, the term "vacuum state" formed in the inside of the heater module means that the heater module has a low air pressure that can prevent heat generated by the heater from being radiated to the outside of the heater module, and does not mean a perfect vacuum state in which no air exists. Accordingly, the vacuum state of the inside of the heater module includes a state having a pressure lower than atmospheric pressure. For example, assuming that atmospheric pressure is 1 atm (760 mmHg), the vacuum state of the inside of the heater module can include a low pressure state of about 0.3 atm to about 0.8 atm.

[0039] Figures 3 to 12 is a view illustrating a method of manufacturing a heater module according to Figure 1 and Figure 2 is a view illustrating an operation of a method of manufacturing a heater module according to the embodiment shown in

[0040] Figure 3 is shown (see S100 in Figure 1 ). The heat transfer pipe 10 can be made of a heat-conductive metal material including any one of stainless steel, aluminum, and copper or a combination thereof. The heat transfer pipe 10 performs a function of transferring heat generated by a heater to an object to be heated.

[0041] The heat transfer pipe 10 can be prepared by, for example, a process of cutting and bending a metal pipe or a forging process. Alternatively, the heat transfer pipe 10 can be prepared by a casting process using a previously prepared mold.

[0042] The heat transfer pipe 10 is formed as a cylindrical pipe including a receiving passage 10v capable of accommodating an object to be heated in the receiving passage 10v. The heat transfer pipe 10 includes a flange 11p radially protruding from one end 11 of the heat transfer pipe 10 for coupling with a cover to be described below.

[0043] Since the heater is disposed outside the heat transfer pipe 10, the heat transfer pipe 10 can mainly perform a role of transferring heat transferred through the outer surface 10f to the receiving passage 10v.

[0044] The embodiments are not limited to the structure of the heat transfer pipe 10 shown in the drawings, and the heat transfer pipe 10 can have, for example, a polygonal cylindrical shape having a polygonal cross section.

[0045] Figure 4 is shown (see S100 in Figure 1The heat transfer tube 10 and the cover 20 are integrally formed by an insert molding process. The heat transfer tube 10 and the cover 20 are integrally molded in the operation of molding the assembly of the heat transfer tube and the cover (see S110 in FIG. 1). In the operation of molding the assembly of the heat transfer tube and the cover, the heat transfer tube 10 is arranged in the cavity 7v of the mold 7a and 7b, and the heat transfer tube 10 and the cover are integrated by an insert molding process in which molten resin is injected into the mold 7a and 7b. Thus, the assembly of the heat transfer tube and the cover is integrally molded.

[0046] Figure 5 An assembly 10a of the heat transfer tube 10 and the cover 20 integrally formed by the insert molding process is shown.

[0047] One of, for example, polycarbonate (PC), polybutylene terephthalate (PBT), and polyether ether ketone (PEEK), or a mixture thereof can be used as the material of the cover 20.

[0048] The cover 20 includes a side wall 22 and one end portion 21 integrally coupled to one end portion 11 of the heat transfer tube 10, the side wall 22 being connected to the one end portion 21 and spaced apart from the outer surface 10f of the heat transfer tube 10 to surround the outer surface 10f of the heat transfer tube 10. In the assembly 10a of the heat transfer tube 10 and the cover 20, the side wall 22 of the cover 20 is spaced apart from the outer surface 10f of the heat transfer tube 10.

[0049] Figure 6 An example of the operation of forming a heat reflector inside the cover 20 is shown (see S130 in FIG. 1). The operation of forming a heat reflector inside the cover 20 includes an operation of preparing a heat reflecting tube 30p including a material that reflects heat, and an operation of inserting the heat reflecting tube 30p inside the cover 20. Figure 1

[0050] The heat reflecting tube 30p having an outer diameter corresponding to the inner diameter of the cover 20 can be prepared in advance. Thus, when the heat reflecting tube 30p is inserted inside the cover 20, the heat reflecting tube 30p can be fixed to the inside of the cover 20. According to the embodiment, a heat conductive adhesive layer can be arranged between the heat reflecting tube 30p and the cover 20. That is, the adhesive layer having adhesive properties and good heat conductivity is arranged on the outer surface of the heat reflecting tube 30p and / or the inner surface of the cover 20, and the heat reflecting tube 30p and the cover 20 can be coupled to each other by inserting the heat reflecting tube 30p inside the cover 20.

[0051] The heat reflecting tube 30p can include at least one of a reinforced carbon material layer, an alumina reflective layer coating, and a white protective layer. These layers can be stacked inside the heat reflecting tube 30p.

[0052] Figure 7 Another example of the operation of forming a heat reflector inside the cover 20 is shown (see S130 in FIG. 1). The operation of forming a heat reflector inside the cover 20 includes an operation of preparing a heat reflecting tube 30p including a material that reflects heat, and an operation of inserting the heat reflecting tube 30p inside the cover 20.​Figure 1 The operation of forming the heat reflector on the inside of the cover 20 can include an operation of applying a heat reflecting material on the inside of the cover 20. In the operation of applying the heat reflecting material on the inside of the cover 20, a coating layer 30c can be formed by using a spraying method of spraying the heat reflecting material toward the inside of the cover 20 by using a nozzle 30n, as shown in Figure 7

[0053] When the coating layer 30c is formed, the remaining area of the inside of the assembly 10a of the heat transfer tube 10 and the cover 20, that is, the outer surface of the heat transfer tube 10 can be temporarily covered with a protection member to prevent the heat reflecting material from being applied to the outer surface of the heat transfer tube 10.

[0054] The embodiments are not limited to the example of applying the heat reflecting material on the inside of the cover 20 using the spraying method. For example, the heat reflecting material can be applied on the inside of the cover 20 by using a method of immersing the assembly 10a of the heat transfer tube 10 and the cover 20 in a storage tank in which the heat reflecting material is contained, or by using various other deposition methods.

[0055] Figure 8 A state in which the heat reflector 30 is formed on the inside of the cover 20 after the operations shown in Figure 6 or Figure 7 are performed is shown.

[0056] After the heat reflecting material is applied on the inside of the cover 20, the heat reflecting material applied on the inside of the cover 20 can be sufficiently dried by performing drying at room temperature or by using hot air.

[0057] Figure 9 and Figure 10 An operation of arranging the heater 40c on the outside of the heat transfer tube 10 is shown. The operation of arranging the heater 40c includes an operation of preparing the heater 40c in which a heating wire is wound to form a cylindrical shape corresponding to the shape of the heat transfer tube 10, and an operation of arranging the heater 40c so as to surround the outer surface of the heat transfer tube 10.

[0058] The heater 40c formed of a coil includes a lead wire 40f for receiving electricity from the outside. A protective layer can be formed on one of the outer side and the inner side of the heater 40c, or the protective layer can be formed on both of the outer side and the inner side of the heater 40c. The heater 40c can be a resistance heater capable of generating heat when electricity is applied to the lead wire 40f from the outside. For the heater 40c, a metal material having an electric heating function, such as copper or stainless steel, can be used.

[0059] ​The embodiments are not limited to the operation of arranging the heater 40c on the outer surface of the heat transfer pipe 10, such as Figure 9 and Figure 10 shown in . For example, the heater 40c can be arranged on the outer surface of the heat transfer pipe 10 by directly winding a heating wire on the outer surface of the heat transfer pipe 10.

[0060] Further, the overall shape of the heater 40c is not necessarily limited to a cylindrical shape, and the heater 40c can be manufactured to have a hollow cylindrical shape having a polygonal cross section corresponding to the shape of the heat transfer pipe 10.

[0061] Figure 11 and Figure 12 An operation of sealing the space 20v between the heat transfer pipe 10 and the cover 20 in the assembly 10a of the heat transfer pipe 10 and the cover 20 with the sealing stopper 50 is shown (see S140 in Figure 1 ). The operation of sealing the space 20v includes an operation of placing the assembly 10a of the heat transfer pipe 10 and the cover 20 in a high-temperature environment, and an operation of coupling the sealing stopper 50 to an end portion of the cover 20 different from the end portion of the cover 20 coupled to the heat transfer pipe 10 in the high-temperature environment.

[0062] The sealing stopper 50 can include a heat-resistant material such as heat-resistant rubber, heat-resistant silicon, or heat-resistant plastic. The sealing stopper 50 includes a central through-hole in a central portion of the sealing stopper 50 through which the lower end portion of the heat transfer pipe 10 can pass, and further includes a through-hole 50f through which the lead 40f of the heater 40c can pass.

[0063] In order to couple the sealing stopper 50 to the end portion of the cover 20, an adhesive can be placed between the sealing stopper 50 and the cover 20, thereby securing a firm coupling state between the sealing stopper 50 and the cover 20. Further, after the lead 40f is pulled to the outside of the sealing stopper 50 through the through-hole 50f of the sealing stopper 50 while the sealing stopper 50 is coupled to the cover 20, the through-hole 50f can be completely sealed by applying a sealing material such as heat-resistant silicon to the through-hole 50f.

[0064] As shown in Figure 12 , after the heater module is assembled by coupling the sealing stopper 50 to the assembly 10a of the heat transfer pipe 10 and the cover 20, an operation of cooling the heater module can be performed. Thus, the air expanded in the high-temperature environment is cooled and shrinks, thereby naturally forming a vacuum state inside the heater module.

[0065] Figure 13Ais an exploded view of a heater module manufactured through a method for manufacturing a heater module according to another embodiment, and Figure 13B is a flowchart illustrating an example of operations of a method of manufacturing a heater module according to the embodiment shown in Figure 13A

[0066] Figure 13A and Figure 13B Another example of sealing a space between a heat transfer pipe and a cover with a sealing stopper is illustrated.

[0067] A heater module according to the embodiment shown in Figure 13A The heater module according to the embodiment shown in includes a heat transfer pipe 10, a cover 20, a heat reflecting pipe 30p, a heater 40c, and a sealing stopper 50. The heat transfer pipe 10 has a hollow shape and includes a material capable of transferring heat. The cover 20 has a hollow shape and includes one end portion 21 including a coupling hole 21a coupled integrally with one end portion 11 of the heat transfer pipe 10, and a side wall 22 connected to the one end portion 21 and spaced apart from the heat transfer pipe 10 to surround the heat transfer pipe 10. The heat reflecting pipe 30p is disposed inside the cover 20 to serve as a heat reflector. The heater 40c is disposed outside the heat transfer pipe 10 and generates heat by a signal applied from the outside. The sealing stopper 50 seals a space between the heat transfer pipe 10 and the cover 20 so that the space between the heat transfer pipe 10 and the cover 20 is in a vacuum state in which an internal pressure of the space is lower than an atmospheric pressure.

[0068] When assembly of the heater module is completed by coupling the sealing stopper 50 to the assembly 10a of the heat transfer pipe 10 and the cover 20, the controller 70 can be electrically connected to the lead wire 40f pulled to the outside of the sealing stopper 50 through the through hole 50f of the sealing stopper 50. The controller 70 can include a circuit board having a memory and / or a control semiconductor chip, the memory storing a control program for controlling the heater 40c or information related to program execution.

[0069] Referring to Figure 13A and Figure 13B The operation of sealing a space between a heat transfer pipe and a cover with a sealing stopper includes an operation S144 of coupling the sealing stopper 50 to the other end portion of the cover 20, an operation S145 of extracting air in the space between the heat transfer pipe 10 and the cover 20 to the outside of the cover 20 through the air outlet 50c formed in the sealing stopper 50, and an operation S146 of sealing the air outlet 50c of the sealing stopper 50.

[0070] ​The operation S145 of extracting air from the space between the heat transfer tube 10 and the cover 20 can be performed by connecting an air pump operated by electricity or fluid pressure or a manual air pump to the air outlet 50c and extracting the air inside the heater module to the outside.

[0071] Figure 14 This is a cross-sectional view showing an aerosol generating apparatus including a heater module according to an embodiment. Figures 1 to 1 The heater module of the embodiment shown in 3 can be applied to Figure 14 The aerosol generating device shown is shown.

[0072] according to Figure 14 The aerosol generating apparatus of the embodiment shown includes: a heater module 5; a controller 70 electrically connected to a lead 40f of the heater module 5 to control the operation of the heater 40c; and a battery 70b for supplying power to the controller 70 and the heater module 5. The heater module 5 includes: a heat transfer tube 10 having a hollow shape; a cover 20 including an end 21 integrally connected to the heat transfer tube 20 and a sidewall 22 spaced apart from the heat transfer tube 10; a heater 40c disposed outside the heat transfer tube 10 to generate heat; a heat reflector 30 disposed inside the cover 20 to reflect heat; and a sealing stop 50 for sealing the space 20v between the heat transfer tube 10 and the cover 20.

[0073] Cigarette 7 can be inserted into heat transfer tube 10 of heater module 5 installed on aerosol generating device. Support plate 9b for supporting the end of cigarette 7 is installed at the lower end of heat transfer tube 10.

[0074] The heater module 5, controller 70, and battery 70b of the aerosol generating device can be housed in the housing 8.

[0075] exist Figure 14 In this embodiment, the heater module 5, controller 70, and battery 70b are arranged in a linear fashion. However, the embodiments are not limited to this arrangement, and the arrangement of the heater module 5, controller 70, and battery 70b can be modified in various ways.

[0076] When the cigarette 7 is inserted into the aerosol-generating device, the aerosol-generating device heats the heater 40c. The temperature of the aerosol-generating substance in the cigarette 7 is raised by the heated heater 40c, thereby generating an aerosol. The generated aerosol is delivered to the user through the filter of the cigarette 7. In this context, the term "cigarette" can refer to an aerosol-generating article (i.e., a substrate) having a shape similar to that of a conventional combustible cigarette. Such a cigarette (i.e., a cigarette-type aerosol-generating article) can contain an aerosol-generating substance and generate an aerosol by the operation (e.g., heating) of the aerosol-generating device.

[0077] The battery 70b supplies power for operating the aerosol-generating device. For example, the battery 70b can supply power to heat the heater 40c, and can supply power required for the controller 70 to operate. In addition, the battery 70b can supply power required for the display, the sensor, and the motor mounted in the aerosol-generating device to operate.

[0078] The controller 70 controls the overall operation of the aerosol-generating device. Specifically, the controller 70 controls the operation of the battery 70b and the heater 40c, and other components included in the aerosol-generating device. In addition, the controller 70 can determine whether the aerosol-generating device is in an operable state by checking the state of each of the components of the aerosol-generating device.

[0079] The controller 70 includes at least one processor. The processor can be implemented as an array of a plurality of logic gates, or can be implemented as a combination of a general-purpose microprocessor and a memory in which a program executable in the microprocessor is stored. In addition, the controller 70 can be implemented with other types of hardware.

[0080] The heater 40c is heated by power supplied by the battery 70b. When the cigarette 7 is inserted into the heat transfer pipe 10 of the heater module 5, the heater 40c heats the cigarette 7 to raise the temperature of the aerosol-generating substance in the cigarette 7.

[0081] In addition to the battery 70b, the controller 70, and the heater 40c, the aerosol-generating device can include general-purpose components. For example, the aerosol-generating device can include a display capable of outputting visual information and / or a motor for outputting tactile information. In addition, the aerosol-generating device can include at least one sensor (e.g., a puff detection sensor, a temperature detection sensor, a cigarette insertion detection sensor, etc.).

[0082] In addition, the aerosol-generating device can be manufactured to have a structure in which external air can flow in or internal gas can flow out even when the cigarette 7 is inserted into the aerosol-generating device.

[0083] As another example, the heater 40c can be an induction heating type heater. Specifically, the heater 40c can include an electrically conductive coil for heating a cigarette by an induction heating method, and the cigarette can include a susceptor that can be heated by the induction heating type heater.

[0084] Although not shown in Figure 14 , the aerosol generating device can be included in a system together with a separate cradle. For example, the cradle can be used to charge the battery 70b of the aerosol generating device. Also, the heater 40c can be heated in a state in which the cradle and the aerosol generating device are coupled to each other.

[0085] The cigarette 7 can be similar to a general combustion type cigarette. For example, the cigarette 7 can be divided into a first portion including an aerosol generating material and a second portion including a filter or the like. Alternatively, the aerosol generating material can be included in the second portion of the cigarette 7. For example, the aerosol generating material made in the form of a granule or a capsule can be inserted into the second portion.

[0086] The first portion can be completely inserted into the aerosol generating device, and the second portion can be exposed to the outside. Alternatively, the first portion can be partially inserted into the aerosol generating device, or a portion of the second portion and the first portion can be inserted into the aerosol generating device. The user can inhale an aerosol while holding the second portion with the user's mouth. In this case, the aerosol is generated by passing external air through the first portion, and the generated aerosol is delivered to the user's mouth through the second portion.

[0087] As an example, external air can be introduced through at least one air passage formed in the aerosol generating device. For example, the opening and closing of the air passage formed in the aerosol generating device and / or the size of the air passage can be adjusted by the user. Accordingly, the amount of smoking and the smoking experience can be adjusted by the user. As another example, external air can be introduced into the cigarette 7 through at least one hole formed on the surface of the cigarette 7.

[0088] Figure 15 is an enlarged cross-sectional view showing a portion including a heater module of an aerosol generating device according to another embodiment.

[0089] The aerosol generating device according to the embodiment shown in Figure 15 is the same as the aerosol generating device according to Figure 14The aerosol-generating device of the embodiment shown in FIG. 1 is substantially similar to the aerosol-generating device of the embodiment shown in FIG. 2, but further includes a cigarette receiving tube 9 having a hollow shape and a diameter corresponding to the outer diameter of the cigarette 7 inside the heat transfer tube 10. The cigarette receiving tube 9 can include a metal material capable of well transferring heat, and the cigarette receiving tube 9 can perform a function of stably supporting the cigarette 7 when transferring heat transferred from the heat transfer tube 10 to the cigarette 7.

[0090] The wire 40g for supplying electricity to the heater 40c does not pass through the seal stopper 50. Rather, the wire 40g is electrically connected to an upper electrode 50p formed on the upper side of the seal stopper 50. The wire 40g can be electrically connected to the upper electrode 50p by a soldering method, or the wire 40g can be electrically connected to the upper electrode 50p by using a separate connector.

[0091] The upper electrode 50p of the seal stopper 50 is electrically connected to a lower electrode 50r of the seal stopper 50. The upper electrode 50p and the lower electrode 50r of the seal stopper 50 can be electrically connected to each other by a circuit pattern formed inside the seal stopper 50. When the heater module 5 is installed in the aerosol-generating device, the lower electrode 50r of the seal stopper 50 is electrically connected to a connection pad 70r of the controller 70.

[0092] The connection pad 70r is a connection terminal for transmitting an electrical signal of the controller 70 to the heater 40c. The connection pad 70r can be formed, for example, by a pogo pin elastically supported by an elastic unit such as a spring or by a circuit pattern directly formed on a circuit board and exposed to the outside of the controller 70.

[0093] According to the coupling structure of the heater 40c and the seal stopper 50 as described above, the wire 40g for supplying electricity to the heater 40c can be stably connected to the controller 70 without passing through the seal stopper 50. Accordingly, a sealing operation to be performed on the seal stopper 50 in relation to an electrical connection portion between the heater 40c and the controller 70 can be omitted.

[0094] When power is supplied to the heater module 5 located in the aerosol-generating device according to the above-described embodiment, the heater 40c generates heat to heat the cigarette 7. Referring to Figure 15 The heat generated by the heater 40c is radiated from an outer surface and an inner surface of the heater 40c. The inner surface of the heater 40c is a surface facing the cigarette 7, and the outer surface of the heater 40c is an opposite surface.

[0095] The heat radiated from the inner surface of the heater 40c is transferred to the cigarette 7 through the heat transfer tube 10 and the cigarette receiving tube 9, and thus, an aerosol-generating action in the cigarette 7 is smoothly performed.

[0096] The heat radiated from the outer surface of the heater 40c is radiated to the space 20v between the heat transfer pipe 10 and the cover 20. When air having a pressure level similar to atmospheric pressure exists in the space 20v between the heat transfer pipe 10 and the cover 20, the heat can be directly conducted to the cover 20 through the air, or the heat can be transferred to the cover 20 through the convection action of the air, and thus heat loss in which the heat of the heater 40c is radiated to the outside of the cover 20 can occur. Such heat loss can decrease the heating performance of the heater 40c that heats the cigarette 7, and can also cause danger and discomfort to the user due to the transfer of heat to the user's body in contact with the case 8.

[0097] In the aerosol-generating device according to the above-described embodiment, since the space 20v between the heat transfer pipe 10 and the cover 20 is maintained in a vacuum state, which means a state having a lower pressure than atmospheric pressure as previously described, a heat transfer action in which the heat is directly conducted to the cover 20 through the air in the space 20v between the heat transfer pipe 10 and the cover 20 or the heat is transferred to the cover 20 through the convection action of the air can be reduced.

[0098] Further, the heat radiated from the heater 40c toward the cover 20 is reflected by the heat reflector 30 located inside the cover 20, and the reflected heat is transferred back to the heat transfer pipe 10 and the cigarette 7. Accordingly, the effect of the heating action that heats the cigarette 7 can be improved, thereby improving the flavor of the aerosol generated by the cigarette 7, and the amount of the generated aerosol is increased while heat loss is reduced.

[0099] Figure 16 FIG. 1 is a perspective view showing some components of a heater module according to an embodiment, and Figure 17 FIG. 2 is a perspective view showing some components of a heater module according to an embodiment, Figure 16 FIG. 3 is a cross-sectional view showing a coupling relationship between some components of a heater module according to the embodiment shown in FIG. 2.

[0100] In the heater module according to the embodiments shown in Figure 16 and Figure 17 In the heater module according to the embodiments shown in

[0101] The cover 20 coupled to the heat transfer pipe 10 by the insert molding process has a side wall 22 connected to one end 21 that is integrally coupled to the coupling through-hole 11h of the flange 11p of the heat transfer pipe 10 and spaced apart from the outer surface of the heat transfer pipe 10 to surround the outer surface of the heat transfer pipe 10, and the one end 21 that is integrally coupled to the coupling through-hole 11h of the flange 11p of the heat transfer pipe 10. Figure 17As shown in FIG. 1, in the operation of molding the cover 20 by the insert molding process, molten resin for molding the cover 20 can flow into the coupling through-hole 11h of the flange 11p of the heat transfer pipe 10, and thus the coupling between the cover 20 and the heat transfer pipe 10 can be more robust.

[0102] Figure 18 FIG. 6 is a cross-sectional view showing a coupling relationship between some components of a heater module according to another embodiment.

[0103] In the heater module according to the embodiment shown in FIG. 1, the heat transfer pipe 10 includes a flange 11p radially protruding from one end of the heat transfer pipe 10, and a coupling protrusion 11j and a coupling groove 11i formed in the flange 11p. Figure 18

[0104] Thus, in the operation of molding the cover 20 by the insert molding process, molten resin for molding the cover 20 can flow around the coupling protrusion 11j of the flange 11p of the heat transfer pipe 10 and into the coupling groove 11i, and thus the coupling between the cover 20 and the heat transfer pipe 10 can be more robust.

[0105] Figure 19 FIG. 7 shows a method of manufacturing a heater module according to an embodiment.

[0106] According to the method of manufacturing a heater module according to the embodiment shown in FIG. 1, the operation of arranging the heater on the outer surface of the heat transfer pipe can correspond to the operation S120 of arranging the heater on the outer surface of the heat transfer pipe. Figure 19 Figure 1 The operation of arranging the heater 140 on the outer surface of the heat transfer pipe 10 includes an operation of manufacturing a film heater including a cylindrical film 140f corresponding to the outer shape of the heat transfer pipe 10 and a conductive wire 140p arranged on the cylindrical film 140f to generate heat when electricity is applied from the outside, and an operation of arranging the film heater so as to surround the outer surface of the heat transfer pipe 10.

[0107] The operation of manufacturing the film heater can include an operation of manufacturing a flexible printed circuit substrate by printing a circuit pattern such as a copper pattern on a flexible substrate made of a flexible material such as polyimide, or laminating the flexible substrate and the circuit layer by using a process such as lamination.

[0108] The operation of arranging the film heater so as to surround the outer surface of the heat transfer pipe 10 can be performed by winding a rectangular plate-shaped flexible substrate into a cylindrical shape corresponding to the shape of the outer surface of the heat transfer pipe 10, and then inserting the heat transfer pipe 10 into the film heater having the cylindrical shape.

[0109] The operation of arranging the film heater so as to surround the outer surface of the heat transfer pipe 10 can be performed by winding a rectangular plate-shaped flexible substrate into a cylindrical shape corresponding to the shape of the outer surface of the heat transfer pipe 10, and then inserting the heat transfer pipe 10 into the film heater having the cylindrical shape. ​​

[0110] Alternatively, by modifying the method, in the operation of arranging the film heater on the outer surface of the heat transfer pipe 10, a rectangular plate-shaped flexible circuit substrate can be prepared, and then the flexible circuit substrate can be directly wound on the outer surface of the heat transfer pipe 10, so that the final shape of the film heater fixed to the outer surface of the heat transfer pipe 10 can be a cylindrical shape.

[0111] As described above, the heater 140 arranged on the outer surface of the heat transfer pipe 10 finally has a cylindrical shape, but the cross section of the heater 140 does not have to be a completely closed circle, but can have an arc shape in which a part of the cross section of the heater 140 is open.

[0112] The heater 140 includes a lead 140c for receiving electricity from the outside. The sealing stopper 50 includes a through hole 50f through which the lead 140c of the heater 140 can pass.

[0113] Those of ordinary skill in the art related to the embodiments of the present application can understand that various changes in form and details can be made in the embodiments without departing from the scope of the features described above. The disclosed method should be considered as merely illustrative in nature and not for the purpose of limitation. The scope of the present disclosure is defined by the appended claims rather than by the foregoing description, and all differences within the scope of equivalents of the present disclosure should be construed as included in the present disclosure.

[0114] Industrial applicability

[0115] The embodiments relate to a heater module having improved heating performance and safety, a method of manufacturing the same, and an aerosol-generating device including the same.

Claims

1. A method of manufacturing a heater module for an aerosol-generating device, wherein, The method includes: preparing a heat transfer pipe having a hollow shape and including a heat conductive material; forming an assembly of the heat transfer pipe and a cover by insert molding such that one end portion of the cover is integrally coupled to an end portion of the heat transfer pipe while a side wall of the cover is spaced apart from the heat transfer pipe and surrounds the heat transfer pipe, in the insert molding, the heat transfer pipe is placed in a mold and resin is injected into the mold; arranging a heater on an outer surface of the heat transfer pipe; and sealing a space between the heat transfer pipe and the cover with a sealing stopper such that an internal pressure of the space is lower than an atmospheric pressure.

2. The method of claim 1, wherein, The sealing of the space with the sealing stopper includes: placing the assembly of the heat transfer pipe and the cover in a high-temperature environment; and coupling the sealing stopper to another end portion of the cover.

3. The method of claim 1, wherein, The sealing of the space with the sealing stopper includes: coupling the sealing stopper to another end portion of the cover; extracting air from the space between the heat transfer pipe and the cover through an air outlet formed in the sealing stopper; and sealing the air outlet.

4. The method of claim 1, further comprising: forming a heat reflector inside the cover between the molding of the assembly of the heat transfer pipe and the cover and the arrangement of the heater.

5. The method of claim 4, wherein, The formation of the heat reflector includes: preparing a heat reflector pipe including a heat reflective material; and inserting the heat reflector pipe into the cover.

6. The method of claim 4, wherein, The formation of the heat reflector includes coating a heat reflective material on an inside of the cover.

7. The method of claim 1, wherein, The arrangement of the heater includes: preparing a coil heater in which a heating wire is wound to form a cylindrical shape corresponding to a shape of the heat transfer pipe; and arranging the coil heater on the outer surface of the heat transfer pipe.

8. The method of claim 1, wherein, The arrangement of the heater includes: manufacturing a film heater including a cylindrical film corresponding to the shape of the heat transfer pipe and a conductive wire arranged on the cylindrical film and configured to generate heat when electricity is applied; and arranging the film heater on the outer surface of the heat transfer pipe.

9. The method of claim 1, wherein, The heat transfer pipe includes a flange protruding radially from the end portion of the heat transfer pipe, and at least one of a groove, a protrusion, and a through-hole is formed in the flange such that the cover is integrally coupled to the at least one of the groove, the protrusion, and the through-hole. 10.A heater module for an aerosol-generating device, wherein, The heat transfer pipe includes a flange protruding radially from the end portion of the heat transfer pipe, and at least one of a groove, a protrusion, and a through-hole is formed in the flange such that the cover is integrally coupled to the at least one of the groove, the protrusion, and the through-hole. The heater module includes: a heat transfer pipe having a hollow shape and including a heat conductive material; a cover having a side wall and one end portion integrally molded to an end portion of the heat transfer pipe by an insert molding process, the side wall being spaced apart from the heat transfer pipe and surrounding the heat transfer pipe; a heater arranged on an outer surface of the heat transfer pipe and configured to generate heat; and a sealing stopper sealing a space between the heat transfer pipe and the cover such that an internal pressure of the space is lower than an atmospheric pressure, The cover is formed of resin as a single piece such that the one end portion of the cover and a sidewall of the cover are connected. 11.The heater module of claim 10, further comprising: a heat reflector disposed inside the cover and configured to reflect heat generated by the heater.

12. The heater module of claim 10, wherein, The heater is wound to form a cylindrical shape corresponding to a shape of the heat transfer pipe.

13. The heater module of claim 10, wherein, The heater includes a cylindrical film corresponding to a shape of the heat transfer pipe and a conductive wire disposed on the cylindrical film and configured to generate heat when electricity is applied.

14. The heater module of claim 10, wherein, The heat transfer pipe includes at least one of a groove, a protrusion, and a through-hole formed in a flange radially protruding from the end portion of the heat transfer pipe such that the cover is integrally molded to the at least one of the groove, the protrusion, and the through-hole.

15. An aerosol-generating device comprising, The aerosol generating device includes: a heater module according to one of claims 10 to 14; and a controller electrically connected to the heater module and configured to control an operation of the heater module.

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