Aerosol supply device

Abstract

An aerosol supply device includes a plurality of electrical components (118, 120, 122, 124, 126, 128). The apparatus also includes a plastic body (116) including at least one electrically conductive track (132A, 132B, 132C) configured to provide an electrical connection between at least two of the plurality of electrical components (118, 120, 122, 124, 126, 128). The at least one conductive track (132A, 132B, 132C) is formed by a laser direct structuring technique.

Description

Technical Field

[0001] The present invention relates to an aerosol supply device and an aerosol supply system. Background Art

[0002] Smoking articles (such as cigarettes, cigars, etc.) burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these smoking articles that burn tobacco by developing products that release compounds without combustion. Examples of such products are heating devices that release compounds by heating but not burning a material. The material can be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided an aerosol supply device comprising:

[0004] a plurality of electrical components; and

[0005] a plastic body including at least one conductive track configured to provide an electrical connection between at least two of the plurality of electrical components, wherein the at least one conductive track is formed by laser direct structuring technology.

[0006] Using a plastic body including at least one conductive track formed by laser direct structuring technology can reduce the number of cables required within the device, the at least one conductive track providing an electrical connection between at least two electrical components within the aerosol supply device. This can reduce the space required for routing such cables, thereby potentially allowing the aerosol supply device to be made more compact. Using conductive tracks formed by laser direct structuring technology can also simplify the manufacture and assembly of the aerosol supply device.

[0007] The plastic body may be configured to support at least one of the plurality of electrical components.

[0008] The plastic body may be configured to house at least one of the plurality of electrical components.

[0009] The aerosol supply device may include a housing, and the plastic body may be housed within the housing or at least partially define the housing.

[0010] The plastic body may be formed of modified polyetheretherketone (PEEK).

[0011] The plurality of electrical components may include at least one of the following electrical components: an electrical power source (such as a battery), a heating device, a temperature sensor, a controller, a light source, a haptic device, and a speaker.

[0012] The aerosol supply device may include at least one electrical connector arranged to connect a conductive track to at least one of a plurality of electrical components.

[0013] The at least one conductive track may include a plurality of conductive tracks.

[0014] Furthermore, at least two of the plurality of conductive tracks may be electrically insulated from each other.

[0015] The plastic body may be made of a plastic material capable of withstanding a temperature of at least 200 °C, such as at least 220 °C, such as at least 250 °C, for a continuous period of time.

[0016] The continuous period of time may include at least 60 seconds, such as at least 2 minutes, such as at least 5 minutes.

[0017] The plastic body may be electrically insulating.

[0018] The plastic body may have high chemical resistance.

[0019] The at least one conductive track may extend in a plurality of different planes.

[0020] According to a second aspect of the present invention, there is provided an aerosol supply system comprising:

[0021] an aerosol supply device according to any one of the embodiments described above; and

[0022] an article comprising aerosol-generating material.

[0023] According to a third aspect of the present invention, there is provided a method of forming a component for use in an aerosol supply device, the method comprising:

[0024] forming a plastic body;

[0025] irradiating tracks on the plastic body using a laser;

[0026] coating the irradiated tracks with a conductive material.

[0027] The step of coating the irradiated tracks with a conductive material may include coating the tracks with a conductive material a plurality of times.

[0028] The step of forming the plastic body may include forming a plastic body having a three-dimensional shape and having support features for mounting electrical components to the plastic body.

[0029] The step of forming the plastic body may include forming the plastic body from a material comprising an additive, the additive including a metal inorganic compound configured to be activated by a laser. Description of the Drawings

[0030] Embodiments will now be described by way of example only with reference to the accompanying drawings, in which:

[0031] Figure 1 shows a side view of an aerosol supply system according to an embodiment of the present invention;

[0032] Figure 2 shows a perspective view of a plastic body of an aerosol supply device according to an embodiment of the present invention;

[0033] Figure 3 shows a plan view of a part of the plastic body including conductive tracks, the conductive tracks including electrical connectors at their ends; and

[0034] Figure 4 is a flow chart of a method according to an embodiment of the present invention. Detailed Embodiments

[0035] As used herein, the term "aerosol - generating material" is a material that is capable of generating an aerosol when supplied with energy, for example, by heating, radiation, or any other means. The aerosol - generating material can be, for example, in solid, liquid, or gel form, and may or may not contain active substances and / or flavorants. The aerosol - generating material can include any plant - based material (such as a material containing tobacco), and can include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The aerosol - generating material can also include other non - tobacco products, which may or may not contain nicotine depending on the product. The aerosol - generating material can be, for example, in the form of a solid, liquid, gel, wax, etc. The aerosol - generating material can also be, for example, a combination or mixture of materials. The aerosol - generating material can also be referred to as "puffable material".

[0036] The aerosol - generating material can include binders and aerosol - forming agents. Optionally, active agents and / or fillers may also be present. Optionally, a solvent (such as water) is also present, and one or more other components of the aerosol - generating material may be soluble or insoluble in the solvent. In some embodiments, the aerosol - generating material is substantially free of plant material. In some embodiments, the aerosol - generating material is substantially free of tobacco.

[0037] The aerosol - forming material may comprise or may be an "amorphous solid". The amorphous solid may be a "monolithic solid". In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid (such as a liquid) within it. In some embodiments, the aerosol - forming material may, for example, comprise from about 50 wt%, 60 wt% or 70 wt% amorphous solid to about 90 wt%, 95 wt% or 100 wt% amorphous solid.

[0038] The aerosol - forming material may comprise an aerosol - forming film. The aerosol - forming film may comprise or may be a sheet, which may optionally be shredded to form pieces. The aerosol - forming sheet or pieces may be substantially tobacco - free.

[0039] According to the present disclosure, a "non - combustible" aerosol supply system is an aerosol supply system in which the constituent aerosol - forming material of the aerosol supply system (or its components) does not burn or ignite and can deliver at least one substance to a user. Any aerosol supply system described herein may be a non - combustible aerosol supply system.

[0040] In some embodiments, the delivery system is a non - combustible aerosol supply system, such as a powered non - combustible aerosol supply system.

[0041] In some embodiments, the non - combustible aerosol supply system is an electronic cigarette, also known as a vaping device or an electronic nicotine delivery system (ENDS), but it should be noted that the presence of nicotine in the aerosol - forming material is not necessary.

[0042] In some embodiments, the non - combustible aerosol supply system is an aerosol - forming material heating system, also known as a heat - not - burn system. An example of such a system is a tobacco heating system.

[0043] In some embodiments, the non - combustible aerosol supply system is a hybrid system that uses a combination of aerosol - forming materials to generate an aerosol, and one or more of these aerosol - forming materials may be heated. Each of these aerosol - forming materials may be in the form of, for example, a solid, a liquid or a gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol - forming material and a solid aerosol - forming material. The solid aerosol - forming material may comprise, for example, tobacco or non - tobacco products.

[0044] Generally, a non - combustible aerosol supply system may comprise a non - combustible aerosol supply device and a consumable for use with the non - combustible aerosol supply device.

[0045] In some embodiments, the present disclosure relates to a consumable that includes an aerosol - forming material and is configured to be used with a non - combustible aerosol supply device. These consumables are sometimes referred to as articles in the present disclosure.

[0046] In some embodiments, a non - combustible aerosol supply system (such as its non - combustible aerosol supply device) may include a power source and a controller. For example, the power source may be an electrical power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon matrix, which can be energized to distribute power in the form of heat to the aerosol - forming material or heat - transfer material in the vicinity of the exothermic power source.

[0047] In some embodiments, a non - combustible aerosol supply system may include an area for receiving a consumable, an aerosol generator, an aerosol - forming area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0048] In some embodiments, a consumable for use with a non - combustible aerosol supply device may include an aerosol - forming material, an aerosol - forming material storage area, an aerosol - forming material transfer component, an aerosol generator, an aerosol - forming area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0049] An aerosol supply device can receive an article that includes an aerosol - forming material for heating. The "article" in context is a component that includes or contains an aerosol - forming material (which is heated to volatilize the aerosol - forming material) in use, and optionally other components in use. A user can first insert the article into the aerosol supply device and then heat the article to generate an aerosol, which the user then inhales. The article may, for example, have a predetermined or specific size and is configured to be placed in a heating chamber of the device, the size of which is designed to receive the article.

[0050] Reference Figure 1 , shows an aerosol supply system 2 according to an embodiment of the present invention. The aerosol supply system 2 includes an aerosol supply device 4 for generating an aerosol from an aerosol - forming material. The aerosol supply system 2 further includes a replaceable article 6 that contains the aerosol - forming material. Generally speaking, the aerosol - forming device 4 can be used to heat the article 6 to generate an aerosol or other inhalable medium for inhalation by a user of the device 4.

[0051] The aerosol - forming device 4 includes a body 8. The body can be considered to form a housing that encloses and houses the various components of the device 4. An article orifice 10 is formed at one end of the body 8 through which the article 6 can be inserted to be heated by an aerosol generator 12.

[0052] The device 4 may further include a user-operable control element 14, such as a button or a switch, which operates the device 4 when pressed. For example, the user may operate the switch 14 to turn on the device 4.

[0053] The aerosol generator 12 defines a longitudinal axis that is aligned with the axis of the article 6.

[0054] In use, the article 6 may be fully or partially inserted into the aerosol generator 12, and the article may be heated by one or more components of the aerosol generator 12 within the aerosol generator.

[0055] The device 4 includes means for heating an aerosol-forming material, namely the aerosol generator 12. The means includes an aerosol-forming assembly, a controller (control circuit), and a power source. The means forms part of the body 8. The aerosol-forming assembly is configured to heat the aerosol-forming material of the article 6 inserted through the article aperture 10 such that an aerosol is generated from the aerosol-forming material. The power source supplies electrical power to the aerosol-forming assembly, and the aerosol-forming assembly converts the supplied electrical energy into heat energy for heating the aerosol-forming material. The power source may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries.

[0056] The power source may be electrically connected to the aerosol-forming assembly to supply electrical power for heating the aerosol-forming material when required and under the control of the controller. The control circuit may be configured to enable and disable the aerosol-forming assembly based on user input. The user input may be via a button press or opening the door of the device (e.g., the door covering the consumable receiving container). The control circuit may be configured to automatically enable and disable, for example, when an article is inserted.

[0057] An aerosol-generating assembly may include various components that heat an aerosol-generating material via an induction heating process. Induction heating is a process of heating a conductive heating element (such as a susceptor) by electromagnetic induction. An induction heating assembly may include an induction element (e.g., one or more induction coils) and means for passing a varying current (such as an alternating current) through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field passes through a susceptor (heating element) that is appropriately positioned relative to the induction element and induces eddy currents within the susceptor. The susceptor has a resistance to the eddy currents, and thus the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In the case where the susceptor contains a ferromagnetic material (such as iron, nickel, or cobalt), heat may also be generated by hysteresis losses in the susceptor, i.e., by the magnetic dipoles in the magnetic material changing orientation as they align with the varying magnetic field. Compared to heating, for example, by conduction, in induction heating, heat is generated within the susceptor, allowing for rapid heating. Additionally, no physical contact is required between the induction element and the susceptor, allowing for increased freedom in construction and application. In some embodiments, the aerosol-generating device may include resistive heating means.

[0058] Figure 1 The illustrated aerosol supply system 2 may include any features of the various embodiments discussed below.

[0059] Figure 2 A perspective view of a plastic body 116 is shown, which may form Figure 1 part of a body 8 of the aerosol-generating device 4 shown in. The plastic body 116 may house / support a plurality of electrical components, including but not limited to: an electrical power source 118 (such as a battery), a heating device 120 (such as a resistive or induction heating device), a controller 122 (such as including a processor), a temperature sensor 124 (such as a thermistor), a haptic device 126, a speaker 126, and / or a light source 128 (such as an LED).

[0060] A plurality of electrical components may be housed within the plastic body 116. In some embodiments, the aerosol supply device may include a housing, and the plastic body 116 may at least partially define the housing of the aerosol supply device. For example, the plastic body 116 may form Figure 1 part of the body 8 shown in. In some embodiments, the plastic body 116 may be housed within the housing. Thus, the plastic body 116 may be an internal component of the aerosol supply device. In such an embodiment, the plastic body 116 may, for example, form part of an internal support structure that defines the internal structure of the aerosol supply device.

[0061] In some embodiments, a plurality of electrical components may be supported by a plastic body 116. For example, the plastic body 116 may include a first support member 130A and a second support member 130B arranged to support a heating device 120. Similarly, the plastic body may include a third support member 130C arranged to support an electrical power source 118 and a fourth support member 130D arranged to support a temperature sensor 124. Any number of the first support member 130A, the second support member 130B, the third support member 130C, and the fourth support member 130D may be integrally formed with the plastic body 116. The form of the support member may depend on the component being supported. The support member may be integrally formed with the plastic body 116, such as during the molding of the integral body. In some embodiments, the plastic body 116 may include support members that are attached or mounted to the plastic body 116 during the manufacture / assembly of the device. Supporting the components by the plastic body 116 may advantageously provide a simple and effective means for supporting electrical components within the device.

[0062] As can be seen in Figure 2 , the plastic body 116 includes a plurality of conductive tracks (hereinafter referred to as "electrical tracks"), which include, for example, a first electrical track 132A, a second electrical track 132B, a third electrical track 132C, and a fourth electrical track 132D. The first electrical track 132A provides an electrical connection between the controller 122 and the heating device 120. The second electrical track 132B provides an electrical connection between the electrical power source 118 and the controller 122. The third electrical track 132C provides an electrical connection between the controller 122 and the haptic component 126. The fourth electrical track 132D provides an electrical connection between the controller 122 and the temperature sensor 124. Although not shown, additional electrical tracks may be provided to provide an electrical connection between the light source 128 and the speaker 126. Each of the first electrical track 132A, the second electrical track 132B, the third electrical track 132C, and the fourth electrical track 132D is formed by a laser direct structuring technique. The applicant has recognized that using conductive tracks formed on the plastic body 116 by a laser direct structuring technique can provide a convenient means for achieving electrical connections between various electrical components without the need to route cables within the device. Thus, this can reduce the amount of cable routing space required within the device, which can minimize the size of the device or provide more space for other components within the device, such as more battery space.

[0063] As depicted in Figure 2 , in some embodiments, at least two of the conductive tracks 132A - 132D are electrically insulated from each other. The electrical insulation of the conductive tracks 132A - 132D can be achieved by appropriately arranging the electrical components relative to the plastic body 116.

[0064] The specific form of the electrical track may depend on the plastic body or the part of the plastic body that forms the electrical track. In some embodiments, as depicted in Figure 2 , at least one electrical track (e.g., a first electrical track 132A, a second electrical track 132B, a third electrical track 132C, or a fourth electrical track 132D) extends in a plurality (e.g., at least two) of different planes. This can advantageously allow for electrical connection between electrical components in the device that are not arranged in a single plane. Thus, compared to other possible scenarios, such an arrangement can facilitate a more complex arrangement of electrical components within the device while still providing electrical connection to the conductive tracks. In some embodiments, the plastic body 116 may be non-planar. In other words, the plastic body 116 may not be a flat plastic sheet, but may have a more complex three-dimensional form. The exact form can be determined according to the use of the plastic body 116 as part of the device.

[0065] Although the various electrical components and conductive tracks shown have been depicted and described above, it will be understood that any number of different electrical components and any suitable number of electrical tracks may be included.

[0066] The plastic body 116 may be made of any suitable plastic material. In some embodiments, the plastic body is formed from a modified polyetheretherketone (PEEK), i.e., made of a modified polyetheretherketone (PEEK).

[0067] At least some parts of the aerosol supply device may reach relatively high temperatures during use. Thus, it may be desirable for the plastic body 116 to be able to withstand such temperatures. Additionally, during use of the aerosol supply device, the plastic body 116 may be subjected to such temperatures for a long period of time. Thus, in some embodiments, the plastic body 116 may be made of a plastic material that can tolerate a temperature of at least 200 °C (e.g., at least 220 °C, e.g., at least 250 °C) for a continuous period of time. This can help ensure that the plastic body 116 can withstand the elevated temperatures to which it may be exposed during use, thus ensuring that it properly performs its function, such as being part of the housing of the aerosol supply device or as a support component within the device. A continuous period of time may include at least 60 seconds, e.g., at least 2 minutes, e.g., at least 5 minutes.

[0068] The plastic body 116 can be electrically insulating, which can ensure that the electrical tracks 132A - 132D can properly perform their functions. In some embodiments, the plastic body 116 has high chemical resistance. Having high chemical resistance can advantageously ensure that the plastic body 116 does not deteriorate in the presence of chemicals, such as any chemical that forms part of or is formed by an aerosol - generating article that can be inserted into an aerosol - supply device, and the plastic body 116 forms part of the aerosol - supply device.

[0069] In any of the embodiments discussed above, the electrical components 118 - 128 can be electrically connected to their respective electrical tracks 132A - 132D in any suitable manner. For example, in some embodiments, the electrical components 118 - 128 can be soldered to their respective electrical tracks 132A - 132D. However, this is not necessary, and in some embodiments, the electrical components 118 - 128 can be connected via electrical connectors. Such embodiments will be described in more detail below.

[0070] Figure 3 A plan view of a portion of a plastic body 216 according to an embodiment of the present invention is shown. As depicted, the plastic body 216 includes a conductive track 232. An electrical connector 234 is mounted, for example, at an end of the conductive track 232 to the conductive track. The electrical connector 234 can be arranged to connect the conductive track 232 to an electrical component (e.g., any one of the electrical components discussed above). The electrical connector 234 can thus facilitate connecting the electrical component to the conductive track 232. The electrical component can include a corresponding electrical connector configured to mate with the electrical connector 234. In some embodiments, at least one of these electrical tracks can include an electrical connector. The presence of the electrical connector can improve the ease of installing the electrical component into the aerosol - supply device 4. The presence of such an electrical connector 234 can also make it easier to remove and replace the electrical component within the device 4.

[0071] The electrical connector 234 can have any suitable form. In some embodiments, the electrical connector 234 includes at least one connector pin 236, for example two connector pins 236, which provide an electrical connection to the electrical component attached to it.

[0072] Figure 4 is a flowchart depicting a method of forming a component for use in an aerosol - supply device according to an embodiment of the present invention. Reference will be made to Figure 2The plastic body 116 shown in [description] illustrates the method, but it should be understood that the method can be used to form any suitable component having any suitable form for use in an aerosol supply device. In step S1, the method includes forming a plastic body, such as the plastic body 116 described above. The step S1 of forming the plastic body may include forming a plastic body having a three-dimensional shape, the plastic body having support features for mounting electrical components to the plastic body. The support features may include, for example, the supports 130A - 130D shown in Figure 2 . The three-dimensional shape may be any non-planar shape.

[0073] The step S1 of forming the plastic body 116 may include forming the plastic body 116 from a material containing an additive, the additive including a metal inorganic compound configured to be activated by a laser.

[0074] In step S2, the method includes irradiating tracks on the plastic body 116 using a laser, such as at least one of the tracks 132A - 132D. Any suitable laser may be used, such as an infrared laser.

[0075] In step S3, the method includes plating the irradiated tracks with a conductive material (such as a conductive metal). Step S3 may include plating the tracks with the conductive material multiple times.

[0076] At least method steps S2 and S3 may be performed multiple times to form multiple conductive tracks.

[0077] The above method of forming a component can advantageously form a component for use in an aerosol supply device, the component including at least one conductive track that can provide an electrical connection between various electrical components within the device. Such a method of forming a component can form part of a larger method of manufacturing / assembling the device. By forming the component according to this method, further manufacturing / assembly steps (such as those related to the production and arrangement of cables for use in the device) can be minimized or even completely omitted. Thus, this can make the manufacturing / assembly process more efficient.

[0078] The various embodiments described herein are only for helping to understand and teach the claimed features. These embodiments are provided only as representative examples of various embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention defined by the claims or on equivalents of the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. In addition to the elements, components, features, parts, steps, devices, etc. specifically described herein, the various embodiments of the invention may suitably include, consist of, or consist essentially of suitable combinations of the disclosed elements, components, features, parts, steps, devices, etc. Further, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An aerosol supply device, comprising: a plurality of electrical components; and a plastic body including at least one conductive track, at least one of the at least one conductive track being configured to provide an electrical connection between at least two of the plurality of electrical components, wherein at least one of the at least one conductive track is formed by laser direct structuring technology.

2. The aerosol supply device according to any one of the preceding claims, wherein, the plastic body is configured to support at least one of the plurality of electrical components.

3. The aerosol supply device according to any one of the preceding claims, wherein, the plastic body is configured to house at least one of the plurality of electrical components.

4. The aerosol supply device according to any one of the preceding claims, wherein, the device includes a housing, and wherein the plastic body is housed within the housing or at least partially defines the housing.

5. The aerosol supply device according to any one of the preceding claims, wherein, the plastic body is formed of modified polyetheretherketone (PEEK).

6. The aerosol supply device according to any one of the preceding claims, wherein, the plurality of electrical components includes at least one of the following electrical components: an electrical power source (e.g., a battery), a heating device, a temperature sensor, a controller, a light source, a haptic device, and a speaker.

7. The aerosol supply device according to any one of the preceding claims, including at least one electrical connector arranged to connect the conductive track to at least one of the plurality of electrical components.

8. The aerosol supply device according to any one of the preceding claims, wherein, at least one of the at least one conductive track includes a plurality of the conductive tracks.

9. The aerosol supply device according to claim 8, wherein, at least two of the plurality of conductive tracks are electrically insulated from each other.

10. The aerosol supply device according to any one of the preceding claims, wherein, the plastic body is made of a plastic material capable of withstanding a temperature of at least 200 °C, such as at least 220 °C, such as at least 250 °C, for a continuous period of time.

11. The aerosol supply device according to claim 10, wherein, the continuous period of time includes at least 60 seconds, such as at least 2 minutes, such as at least 5 minutes.

12. The aerosol supply device according to any one of the preceding claims, wherein, the plastic body is electrically insulating.

13. The aerosol supply device according to any one of the preceding claims, wherein, the plastic body has high chemical resistance.

14. The aerosol supply device according to any one of the preceding claims, wherein, at least one of the at least one conductive track extends in a plurality of different planes.

15. An aerosol supply system, comprising: the aerosol supply device according to any one of the preceding claims; and an article comprising an aerosol-generating material.

16. A method of forming a component for use in an aerosol supply device, the method comprising: forming a plastic body; irradiating tracks on the plastic body using a laser; Coat the irradiated track with a conductive material.

17. The method according to claim 16, wherein the step of coating the irradiated track with a conductive material includes coating the track with the conductive material multiple times.

18. The method according to claim 16 or 17, wherein the step of forming the plastic body includes forming the plastic body having a three-dimensional shape, the plastic body having support features for mounting electrical components to the plastic body.

19. The method according to any one of claims 16 to 18, wherein the step of forming the plastic body includes forming the plastic body from a material containing additives, the additives including metal inorganic compounds configured to be activated by a laser.

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