Induction heating type aerosol generating device having multi-conductor induction coil

Abstract

The present invention relates to an aerosol-generating device (10) for generating aerosol by inductively heating an aerosol-forming substrate (97). The device (10) comprises a device housing (19) comprising a cavity (20). The cavity is configured to removably receive at least a portion of an aerosol-forming substrate (97) to be heated. The aerosol-generating device (10) further comprises an inductive heating device comprising an induction coil (31) for generating an alternating magnetic field within the cavity (20). The induction coil (31) is formed by a plurality of turns of a composite cable (32) arranged around at least a portion of the cavity (20). The composite cable (32) comprises an electrical conductor (33) at least partially embedded in an insulating conductor package (34). The conductor (33) comprises a plurality of uninsulated wires (35) in electrical contact with each other.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an inductively heated aerosol-generating device for use with a substrate capable of forming an inhalable aerosol upon heating. The invention also relates to an aerosol-generating system comprising such a device and an aerosol-generating article, wherein the article comprises an aerosol-forming substrate to be heated. BACKGROUND

[0002] Aerosol-generating devices for generating an inhalable aerosol by inductively heating an aerosol-forming substrate are generally known from the prior art. Typically, such devices comprise a cavity for removably receiving a substrate and an inductive heating device for generating an alternating magnetic field within the cavity. Within the cavity, the field is used to induce at least one of a heat-generating eddy current or a magnetic hysteresis loss in a susceptor which in turn is arranged in thermal proximity or direct physical contact with the substrate to be heated. Both the aerosol-forming substrate and the susceptor can be an integral part of an aerosol-generating article receivable in the cavity. Alternatively, only the substrate can be comprised in the article, while the susceptor can be part of the device.

[0003] For generating an alternating magnetic field within the cavity, the inductive heating device typically comprises an induction coil formed by a plurality of turns of an electrical conductor arranged around at least a portion of the cavity. Typically, the volume of the cavity corresponds approximately to the volume of a single user experience of a substrate and thus is only in the order of a few cubic centimetres. This applies in particular to handheld aerosol-generating devices. Therefore, the radius of the induction coil is typically small. This can result in a rather complex or even error-prone manufacturing of the coil, thus potentially leading to faulty or malfunctioning devices. In addition to this, it is often desirable to have a special cross-sectional profile of the electrical conductor, for example to make optimal use of the limited installation space in such devices. However, electrical conductors with a special cross-section, for example a rectangular cross-section, are typically more expensive than electrical conductors with a standard cross-section. This can result in a higher manufacturing cost of such devices. SUMMARY

[0004] Therefore, there is a need for inductively heated aerosol-generating devices and aerosol-generating systems having the advantages of prior art solutions while mitigating their limitations. In particular, it is desirable to have inductively heated aerosol-generating devices and systems comprising an induction coil which can be manufactured in a simple, customized and cost-effective manner, in particular with a low failure rate.

[0005] According to the present invention, there is provided an aerosol-generating device for generating an aerosol by inductively heating an aerosol-forming substrate. The device comprises a device housing comprising a cavity. The cavity is configured for removably receiving at least a portion of an aerosol-forming substrate to be heated. The aerosol-generating device further comprises an inductive heating device comprising an induction coil for generating an alternating magnetic field within the cavity. The induction coil is formed by a plurality of turns of a composite cable arranged around at least a portion of the cavity. The composite cable comprises an electrical conductor at least partially embedded in an insulation conductor package. The electrical conductor comprises a plurality of non-insulated wires in electrical contact with each other.

[0006] According to the present invention, it has been recognized that the limitations of induction coils formed from electrical conductors comprising a single solid wire are mainly due to the rigid properties of the solid wire. In particular, when it comes to small winding radii, the winding of electrical conductors comprising a single solid wire can result in high mechanical stresses in the wire material, which in turn can lead to material fatigue or even material breakage, thus resulting in a malfunctioning or even a dysfunctional coil. In contrast, a conductor comprising a plurality of non-insulated wires in electrical contact with each other is more flexible than a conductor comprising a solid wire of the same total cross-sectional area. Thus, the winding of an electrical conductor comprising a plurality of non-insulated wires is easier and less prone to material fatigue or even material breakage. Furthermore, the plurality of non-insulated wires can be arranged within the composite in various configurations in order to achieve different cross-sectional shapes of the conductor. Advantageously, this allows for manufacturing induction cables comprising electrical conductors with customized cross-sectional shapes in a cost-effective manner.

[0007] The plurality of non-insulated wires are in electrical contact with each other in order to act as a single conductor, in particular in order to have essentially the same electrical properties, in particular essentially the same electrical resistance, as a single conductor of the same total cross-sectional area.

[0008] The plurality of non-insulated wires in electrical contact with each other can also be denoted as a strand. A strand is composed of a number of wires that are bundled or twisted together to form a composite conductor. Thus, the electrical conductor according to the present invention can also be denoted as a composite (electrical) conductor comprising a plurality of non-insulated wires in electrical contact with each other or comprising a strand, respectively.

[0009] Generally, the plurality of non-insulated wires can be arranged in different configurations: The wires can be bundled together or twisted together or braided together or twisted together. Likewise, the wires can extend parallel to each other, in particular without crossing each other and without being braided or twisted together, along the length of the composite cable. In a parallel arrangement, the contact between adjacent wires is along the wires and not only at a few points. Advantageously, this results in a larger contact area, increasing the electrical contact between the wires compared to a contact at only a few points. In addition, the linear contact area also reduces the mechanical stress between the wires and, thus, improves the flexibility and the bending strength of the electrical conductor.

[0010] Preferably, the conductive wires can extend parallel to each other in a single layer or in multiple layers arranged one above the other, in particular two, three or four layers arranged one above the other, along the length of the composite cable, wherein the layers are arranged parallel to each other. That is, the conductive wires can be arranged parallel to each other next to each other in a single row or plane. Alternatively, the conductive wires can be arranged parallel to each other next to each other in multiple rows arranged one above the other, in particular two, three or four rows arranged one above the other.

[0011] In the multiple layer configuration, it is preferred that at least a portion of the conductive wires of each layer (row) are arranged in grooves formed between adjacent conductive wires of adjacent layers (rows). This interleaved arrangement is very compact, thus allowing for a compact design of the electrical conductor.

[0012] Each layer of the single layer or the multiple layers can be a flat layer. As used herein, the term flat layer refers to a configuration in which each layer of the single layer or the multiple layers is aligned along a straight line, as seen in a cross-sectional view of the composite cable extending transverse to the length of the cable, i.e. transverse to the winding direction of the cable around the cavity. In other words, the conductive wires of the single layer or the conductive wires of each layer of the multiple layers extend parallel to each other on the same plane. The flat configuration of the layers can be particularly advantageous for a helically wound composite cable so as to form a cylindrical inductive coil.

[0013] Likewise, each layer of the single layer or the multiple layers can be a curved layer. As used herein, the term curved layer refers to a configuration in which each layer of the single layer or the multiple layers is aligned along a curved line, as seen in a cross-sectional view of the composite cable extending transverse to the length of the cable, i.e. transverse to the winding direction of the cable around the cavity. In other words, the conductive wires of the single layer or the conductive wires of each layer of the multiple layers extend parallel to each other on the same curved plane. The curved configuration of the layers can be particularly advantageous for a composite cable wound around a body forming a cylindrical cavity, wherein the outer surface of the body is curved in a direction transverse to the winding direction.

[0014] Preferably, each layer of the single layer or the multiple layers is parallel to a circumferential plane defined by the multiple turns of the composite cable. In this configuration, the radial extension of the inductive coil is very compact.

[0015] In any of these layered configurations, the conductive wires do not cross each other, nor are they braided or intertwined together. In particular, the conductive wires are untwisted. Thus, mechanical stress between the conductive wires is even further reduced, resulting in an even better flexibility and bending strength of the electrical conductor.

[0016] Additionally, arranging the conductors in a layered configuration is particularly suitable for achieving different cross-sectional shapes of the electrical conductor. For example, the conductor can comprise twenty conductors extending parallel to each other along the length of the composite cable, with two flat layers arranged one above the other, wherein each layer comprises ten conductors arranged next to each other. In this configuration, the combination of all conductors can form an electrical conductor with a substantially rectangular cross-section, with each conductor of one layer arranged on top of a conductor of the adjacent layer. Likewise, with the layers shifted relative to each other, the combination of all conductors can form an electrical conductor with a substantially parallelogram cross-section, with the conductors of one layer arranged in recesses formed between adjacent conductors of the adjacent layer.

[0017] Each of the plurality of conductors can have one of a circular outer cross-section or an elliptical outer cross-section or an oval outer cross-section or a rectangular outer cross-section or a square outer cross-section. Conductors with a circular outer cross-section can be preferred for economic reasons due to their good availability as standard conductors.

[0018] The diameter of each of the plurality of conductors can be in the range between 0.2 mm and 2.3 mm, in particular between 0.25 mm and 1.2 mm, or between 0.15 mm and 1.5 mm, in particular in the range between 0.25 mm and 0.75 mm.

[0019] Likewise, the cross-sectional area of each of the plurality of conductors can be in the range between 0.1 mm2and 17 mm2, in particular between 0.2 mm2and 4.5 mm2, or between 0.07 mm2and 7 mm2, in particular in the range between 0.2 mm2and 1.8 mm2.

[0020] Advantageously, the conductors of the electrical conductor are embedded in the material of the insulating conductor package by extrusion or lamination.

[0021] Generally, the composite cable can have any outer cross-section as can be seen in a cross-sectional view of the composite cable extending transversely to the length of the cable or transversely to the winding direction of the cable around the cavity, respectively. For example, the composite cable can have a substantially circular outer cross-section or a substantially rectangular outer cross-section or a substantially square outer cross-section or a substantially elliptical outer cross-section or a substantially oval outer cross-section or a substantially parallelogram outer cross-section or a substantially trapezoidal outer cross-section or a substantially arcuate outer cross-section. In particular, the composite cable can have a non-circular outer cross-section, for example a substantially rectangular outer cross-section or a substantially square outer cross-section or a substantially elliptical outer cross-section or a substantially oval outer cross-section or a substantially parallelogram outer cross-section or a substantially trapezoidal outer cross-section or a substantially arcuate outer cross-section. A substantially arcuate cross-section has the shape of an arc or an arc segment.

[0022] Preferably, the composite cable is a flat composite cable. That is, the outer cross-section of the composite cable has a width dimension and a thickness dimension, wherein the thickness dimension is smaller than the width extension. Advantageously, the flat composite cable allows for a compact design of the induction coil. In this configuration, the composite cable has a non-circular or non-square outer cross-section. That is, the outer cross-section of the composite cable is neither circular nor square. For example, the outer cross-section of the composite cable is substantially rectangular, substantially elliptical, substantially oval, substantially parallelogram-shaped, substantially trapezoidal or substantially arc-shaped. In this configuration layer, the composite cable can also be denoted as a multi-conductor flat cable or a ribbon cable.

[0023] The composite cable can comprise a first side facing inwardly towards the cavity when arranged around the cavity and a second side facing outwardly away from the cavity opposite the first side. For example, in case of a rectangular outer cross-section, the first side corresponds to the side of the rectangular outer cross-section facing inwardly towards the cavity. Likewise, the second side corresponds to the side of the rectangular outer cross-section opposite the first side, i.e. the side of the rectangular outer cross-section facing outwardly away from the cavity. In case of an elliptical outer cross-section, the first side corresponds to the half side of the elliptical outer cross-section facing inwardly towards the cavity.

[0024] The outer cross-section of the composite cable, in particular the non-circular outer cross-section, can have a first axis of symmetry, in particular a first axis of symmetry extending in a radial direction with respect to the plurality of turns of the composite cable. In particular, the first axis of symmetry can extend between the first side and the second side of the composite cable. Alternatively or in addition, the outer cross-section of the composite cable, in particular the non-circular outer cross-section, can have a second axis of symmetry transverse, in particular perpendicular, to the first axis of symmetry. That is, the non-circular outer cross-section of the composite cable can have a second axis of symmetry extending transverse, in particular perpendicular, to the radial direction with respect to the plurality of turns of the composite cable.

[0025] The maximum dimension of the cross-section of the composite cable in the radial direction with respect to the plurality of turns of the composite cable, in particular the maximum dimension of the composite cable along an axis orthogonal to the first side and the second side, in particular the maximum thickness dimension of the cross-section of the composite cable, can be in the range between 0.5 mm and 9 mm, in particular between 0.7 mm and 9 mm, preferably between 0.9 mm and 5 mm.

[0026] Likewise, the maximum dimension of the cross-section of the composite cable perpendicular to the radial direction with respect to the plurality of turns of the composite cable, in particular, the maximum dimension of the cross-section of the composite cable in a direction perpendicular to an axis orthogonal to the first and second sides or in a direction parallel to at least one of the first and second sides, in particular, the maximum width dimension of the cross-section of the composite cable, can be in the range between 1 millimeter and 7 millimeters, in particular, between 1.5 millimeters and 5 millimeters.

[0027] The circumferential curve of the electrical conductor or of the enclosed electrical conductor can have any cross-section as can be seen in a cross-sectional view of the composite cable, respectively, extending transversely to the length of the electrical cable or transversely to the winding direction of the electrical cable around the cavity. For example, the electrical conductor can have a substantially circular cross-section. Likewise, the electrical conductor can have a non-circular cross-section, in particular, a substantially elliptical cross-section or a substantially oval cross-section or a substantially rectangular cross-section or a substantially square cross-section or a substantially parallelogrammatic cross-section or a substantially trapezoidal cross-section or a substantially arcuate cross-section. A substantially arcuate cross-section has the shape of an arc or an arc segment. As mentioned above, different cross-sectional shapes of the electrical conductor can be achieved by a corresponding arrangement of the plurality of non-insulated wires.

[0028] Preferably, the electrical conductor is a flat electrical conductor. That is, the cross-section of the electrical conductor has a width dimension and a thickness dimension, wherein the thickness dimension is smaller than the width extension. Advantageously, the flat electrical conductor allows for a compact design of the induction coil. In this configuration, the electrical conductor has a non-circular or non-square outer cross-section. That is, the cross-section of the electrical conductor is neither circular nor square. For example, the cross-section of the electrical conductor is substantially rectangular, substantially elliptical, substantially oval, substantially parallelogrammatic, substantially trapezoidal or substantially arcuate.

[0029] The maximum dimension of the cross-section of the electrical conductor in the radial direction with respect to the plurality of turns of the composite cable, in particular, the maximum thickness dimension of the cross-section of the electrical conductor, in particular, the maximum thickness dimension of the cross-section of the electrical conductor perpendicular to the first side, can be in the range between 0.2 millimeters and 2.3 millimeters, in particular, between 0.25 millimeters and 1.2 millimeters.

[0030] Likewise, the maximum dimension of the cross-section of the electrical conductor perpendicular to the radial direction with respect to the plurality of turns of the composite cable, in particular, the maximum width dimension of the cross-section of the electrical conductor, in particular, the maximum width dimension of the cross-section of the electrical conductor parallel to the first side, can be in the range between 0.75 millimeters and 6 millimeters, in particular, between 1 millimeter and 4 millimeters.

[0031] The electrical conductor can be arranged asymmetrically with respect to the outer cross-section of the composite cable so as to be closer to a first side of the composite cable facing inwards towards the cavity than to a second side of the composite cable facing outwards away from the cavity. Thus, the insulating conductor package is located predominantly towards the second side of the composite cable and is therefore further outwards in a radial direction than the electrical conductor. In particular, the electrical conductor can be arranged asymmetrically with respect to a second axis of symmetry of the outer cross-section of the composite cable. As mentioned above, the second axis of symmetry can extend transversely, in particular perpendicularly, to the radial direction with respect to the plurality of turns of the composite cable. More specifically, the electrical conductor can be arranged between the first side and the second axis of symmetry. As a result of this, the insulating conductor package can act as a protective sheath around the electrical conductor when the composite cable is arranged around the cavity. In addition, the asymmetric arrangement reduces the radial distance between the electrical conductor and the cavity, which is advantageous for the field strength of the alternating magnetic field.

[0032] Additionally or alternatively, the electrical conductor can be arranged asymmetrically with respect to a first axis of symmetry of the outer cross-section of the composite cable. As mentioned above, the first axis of symmetry can extend in the radial direction with respect to the plurality of turns of the composite cable, in particular between the first side and the second side of the composite cable.

[0033] Advantageously, the electrical conductor is arranged as close to the cavity as possible. Thus, the minimum distance between the electrical conductor and the first side can be at most between 0.1 mm and 0.5 mm, in particular in the range of 0.1 mm and 0.3 mm, or between 0.1 mm and 1 mm, in particular in the range of 0.2 mm and 0.5 mm.

[0034] According to the present application, the conductor package is electrically insulating so as to electrically insulate adjacent turns of the induction coil from each other and thus prevent short circuits.

[0035] The insulating conductor package can comprise a magnetic flux concentrator material. Thereby, the insulating conductor package can also act as a magnetic flux concentrator. As used herein, the term “magnetic flux concentrator material” refers to a material capable of twisting a magnetic field and thus capable of concentrating and guiding the magnetic field or magnetic field lines generated by the induction coil. By twisting the magnetic field towards the cavity, the magnetic flux concentrator material of the insulating conductor package can advantageously concentrate or focus the magnetic field within the cavity. This can increase the level of heat generated in the susceptor for a given power level through the induction coil compared to an induction coil without a flux concentrator. Thus, the efficiency of the aerosol-generating device can be improved. Also, by twisting the magnetic field towards the cavity, the magnetic flux concentrator material of the insulating conductor package reduces the extent to which the magnetic field propagates outside of the induction coil. That is, the flux concentrator material of the insulating conductor package acts as a magnetic shield. Advantageously, this can reduce undesirable interference of the magnetic field with other sensitive components of the aerosol-generating device, for example having a metallic outer housing, or with sensitive external items in close proximity to the device.

[0036] In particular, the magnetic flux concentrator material with integrated composite cable allows both the induction coil and the appropriate magnetic flux concentrator to be provided in one part and thus in one step. Advantageously, this reduces the effort required to manufacture the aerosol-generating device in terms of costs and time.

[0037] Furthermore, the magnetic flux concentrator as an integral part of the coil winding provides good damping characteristics. Thus, it can withstand higher over-force impacts or vibrations without breaking, compared to other flux concentrator configurations, such as ferrous solid configurations. For example, compared to a susceptor made of sintered iron oxide powder, the magnetic flux concentrator as an integral part of the coil winding provides substantially improved resistance to vibration loading, e.g. resulting from an accidental drop. In addition, the magnetic flux concentrator as an integral part of the coil winding allows for a more compact design of the aerosol-generating device.

[0038] In particular, the term "magnetic flux concentrator material" refers to a material having a high relative magnetic permeability. As used herein, the term "high relative magnetic permeability" refers to a relative magnetic permeability of at least 1000, preferably at least 10000. These example values refer to the maximum value of the relative magnetic permeability for a frequency of up to 50 kHz and a temperature of 25 degrees Celsius. Thus, the magnetic flux concentrator material can comprise one or more materials having a relative magnetic permeability of at least 1000, preferably at least 10000, for a frequency of up to 50 kHz and a temperature of 25 degrees Celsius. As used herein and within the art, the term "relative magnetic permeability" refers to the ratio of the magnetic permeability of a material or medium, such as a flux concentrator, to the magnetic permeability of free space, μ_0, where μ_0 is 4π·10-7N·A-2 (4·Pi·10E-07 Newton per square Ampere).

[0039] Generally, the insulated conductor package can comprise or can be made of any material or combination of materials suitable to provide the properties of the flux concentrator. In particular, the insulated conductor package can comprise a flux concentrator material held in a matrix. The matrix can comprise a binder, such as a polymer, e.g. a silicone. Thus, the matrix can be a polymer matrix, e.g. a silicone matrix.

[0040] The insulated conductor package, in particular the flux concentrator material, comprises a ferrimagnetic or ferromagnetic material, such as a ferrite material (e.g. ferrite particles, ferrite powder held in a matrix), or any other suitable material comprising a ferromagnetic material (e.g. iron, ferromagnetic iron, ferrosilicon or ferromagnetic stainless steel). Likewise, the insulated conductor package, in particular the flux concentrator material, can comprise a ferrimagnetic or ferromagnetic material, such as ferrimagnetic or ferromagnetic particles or ferrimagnetic or ferromagnetic powder held in a matrix.

[0041] The ferromagnetic material can include at least one metal selected from iron, nickel, and cobalt, and combinations thereof, and can contain other elements such as chromium, copper, molybdenum, manganese, aluminum, titanium, vanadium, tungsten, tantalum, silicon. The ferromagnetic material can include about 78 wt% to about 82 wt% nickel, 0 wt% to 7 wt% molybdenum, with the remainder being iron.

[0042] For example, the insulated conductor package, in particular the flux concentrator material, can include a laminate, a pure ferrite, or a proprietary composition based on iron or ferrite. More specifically, the insulated conductor package, in particular the flux concentrator material, can include a laminate, a pure ferrite, or a proprietary composition based on iron or ferrite available under one of the trade names Fluxtrol 100, Fluxtrol A, Fluxtrol 50, Ferrotron 559H from Fluxtrol, Alphaform LF and Alphaform MF from Fluxtrol Inc. (located at 1388 Atlantic Blvd. Auburn Hills, MI 48326, USA).

[0043] The materials Fluxtrol 100, Fluxtrol A, Fluxtrol 50 include electrically insulated iron particles and an organic binder. They are suitable for different frequency ranges. While Fluxtrol 100 and Fluxtrol A are particularly suitable for frequencies up to 50 kilohertz, Fluxtrol 50 is suitable for frequencies between 10 kilohertz and 1000 kilohertz. All three materials are characterized by good mechanical strength, processability, and thermal conductivity.

[0044] Ferrotron 559H includes electrically insulated iron particles and an organic binder, but includes a larger volume of binder than the aforementioned Fluxtrol materials. Ferrotron 559H is suitable for medium-high frequencies between 10 kilohertz and 3000 kilohertz.

[0045] Alphaform LF and Alphaform MF are formable soft magnetic composites based on magnetic particles with a thermosetting epoxy resin binder. Alphaform LF is suitable for frequencies between 1 kilohertz and 80 kilohertz, while Alphaform MF is suitable for frequencies between 10 kilohertz and 1000 kilohertz.

[0046] Alternatively or additionally, the insulation conductor package, in particular the flux concentrator material, can comprise at least one of a magnetically permeable metal or a permalloy. A magnetically permeable metal is a nickel-iron soft ferromagnetic alloy with very high magnetic permeability, in particular about 80000 to 100000. For example, the magnetically permeable metal can comprise approximately 77% by weight of nickel, 16% by weight of iron, 5% by weight of copper and 2% by weight of chromium or molybdenum. Likewise, the magnetically permeable metal can comprise 80% by weight of nickel, 5% by weight of molybdenum, small amounts of various other elements, such as silicon, and the remaining 12 to 15% by weight of iron. A permalloy is a nickel-iron magnetic alloy, which usually contains additional elements, such as molybdenum, copper and / or chromium.

[0047] In order to increase the magnetic flux between the insulation conductor packages of adjacent turns of the induction coil, the plurality of turns is preferably in physical contact with each other, i.e. the plurality of turns is preferably contiguous with each other. In particular, the plurality of turns can preferably be in physical contact with each other such that at least the insulation conductor packages of adjacent turns are in contact with each other, i.e. contiguous with each other. However, there can also be small gaps between adjacent turns of the induction coil. The gaps can be at most 0.75 millimetres, in particular at most 0.5 millimetres, preferably at most 0.25 millimetres.

[0048] Although the conductor package can comprise a metallic material and thus an electrically conductive material, the conductor package as a whole is still electrically insulating, i.e. non-conductive, in order to prevent a short circuit between adjacent turns of the induction coil.

[0049] According to a particular aspect of the present application, the composite cable can be a multi-layer composite cable comprising an electrically insulating conductor package layer forming the insulation conductor package and further comprising at least one of a support layer, a flux concentrator layer or a shielding layer. The layered configuration of the composite cable allows to combine several functions in one cable and in particular to achieve these functions in one step. Advantageously, this reduces the effort required for manufacturing the aerosol-generating device in terms of costs and time.

[0050] The support layer is mainly used to increase the mechanical resistance of the composite cable. Preferably, the support layer does not affect the inductive performance of the magnetic field generated by the electric current through the electric conductor. That is, the support layer is preferably electromagnetically inert. Accordingly, the support layer preferably comprises an electromagnetically inert material, in particular at least one of polyether ether ketone or polyaryletherketone.

[0051] The layer thickness of the support layer can be in the range between 0.1 millimetres and 1 millimetres, in particular between 0.2 millimetres and 0.5 millimetres, or between 0.25 millimetres and 1 millimetres, in particular in the range between 0.25 millimetres and 0.5 millimetres. On the one hand, these thicknesses are large enough to ensure sufficient mechanical resistance. On the other hand, these thicknesses are still small enough to keep the radial extension of the coil winding as small as possible in order to best utilize the limited installation space in such devices.

[0052] The support layer is preferably arranged on a side of the insulating conductor package layer that faces inward towards the cavity when the composite cable is arranged around the cavity.

[0053] The electrical conductor can be partially embedded in the support layer. That is, the support layer can cover at least a portion of the electrical conductor. In particular, the support layer can cover at least a side of the electrical conductor that faces inward towards the cavity when the composite cable is arranged around the cavity.

[0054] Even more preferably, the support layer is an edge layer, in particular an edge layer forming a first side of the composite cable.

[0055] The flux concentrator layer is configured to act as a magnetic flux concentrator, which is able to distort the magnetic field and thus concentrate and direct the magnetic field generated by the induction coil within the cavity, as described above with respect to the magnetic flux concentrator material optionally comprised in the insulating conductor package. In this regard, it can be preferred to provide the flux concentrator layer instead of a magnetic flux concentrator material comprised in the insulating conductor package. Advantageously, this can help to avoid problems that can arise when using an electrically conductive flux concentrator material, e.g. a metallic flux concentrator material, in a conductor package that should be electrically insulating as a whole in order to prevent short circuits between adjacent turns of the induction coil. However, the insulating conductor package layer can also comprise a flux concentrator material in addition to the flux concentrator layer.

[0056] In order to act as a magnetic flux concentrator, the flux concentrator layer can comprise a magnetic flux concentrator material, in particular any of the magnetic flux concentrator materials described above with respect to the insulating conductor package. Details of these materials have been described herein and equally apply to the flux concentrator layer.

[0057] The flux concentrator layer is preferably arranged on a side of the insulating conductor package layer that faces outward away from the cavity when the composite cable is arranged around the cavity.

[0058] The shielding layer can serve to reduce adverse effects of the magnetic field in regions outside the shielding layer, and vice versa, to reduce distortion of the magnetic field by electrically conductive or highly magnetically sensitive materials in close proximity to the device or in a housing of the device itself.

[0059] To this end, the shielding layer can comprise an electrically conductive material, e.g. a metal. In particular, the shielding layer can comprise at least one of aluminum, copper, tin, steel, gold, silver, an electrically conductive polymer, a ferrite, or any combination thereof. For example, the shielding layer can be a metallic coating applied on a side of the electrically insulating conductor package layer that faces outward away from the cavity when the composite cable is arranged around the cavity. The metallic coating can be applied in any suitable manner, e.g. as a metallic paint, a metallic ink, or by a vapor deposition process.

[0060] When the composite cable is arranged around the cavity, the shielding layer is preferably arranged on the side of the insulating conductor package layer facing outwards away from the cavity. Preferably, the shielding layer can be an edge layer, in particular an edge layer forming the second side of the composite cable.

[0061] If the multi-layer composite cable comprises both a flux concentrator layer and a shielding layer, the flux concentrator layer is preferably arranged on top of the electrically insulating conductor package layer (preferably on the side of the insulating conductor package layer facing outwards away from the cavity when the composite cable is arranged around the cavity), and the shielding layer is arranged on top of the flux concentrator layer, preferably for example becoming an edge layer, in particular an edge layer forming the second side of the composite cable.

[0062] To improve the shielding effect, the induction coil can additionally be surrounded by a tube, sleeve, tape or foil having electrical conductivity. Preferably, the surrounding tube, sleeve, tape or foil is in physical contact with the shielding layer of each turn of the induction coil.

[0063] The layer thickness of the shielding layer can be between 0.3 mm and 3 mm, in particular in the range of 0.3 mm and 2 mm, or between 0.25 mm and 5.5 mm, in particular in the range of 0.25 mm and 1.75 mm. These thicknesses are very suitable for keeping the radial extension of the coil winding as small as possible, but still allowing a sufficient shielding effect.

[0064] Likewise, the flux concentrator layer can have a layer between 0.3 mm and 3 mm, in particular in the range of 0.3 mm and 2 mm, or between 0.25 mm and 5.5 mm, in particular in the range of 0.25 mm and 1.75 mm.

[0065] The layer thickness of the insulating conductor package layer can be between 0.2 mm and 6 mm, in particular in the range of 0.4 mm and 2 mm, or between 0.15 mm and 3 mm, in particular in the range of 0.3 mm and 1 mm, or between 0.25 mm and 3 mm, in particular in the range of 0.3 mm and 1.5 mm, or between 0.5 mm and 7 mm, in particular in the range of 0.7 mm and 4 mm or between 0.7 mm and 3 mm, or between 0.4 mm and 9.2 mm, in particular in the range of 0.45 mm and 3.1 mm, or between 0.4 mm and 7.2 mm, in particular in the range of 0.45 mm and 2.6 mm, or between 0.45 mm and 3.7 mm, in particular in the range of 0.5 mm and 2.85 mm.

[0066] The thickness of the insulating conductor package layer portion in which the conductor is embedded on the side opposite the first side can be between 0.2 millimeters and 7 millimeters, in particular in the range of 0.2 millimeters and 2 millimeters, or between 0.25 millimeters and 1.5 millimeters, in particular in the range of 0.25 millimeters and 0.75 millimeters, or between 0.2 millimeters and 5 millimeters, in particular in the range of 0.2 millimeters and 1.5 millimeters. These thicknesses are particularly suitable to ensure a sufficient concentration of magnetic field flux in case the insulating conductor package comprises a flux concentrator material.

[0067] The conductor can be fully embedded in the insulating conductor package. Alternatively, the conductor can be partially embedded in the insulating conductor package, in particular in the insulating conductor package layer, and partially embedded in the support layer, so as to be completely surrounded by the insulating conductor package, in particular the insulating conductor package layer and the support layer.

[0068] The aerosol-generating device can further comprise at least one susceptor which is part of the device. Alternatively, the at least one susceptor can be an integral part of an aerosol-generating article comprising aerosol-forming substrate to be heated. As part of the device, the at least one susceptor is arranged or can be arranged at least partially within the cavity for thermal proximity or thermal contact, preferably physical contact, with the aerosol-forming substrate during use.

[0069] The susceptor can be formed of any material capable of being inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. Preferred susceptors comprise a metal or carbon. Preferred susceptors can comprise a ferromagnetic material, such as ferritic iron or ferromagnetic steel or stainless steel. Suitable susceptors can be aluminium or comprise aluminium. Preferred susceptors can be made of a 400 series stainless steel, such as a 410 grade or 420 grade or 430 grade stainless steel.

[0070] The susceptor can comprise various geometric configurations. The susceptor can comprise or can be a susceptor pin, a susceptor rod, a susceptor blade, a susceptor strip or a susceptor plate. In case the susceptor is part of the aerosol-generating device, the susceptor pin, the susceptor pin, the susceptor rod, the susceptor blade, the susceptor strip or the susceptor plate can protrude into the cavity of the device, preferably towards the opening of the cavity for insertion of an aerosol-generating article into the cavity.

[0071] The susceptor can comprise or can be a filament susceptor, a mesh susceptor, a core susceptor.

[0072] Likewise, the susceptor can comprise or can be a susceptor sleeve, a susceptor cup, a cylindrical susceptor or a tubular susceptor. Preferably, the interior void of the susceptor sleeve, the susceptor cup, the cylindrical susceptor or the tubular susceptor is configured to removably receive at least a portion of an aerosol-generating article.

[0073] The aforementioned receptors can have any cross-sectional shape, such as circular, elliptical, square, rectangular, triangular, or any other suitable shape.

[0074] In addition to the induction coil, the induction heating device may include an alternating current (AC) generator. This AC generator may be powered by the aerosol generating device. The AC generator is operatively coupled to at least one induction coil. Specifically, the at least one induction coil may be an integral part of the AC generator. The AC generator causes a high-frequency oscillating current to pass through the induction coil to generate an alternating electromagnetic field. The AC current may be continuously supplied to the induction coil after system activation, or it may be supplied intermittently, for example, on a per-port suction basis.

[0075] Preferably, the induction heating device includes a DC / AC converter connected to a DC power supply comprising an LC network, wherein the LC network comprises a capacitor and an induction coil connected in series.

[0076] The induction heating device is preferably configured to generate a high-frequency electromagnetic field. As mentioned herein, the high-frequency electromagnetic field can range from 500 kHz to 30 MHz, particularly from 5 MHz to 15 MHz, and preferably between 5 MHz and 10 MHz.

[0077] The aerosol generating apparatus may also include a controller configured to control the operation of the device. Specifically, the controller may be configured to control the operation of the induction heating device, preferably in a closed-loop configuration, for controlling the heating of the aerosol forming matrix to a predetermined operating temperature. The operating temperature for heating the aerosol forming matrix can be at least 180 degrees Celsius, particularly at least 300 degrees Celsius, preferably at least 350 degrees Celsius, more preferably at least 370 degrees Celsius, and most preferably at least 400 degrees Celsius. These temperatures are typical operating temperatures for heating but not burning the aerosol forming matrix. For example, the operating temperature is between 180 degrees Celsius and 370 degrees Celsius, particularly between 180 degrees Celsius and 240 degrees Celsius or in the range between 280 degrees Celsius and 370 degrees Celsius. Generally, the operating temperature may depend on at least one of the type of aerosol forming matrix to be heated, the construction of the sensor, and the arrangement of the sensor relative to the aerosol forming matrix when using the system. For example, when the sensor is constructed and arranged to surround the aerosol-forming matrix, for example, during system use, the operating temperature can be in the range of 180 degrees Celsius to 240 degrees Celsius. Similarly, when the sensor is constructed, for example, arranged within the aerosol-forming matrix during system use, the operating temperature can be in the range of 280 degrees Celsius to 370 degrees Celsius. The operating temperature described above preferably refers to the temperature of the sensor in use.

[0078] The controller may include a microprocessor, such as a programmable microprocessor, microcontroller, or application-specific integrated circuit (ASIC), or other electronic circuitry capable of providing control. The controller may include other electronic components, such as at least one DC / AC inverter and / or power amplifier, such as a Class C, Class D, or Class E power amplifier. In particular, the induction heating device may be part of the controller.

[0079] The aerosol generating device may include a power source, particularly a DC power source, configured to provide a DC power supply voltage and a DC power supply current to the induction heating device. Preferably, the power source is a battery, such as a lithium iron phosphate battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require charging; that is, the power source may be rechargeable. The power source may have a capacity that allows sufficient energy to be stored for one or more user experiences. For example, the power source may have sufficient capacity to allow continuous aerosol generation in time intervals of approximately six minutes or multiples of six minutes. In another example, the power source may have sufficient capacity to allow a predetermined number of suctions or intermittent activation of the induction heating device.

[0080] The aerosol generating apparatus may include a body, which preferably includes at least one induction heating device, particularly at least one induction coil, a controller, a power supply, and at least a portion of a cavity.

[0081] In addition to the main body, the aerosol generating device may also include a mouthpiece, particularly where the aerosol generating article to be used with the device does not include a mouthpiece. The mouthpiece can be mounted to the main body of the device. The mouthpiece can be configured to close a cavity when mounted to the main body. To attach the mouthpiece to the main body, the proximal portion of the main body may include a magnetic or mechanical mounting element, such as a bayonet mount or snap-fit ​​mount, which engages with a corresponding element at the distal portion of the mouthpiece. Where the device does not include a mouthpiece, the aerosol generating article to be used with the aerosol generating device may include a mouthpiece, such as a filter tip segment.

[0082] The aerosol generating device may include at least one air outlet, such as an air outlet in a mouthpiece (if present).

[0083] Preferably, the aerosol generating device includes an air path extending through the cavity from at least one air inlet, and possibly further extending to an air outlet in the mouthpiece, if present. Preferably, the aerosol generating device includes at least one air inlet in fluid communication with the cavity. Therefore, the aerosol generating system may include an air path extending from at least one air inlet into the cavity, and may further enter the user's mouth through the aerosol forming matrix within the article and the mouthpiece.

[0084] According to another aspect of the application, the device can comprise an induction module defining at least a portion of the cavity. The induction coil can be arranged at an inner surface of the induction module. Alternatively, the induction coil can be arranged at an outer surface of the induction module. In particular, the induction coil can be arranged in a recess, e.g. an annular recess, at the inner or outer surface of the induction module.

[0085] The induction module can be a sleeve-shaped induction module, in particular a cylindrical induction module, so as to define a cylindrical cavity. Preferably, the induction module is arranged, in particular removably arranged, within the device housing.

[0086] In this regard, the application also provides an induction module which is arrangeable within an aerosol-generating device so as to form or be arranged circumferentially around at least a portion of a cavity of the device, wherein the cavity is configured for removably receiving an aerosol-forming substrate to be inductively heated. The induction module comprises at least one induction coil for generating, in use, an alternating electromagnetic field within the cavity, wherein the at least one induction coil is arranged around at least a portion of the cavity when the induction module is arranged in the device. The induction coil is formed by a plurality of turns of a composite cable arranged around at least a portion of the cavity, wherein the composite cable comprises an electrical conductor at least partially embedded in an insulation conductor package, and wherein the conductor comprises a plurality of uninsulated wires in electrical contact with each other.

[0087] Further features and advantages of the induction module, in particular the induction coil and the composite cable, have been described with respect to the aerosol-generating device and will not be repeated.

[0088] According to the application, there is also provided an aerosol-generating system comprising an aerosol-generating device according to the application and as described herein. The system further comprises an aerosol-generating article for use with the device, wherein the article comprises an aerosol-forming substrate to be inductively heated by the device. The aerosol-generating article is at least partially received or receivable in the cavity of the device.

[0089] As previously mentioned, the at least one susceptor for inductively heating the aerosol-forming substrate can be an integral part of the aerosol-generating article, rather than a part of the aerosol-generating device. Thus, the aerosol-generating article can comprise at least one susceptor positioned in thermal proximity or contact with the aerosol-forming substrate, such that, in use, when the article is received in the cavity of the device, the susceptor can be inductively heated by the inductive heating device.

[0090] Further features and advantages of the aerosol-generating system according to the application have been described with respect to the aerosol-generating device and will not be repeated.

[0091] As used herein, the term "aerosol-generating device" generally refers to an electrically operated device capable of interacting with at least one aerosol-forming substrate, in particular with an aerosol-forming substrate provided within an aerosol-generating article, in order to generate an aerosol by heating the substrate. Preferably, the aerosol-generating device is a smoking device for generating an aerosol that is directly inhaled by a user through the user's mouth. In particular, the aerosol-generating device is a hand-held aerosol-generating device.

[0092] As used herein, the term "susceptor" refers to an element capable of converting electromagnetic energy into heat when subjected to an alternating magnetic field. This can be the result of hysteresis losses and / or eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material. In ferromagnetic or ferrimagnetic susceptors, hysteresis losses occur due to the switching of magnetic domains within the material under the influence of an alternating electromagnetic field. If the susceptor is electrically conductive, eddy currents can be induced. In the case of an electrically conductive ferromagnetic or ferrimagnetic susceptor, heat can be generated as a result of both eddy currents and hysteresis losses.

[0093] As used herein, the term "aerosol-generating article" refers to an article comprising at least one aerosol-forming substrate that, when heated, releases volatile compounds that can form an aerosol. Preferably, the aerosol-generating article is a heated-type aerosol-generating article. That is, the aerosol-generating article comprises at least one aerosol-forming substrate that is intended to be heated rather than combusted in order to release volatile compounds that can form an aerosol. The aerosol-generating article can be a consumable, in particular a consumable that will be discarded after a single use. For example, the article can be a cartridge comprising a liquid aerosol-forming substrate to be heated. Alternatively, the article can be a rod-shaped article, in particular a tobacco article, similar to a conventional cigarette. As mentioned above, the article can further comprise a susceptor positioned in thermal proximity or thermal contact with the aerosol-forming substrate, such that, in use, when the article is received in the cavity of the device, the susceptor can be inductively heated by the inductive heating device.

[0094] As used herein, the term "aerosol-forming substrate" means a substrate formed from or comprising aerosol-forming material, which is capable of releasing volatile compounds to generate an aerosol upon heating. The aerosol-forming substrate is intended to be heated, rather than combusted, in order to release the volatile compounds that form the aerosol. The aerosol-forming substrate can be a solid aerosol-forming substrate or a liquid aerosol-forming substrate or a gel-like aerosol-forming substrate, or any combination thereof. That is, the aerosol-forming substrate can comprise both, for example, solid and liquid components. The aerosol-forming substrate can comprise a tobacco-containing material, which contains volatile tobacco flavour compounds that are released from the substrate upon heating. Alternatively or additionally, the aerosol-forming substrate can comprise a non-tobacco material. The aerosol-forming substrate can also comprise an aerosol former. Examples of suitable aerosol formers are glycerol and propylene glycol. The aerosol-forming substrate can also comprise other additives and ingredients, such as nicotine or flavourings. The aerosol-forming substrate can also be a paste-like material, a porous material pocket comprising the aerosol-forming substrate, or loose tobacco, for example, mixed with a gelling or binding agent, which can include a common aerosol former such as glycerol, and which is compressed or moulded into a rod.

[0095] As used herein, the term "aerosol-generating system" refers to the combination of an aerosol-generating article as further described herein with an aerosol-generating device according to the application and as described herein. In the system, the article and the device cooperate to produce an inhalable aerosol.

[0096] A non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples can be combined with any one or more features of another example, embodiment, or aspect described herein.

[0097] Example 1 : An aerosol-generating device for generating an aerosol by inductively heating an aerosol-forming substrate, the device comprising

[0098] a device housing comprising a cavity configured for removably receiving at least a portion of an aerosol-forming substrate to be heated;

[0099] an inductive heating device comprising an induction coil for generating an alternating magnetic field within the cavity, wherein the induction coil is formed from a plurality of turns of a composite cable arranged around at least a portion of the cavity, wherein the composite cable comprises an electrical conductor at least partially embedded in an insulation conductor package, and wherein the conductor comprises a plurality of uninsulated wires in electrical contact with one another.

[0100] Example 2: The aerosol-generating device according to Example 1, wherein the wires extend parallel to one another along the length of the composite cable.

[0101] Example 3: An aerosol-generating device according to any one of the preceding Examples, wherein the conductive wires extend parallel to each other in a single layer along the length of the composite cable.

[0102] Example 4: An aerosol-generating device according to any one of the preceding Examples, wherein the conductive wires extend parallel to each other in a plurality of layers arranged one above the other, in particular two, three or four layers arranged one above the other, along the length of the composite cable.

[0103] Example 5: An aerosol-generating device according to any one of the preceding Examples, wherein at least a portion of the conductive wires of each layer are arranged in a groove formed between adjacent conductive wires of an adjacent layer.

[0104] Example 6: An aerosol-generating device according to any one of the preceding Examples, wherein the single layer or each layer of the plurality of layers is a flat layer.

[0105] Example 7: An aerosol-generating device according to any one of the preceding Examples, wherein the single layer or each layer of the plurality of layers is a curved layer.

[0106] Example 8: An aerosol-generating device according to any one of the preceding Examples, wherein the single layer or each layer of the plurality of layers is parallel to a circumferential plane defined by the plurality of turns of the composite cable.

[0107] Example 9: An aerosol-generating device according to any one of the preceding Examples, wherein each of the plurality of conductive wires has a circular outer cross-section or an elliptical outer cross-section or an oval outer cross-section or a rectangular outer cross-section or a square outer cross-section.

[0108] Example 10: An aerosol-generating device according to any one of the preceding Examples, wherein each of the plurality of conductive wires has a diameter in the range of between 0.2 millimetres and 2.3 millimetres, in particular between 0.25 millimetres and 1.2 millimetres, or between 0.15 millimetres and 1.5 millimetres, in particular between 0.25 millimetres and 0.75 millimetres.

[0109] Example 11: An aerosol-generating device according to any one of the preceding Examples, wherein each of the plurality of conductive wires has a cross-sectional area in the range of between 0.1 square millimetres and 17 square millimetres, in particular between 0.2 square millimetres and 4.5 square millimetres, or between 0.07 square millimetres and 7 square millimetres, in particular between 0.2 square millimetres and 1.8 square millimetres.

[0110] Example 12: An aerosol-generating device according to any one of the preceding Examples, wherein the composite cable is a flat composite cable.

[0111] Example 13: Aerosol-generating device according to any one of the preceding examples, wherein the composite cable has a circular cross-section.

[0112] Example 14: Aerosol-generating device according to any one of the preceding examples, wherein the composite cable has a non-circular outer cross-section, in particular, a substantially rectangular outer cross-section or a substantially square outer cross-section or a substantially oval outer cross-section or a substantially ovoid outer cross-section or a substantially outer parallelogram cross-section or a substantially trapezoidal outer cross-section or a substantially arcuate outer cross-section.

[0113] Example 15: Aerosol-generating device according to any one of the preceding examples, wherein the composite cable, when arranged around the cavity, comprises a first side facing inwardly towards the cavity and a second side facing outwardly away from the cavity opposite the first side.

[0114] Example 16: Aerosol-generating device according to any one of the preceding examples, wherein the outer cross-section, in particular the non-circular outer cross-section, of the composite cable has a first axis of symmetry, in particular a first axis of symmetry extending between the first side and the second side or in a radial direction with respect to the plurality of turns of the composite cable.

[0115] Example 17: Aerosol-generating device according to example 16, wherein the outer cross-section, in particular the non-circular outer cross-section, of the composite cable has a second axis of symmetry transverse to the first axis of symmetry, in particular a second axis of symmetry perpendicular to the first axis of symmetry.

[0116] Example 18: Aerosol-generating device according to any one of the preceding examples, wherein a maximum dimension of a cross-section of the composite cable in a radial direction with respect to the plurality of turns of the composite cable, in particular a maximum dimension of the composite cable along an axis orthogonal to the first side and the second side, in particular a maximum thickness dimension of the cross-section of the composite cable, is in a range between 0.5 millimetres and 9 millimetres, in particular between 0.7 millimetres and 9 millimetres, preferably between 0.9 millimetres and 5 millimetres.

[0117] Example 19: Aerosol-generating device according to any one of the preceding examples, wherein a maximum dimension of a cross-section of the composite cable perpendicular to a radial direction with respect to the plurality of turns of the composite cable, in particular a maximum dimension of the composite cable in a direction perpendicular to an axis orthogonal to the first and the second side or in a direction parallel to at least one of the first side and the second side, in particular a maximum width dimension of the cross-section of the composite cable, is in a range between 1 millimetre and 7 millimetres, in particular between 1.5 millimetres and 5 millimetres.

[0118] Example 20: Aerosol-generating device according to any one of the preceding Examples 1 to 19, wherein the electrical conductor has a substantially circular outer cross-section.

[0119] Example 21 : Aerosol-generating device according to any one of the preceding Examples 1 to 19, wherein the electrical conductor has a non-circular outer cross-section, in particular a substantially rectangular outer cross-section or a substantially square outer cross-section or a substantially oval outer cross-section or a substantially ovoid outer cross-section or a substantially parallelogram outer cross-section or a substantially trapezoidal outer cross-section or a substantially arcuate outer cross-section.

[0120] Example 22: Aerosol-generating device according to any one of the preceding Examples, wherein the electrical conductor is a flat electrical conductor.

[0121] Example 23: Aerosol-generating device according to any one of the preceding Examples, wherein a maximum dimension of a cross-section of the electrical conductor in a radial direction with respect to the plurality of turns of the composite cable, in particular a maximum thickness dimension of a cross-section of the electrical conductor, in particular a maximum thickness dimension of a cross-section of the electrical conductor perpendicular to the first side, can be in a range between 0.2 millimetres and 2.3 millimetres, in particular between 0.25 millimetres and 1.2 millimetres.

[0122] Example 24: Aerosol-generating device according to any one of the preceding Examples, wherein a maximum dimension of a cross-section of the electrical conductor perpendicular to a radial direction with respect to the plurality of turns of the composite cable, in particular a maximum width dimension of a cross-section of the electrical conductor, in particular a maximum width dimension of a cross-section of the electrical conductor parallel to the first side, can be in a range between 0.75 millimetres and 6 millimetres, in particular between 1 millimetre and 4 millimetres.

[0123] Example 25: Aerosol-generating device according to any one of the preceding Examples, wherein the composite cable, when arranged around the cavity, comprises a first side facing inwardly towards the cavity and a second side facing outwardly away from the cavity opposite the first side, and wherein the electrical conductor is asymmetrically arranged with respect to an outer cross-section of the composite cable so as to be closer to the first side than to the second side of the composite cable, in particular asymmetrically arranged with respect to a second axis of symmetry of the outer cross-section of the composite cable extending transversely to a radial direction with respect to the plurality of turns of the composite cable, in particular perpendicular to a radial direction with respect to the plurality of turns of the composite cable.

[0124] Example 26: Aerosol-generating device according to any of the preceding examples, wherein the minimum distance between the electrical conductor and the first side of the electrical cable facing inward towards the cavity is at most between 0.1 millimeter and 0.5 millimeter, in particular in the range of 0.1 millimeter and 0.3 millimeter, or between 0.1 millimeter and 1 millimeter, in particular in the range of 0.2 millimeter and 0.5 millimeter.

[0125] Example 27: Aerosol-generating device according to any of the preceding examples, wherein the insulated conductor package comprises a magnetic flux concentrator material.

[0126] Example 28: Aerosol-generating device according to example 27, wherein the flux concentrator material is held in a matrix.

[0127] Example 29: Aerosol-generating device according to any of the preceding examples, wherein the insulated conductor package, in particular the magnetic flux concentrator material, comprises at least one of a ferrimagnetic material or a ferromagnetic material or a magnetically permeable metal or a permalloy.

[0128] Example 30: Aerosol-generating device according to any of the preceding examples, wherein the insulated conductor package, in particular the magnetic flux concentrator material, comprises one or several materials having a relative maximum magnetic permeability of at least 1000, preferably at least 10000, for frequencies up to 50 kHz and temperatures of 25 degrees Celsius.

[0129] Example 31 : Aerosol-generating device according to any of the preceding examples, wherein the plurality of turns are in contact with each other, preferably abutting each other.

[0130] Example 32: Aerosol-generating device according to any of the preceding examples, wherein the composite cable is a multi-layer composite cable comprising an electrically insulating conductor package layer forming the insulated conductor package, and further comprising at least one of a support layer, a flux concentrator layer or a shielding layer.

[0131] Example 33: Aerosol-generating device according to example 32, wherein the support layer comprises an electromagnetically inert material, in particular at least one of polyether ether ketone or polyaryletherketone.

[0132] Example 34: Aerosol-generating device according to any of examples 32 or 33, wherein the support layer has a layer thickness of between 0.1 millimeter and 1 millimeter, in particular in the range of 0.2 millimeter and 0.5 millimeter, or between 0.25 millimeter and 1 millimeter, in particular in the range of 0.25 millimeter and 0.5 millimeter.

[0133] Example 35: Aerosol-generating device according to any of examples 32 to 34, wherein the conductor is partially embedded in the support layer.

[0134] Example 36: Aerosol-generating device according to any one of the Examples 32 to 35, wherein the support layer is an edge layer, in particular an edge layer forming a first side of the composite cable.

[0135] Example 37: Aerosol-generating device according to any one of the Examples 32 to 36, wherein the shielding layer comprises an electrically conductive material, in particular at least one of aluminum, copper, tin, steel, gold, silver, an electrically conductive polymer, a ferrite, or any combination thereof.

[0136] Example 38: Aerosol-generating device according to any one of the Examples 32 to 37, wherein the shielding layer is an edge layer, in particular an edge layer forming a second side of the composite cable.

[0137] Example 39: Aerosol-generating device according to any one of the Examples 32 to 38, wherein the layer thickness of the shielding layer is between 0.3 millimeters and 3 millimeters, in particular in the range of 0.3 millimeters and 2 millimeters, or between 0.25 millimeters and 5.5 millimeters, in particular in the range of 0.25 millimeters and 1.75 millimeters.

[0138] Example 40: Aerosol-generating device according to any one of the Examples 32 to 39, wherein the flux concentrator layer comprises a magnetic flux concentrator material.

[0139] Example 41: Aerosol-generating device according to Example 40, wherein the flux concentrator material is held in a matrix.

[0140] Example 42: Aerosol-generating device according to any one of the Examples 32 to 41, wherein the flux concentrator layer, in particular the magnetic flux concentrator material of the flux concentrator layer, comprises at least one of a ferrimagnetic material or a ferromagnetic material or a magnetically permeable metal or a permalloy.

[0141] Example 43: Aerosol-generating device according to any one of the Examples 32 to 42, wherein the flux concentrator layer, in particular the magnetic flux concentrator material of the flux concentrator layer, comprises one or several materials having a relative maximum magnetic permeability of at least 1000, preferably at least 10000, for frequencies up to 50 kHz and temperatures of 25 degrees Celsius.

[0142] Example 44: Aerosol-generating device according to any one of the Examples 32 to 43, wherein the electrically insulating conductor package layer is free of magnetic flux concentrator material.

[0143] Example 45: Aerosol-generating device according to any one of the Examples 32 to 44, wherein the support layer is arranged on one side of the insulating conductor package when the composite cable is arranged around the cavity.

[0144] Example 46: Aerosol-generating device according to any one of the examples 32 to 45, wherein the flux concentrator layer is arranged on a side of the insulating conductor package layer facing outwards away from the cavity when the composite cable is arranged around the cavity.

[0145] Example 47: Aerosol-generating device according to any one of the examples 32 to 46, wherein the shielding layer is arranged on a side of the insulating conductor package layer facing outwards away from the cavity when the composite cable is arranged around the cavity.

[0146] Example 48: Aerosol-generating device according to any one of the examples 32 to 47, wherein the multi-layer composite cable comprises both a flux concentrator layer and a shielding layer, wherein the flux concentrator layer is arranged on top of the electrically insulating conductor package layer, preferably on a side of the insulating conductor package layer facing outwards away from the cavity, when the composite cable is arranged around the cavity, and wherein the shielding layer is arranged on top of the flux concentrator layer, preferably as an edge layer, in particular an edge layer forming a second side of the composite cable.

[0147] Example 49: Aerosol-generating device according to any one of the examples 32 to 48, wherein the layer thickness of the insulating conductor package layer is between 0.2 millimeters and 6 millimeters, in particular in the range of 0.4 millimeters and 2 millimeters, or between 0.15 millimeters and 3 millimeters, in particular in the range of 0.3 millimeters and 1 millimeter, or between 0.25 millimeters and 3 millimeters, in particular in the range of 0.3 millimeters and 1.5 millimeters, or between 0.5 millimeters and 7 millimeters, in particular in the range of 0.7 millimeters and 4 millimeters or 0.7 millimeters and 3 millimeters, or between 0.4 millimeters and 9.2 millimeters, in particular in the range of 0.45 millimeters and 3.1 millimeters, or between 0.4 millimeters and 7.2 millimeters, in particular in the range of 0.45 millimeters and 2.6 millimeters, or between 0.45 millimeters and 3.7 millimeters, in particular in the range of 0.5 millimeters and 2.85 millimeters.

[0148] Example 50: Aerosol-generating device according to any one of the examples 32 to 49, wherein the thickness of the insulating conductor package layer portion embedding a conductor at a side opposite to the first side is between 0.2 millimeters and 7 millimeters, in particular in the range of 0.2 millimeters and 2 millimeters, or between 0.25 millimeters and 1.5 millimeters, in particular in the range of 0.25 millimeters and 0.75 millimeters, or between 0.2 millimeters and 5 millimeters, in particular in the range of 0.2 millimeters and 1.5 millimeters.

[0149] Example 51: An aerosol generating apparatus according to any of the preceding examples, wherein the conductor is completely embedded in the insulating conductor package.

[0150] Example 52: An aerosol generating apparatus according to any of the preceding examples, wherein the apparatus includes a sensing module defining at least a portion of the cavity, wherein the sensing coil is disposed on the inner surface of the sensing module or on the outer surface of the sleeve-shaped sensing module.

[0151] Example 53: An aerosol generating apparatus according to Example 52, wherein the sensing module is a sleeve-shaped sensing module, particularly a cylindrical sensing module, in order to define a cylindrical cavity.

[0152] Example 54: An aerosol generating apparatus according to any of Examples 52 or 53, wherein the sensing module is arranged, in particular, in a removable manner within the apparatus housing.

[0153] Example 55: An aerosol generating apparatus according to any of the preceding examples further includes at least one sensor arranged at least partially within the cavity.

[0154] Example 56: An aerosol generating apparatus according to Example 46, wherein the sensor is a tubular sensor or a sensor sleeve.

[0155] Example 57: An aerosol generation system comprising an aerosol generation apparatus according to any of the preceding examples and an aerosol generation article that at least partially receives or can be received in a cavity of the apparatus, wherein the aerosol generation article comprises an aerosol forming matrix to be heated.

[0156] Example 58: An aerosol generation system according to Example 57, wherein the aerosol generation article includes at least one sensor positioned in thermal proximity or thermal contact with the aerosol forming matrix, such that, in use, when the article is received in the cavity of the device, the sensor can be inductively heated by the induction heating device. Attached Figure Description

[0157] Several examples will now be described further with reference to the accompanying drawings, in which:

[0158] Figure 1 A schematic longitudinal cross-sectional view of an aerosol generation system according to a first embodiment of the present invention is shown;

[0159] Figure 2 A schematic longitudinal cross-sectional view of an aerosol generation system according to a second embodiment of the present invention is shown;

[0160] Figure 3 It shows the method for using according toFigure 1 A first embodiment of the sensing module in an aerosol generation system;

[0161] Figure 4 A second embodiment of a sensing module that can be used in an aerosol generation system according to the present invention is shown;

[0162] Figure 5 A third embodiment of a sensing module that can be used in an aerosol generation system according to the present invention is shown;

[0163] Figure 6 As shown Figure 1 A first embodiment of a composite cable used in an aerosol generation system;

[0164] Figure 7 A second embodiment of the composite cable that can be used in the aerosol generation system according to the present invention is shown;

[0165] Figure 8 A third embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0166] Figure 9 A fourth embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0167] Figure 10 A fifth embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0168] Figure 11 A sixth embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0169] Figure 12 A seventh embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0170] Figure 13 An eighth embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0171] Figure 14 A ninth embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0172] Figure 15 A tenth embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0173] Figure 16 An eleventh embodiment of a composite cable that can be used in an aerosol generation system according to the present invention is shown;

[0174] Figure 17 A twelfth embodiment of a composite cable usable in an aerosol-generating system according to the present application is shown;

[0175] Figure 18 A thirteenth embodiment of a composite cable usable in an aerosol-generating system according to the present application is shown;

[0176] Figure 19 A fourteenth embodiment of a composite cable usable in an aerosol-generating system according to the present application is shown;

[0177] Figure 20 A fifteenth embodiment of a composite cable usable in an aerosol-generating system according to the present application is shown; and

[0178] Figure 21 A sixteenth embodiment of a composite cable usable in an aerosol-generating system according to the present application is shown. DETAILED DESCRIPTION

[0179] Figure 1 A schematic cross-sectional view of a first exemplary embodiment of an aerosol-generating system 1 according to the present application is shown. The system 1 is configured for generating aerosol by inductively heating an aerosol-forming substrate 97. The system 1 comprises two main components: an aerosol-generating article 90 comprising the aerosol-forming substrate 97 to be heated; and an aerosol-generating device 10 for use with the article 90. The device 10 comprises a cavity 20 for receiving the article 90, and an inductive heating arrangement 30 for heating the substrate 97 within the article 90 when the article 90 is inserted into the cavity 20.

[0180] The article 90 has a rod shape similar to the shape of a conventional cigarette. In the present embodiment, the article 90 comprises four elements arranged in coaxial alignment: a substrate element 91, a support element 92, an aerosol-cooling element 94, and a filter plug 95. The substrate element is arranged at the distal end of the article 90 and comprises the aerosol-forming substrate to be heated. The aerosol-forming substrate 97 can comprise, for example, a rolled sheet of homogenized tobacco material comprising glycerol as an aerosol-former. The support element 92 comprises a hollow core forming a central air passage 93. The filter plug 95 serves as a mouthpiece and can comprise, for example, cellulose acetate fibers. All four elements are generally cylindrical elements arranged sequentially one after the other. The elements have substantially the same diameter and are surrounded by an outer wrapper 96 made of cigarette paper in order to form a cylindrical rod. The wrapper 96 can be wrapped around the aforementioned elements such that the free ends of the wrapper overlap each other. The wrapper can also comprise an adhesive that adheres the overlapping free ends of the wrapper to each other.

[0181] The device 10 comprises a substantially rod-like main body 11 formed by a substantially cylindrical device housing 19. Within the distal portion 13, the device 10 comprises a power source 16, e.g. a lithium-ion battery, and an electric circuit 17 comprising a controller for controlling the operation of the device 10, in particular for controlling the heating process. Within the proximal portion 14, which is opposite to the distal portion 13, the device 10 comprises a cavity 20. The cavity 20 is open at the proximal end 12 of the device 10, thereby allowing an easy insertion of an article 90 into the cavity 20.

[0182] A bottom portion 21 of the cavity separates the distal portion 13 from the proximal portion 14, in particular from the cavity 20, of the device 10. Preferably, the bottom portion is made of a thermally insulating material, e.g. PEEK (polyether ether ketone). Thus, the electronic components within the distal portion 13 can be kept separate from the aerosol or residues generated within the cavity 20 by the aerosol-generating process.

[0183] The induction heating device 30 comprises an induction coil 31 for generating an alternating, in particular high-frequency, magnetic field within the cavity 20. Preferably, the high-frequency magnetic field can range between 500 kHz (kilo-Hertz) and 30 MHz (mega-Hertz), in particular between 5 MHz (mega-Hertz) and 15 MHz (mega-Hertz), preferably between 5 MHz (mega-Hertz) and 10 MHz (mega-Hertz). In the present embodiment, the induction coil 31 is a spiral coil circumferentially surrounding the cylindrical cavity 20 along its length axis. The induction coil 31 is formed by a plurality of turns of a composite cable 32 comprising a multi-conductor electric conductor 33. Details of the composite cable 32 will be further described below, in particular with reference to Fig. 4. Figures 3-18 .

[0184] The induction heating device 30 further comprises a susceptor 60 arranged within the cavity 20 so as to be subjected to the magnetic field generated by the induction coil 31. In the present embodiment, the susceptor 60 is a susceptor blade 61. The susceptor blade is arranged at the bottom portion 21 of the cavity 20 of the device with its distal end 64. From there, the susceptor blade 61 extends into the inner void of the cavity 20 towards the opening of the cavity 20 at the proximal end 12 of the device 10. The other end of the susceptor blade 60, i.e. the distal free end 63, is tapered so as to allow the susceptor blade to easily penetrate the aerosol-forming substrate 97 within the distal end portion of the article 90.

[0185] Alternatively, as shown in Figure 2 , the susceptor 60 can be a part of the aerosol-generating article 90. Here, the susceptor 99 is a susceptor strip made of a sensitive material embedded within the aerosol-forming substrate 97 of the article 90. The susceptor strip 99 is arranged so as to extend along the center of the substantially cylindrical article 90. In addition to this, the embodiment of the aerosol-generating system according to Figure 2 corresponds to the embodiment according to Figure 1The same applies to the embodiments of the aerosol-generating system of the first aspect. Thus, identical or similar features are denoted with the same reference signs.

[0186] With reference to both embodiments, the induction heating process is as follows: When the device 10 is actuated, a high-frequency alternating current passes through the induction coil 31. Since the coil is arranged around the cavity 20, the alternating current through the coil induces an alternating magnetic field within the cavity 20. Depending on the electrical, magnetic properties of the respective susceptor material, the alternating magnetic field induces at least one of an eddy current or a hysteresis loss in the susceptor blades 61 or the susceptor strip 99, respectively. Accordingly, the susceptor blades 61 or the susceptor strip 99, respectively, are heated until a temperature is reached that is sufficient to form an aerosol from the substrate 97 in thermal proximity thereto or in direct physical contact therewith. The generated aerosol can be drawn downstream through the aerosol-generating article 90 for inhalation by a user.

[0187] As can be seen in Figure 1 and Figure 2 the induction coil 31 is part of an induction module 40 which is arranged together with the proximal portion 14 of the aerosol-generating device 10. The induction module 40 has a generally cylindrical shape which is coaxially aligned with the longitudinal central axis 71 of the rod-like device 10. From Figure 1 it can be seen that the induction module 40 forms at least a portion of the cavity 20 or at least a portion of the inner surface of the cavity 20.

[0188] Figure 3 The induction module 40 is shown in more detail. In addition to the induction coil 31, the induction module 40 comprises a tubular support sleeve 42 which carries the helically wound cylindrical induction coil 31. At its inner surface, the tubular support sleeve 42 comprises an annular recess 41 which receives the cylindrical induction coil 31. Accordingly, both end portions 44 of the support sleeve 42 protrude radially inwards towards the central axis 71 in order to hold the induction coil 31 in place in the recess of the support sleeve 42. The support sleeve 42 can be made of any suitable material such as plastic. In particular, the support sleeve 42 can form at least a portion of the cavity 20, i.e. at least a portion of the inner surface of the cavity 20.

[0189] Figure 4 A second embodiment of the induction module 40 is shown. Here, the tubular support sleeve 42 comprises an annular recess 43 at its outer surface in order to receive the cylindrical induction coil 31 therein. Accordingly, both end portions 44 of the support sleeve 42 protrude radially outwards away from the central axis 71 in order to hold the induction coil 31 in place in the recess 43.

[0190] Figure 5 A third embodiment of the induction module 40 is shown. The induction module 40 is arranged together with the proximal portion 14 of the aerosol-generating device 10 according to Figure 4The modules are almost identical. Additionally, the sensing module 40 of the third embodiment includes a sensor sleeve 69 surrounded by an induction coil 32. That is, the sensor sleeve 69 is part of the aerosol generation apparatus, not part of the aerosol generation article. The sensor sleeve 69 is arranged in an annular recess 45 on the inner surface of a support sleeve. Therefore, the sensor sleeve 69 forms at least a portion of the inner surface of the cavity 20. Thus, when the article is inserted into the cavity, the sensor sleeve 69 surrounds the matrix element 91 to heat the aerosol forming matrix from the outside. In this configuration, the sensor sleeve 69 acts as an oven heater. This is similar to... Figure 1 and Figure 2 The embodiments shown in the illustration form a contrast, wherein the receptor blade 61 or the receptor strip 99 respectively heats the aerosol from the inside to form a matrix.

[0191] Figure 6 The method for forming is shown in more detail. Figure 1 and Figure 2 The apparatus 10 shown includes a composite cable 32 for the induction coil 31. The composite cable 32 includes an electrical conductor 33 for carrying current used to generate a magnetic field. The conductor 33 is fully embedded in an insulated conductor package 34 to electrically insulate adjacent turns of the induction coil from each other and thus prevent short circuits. According to the invention, the conductor 33 includes a plurality of non-insulated wires 35 electrically in contact with each other. In this embodiment, the conductor 33 comprises a total of twenty-two wires 35 arranged in two layers, each layer comprising eleven wires 35. The layers are aligned such that the wires 35 of one layer are arranged in grooves formed between adjacent wires 35 of the other layer. Thus, the combination of all the wires 35 forms an electrical conductor 33 having a substantially trapezoidal cross-section.

[0192] Each conductor 35 may have a diameter ranging from 0.25 mm to 0.75 mm, for example, 0.5 mm. Therefore, the width dimension 33.1 of the conductor 33 is given by 11.5 times the conductor diameter. That is, the width dimension 33.1 of the conductor 33 may be in the range of 2.875 mm to 8.625 mm, for example, 5.75 mm. Similarly, the thickness dimension 33.2 of the conductor 33 is given by approximately 1.73 times the conductor diameter. That is, the width dimension 33.1 of the conductor 33 may be in the range of approximately 0.4 mm to approximately 1.3 mm, for example, approximately 6.5 mm. In this embodiment, the width dimension of the conductor 33 is perpendicular to the radial direction 70 with respect to the plurality of turns of the composite cable (see...). Figures 4-6 The maximum dimension of the cross-section of the conductor (as indicated by the dashed arrow in the diagram) corresponds to this. Similarly, the thickness dimension of the conductor 33 corresponds to the radial direction 70 of the multiple turns of the composite cable 32 (see [reference needed]). Figures 4-6(The dashed arrow in the figure) represents the maximum cross-sectional dimension of the conductor 33. Since the width dimension 33.1 of the conductor 33 is much larger than its thickness dimension 33.2, the conductor 33 can be represented as a flat conductor 33.

[0193] This also applies to the entire cable 32, whose width dimension 32.1 is much larger than its thickness dimension 32.2. Therefore, the composite cable 32 can be represented as a flat composite cable 32. In this embodiment, the width dimension 32.1 of the composite cable 32 is perpendicular to the radial direction 70 with respect to the plurality of turns of the composite cable 32 (see...). Figures 4-6 The maximum cross-sectional dimension of the composite cable 32 (as indicated by the dashed arrow in the figure) can be between 1 mm and 7 mm, particularly in the range of 1.5 mm and 5 mm. Similarly, the thickness dimension 32.2 of the composite cable 32, i.e., the radial direction 70 of the composite cable with respect to multiple turns (see...) Figures 4-6 The maximum cross-sectional dimension of the composite cable 32 (as indicated by the dashed arrow in the figure) can be between 0.5 mm and 9 mm, particularly between 0.7 mm and 9 mm, and preferably between 0.9 mm and 5 mm. The outer cross-section of the composite cable 32 is substantially rectangular with rounded edges.

[0194] When arranged around cavity 20, composite cable 32 includes a first side 38 facing inward toward cavity 20 and a second side 39 opposite to the first side, the second side facing outward away from cavity 20. This is in Figure 6 The diagram shows the cross-section of a composite cable in terms of its winding construction.

[0195] like Figure 6 As can be further seen, the electrical conductor 33 is arranged substantially symmetrically about the first axis of symmetry 32.3 of the outer cross-section of the cable 32, which extends in the radial direction 70 between the first side 38 and the second side 39. In contrast, the electrical conductor 33 is arranged asymmetrically about the second axis of symmetry 32.4 of the outer cross-section of the composite cable 32, so as to be closer to the first side 38 of the composite cable than the second side 39. That is, the insulating conductor encapsulation 34 is positioned mainly towards the second side 39 of the composite cable, and therefore positioned further outward in the radial direction than the electrical conductor 33. Specifically, the electrical conductor 33 is arranged between the first side 38 and the second axis of symmetry. As a result, when the composite cable 32 is arranged around the cavity, the insulating conductor encapsulation 34 can act as a protective sheath around the conductor 33. Here, the minimum distance 33.8 between the conductor 33 and the first side 38 is at most between 0.1 mm and 0.5 mm, particularly in the range between 0.1 mm and 0.3 mm.

[0196] Additionally, the insulated conductor package 34 can serve other purposes. In the present embodiment, the insulated conductor package 34 comprises a magnetic flux concentrator material in order to concentrate or focus the magnetic field within the cavity 20. Advantageously, this can increase the level of heat generated in the susceptor for a given power level through the induction coil 31 compared to an induction coil without a flux concentrator. Thus, the efficiency of the aerosol-generating device 10 is improved. Moreover, by distorting the magnetic field towards the cavity, the magnetic flux concentrator material of the insulated conductor package 34 reduces the extent to which the magnetic field propagates outside of the induction coil 31. That is, the flux concentrator material of the insulated conductor package 34 acts as a magnetic shield. Advantageously, this can reduce unwanted interference of the magnetic field with other sensitive parts of the aerosol-generating device 10, for example, with the metallic outer housing, or with sensitive external items in close proximity to the device 10. In particular, integrating the magnetic flux concentrator material into the composite cable 32 allows both the induction coil 31 and the appropriate magnetic flux concentrator to be provided in one part. Advantageously, this reduces the amount of work required to manufacture the aerosol-generating device 10 in terms of cost and time. For example, the insulated conductor package 34 can comprise or be made of a laminate, a pure ferrite or a proprietary composition based on ferrite or ferrite. Here, the insulated conductor package 34 is made of Alphaform MF available from Fluxtrol Inc. company (located at 1388 Atlantic Blvd. Auburn Hills, MI 48326, USA). Alphaform MF is a formable soft magnetic composite developed based on magnetic particles with a thermosetting epoxy resin binder suitable for frequencies between 10 kHz and 1000 kHz.

[0197] Advantageously, the conductive wires 35 of the conductor 33 are embedded in the material of the insulated conductor package 34 by extrusion or lamination.

[0198] Figure 7 A second embodiment of the composite cable 32 is shown which is very similar to the first embodiment of the composite cable 32 as shown in Figure 6 Therefore, identical or similar features are denoted with identical reference signs. In contrast to the first embodiment, the composite cable 32 according to Figure 7 comprises a conductor 33 which is composed of a single layer of seven conductive wires 35. Each of the seven conductive wires 35 has a larger diameter than the conductive wires 35 shown in Figure 6 The diameter is chosen such that the cross-sectional area of the electrical conductor 33 in Figure 7 i.e. the sum of the cross-sectional areas of all seven conductive wires 35, substantially corresponds to the cross-sectional area of the electrical conductor 33 in Figure 6 i.e. the sum of the cross-sectional areas of all twenty-two conductive wires 35. Thus, the composite cable 32 shown in Figure 6 and the composite cable 32 shown in Figure 7The composite cables 32 shown have substantially the same electrical characteristics, particularly substantially the same resistance. However, due to the larger number and smaller diameter of the conductors 35, according to Figure 6 The composite cable 32 is more flexible.

[0199] Figures 8-10 Three additional embodiments of the composite cable 132 are shown. In all three embodiments, the composite cable 132 is implemented as a multilayer composite cable 132, which includes an electrically insulating conductor encapsulation layer 134 forming an insulated conductor encapsulation as described above, and a support layer 136 in addition. The two layers 134, 136 completely surround the electrical conductor 133. Advantageously, the different layers can be attached to each other by a lamination process.

[0200] The support layer 136 is used to increase the mechanical resistance of the composite cable 134. In order not to affect the inductive properties of the magnetic field generated by the current passing through the conductor 132, the support layer 136 is electromagnetically inert in all three embodiments. For example, the support layer 136 can be made of polyetheretherketone or polyaryletherketone, both of which are electromagnetically inert materials.

[0201] In all three embodiments, the corresponding support layer 136 is an edge layer, particularly the edge layer forming the first side 138 of the composite cable 132.

[0202] exist Figure 8 and Figure 9 In the illustrated embodiment, the electrical conductor 133 is at least partially embedded in the corresponding support layer 136 and partially embedded in the insulating conductor encapsulation layer 134. In addition to the support layer 136 and the partial embedding in the insulating conductor encapsulation layer, Figure 8 and Figure 9 The composite cable 132 shown is respectively with Figure 6 and Figure 7 The composite cable 32 shown is very similar. Therefore, the same or similar features are indicated by the same reference numerals but incremented by 100.

[0203] In contrast, Figure 10 In the illustrated embodiment, the conductor 133 is not embedded in the support layer 136. Instead, when the composite cable 132 is arranged around the cavity 20, the support layer 136 covers the inward-facing side of the conductor 133 towards the cavity. Therefore, the support layer 136 is more... Figure 8 and Figure 9 The support layer 136 is thin. Furthermore, with... Figure 8 and Figure 9 Compared to the implementation scheme shown, Figure 10The insulating conductor encapsulation layer 134 of the cable 132 shown consists of three parts: a first part 134.1 disposed on the side of the conductor 133 opposite to the first side 138, and a second part 134.2 and a third part 134.3 disposed laterally on the narrow side of the flat conductor 133. Furthermore, according to... Figure 10 The composite cable 132 does not have rounded edges, but rather sharp edges.

[0204] According to Figure 8 and Figure 9 In one embodiment, the support layer 136 may have a layer thickness between 0.1 mm and 1 mm, particularly between 0.2 mm and 0.5 mm. Similarly, according to... Figure 10 In one embodiment, the support layer 136 may have a layer thickness between 0.25 mm and 1 mm, particularly between 0.25 mm and 0.5 mm.

[0205] The total thickness of the insulating conductor encapsulation layer 134 can be between 0.5 mm and 7 mm, particularly between 0.7 mm and 4 mm, or in the range of 0.7 mm and 3 mm, or between 0.4 mm and 7.2 mm, particularly in the range of 0.45 mm and 2.6 mm. Similarly, the thickness of the portion of the insulating conductor encapsulation layer 134 on the side opposite to the first side, particularly the first portion 134.1, can be between 0.2 mm and 5 mm, particularly in the range of 0.2 mm and 1.5 mm.

[0206] Figures 11-13 It shows the relationship with Figures 8-10 Three other embodiments of the composite cable 232, similar to the embodiment shown, are also described. Therefore, identical or similar features are indicated by the same reference numerals, only incremented by 100. Figures 8-10 Compared to the implementation scheme shown, Figures 11-13 The composite cable 232 shown further includes a shielding layer 237 disposed on top of the insulating conductor encapsulation layer 234, opposite the support layer 236. The shielding layer 237 primarily serves to reduce the adverse effects of magnetic fields in the external region of the shielding layer 237, and vice versa, to reduce the distortion of magnetic fields by conductive or highly magnetically sensitive materials in the immediate vicinity of the device or within the housing of the device itself. Therefore, the shielding layer 237 preferably comprises a conductive material, such as a metallic coating applied to the outward-facing side of the electrically insulating conductor encapsulation layer away from the cavity. This can be seen from… Figures 11-13 Furthermore, the corresponding shielding layer 237 is the edge layer of the second side 239 forming the multilayer composite cable 232.

[0207] The shielding layer 237 may have a layer thickness in the range of 0.3 mm to 3 mm, particularly in the range of 0.3 mm to 2 mm.

[0208] To compensate for the additional layer 237, Figures 11-13 The layer thicknesses of the insulating conductor package layer 234 in the embodiments shown in Figures 8-10 may differ from the respective layer thicknesses in the embodiments shown in Figures 11-13 The total layer thickness of the insulating conductor package layer of the embodiments shown in

[0209] Figures 14-16 Three further embodiments of a composite cable 332 are shown which are similar to the embodiments shown in Figures 11-13 Therefore, identical or similar features are denoted by the same reference signs but incremented by 100. Compared to the embodiments shown in Figures 11-13 Figures 14-16 The composite cable 332 shown in Figures 11-13 comprises a flux concentrator layer 337 instead of a shielding layer. For example, the flux concentrator layer 337 can comprise a ferrite material. The ferrite material acts as a flux concentrator material. Further, the layer thicknesses differ slightly from those of the embodiments shown in Figures 14-16 Here, the total layer thickness of the insulating conductor package layer 334 of the embodiments shown in

[0210] As shown in Figure 17 , the composite cable 432 can also not comprise a support layer, but only a shielding layer 437 and an insulating conductor package layer 434 in which the conductor 433 is embedded. Alternatively, as shown in Figure 18 , the composite cable 532 can also only comprise a flux concentrator layer 537 and an insulating conductor package layer 534 in which the conductor 533 is embedded, but not a support layer. In this configuration, the ​

[0211] As Figure 19 shown in Figures 1-18 , the composite cable 632 can also include a cross-section other than the substantially rectangular cross-section as shown. In the present embodiment, the composite cable 632 has an arcuate cross-section. The cable 632 is also a multi-layer composite cable that includes a shield layer or flux concentrator layer 637 and an insulating conductor encapsulation layer 634 that embeds the substantially arcuate conductor 633. With respect to the arcuate cross-section, the width dimension of the composite is measured along the first side 638 or along the second side 639 or along a midline parallel to the first side 638 and the second side 639 between the first side 638 and the second side 639. Likewise, the thickness dimension can be measured in a radial direction along an axis that is orthogonal to the first side 638 and the second side 639.

[0212] Figure 20 Another embodiment of a multi-layer composite cable 732 is shown that is a combination of the composite cables according to Figure 11 and Figure 14 . The multi-layer composite cable 732 includes a support layer 736, an insulating conductor encapsulation layer 734 that embeds a conductor 733 on top of the support layer 736, a flux concentrator layer 737 on top of the insulating conductor encapsulation layer 734, and a shield layer 770 disposed on top of the flux concentrator layer 737 opposite the support layer 736. The shield layer 770 can be, for example, a metallic coating on top of the flux concentrator layer 737.

[0213] As Figure 21 shown, the support layer can also be omitted as in Figure 17 and Figure 18 . Thus, Figure 21 Yet another embodiment of a multi-layer composite cable 832 is shown that is a combination of the composite cables according to Figure 17 and Figure 18 . The multi-layer composite cable 832 includes a conductor 833 embedded in an insulating conductor encapsulation layer 834, a flux concentrator layer 837 on top of the insulating conductor encapsulation layer 834, and a shield layer 870 disposed on top of the flux concentrator layer 837.

[0214] In Figures 14-16 , Figure 18 and Figures 20-21 , the respective insulating conductor encapsulation layer 334, 535, 734, 834 preferably does not contain any flux concentrator material due to the presence of the respective additional flux concentrator layer 337, 537, 737, 837. However, the respective insulating conductor encapsulation layer 334, 535, 734, 834 can include flux concentrator material in addition to the respective flux concentrator layer 337, 537, 737, 837.

[0215] For purposes of the present description and accompanying claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about." Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges not expressly disclosed. Accordingly, in this context, a number A is understood as A ± 5% of A.

Claims

1. An aerosol generating apparatus for generating aerosols by induction heating of an aerosol-forming matrix, the aerosol generating apparatus comprising: A device housing, the device housing including a cavity configured to removably receive at least a portion of an aerosol forming matrix to be heated; An induction heating device includes an induction coil for generating an alternating magnetic field in the range of 500 kHz to 30 MHz within a cavity, wherein the induction coil is formed by a plurality of turns of a composite cable arranged around at least a portion of the cavity, wherein the composite cable includes electrical conductors at least partially embedded in an insulated conductor package, and wherein the electrical conductors include a plurality of non-insulated wires in electrical contact with each other. The composite cable arranged around the cavity includes a first side facing inward toward the cavity and a second side facing outward away from the cavity opposite to the first side, wherein the electrical conductor is arranged asymmetrically with respect to the outer cross-section of the composite cable so as to be closer to the first side than the second side of the composite cable.

2. The aerosol generating apparatus according to claim 1, wherein the conductors extend parallel to each other in a single layer along the length direction of the composite cable, or wherein the conductors extend parallel to each other in multiple layers arranged vertically to each other along the length direction of the composite cable.

3. The aerosol generating apparatus according to claim 2, wherein each of the single layer or the multilayer is a flat layer, or wherein each of the single layer or the multilayer is a curved layer.

4. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the composite cable has a substantially circular outer cross-section or a non-circular outer cross-section.

5. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the composite cable has a substantially elliptical outer cross-section, a substantially oval outer cross-section, a substantially trapezoidal outer cross-section, or a substantially arcuate outer cross-section.

6. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the composite cable has a substantially rectangular outer cross-section.

7. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the composite cable has a substantially square outer cross-section.

8. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the composite cable has a substantially parallelogram-shaped outer cross-section.

9. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the composite cable is a flat cable, and / or wherein the electrical conductor is a flat conductor.

10. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the electrical conductor has a substantially elliptical outer cross-section, a substantially oval outer cross-section, a substantially trapezoidal outer cross-section, or a substantially arcuate outer cross-section.

11. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the electrical conductor has a substantially rectangular outer cross-section.

12. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the electrical conductor has a substantially square outer cross-section.

13. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the electrical conductor has a substantially parallelogram-shaped outer cross-section.

14. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the insulating conductor encapsulation comprises a magnetic flux concentrator material.

15. The aerosol generating apparatus of claim 14, wherein the magnetic flux concentrator material is one or more materials having a relative maximum permeability of at least 1000 for frequencies up to 50 kHz and temperatures of 25 degrees Celsius.

16. The aerosol generating apparatus of claim 14, wherein the magnetic flux concentrator material is one or more materials having a relative maximum permeability of at least 10,000 for frequencies up to 50 kHz and temperatures of 25 degrees Celsius.

17. The aerosol generating apparatus according to any one of claims 1 to 3, wherein the composite cable is a multilayer composite cable, the multilayer composite cable comprising an electrically insulating conductor encapsulation layer forming the insulating conductor encapsulation, and further comprising at least one of a support layer, a flux concentrator layer, or a shielding layer.

18. The aerosol generating apparatus according to claim 17, wherein the support layer comprises an electromagnetically inert material.

19. The aerosol generating apparatus according to claim 18, wherein the electromagnetic inert material is at least one of polyetheretherketone or polyaryletherketone.

20. The aerosol generating apparatus of claim 17, wherein the support layer is an edge layer, and wherein one of the flux concentrator layer or the shielding layer is an edge layer.

21. The aerosol generating apparatus of claim 20, wherein the support layer is an edge layer forming the first side of the composite cable.

22. The aerosol generating apparatus of claim 20, wherein one of the flux concentrator layer or the shielding layer is an edge layer forming the second side of the composite cable.

23. The aerosol generating apparatus according to claim 17, wherein the shielding layer comprises a conductive material.

24. The aerosol generating apparatus according to claim 23, wherein the conductive material is at least one of aluminum, copper, tin, steel, gold, silver, conductive polymer, ferrite, or any combination thereof.

25. The aerosol generating apparatus according to any one of claims 1 to 3, further comprising at least one sensor disposed at least partially within the cavity.

26. An aerosol generation system comprising an aerosol generation apparatus according to any one of claims 1 to 25 and an aerosol generation article at least partially received or capable of being received in a cavity of the aerosol generation apparatus, wherein the aerosol generation article comprises an aerosol forming matrix to be heated.

27. The aerosol generation system of claim 26, wherein the aerosol generation article includes at least one sensor positioned in thermal proximity or thermal contact with the aerosol forming matrix, such that, in use, when the aerosol generation article is received in the cavity of the aerosol generation apparatus, the sensor can be inductively heated by the induction heating device.

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