Heater assembly with shielded microporous insulation

Abstract

The present invention relates to a heater assembly (12) for an aerosol-generating device. The aerosol-generating device comprises a heating chamber (18) for heating an aerosol-forming substrate. The aerosol-generating device includes a heater housing (22) disposed around a heating chamber (18). The heater housing (22) is arranged radially spaced from the heating chamber (18). The heater housing (22) includes an airtight space. The gas-tight space includes a microporous insulating material (38). The airtight space includes a shielding element. The shielding element is configured to cover at least a portion of the microporous insulating material (38).

Description

Technical Field

[0001] The present invention relates to a heater assembly. The present invention relates to an aerosol generating device. The present invention relates to an aerosol generating system. The present invention relates to a method for manufacturing a heater assembly. Background Art

[0002] It is known to provide an aerosol-generating device for generating an inhalable vapor. Such a device can heat an aerosol-forming substrate to a temperature that volatilizes one or more components of the aerosol-forming substrate without burning the aerosol-forming substrate. The aerosol-forming substrate can be provided as part of an aerosol-generating article. The aerosol-generating article can have a strip shape for inserting the aerosol-generating article into a cavity (such as a heating chamber) of the aerosol-generating device. A heating element can be arranged in or around the heating chamber to heat the aerosol-forming substrate once the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device.

[0003] It is desirable to provide an aerosol generating device that can reduce heat loss from a heating chamber. It is desirable to thermally insulate the heating chamber from other components of the aerosol generating device. It is desirable to have an aerosol generating device that can reduce the temperature rise of the outer housing of the device when it is to be grasped by a user. It is desirable to have an aerosol generating device that can provide effective thermal insulation. It is desirable to have an aerosol generating device that can provide thermal insulation at low manufacturing cost. It is desirable to have an aerosol generating device that can have improved thermal insulation. It is desirable to have an aerosol generating device that can have a more compact device size. It is desirable to provide an aerosol generating device with reduced power consumption. It is desirable to provide an aerosol generating device with a reduced risk of contamination of the heating chamber and other components of the aerosol generating device. It is desirable to provide a simplified method for producing a heater assembly. Summary of the Invention

[0004] According to an embodiment of the present invention, a heater assembly for an aerosol-generating device is provided. The heater assembly may include a heating chamber for heating an aerosol-forming substrate. The heater assembly may include a heater housing disposed around the heating chamber. The heater housing may be radially spaced from the heating chamber. The heater housing may include an airtight space. The airtight space may include microporous insulating material. The airtight space may include a shielding element. The shielding element may be configured to cover at least a portion of the microporous insulating material.

[0005] According to an embodiment of the present invention, a heater assembly for an aerosol-generating device is provided. The heater assembly includes a heating chamber for heating an aerosol-forming substrate. The heater assembly includes a heater housing disposed around the heating chamber. The heater housing is radially spaced from the heating chamber. The heater housing includes an airtight space. The airtight space includes a microporous insulating material. The airtight space includes a shielding element. The shielding element is configured to cover at least a portion of the microporous insulating material.

[0006] The aerosol-generating device may have reduced heat loss from the heating chamber. The heating chamber may be thermally insulated from other components of the aerosol-generating device. The aerosol-generating device may provide reduced heating of the outer housing of the device when handled by a user. The aerosol-generating device may provide effective thermal insulation. The aerosol-generating device may provide thermal insulation at low manufacturing cost. The aerosol-generating device may have improved thermal insulation. The aerosol-generating device may have a more compact device size. The aerosol-generating device may have reduced power consumption. The aerosol-generating device may provide a reduced risk of contamination of the heating chamber and other components of the aerosol-generating device. The production method of the heater assembly may be simpler. Shielded microporous insulation material may reduce heat loss from the aerosol-generating device. Shielded microporous insulation material may reduce heating of the outer housing of the device when handled by a user. Shielded microporous insulation material may provide effective thermal insulation. Shielded microporous insulation material may provide thermal insulation at a lower manufacturing cost. Shielded microporous insulation material may reduce the risk of contamination of the heating chamber and other components of the aerosol-generating device.

[0007] The shielding element may be configured to completely cover the microporous insulating material. The shielding element may be arranged within the airtight space. The shielding element may be completely arranged within the airtight space.

[0008] The shielding element may be configured to isolate the microporous insulating material from other components of the heater assembly. The shielding element may be configured to isolate the microporous insulating material from other components of the aerosol generating device. The shielding element may be configured to isolate the microporous insulating material from the heater housing. The shielding element may be configured to isolate the microporous insulating material from the heating chamber. The shielding element may be configured to isolate the microporous insulating material from the heating element. The shielding element may be configured to contain loose portions of the microporous insulating material in a space isolated from other components of the heater assembly.

[0009] A shielding element may be arranged between the microporous insulating material and the heater housing. A shielding element may be arranged between the microporous insulating material and the heating chamber. A shielding element may be arranged between the microporous insulating material and the heating element.

[0010] The shielding element can reduce the risk of contamination of one or more of the heater housing, the heating chamber, and the heating element by loose portions of the microporous insulation material. The shielding element can block portions of the microporous insulation material from contacting other components of the heater assembly. The shielding element can be configured to serve as a barrier between the microporous insulation material and other components of the heater assembly. The shielding element can be configured to trap unwanted debris within the shielding element.

[0011] The shielding element may be made of a non-porous material. The shielding element may be made of a solid material. The shielding element may be configured to be impermeable to loose portions of the microporous insulating material. The shielding element may be configured to be impermeable to dust particles in the microporous insulating material.

[0012] The heater housing may include a compartment configured to hold a microporous insulating material. The compartment may be at least partially formed by a shielding element. The shielding element may include at least one partition wall. The shielding element may include two partition walls. The partition wall may be arranged between the microporous insulating material and the heating chamber. The partition wall may be arranged between the microporous insulating material and at least a portion of the heater housing. The partition wall may be arranged between the microporous insulating material and the heating element. The compartment may be arranged in an airtight space. The partition wall may be arranged in the airtight space. The partition wall may be configured to divide the airtight space into at least two separate areas. Fluid communication between the at least two separate areas may be blocked by the partition wall. The two partition walls may be configured to divide the airtight base into three separate areas. Fluid communication between the three separate areas may be blocked by the two partition walls. The compartment configured to hold the microporous insulating material may be one of the areas. The compartment configured to hold the microporous insulating material may be a centrally arranged area. The partition wall may be configured to be impermeable to loose particles of the microporous insulating material.

[0013] The shielding element may have a circular cross-section. The shielding element may have an elliptical or oval cross-section. The shielding element may have a rectangular cross-section. The shape of the shielding element may match the shape of the microporous insulating material. The shielding element may be cylindrical. The shielding element may have a hollow tubular shape. The shielding element may have an elongated ring shape.

[0014] A microporous insulating material covered by a shielding element may be referred to as a "shielding microporous insulating material." A microporous insulating material at least partially covered by a shielding element may be referred to as a "shielding microporous insulating material." The term "shielding microporous insulating material" may refer to a microporous insulating material at least partially enclosed by a membrane. The term "shielding microporous insulating material" may refer to a microporous insulating material completely enclosed by a membrane. The term "shielding microporous insulating material" may refer to a microporous insulating material at least partially enclosed by a coating. The term "shielding microporous insulating material" may refer to a microporous insulating material completely enclosed by a coating.

[0015] The shielding element may extend in a direction parallel to the longitudinal axis of the aerosol generating device.

[0016] The shielding element may include a cavity. The shielding element may enclose the cavity. The cavity of the shielding element may be configured to retain the microporous insulating material. The shape of the microporous insulating material may match the shape of the cavity. The shape of the microporous insulating material may closely match the shape of the cavity. The cavity may be isolated from the heating element. The cavity may be isolated from the heating chamber. The shielding element may be a hollow ring. The shielding element may be an elongated hollow ring. The cavity may be sealed from other components of the heater assembly.

[0017] The shielding element may include an outer wall. The shielding element may include an inner wall. The outer wall of the shielding element may define an inner wall of the shielding element. The shielding element may include a first intermediate wall. The first intermediate wall of the shielding element may be a proximal intermediate wall. The first intermediate wall may connect the inner wall and the outer wall of the shielding element. The shielding element may include a second intermediate wall. The second intermediate wall of the shielding element may be a distal intermediate wall. The second intermediate wall may connect the inner wall and the outer wall of the shielding element. The first intermediate wall and the second intermediate wall may be arranged at opposite ends of the shielding element.

[0018] The outer wall, inner wall, first intermediate wall, and second intermediate wall of the shielding element may enclose the cavity of the shielding element. The outer wall, inner wall, first intermediate wall, and second intermediate wall of the shielding element may enclose the microporous insulation material. The outer wall of the shielding element may be positioned adjacent to the heater housing. The inner wall of the shielding element may be positioned adjacent to the heating chamber. The inner wall of the shielding element may be positioned adjacent to the heating element. The outer wall of the shielding element may abut the heater housing. The inner wall of the shielding element may abut the heating chamber. The inner wall of the shielding element may abut the heating element. The cavity of the shielding element may be isolated from other components of the heater assembly by one or more of the outer wall, inner wall, first intermediate wall, and second intermediate wall of the shielding element.

[0019] The shielding element may be shaped to match the shape of the heater housing. The shielding element may be shaped to match the shape of the heating chamber. The shielding element may be coaxially aligned around the heating chamber. The heater housing may be coaxially aligned around the shielding element. The heater housing may be coaxially aligned around the microporous insulation material. The microporous insulation material may be coaxially aligned around the heating chamber. The shielding element may be coaxially aligned around the heating element.

[0020] The shielding element may be arranged along at least a portion of the longitudinal axis of the heating chamber.

[0021] The shielding element can be made of a low thermal conductivity material. The microporous insulation material can be a low thermal conductivity material. This can reduce heat loss from the heating chamber.

[0022] The "operating temperature" may depend on the type of aerosol-generating device and the aerosol-forming substrate used. The operating temperature of the aerosol-generating device may be between 150 and 300 degrees Celsius. The operating temperature of the aerosol-generating device may be between 200 and 230 degrees Celsius. The operating temperature of the aerosol-generating device may not exceed 280 degrees Celsius.

[0023] The airtight hollow space can include air as the insulating material. However, at higher temperatures, the thermal conductivity of air may increase. Microporous insulating materials may include small cavities or pores. Air or other gaseous compositions may be encapsulated within these cavities, resulting in a lower thermal conductivity of the microporous insulating material compared to air at elevated temperatures. Compared to its thermal conductivity at room temperature, the microporous insulating material can maintain its thermal conductivity at the operating temperature of the aerosol generating device. The low thermal conductivity of the microporous insulating material can provide better thermal insulation.

[0024] Due to better thermal insulation, the heater housing comprising microporous insulation material may have a reduced outer diameter.Providing the heater housing with an airtight space comprising microporous insulation material may result in an aerosol generating device that may have a more compact device size.

[0025] As used herein, the terms "upstream" and "downstream" are used to describe the relative position of components or parts of components of an aerosol-generating device relative to the direction of airflow through the aerosol-generating device during use. An aerosol-generating device according to the present invention comprises a proximal end through which, in use, aerosol exits the device. The proximal end of the aerosol-generating device may also be referred to as an oral end or a downstream end. The oral end is downstream from the distal end. The distal end of the aerosol-generating article may also be referred to as an upstream end. Components or parts of components of an aerosol-generating device may be described as being upstream or downstream of each other based on their relative position relative to the airflow path of the aerosol-generating device.

[0026] The proximal end of a heater assembly according to the present invention may be configured to be disposed within the aerosol-generating device in a direction toward the mouth end or downstream end of the device. The distal end of a heater assembly according to the present invention may be configured to be disposed within the aerosol-generating device in a direction toward the distal end or upstream end of the device. The longitudinal axis of the heating chamber may extend between the proximal end of the heating chamber and the distal end of the heating chamber. The longitudinal axis of the heating chamber may extend between the proximal end of the heater assembly and the distal end of the heater assembly.

[0027] The heating chamber may be configured to at least partially receive an aerosol-forming substrate. The heating chamber may include a cavity into which the aerosol-forming substrate may be inserted. The aerosol-forming substrate may be part of an aerosol-generating article. The cavity may have a shape corresponding to the shape of the aerosol-generating article to be received in the cavity. The cavity may have a circular cross-section. The cavity may have an oval or rectangular cross-section. The cavity may have an inner diameter corresponding to the outer diameter of the aerosol-generating article.

[0028] The heating chamber may comprise an opening at the proximal end of the heating chamber for receiving the aerosol-forming substrate. The opening may also serve as an air outlet. The heating chamber may comprise an air inlet at the distal end of the heating chamber.

[0029] The heating chamber may have an elongated shape. The heating chamber may be a hollow tube. The hollow tube may be formed by the walls of the heating chamber. The walls of the heating chamber may include or be made of a metal or alloy. The walls of the heating chamber may include or be made of stainless steel.

[0030] The heater housing may be radially spaced apart from the heating chamber by a distance d. The distance d may be measured in a direction orthogonal to the longitudinal axis of the heating chamber. The heating chamber may include a heating chamber wall. The heater housing may include a heater housing wall. The distance d may be measured radially between the heating chamber wall and the heater housing wall. The distance d may be measured radially between an outer side of the heating chamber wall and an inner side of the heater housing wall. The shielding element may have a radial extension corresponding to the distance d. The outer wall of the shielding element may abut the heater housing wall. The inner wall of the shielding element may abut the heating chamber wall.

[0031] The distance d between the heating chamber and the heater housing may be between 1.5 mm and 7 mm. The distance d between the heating chamber and the heater housing may be between 2 mm and 4 mm, preferably about 3.1 mm.

[0032] The heater housing may be coaxially aligned around the heating chamber. The heating chamber and the heater housing may have matching shapes. The matching shapes may allow a constant radial distance d to be provided between the heater housing and the heating chamber.

[0033] The wall of the heater housing can be shaped to match the shape of the wall of the heating chamber along the longitudinal axis of the heating chamber so that the distance d can be substantially constant. For example, the heating chamber can be a hollow tube, and the wall of the heater housing can be a cylindrical wall coaxially aligned around the heating chamber. The distance d can be measured radially between the outer diameter of the hollow tube of the heating chamber and the inner diameter of the cylindrical wall of the heater housing. For example, the heating chamber can be hollow frustoconical, and the wall of the heater housing can be a conical wall coaxially aligned. Those skilled in the art will appreciate that other types of matching shapes are possible. For example, the matching shape can be curved or wavy, or can include a combination of different shapes along the longitudinal axis of the heating chamber.

[0034] The outer wall of the shielding element may match the shape of the wall of the heater housing.The inner wall of the shielding element may match the shape of the wall of the heating chamber.

[0035] The heating chamber and the heater housing may have deviating shapes. The shape of the heater housing wall may deviate to some extent from the shape of the heating chamber wall along the longitudinal axis of the heating chamber. The shape of the heater housing wall may deviate from the shape of the heating chamber wall along the longitudinal axis of the heating chamber such that the distance d along the longitudinal axis of the heating chamber does not vary by more than 1 millimeter. For example, the heating chamber may be a hollow right circular cylinder, and the heater housing wall may be a slightly conical hollow cylinder coaxially aligned around the heating chamber. Due to the conical shape of the heater housing wall, the distance d may not vary by more than 1 millimeter along the longitudinal axis of the heating chamber.

[0036] The outer diameter of the heater housing may be measured in a direction normal to the longitudinal axis of the heating chamber.The outer diameter of the heater housing may be between 8 and 20 mm, preferably between 14 and 18 mm, and preferably about 16 mm.

[0037] The outer diameter of the heating chamber can be measured in a direction orthogonal to the longitudinal axis of the heating chamber. The ratio of the outer diameter of the heater housing to the outer diameter of the heating chamber can be between 1.3 and 3.5, preferably between 1.5 and 2.5, and more preferably about 2.0. In particular, in one embodiment, the outer diameter of the heating chamber can be about 5.6 mm and the outer diameter of the heater housing can be about 17 mm, resulting in a ratio of about 3.0. In one embodiment, the outer diameter of the heating chamber can be about 5.6 mm and the outer diameter of the heater housing can be about 16.5 mm, resulting in a ratio of about 2.95. In one embodiment, the outer diameter of the heating chamber can be about 7.6 mm and the outer diameter of the heater housing can be about 16.5 mm, resulting in a ratio of about 2.17.

[0038] The airtight space can be hermetically sealed from the outside air. In other words, the interior of the airtight space can be fluidly disconnected from the outside air. This avoids heat loss caused by gas circulation between the airtight space and the air outside the heater assembly.

[0039] The airtight space can be at ambient pressure. The air pressure within the airtight space can be between 0.9 bar and 1.1 bar, preferably about 1.0 bar. The airtight space can be filled with a gaseous composition at about ambient pressure at about 20 degrees Celsius. As known to those skilled in the art, temperature-dependent variations in the air pressure within the airtight space may occur. Providing an airtight space at ambient pressure may be less expensive to manufacture than providing an evacuated airtight space under vacuum. Vacuum-based thermal insulation may be more expensive to manufacture.

[0040] It has been found that an airtight hollow space with a distance d between 1.5 mm and 7 mm substantially reduces heat loss. When this distance d is provided, the air or other gaseous composition enclosed within the airtight space can be considered as still air. Still or non-moving air further reduces convection within the airtight space, thereby reducing heat loss due to convection within the airtight space.

[0041] The thermal conductivity of air increases with increasing temperature. The thermal conductivity of air at 25 degrees Celsius is approximately 0.0262 W / m·K. At an operating temperature of 280 degrees Celsius, the thermal conductivity of air is already approximately 0.043 W / m·K. Therefore, using only air in an airtight hollow space as an insulating material may require a relatively large air gap thickness to provide sufficient thermal insulation.

[0042] The microporous insulation material may have a lower thermal conductivity than air at room temperature. At higher temperatures, the difference between the thermal conductivity of air and the microporous insulation material may be even greater. The thermal conductivity of the microporous insulation material may not increase as quickly as the thermal conductivity of air. The microporous insulation material may nearly maintain its thermal conductivity even at high temperatures. For example, the thermal conductivity of the microporous insulation material may be 0.018 W / m·K at 20 degrees Celsius. At 200 degrees Celsius, the thermal conductivity is 0.022 W / m·K. At a temperature of 400 degrees Celsius, the thermal conductivity increases to 0.028 W / m·K according to ASTM C177. The thermal conductivity of this exemplary microporous insulation material is almost the same as that of air at room temperature even at temperatures higher than the maximum operating temperature of the aerosol generating device. Lower thermal conductivity results in better thermal insulation.

[0043] An airtight space comprising an insulating material with lower thermal conductivity may have a smaller thickness while still providing sufficient thermal insulation. An airtight space comprising a microporous insulating material rather than an airtight hollow space comprising only air may have a smaller distance d. A smaller distance d may result in a smaller outer diameter of the aerosol generating device.

[0044] Suitable microporous insulating materials for use in the present invention may have a pore size of less than 100 nanometers, preferably less than 70 nanometers, more preferably less than 50 nanometers, more preferably less than 20 nanometers, more preferably less than 2 nanometers.

[0045] The microporous insulating material can be inorganic. The microporous insulating material can be ceramic. The microporous insulating material can include silicon dioxide (SiO2). The microporous insulating material can include pyrogenic silica. The microporous insulating material can include other components, such as sunscreens and fibers. Sunscreens can scatter infrared radiation and thereby reduce the transmission of infrared radiation.

[0046] The microporous insulating material of the present disclosure may have a density of less than 500 kg / m 3, preferably less than 400kg / m 3 , more preferably less than 300kg / m 3 Nominal density.

[0047] The microporous insulation material of the present invention may have a thermal conductivity of less than 0.05 W / m·K, preferably less than 0.04 W / m·K, more preferably less than 0.03 W / m·K, and more preferably less than 0.02 W / m·K at 20 degrees Celsius and in accordance with ASTM C177. The microporous insulation material may have a thermal conductivity of less than 0.05 W / m·K, preferably less than 0.04 W / m·K, and more preferably less than 0.03 W / m·K at 280 degrees Celsius and in accordance with ASTM C177. The thermal conductivity of the microporous insulation material at 280 degrees Celsius may be increased by up to 40%, preferably by up to 30%, and more preferably by up to 20%, compared to the thermal conductivity of the microporous insulation material at 20 degrees Celsius.

[0048] At the operating temperature of the aerosol generating device, an airtight space comprising the shielding microporous insulating material may have a lower thermal conductivity than the same airtight hollow space comprising displaced ambient air.

[0049] The airtight space may be completely filled with shielding microporous insulation material.

[0050] Alternatively, the airtight space may not be completely filled with the shielding microporous insulating material. By not completely filling the airtight space with the shielding microporous insulating material, the weight of the aerosol generating device can be reduced. However, the airtight space may be at least partially filled with the shielding microporous insulating material. The airtight space may also be at least partially filled with a gaseous composition. The gaseous composition may be at ambient pressure. The gaseous composition may be air. The gaseous composition may include one or more of nitrogen, argon, carbon dioxide, oxygen, krypton, sulfur hexafluoride, or mixtures thereof, or other suitable gaseous compositions.

[0051] By additionally providing the gaseous composition to the airtight space, the weight of the aerosol generating device can be reduced. Providing the gaseous composition to the airtight space can reduce manufacturing costs.

[0052] The volume of the airtight space filled with shielding microporous insulating material may be 30%, 40%, 50%, 60%, 70%, 80% or 90% by volume. The ratio of microporous insulating material to gaseous composition may depend on the operating temperature of the aerosol generating device. Aerosol generating devices with higher operating temperatures may require more microporous insulating material.

[0053] The airtight space may include at least one air gap. The gaseous composition may be disposed in the air gap.

[0054] The airtight space may include one air gap. The airtight space may include two air gaps. The airtight space may include three air gaps. The shielding microporous insulating material may be sandwiched between the two air gaps in the radial direction.

[0055] The air gap may have a thickness measured in a direction orthogonal to the longitudinal axis of the heating chamber.The thickness of the air gap may be between 0.5 mm and 4 mm, preferably between 1 mm and 3 mm, more preferably about 2 mm.

[0056] The one or more air gaps may be within the microporous insulating material. The air gaps may be located between shielding portions of the microporous insulating material. The one or more air gaps may extend in a direction parallel to the longitudinal axis of the aerosol generating device. The one or more air gaps may have a longitudinal extension that is the same as or shorter than the longitudinal extension of the shielding microporous insulating material. The one or more air gaps may have a circular cross-section. Alternatively, the one or more air gaps may not extend around the entire periphery of the shielding microporous insulating material. The one or more air gaps may be completely surrounded by the shielding microporous insulating material. As described in more detail below, the one or more air gaps may be in direct contact with the first connecting wall and the second connecting wall. The one or more air gaps may be in direct contact with the heating chamber. The one or more air gaps may be in direct contact with the heater housing.

[0057] Providing an air gap within the airtight space can reduce the weight of the aerosol generating device. By providing an air gap within the airtight space, manufacturing costs can be reduced.

[0058] The shielding microporous insulation material may be in direct contact with the heating chamber. The shielding microporous insulation material may be surrounded by an air gap. The temperature around the heating chamber may decrease radially with increasing distance from the longitudinal axis of the heating chamber. The microporous insulation material may provide better thermal insulation at higher temperatures than, for example, air.

[0059] The heater assembly may include a first microporous insulating material and a second microporous insulating material. At least a portion of the first microporous insulating material may be covered by a first shielding element. At least a portion of the second microporous insulating material may be covered by a second shielding element. The first shielding microporous insulating material and the second shielding microporous insulating material may be arranged in an airtight space. The first microporous insulating material and the second microporous insulating material may be separated by an air gap in a radial direction orthogonal to the longitudinal axis of the heating chamber.

[0060] The shielding element may be configured to at least partially circumscribe the microporous insulating material.The shielding element may be configured to completely circumscribe the microporous insulating material.

[0061] The shielding element may be configured to at least partially enclose the microporous insulating material.The shielding element may be configured to completely enclose the microporous insulating material.

[0062] The shielding element may be configured to abut at least a portion of the microporous insulation material.

[0063] The shielding element may be configured to abut the microporous insulating material. The shielding element may be configured to contact at least a portion of the microporous insulating material. The shielding element may be configured to contact the microporous insulating material. The shielding element may be configured to contact a surface of the microporous insulating material. The shielding element may be configured to contact an outer surface of the microporous insulating material. The shielding element may be configured to line the surface of the microporous insulating material. The shielding element may be configured to completely cover the surface of the microporous insulating material. The shielding element may be configured to completely cover the outer surface of the microporous insulating material. The shielding element may be configured to encapsulate the microporous insulating material. The shielding element may be configured as an outer shell for the microporous insulating material.

[0064] The heater assembly may include a heating element. The heating element may be arranged at least partially around the heating chamber.

[0065] The heating chamber may include a heating element. The heating element may be arranged at least partially around a wall of the heating chamber. The heating element may be arranged completely coaxially around an outer periphery of the wall of the heating chamber. The heating element may be arranged along at least a portion of a longitudinal axis of the heating chamber.

[0066] The heating element may comprise one or more conductive tracks on an electrically insulating substrate. The one or more conductive tracks may be resistive heating tracks. The one or more conductive tracks may be configured as susceptors to be inductively heated. The electrically insulating substrate may be a flexible substrate.

[0067] The heating element may be flexible and may be wrapped around the heating chamber.The heating element may be arranged between the heating chamber and the heater housing.

[0068] The shielding microporous insulation material can have a longitudinal extension that is the same as or greater than the longitudinal extension of the heating element.Thereby, appropriate thermal insulation of the heat generated by the heating element can be ensured.

[0069] The shielding microporous insulation material may extend around the heating element.The shielding element may extend around the heating element.

[0070] In all aspects of the present disclosure, the heating element may comprise a resistive material. Suitable resistive materials include, but are not limited to, semiconductors (such as doped ceramics), "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made from ceramic and metallic materials. Such composite materials may comprise doped or undoped ceramics.

[0071] As described, in any of the aspects of the present disclosure, the heating element may be part of a heating chamber of a heater assembly for an aerosol-generating device. The heater assembly may include an internal heating element, an external heating element, or both, where "internal" and "external" refer to the aerosol-forming substrate. The internal heating element may take any suitable form. For example, the internal heating element may take the form of a heating blade. Alternatively, the internal heater may take the form of a sleeve or substrate having different conductive portions, or a resistive metal tube. Alternatively, the internal heating element may be one or more heating needles or rods extending through the center of the aerosol-forming substrate. Other alternatives include heating wires or filaments, for example, Ni-Cr (nickel-chromium), platinum, tungsten or alloy wires, or heating plates. Alternatively, the internal heating element may be deposited in or onto a rigid carrier material. In one such embodiment, the resistive heating element may be formed using a metal having a defined relationship between temperature and resistivity. In such exemplary devices, the metal may be formed as a track on a suitable insulating material (such as a ceramic material) and then sandwiched between another insulating material (such as glass). A heater formed in this manner may be used to both heat and monitor the temperature of the heating element during operation.

[0072] The external heating element can adopt any suitable form.For example, the external heating element can adopt the form of one or more flexible heating foils on a dielectric substrate (for example, polyimide).The flexible heating foil can be shaped to the periphery of the matrix receiving cavity.Alternatively, the external heating element can adopt the form of a metal grid or a plurality of metal grids, a flexible printed circuit board, a molded interconnect device (MID), a ceramic heater, a flexible carbon fiber heater, or can use a coating technology (for example, plasma vapor deposition) to form on a suitable forming substrate.The external heating element can also be formed using a metal with a defined relationship between temperature and resistivity.In such an exemplary device, metal can be formed as a track between two layers of suitable insulating materials.The external heating element formed in this way can be used for both heating and monitoring the temperature of the external heating element during operation.

[0073] Advantageously, the heating element heats the aerosol-forming substrate by heat conduction. The heating element may at least partially contact the substrate or a carrier on which the substrate is placed. Alternatively, heat from an internal heating element or an external heating element may be conducted to the substrate by means of a thermally conductive element.

[0074] During operation, the aerosol-forming substrate may be completely contained within the aerosol-generating device. In this case, the user may draw on the mouthpiece of the aerosol-generating device. Alternatively, during operation, the smoking article containing the aerosol-forming substrate may be partially contained within the aerosol-generating device. In this case, the user may draw directly on the smoking article.

[0075] The heating element may be configured as an induction heating element. The induction heating element may include an induction coil and a susceptor. Generally, a susceptor is a material capable of generating heat when penetrated by an alternating magnetic field. According to the present invention, the susceptor may be electrically conductive or magnetic, or both. The alternating magnetic field generated by one or more induction coils may heat the susceptor, which then transfers the heat to the aerosol-forming substrate, causing aerosol to form. Heat transfer may be primarily by thermal conduction. Such heat transfer may be optimal if the susceptor is in close thermal contact with the aerosol-forming substrate. When an induction heating element is employed, the induction heating element may be configured as an internal heating element as described herein or as an external heater as described herein. If the induction heating element is configured as an internal heating element, the susceptor element is preferably configured as a pin or blade for penetrating the aerosol-generating article. If the induction heating element is configured as an external heating element, the susceptor element is preferably configured as a cylindrical susceptor that at least partially surrounds the cavity or forms a sidewall of the cavity.

[0076] The heating chamber may include a central region comprising the heating element. The term central region refers to the longitudinal direction. The heating chamber may further include a proximal region and a distal region. The proximal region and the distal region may be spaced apart from the heating element in the longitudinal direction. During use, the proximal region and the distal region may be cooler than the central region of the heating chamber. The first connecting wall may contact the heating chamber in the proximal region, and the second connecting wall may contact the heating chamber in the distal region. Thus, during use, the first connecting wall and the second connecting wall may contact the heating chamber at the coldest point of the heating chamber. This may further reduce heat loss from the heating chamber to the connecting walls and the heater housing. This may further improve thermal insulation.

[0077] The shielding element may be arranged radially outside the heating element.

[0078] The shielding element may comprise a membrane.

[0079] The shielding element can be designed as a film.The shielding element can be composed of a film.

[0080] The microporous insulating material may be configured to be wrapped with a membrane.

[0081] The membrane can be made of a low thermal conductivity material. The membrane can be made of a polymer material. The membrane can be a plastic film. The membrane can be flexible. The membrane can be non-porous.

[0082] The membrane may completely cover the microporous insulating material. The membrane may completely cover the surface of the microporous insulating material. The membrane may completely cover the outer surface of the microporous insulating material. The membrane may encapsulate the microporous insulating material. The microporous insulating material may be completely encased in the membrane. The membrane may completely enclose the microporous insulating material. The membrane may coat the microporous insulating material. The membrane may enclose the cavity of the shielding element. The membrane may be positioned adjacent to the microporous insulating material. The membrane may be lined with the microporous insulating material. The membrane may be configured to conform to the shape of the microporous insulating material.

[0083] The membrane may prevent loose portions of the microporous insulation material from contaminating one or more of the heater housing, the heating element, and the heating chamber.

[0084] The film may be stable at the operating temperature of the heater assembly.The film may be stable at the operating temperature of the aerosol generating device.The film may be configured to withstand temperatures between 200 degrees Celsius and 260 degrees Celsius.

[0085] The film may be selected from one of a polyimide film, a polyetheretherketone film, and a polyurethane film.

[0086] The membrane may be made of thermoplastic polyurethane.

[0087] The shielding element may include an adhesive. The adhesive may be configured to couple the membrane to the microporous insulating material.

[0088] The adhesive may be disposed between the microporous insulating material and the membrane. The adhesive may be disposed on at least a portion of an outer surface of the microporous insulating material. The adhesive may be disposed on at least a portion of the membrane. The adhesive may be configured to attach the membrane to the microporous insulating material. The adhesive may line at least a portion of the membrane.

[0089] The adhesive may be a silicone adhesive.

[0090] The film and adhesive together may have a thickness of less than 70 microns, preferably less than 65 microns, and more preferably have a thickness of about 60 microns.

[0091] A film and adhesive together having a thickness of less than 70 microns can provide the shielding element with sufficient flexibility to be placed around the microporous insulation material. A film and adhesive together having a thickness of less than 70 microns can provide the shielding element with sufficient flexibility to conform to the shape of the microporous insulation material.

[0092] The shielding element may be configured as a coating on the microporous insulating material. The coating may be a paint.

[0093] The shielding element may be comprised of a coating. The coating may be disposed on the outer surface of the microporous insulating material. The coating may be disposed on at least a portion of the outer surface of the microporous insulating material. The coating may be disposed on the outer surface of the microporous insulating material. The coating may completely cover the microporous insulating material. The coating may completely cover the surface of the microporous insulating material. The coating may completely cover the outer surface of the microporous insulating material. The coating may completely enclose the microporous insulating material. The coating may encase the microporous insulating material. The coating may be applied to the outer surface of the microporous insulating material. The coating may be adhered to the outer surface of the microporous insulating material.

[0094] The coating may prevent the microporous insulating material from contaminating one or more of the heater housing, the heating element, and the heating chamber. The coating may prevent the microporous insulating material from contacting one or more of the heater housing, the heating element, and the heating chamber.

[0095] The coating may be non-porous. The coating may be made of a low thermal conductivity material. The coating may include an elastomer.

[0096] The coating may be an anti-fouling coating. The coating may be configured to be anti-fouling. The coating may be a non-stick coating. The coating may be stable at the operating temperature of the heater assembly. The coating may be stable at the operating temperature of the aerosol generating device. The coating may be configured to withstand temperatures between 200° C. and 260° C.

[0097] The coating may be a silicone coating.

[0098] The microporous insulating material may include silicon dioxide.

[0099] One or more of the heating chamber, heater housing, microporous insulation material, and heating element may be configured as a hollow tube.

[0100] The heater assembly may include a first connecting wall connecting the heating chamber and the heater housing. The heater assembly may include a second connecting wall connecting the heating chamber and the heater housing. An airtight space may be defined between the heating chamber, the heater housing, and the first connecting wall and the second connecting wall.

[0101] The airtight space can be defined by the walls of the heating chamber and the heater housing, and the first and second connecting walls. The first and second connecting walls can facilitate assembly of the airtight space. The first and second connecting walls can simplify manufacturing of the airtight space. Providing the first and second connecting walls can ensure that the heater housing is a defined distance d from the heating chamber. Providing the first and second connecting walls can ensure proper placement of the shielding microporous insulation material. The first and second connecting walls can contact the shielding microporous insulation material, thereby preventing heat loss via air convection at the proximal and distal ends of the shielding microporous insulation material.

[0102] Each of the first and second connecting walls may extend between a wall of the heating chamber and a wall of the heater housing. The first and second connecting walls may sealingly connect the heater housing to an outer wall of the heating chamber. The connecting walls may be oriented perpendicular to a longitudinal axis of the heating chamber. The first connecting wall may be a proximal connecting wall. The second connecting wall may be a distal connecting wall.

[0103] The first connecting wall may be configured to abut the first intermediate wall.The second connecting wall may be configured to abut the second intermediate wall.

[0104] The shielding element may be in direct contact with the heating chamber. The shielding element may be in direct contact with the heater housing. The shielding element may be in direct contact with the first connecting wall and the second connecting wall. The shielding element may be in direct contact with the heating chamber and the heater housing. The shielding element may be in direct contact with the heating chamber, the heater housing, and the first connecting wall and the second connecting wall. The shielding microporous insulating material may be installed between the first connecting wall and the second connecting wall. The shielding microporous insulating material may be arranged to span the distance between the first connecting wall and the second connecting wall. The shielding microporous insulating material may be installed between the first connecting wall and the second connecting wall while not contacting one or both of the heater housing and the heating chamber.

[0105] The shielding microporous insulating material may have an elongate extension.The shielding microporous insulating material may extend parallel to a longitudinal axis of the heating chamber.The shielding microporous insulating material may be a hollow tube extending around the heating chamber.

[0106] The shielding microporous insulation material may have a thickness measured in a direction perpendicular to the longitudinal axis of the heating chamber. The shielding microporous insulation material may have a thickness that is the same as the distance d. The thickness of the shielding microporous insulation material may be between 1 mm and 7 mm, preferably between 2 mm and 6 mm, and more preferably between 3 mm and 5 mm.

[0107] The microporous insulating material may be formed from a single element. Alternatively, the microporous insulating material may be formed from at least two insulating elements. The heater assembly may include two or more shielding elements as described herein. One or more insulating elements may be covered by a shielding element as described herein. Each insulating element may be at least partially covered by a separate shielding element as described herein. Each insulating element may be covered by a shielding element as described herein. A single shielding element as described herein may cover at least two insulating elements. The microporous insulating material may be formed from two insulating elements. The two insulating elements may each be covered by a shielding element as described herein. The two insulating elements may be covered by a single shielding element as described herein.

[0108] The microporous insulation material can be formed from at least a first insulation element including at least a first connecting element and a second insulation element including at least a second connecting element. The first microporous insulation element can be at least partially covered by a shielding element as described herein. The second microporous insulation element can be at least partially covered by a shielding element as described herein. The shielding element as described herein can enclose the first microporous insulation element. The shielding element as described herein can enclose the second microporous insulation element. The shielding element as described herein can enclose both the first microporous insulation element and the second microporous insulation element. The first and second connecting elements can be configured as matching connecting elements. When connected, the matching connecting elements can connect the first and second microporous insulation elements. The connected first and second connecting elements can form the overall insulation material into a hollow tube. The hollow tube can have an inner diameter corresponding to the outer diameter of the heating chamber. Providing the microporous insulation material from two insulation elements can facilitate assembly of the microporous insulation material around the heating chamber. By forming the shielded microporous insulation material from two insulation elements, a perfect form fit between the shielded microporous insulation material and the heating chamber can be provided. Providing a perfect form fit between the shielded microporous insulation material and the heating chamber can ensure better thermal insulation.

[0109] The first connecting element and the second connecting element can be configured as a male connecting element and a female connecting element, a form-fitting connecting element, a snap-fit connecting element, a bayonet connecting element, or a mixture thereof, or other commonly used connecting elements known to those skilled in the art. The first connecting element may include a male connecting element and the second connecting element may include a female connecting element. The first connecting element and the second connecting element may include a form-fitting connecting element. The first connecting element and the second connecting element may include a snap-fit connecting element. The first connecting element and the second connecting element may include a bayonet connecting element.

[0110] The microporous insulating material can be configured as a two-piece assembly. The two-piece assembly can include a first microporous insulating element and a second microporous insulating element. The first microporous insulating element and the second microporous insulating element can be, for example, in the form of hollow semi-cylindrical elements. The hollow semi-cylindrical elements can include matching first and second connecting elements. When connected, the hollow semi-cylindrical elements can form a single hollow tube. The inner diameter of the hollow tube can be the same size as the outer diameter of the heating chamber. Each of the first microporous insulating element and the second microporous insulating element can be at least partially covered by a shielding element as described herein. The close proximity or direct contact of the shielding microporous insulating material with the heating chamber can improve the thermal insulation of the heating chamber.

[0111] The heating chamber may include a temperature sensor. The temperature sensor may be located on the top of the heating chamber. The shielding microporous insulation material may have a shape that matches the temperature sensor. The shielding microporous insulation material may have a cavity facing the temperature sensor. The shielding microporous insulation material may completely enclose the heating chamber. The temperature sensor may be enclosed by the shielding microporous insulation material. The temperature sensor may be sandwiched between the heating chamber and the shielding microporous insulation material.

[0112] The walls of the heating chamber may be made of stainless steel. This may advantageously enhance the effect that during use, the proximal and distal regions may be cooler than the central region of the heating chamber.

[0113] The thickness of the heater housing wall can be less than approximately 2 mm. The thickness of the heater housing wall can be less than 1.2 mm, preferably approximately 0.8 mm. The thickness of one or both of the first connecting wall and the second connecting wall can be less than 1.2 mm, preferably approximately 0.8 mm. With such thin walls, the thermal mass of the heater housing can be minimized. This can further reduce heat loss from the heating chamber.

[0114] The walls of the heater housing and one or more of the first and second connecting walls may be made of a material with low thermal conductivity. This can further reduce heat loss from the heating chamber. The walls of the heater housing may include or be made of a plastic material. The first and second connecting walls may include or be made of a plastic material. The plastic material may include one or both of polyaryletherketone (PAEK), polyetheretherketone (PEEK), and polyphenylenesulfone (PPSU). Preferably, the plastic material includes polyphenylenesulfone (PPSU).

[0115] The interior of the walls of the heater housing may include a metal coating. The interior of one or both of the first connecting wall and the second connecting wall may include a metal coating. The metal coating may reduce the emissivity of the interior of the wall. For example, the emissivity of a PEEK wall may be reduced from approximately 0.95 to approximately 0.4. The metal coating may reflect thermal radiation emitted from the heating chamber. The metal coating may provide additional thermal insulation of the heating chamber from the exterior of the heater housing. The metal coating may be a low-emissivity metal coating. The metal coating may include one or more of aluminum, gold, and silver.

[0116] The airtight space may be at least partially filled with the microporous insulating material.The airtight space may be only partially filled with the microporous insulating material.

[0117] The airtight space may be only partially filled with shielding microporous insulating material. The airtight space may be only partially filled with shielding microporous insulating material.

[0118] The airtight space may include at least one air gap.

[0119] The microporous insulating material may be sandwiched between the two air gaps in the radial direction.

[0120] The shielding microporous insulation material may be sandwiched between the two air gaps in the radial direction.

[0121] The microporous insulating material may have an elongate extension.The microporous insulating material may extend parallel to a longitudinal axis of the heating chamber.

[0122] The shielding microporous insulating material may have an elongate extension.The shielding microporous insulating material may extend parallel to a longitudinal axis of the heating chamber.

[0123] Preferably, the shielding element is configured as a membrane, and the membrane is configured to completely enclose the microporous insulating material.

[0124] Preferably, the shielding element is configured as a coating, and the coating is configured to completely enclose the microporous insulating material.

[0125] The present invention also relates to an aerosol generating device comprising a heater assembly as described above.

[0126] The aerosol generating device may include a power supply configured to supply power to the heating element. The power supply may include a power source. The power source may be a battery. The power source may be a lithium-ion battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging. For example, the power source may have sufficient capacity to allow continuous aerosol generation for a period of approximately six minutes, or for a multiple of six minutes. In another example, the power source may have sufficient capacity to allow a predetermined number of puffs or discontinuous activation of the heater assembly.

[0127] The power supply may include control electronics. The control electronics may include a microcontroller. The microcontroller may be a programmable microcontroller. The circuitry may include additional electronic components. The circuitry may be configured to regulate the power supply to the heater assembly. Power may be supplied to the heater assembly continuously after system activation, or may be supplied intermittently, such as on a puff-by-puff basis. Power may be supplied to the heater assembly in the form of current pulses.

[0128] The present invention also relates to an aerosol generating system comprising an aerosol generating device as described herein and an aerosol-forming substrate which may be configured to be at least partially received in a heating chamber.

[0129] The present invention also relates to an aerosol generating system comprising an aerosol generating device as described herein and an aerosol-forming substrate configured to be at least partially received in a heating chamber.

[0130] As used herein, the term "aerosol-forming substrate" may refer to a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds can be released by heating or burning the aerosol-forming substrate. As an alternative to heating or burning, in some cases, the volatile compounds can be released by a chemical reaction or by mechanical stimulation (such as ultrasound). The aerosol-forming substrate can be solid or liquid, or can include both solid and liquid components. The aerosol-forming substrate can be part of an aerosol-generating article.

[0131] The aerosol-forming substrate can be a solid aerosol-forming substrate. The aerosol-forming substrate can include both solid components and liquid components. The aerosol-forming substrate can include a tobacco-containing material that contains volatile tobacco flavor compounds released from the substrate when heated. The aerosol-forming substrate can include a non-tobacco material. The aerosol-forming substrate can include an aerosol-forming agent that contributes to the formation of a dense and stable aerosol. Examples of suitable aerosol-forming agents are glycerol and propylene glycol.

[0132] As used herein, the term "aerosol-generating article" may refer to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. The aerosol-generating article may be disposable.

[0133] As used herein, the term "aerosol-generating device" may refer to a device that interacts with an aerosol-forming substrate to generate an aerosol. An aerosol-generating device may interact with one or both of an aerosol-generating article comprising an aerosol-forming substrate and a cartridge comprising an aerosol-forming substrate. In some examples, the aerosol-generating device may heat the aerosol-forming substrate to facilitate release of volatile compounds from the substrate. An electrically operated aerosol-generating device may include an atomizer, such as an electric heater, to heat the aerosol-forming substrate to form the aerosol.

[0134] As used herein, the term "aerosol-generating system" may refer to the combination of an aerosol-generating device and an aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol-generating article, the aerosol-generating system refers to the combination of the aerosol-generating device and the aerosol-generating article. In an aerosol-generating system, the aerosol-forming substrate and the aerosol-generating device cooperate to generate an aerosol.

[0135] The present invention also relates to a method for manufacturing a heater assembly as described above, wherein the method may comprise the following steps:

[0136] a) providing a shielding element configured as a membrane,

[0137] b) applying an adhesive to at least a portion of the film,

[0138] c) coupling the microporous insulating material to at least a portion of the membrane via an adhesive,

[0139] d) folding at least a portion of the membrane over at least a portion of the microporous insulating material to at least partially enclose the microporous insulating material, and

[0140] e) Arranging the at least partially enclosed microporous insulation material in the airtight space.

[0141] The present invention also relates to a method for manufacturing a heater assembly as described above, wherein the method comprises the following steps:

[0142] a) providing a shielding element configured as a membrane,

[0143] b) applying an adhesive to at least a portion of the film,

[0144] c) coupling the microporous insulating material to at least a portion of the membrane via an adhesive,

[0145] d) folding at least a portion of the membrane over at least a portion of the microporous insulating material to at least partially enclose the microporous insulating material, and

[0146] e) Arranging the at least partially enclosed microporous insulation material in the airtight space.

[0147] The membrane may include a protective layer. An adhesive may be applied to the membrane. The protective layer may be removably attached to the adhesive applied to the membrane. The protective layer may be removed before the microporous insulating material is coupled to at least a portion of the membrane via the adhesive. The protective layer may reduce the risk of contamination of the adhesive before application to the membrane. The use of the protective layer may improve the fit between the microporous insulating material and the adhesive.

[0148] In step a), the provided membrane may be a cross-shaped membrane having at least four arms connected by a central portion. In step b), an adhesive may be applied to at least a portion of the central portion of the membrane. In step c), the microporous insulating material may be coupled to at least a portion of the central portion of the cross-shaped membrane via the adhesive. In step d), at least three arms of the cross-shaped membrane may be folded over at least a portion of the microporous insulating material to at least partially enclose the microporous insulating material.

[0149] The membrane may be cross-shaped. The membrane may have a symmetrical cross shape. The membrane may have a center portion. The center portion may be rectangular. The membrane may have four arms. The four arms may be arranged around the center portion of the membrane. One or more of the four arms may be rectangular. Each arm may be arranged along an edge of the center portion of the membrane. The arms at opposite edges of the center portion may be configured to be identical. The arms at opposite edges of the center portion may be configured to be different. The two arms arranged at a first pair of opposite edges of the center portion may be configured to be identical. The two arms arranged at a second pair of opposite edges of the center portion may be configured to be different. The arms arranged at the first edge of the center portion may be configured to be elongated compared to the arms arranged at the second edge of the center portion opposite the first edge. The elongated arms may be wrapped around the microporous insulation material to secure the microporous insulation material to the heating chamber. The four arms and the center portion may form a continuous membrane.

[0150] In step a), the cross-shaped membrane provided may have a first arm that is elongated compared to arms arranged relative to the first arm. In step d), the second arm, the third arm, and the fourth arm may be folded over at least a portion of the central portion of the membrane to at least partially enclose the microporous insulating material. In step e), by wrapping the first arm at least partially around the microporous insulating material, the at least partially enclosed microporous insulating material may be wrapped around the heating chamber and assembled into the heating chamber.

[0151] In step a), the cross-shaped membrane provided may have opposing arms configured identically. In step d), all four arms may be folded toward the central portion of the membrane to completely enclose the microporous insulating material. In step e), the enclosed microporous insulating material may be placed adjacent to the heater housing.

[0152] The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0153] Example 1: A heater assembly for an aerosol generating device, comprising

[0154] a heating chamber for heating the aerosol-forming substrate;

[0155] a heater housing arranged around the heating chamber, wherein the heater housing is arranged radially spaced from the heating chamber, wherein the heater housing includes an airtight space, and wherein the airtight space includes a microporous insulating material,

[0156] The airtight space includes a shielding element, wherein the shielding element is configured to cover at least a portion of the microporous insulating material.

[0157] Example 2: The heater assembly of Example 1, wherein the shielding element is configured to at least partially, and preferably completely, circumscribe the microporous insulating material.

[0158] Example 3: The heater assembly of Example 2, wherein the shielding element is configured to at least partially, and preferably completely, enclose the microporous insulation material.

[0159] Example 4: The heater assembly of any of the preceding examples, wherein the shielding element is configured to abut at least a portion of the microporous insulation material.

[0160] Example 5: The heater assembly according to any of the preceding examples, wherein the heater assembly comprises a heating element, wherein the heating element is preferably arranged at least partially around the heating chamber.

[0161] Example 6: The heater assembly of Example 5, wherein the shielding element is disposed radially outward from the heating element.

[0162] Example 7: The heater assembly of any of the preceding examples, wherein one or more of the heating chamber, the heater housing, the microporous insulation material, and the heating element of example 5 or example 6 are configured as hollow tubes.

[0163] Example 8: The heater assembly according to any one of the preceding examples further includes a first connecting wall connecting the heating chamber and the heater shell and a second connecting wall connecting the heating chamber and the heater shell, wherein the airtight space is defined between the heating chamber, the heater shell and the first connecting wall and the second connecting wall.

[0164] Example 9: The heater assembly of any of the preceding examples, wherein the airtight space is at least partially filled with the microporous insulating material, preferably wherein the airtight space is only partially filled with the microporous insulating material.

[0165] Example 10: The heater assembly of any of the preceding examples, wherein the airtight space comprises at least one air gap.

[0166] Example 11: The heater assembly of Example 10, wherein the microporous insulating material is sandwiched between two air gaps in a radial direction.

[0167] Example 12: The heater assembly of any of the preceding examples, wherein the microporous insulating material has an elongated extension, and wherein the microporous insulating material preferably extends parallel to a longitudinal axis of the heating chamber.

[0168] Example 13: The heater assembly of any of the preceding examples, wherein the shielding element comprises a membrane.

[0169] Example 14: The heater assembly of Example 13, wherein the microporous insulating material is configured to be wrapped by the film.

[0170] Example 15: The heater assembly of Example 13 or Example 14, wherein the film is selected from one of a polyimide film, a polyetheretherketone film, and a polyurethane film.

[0171] Example 16: The heater assembly of any of Examples 13 to 15, wherein the shielding element comprises an adhesive, wherein the adhesive is configured to couple the membrane to the microporous insulating material.

[0172] Example 17: The heater assembly of Example 16, wherein the adhesive is a silicone adhesive.

[0173] Example 18: The heater assembly of Example 16 or Example 17, wherein the film and the adhesive together have a thickness of less than 70 microns, preferably less than 65 microns, and more preferably have a thickness of about 60 microns.

[0174] Example 19: The heater assembly of any of Examples 1 to 12, wherein the shielding element is configured as a coating on the microporous insulating material, preferably wherein the coating is a paint.

[0175] Example 20: The heater assembly of Example 19, wherein the coating is a silicone coating.

[0176] Example 21: The heater assembly of any of the preceding examples, wherein the microporous insulating material comprises silicon dioxide.

[0177] Example 22: An aerosol-generating device comprising a heater assembly according to any of the preceding examples.

[0178] Example 23: An aerosol-generating system comprising an aerosol-generating device according to Example 22 and an aerosol-forming substrate configured to be at least partially received in the heating chamber.

[0179] Example 24: A method for manufacturing a heater assembly according to any one of Examples 13 to 18, comprising the following steps:

[0180] a) providing a shielding element configured as a membrane,

[0181] b) applying an adhesive to at least a portion of the film,

[0182] c) coupling the microporous insulating material to at least a portion of the membrane via the adhesive,

[0183] d) folding at least a portion of the membrane over at least a portion of the microporous insulating material to at least partially enclose the microporous insulating material, and

[0184] e) Arranging the at least partially enclosed microporous insulating material in the airtight space.

[0185] Example 25: The method according to Example 24, wherein in step a), the membrane provided is a cross-shaped membrane having at least four arms connected by a central portion,

[0186] wherein in step b), the adhesive is applied to at least a portion of the central portion of the film,

[0187] wherein in step c), the microporous insulating material is coupled to at least a portion of the central portion of the cross-shaped membrane via the adhesive, and

[0188] wherein in step d), at least three arms of the cross-shaped membrane are folded over at least a portion of the microporous insulating material to at least partially close the microporous insulating material.

[0189] Example 26: The method according to example 25, wherein in step a), the cross-shaped membrane provided has a first arm that is elongated compared to an arm arranged opposite to the first arm,

[0190] wherein in step d), the second arm, the third arm and the fourth arm are folded over at least a portion of the central portion of the membrane to at least partially enclose the microporous insulating material,

[0191] wherein in step e), the at least partially enclosed microporous insulating material is wrapped around the heating chamber and assembled to the heating chamber by wrapping the first arm at least partially around the microporous insulating material.

[0192] Example 27: The method according to Example 25, wherein in step a), the cross-shaped membrane is provided with opposite arms configured to be identical,

[0193] wherein in step d), all four arms are folded towards the central portion of the membrane to completely enclose the microporous insulating material, and

[0194] Therein, in step e), the closed microporous insulation material is preferably arranged adjacent to the heater shell.

[0195] A non-exhaustive list of non-limiting examples is provided below.Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0196] Features described with respect to one embodiment may be equally applicable to other embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0197] The present invention will be further described, by way of example only, with reference to the accompanying drawings, in which:

[0198] Figure 1 An aerosol generating device comprising a heater assembly of the present invention is shown;

[0199] Figure 2 Description of the invention relates to the manufacture of shielded microporous insulation materials using a shielding element comprising a membrane;

[0200] Figure 3 Shown in use in heater assembly Figure 2 Shielding microporous insulation material obtained by the film;

[0201] Figure 4 Describes the use of another embodiment of a shielding element comprising a film to produce a shielded microporous insulation material; and

[0202] Figure 5 Shown in heater assembly for use Figure 4 The shielding microporous insulating material is obtained by the membrane. DETAILED DESCRIPTION

[0203] Figure 1 An embodiment of an aerosol generating device 10 comprising a heater assembly 12 of the present invention is shown (shielding elements not shown). The aerosol generating device 10 comprises a power supply. The power supply comprises a power source 14 and control electronics 16. The power source 14 may be a rechargeable battery.

[0204] The heater assembly 12 includes a heating chamber 18 for heating an aerosol-forming substrate. The heating chamber 18 has an elongated shape. The heating chamber 18 includes a wall 20 of the heating chamber 18, which defines a cavity for inserting the aerosol-forming substrate. The wall 20 of the heating chamber 18 forms a hollow tube. The heater assembly 12 also includes a heater housing 22. The heater housing 22 is coaxially arranged around the heating chamber 18. The heater housing 22 includes a cylindrical wall 24 of the heater housing 22. The heater housing 22 is also arranged to be radially spaced apart from the heating chamber 18 by a distance d. The distance d is measured in a radial direction between the outer diameter of the hollow tube formed by the wall 20 of the heating chamber 18 and the inner diameter of the cylindrical wall 24 of the heater housing 22. The wall 20 of the heating chamber 18 and the wall 24 of the heater housing 22 have matching shapes. As a result, the distance d is constant along the longitudinal axis of the heating chamber 18.

[0205] The heater assembly 12 also includes a first connecting wall 26 at the proximal end of the heater assembly 12. The heater assembly 12 also includes a second connecting wall 28 at the distal end of the heater assembly 12. The first connecting wall 26 and the second connecting wall 28 are oriented perpendicular to the longitudinal axis of the heating chamber 18. The heater assembly 12 also includes an airtight space. The airtight space is defined between the wall 20 of the heating chamber 18, the wall 24 of the heater housing 22, and the first connecting wall 26 and the second connecting wall 28.

[0206] The heating chamber 18 includes a central region containing a heating element. The heating element is partially arranged around the heating chamber 18. The wall 20 of the heating chamber 18 is a metal tube. The heating element is flexible and wrapped around the metal tube. The heating element comprises an electrically conductive heating track 30 on an electrically insulating flexible substrate 32. In the illustrated embodiment, the proximal and distal edge portions of the flexible substrate 32 are not covered by the heating track 30. In other embodiments, different regions, or even the entire surface of the flexible substrate 32, may be covered by the heating track 30. The proximal region 34 and distal region 36 of the heating chamber 18 are longitudinally spaced apart from the heating element. The heating element is arranged between the heating chamber 18 and the heater housing 22.

[0207] The first connecting wall 26 and the second connecting wall 28 sealingly connect the wall 24 of the heater housing 22 and the wall 20 of the heating chamber 18 , thereby hermetically closing the airtight space.

[0208] The airtight space includes a microporous insulating material 38 (shielding elements not shown). The microporous insulating material 38 may be, for example, MICROSIL microporous insulation from ZIRCAR Ceramics, Inc.; and one of the Microtherm 1000 grades from Promat Inc. or other commercially available microporous insulation materials. The microporous insulation material 38 is covered by a shielding member (not shown).

[0209] exist Figure 1 In the embodiment shown in FIG, the entire airtight space is filled with a shielding microporous insulating material 38. The shielding element covered with the microporous insulating material 38 is in contact with the wall 20 of the heating chamber 18, the heating rail 30, the first connecting wall 26 and the second connecting wall 28, and the wall 24 of the heater housing 22. Although not shown, Figure 1 The microporous insulating material 38 shown in FIG may also comprise one or more air gaps extending in a direction parallel to the longitudinal axis of the aerosol generating device. Those air gaps may be in direct contact with the wall 20 of the heating chamber 18, the wall 24 of the heater housing 22, or the first and second connecting walls 26, 28. Those air gaps may have a shorter longitudinal extension than the microporous insulating material 38.

[0210] Figure 2The fabrication of a shielding microporous insulating material 38 is shown. The shielding element comprises a membrane 40. The membrane 40 is wrapped around the microporous insulating material 38 to form the shielding element.

[0211] The membrane 40 has a cross shape. The membrane 40 includes four arms 42, 44, 46, and 48. The arms 42, 44, 46, and 48 are arranged around a central portion 50 of the membrane 40. The central portion 50 of the membrane 40 is indicated by a dotted line. The central portion 50 of the membrane 40 is rectangular. Each arm 42, 44, 46, and 48 is arranged along an edge of the central portion 50 of the membrane 40.

[0212] Arms 42 and 46 are arranged opposite each other. Arms 42 and 46 are arranged along opposite edges of center portion 50. Arms 42 and 46 are constructed identically. Arms 42 and 46 have the same shape. Arms 42 and 46 have the same length. Arms 42 and 46 have the same width. Arms 42 and 46 have the same thickness. Arm 42 has a rectangular shape. Arm 46 has a rectangular shape. The lengths of arms 42 and 46 correspond to the length of center portion 50.

[0213] Arms 44 and 48 are arranged opposite each other. Arms 44 and 48 are arranged along opposite edges of center portion 50. Arms 44 and 48 are configured differently from each other. Arm 48 is shorter than arm 44. Arm 44 is elongated compared to arm 48. Arm 44 has a rectangular shape. Arm 48 has a rectangular shape. The width of arms 44 and 48 corresponds to the width of the center portion.

[0214] The central portion 50 of the membrane 40 has a rectangular shape. The length of the central portion 50 corresponds to the length of the arms 42 and 46. The width of the central portion 50 corresponds to the width of the arms 44 and 48. The central portion 50 is configured to match the shape of the microporous insulating material 38.

[0215] The microporous insulating material 38 can be attached to the membrane 40 by an adhesive. The membrane 40 can at least partially cover the microporous insulating material 38 to form a shielded microporous insulating material 38. Adhesive can be applied to at least a portion of the central portion 50. The microporous insulating material 38 can be attached to the membrane 40 via the adhesive applied to the central portion 50. Adhesive can be applied to at least a portion of one or more of the arms 42, 44, 46, and 48. The arms 42, 46, and 48 can be folded over at least a portion of the microporous insulating material 38 attached to the membrane 40 to at least partially enclose the microporous insulating material 38. The arms 42, 46, and 48 can be attached to the microporous insulating material 38 via the adhesive applied to the arms 42, 46, and 48. The at least partially enclosed microporous insulating material 38 can be wrapped around the heating chamber 18 of the heater assembly 12. The elongated arms 44 can be wrapped around the at least partially enclosed microporous insulating material 38 to mount the microporous insulating material to the outer surface of the heating chamber 18. The shielding microporous insulating material 38 is configured to match the shape of the heating chamber 18. The membrane 40 covers the entire microporous insulating material 38. Figure 2 The film shielding element of the microporous shielding insulating material 38 may be produced simply and cost-effectively.

[0216] Figure 3 A shows a device having a Figure 2 The heating chamber 18 is constructed as a metal tube. The heating chamber 18 includes a central cavity 52. The cavity 52 is configured to receive the aerosol-forming substrate. The heating chamber 18 has a circular cross-section.

[0217] Figure 3 B shows the Figure 3 FIG. 1 is a schematic cross-section of heater assembly 12 including heating chamber 18 and shielding microporous insulating material 38. Heating chamber 18 is centrally located. Shielding microporous insulating material 38 is disposed radially outward from heating chamber 18. Shielding microporous insulating material 38 is coaxially aligned around heating chamber 18. Shielding microporous insulating material 38 defines heating chamber 18. Membrane 40 of shielding microporous insulating material 38 is in contact with heating chamber 18. Air gap 54 is disposed radially outward from shielding microporous insulating material 38. Air gap 54 is coaxially aligned around shielding microporous insulating material 38. Air gap 54 defines shielding microporous insulating material 38. Heater housing 22 is disposed radially outward from air gap 54. Heater housing 22 is coaxially aligned around air gap 54. Heater housing 22 defines air gap 54. A heating element (not shown) may be disposed around heating chamber 18. The heating element may be disposed between heating chamber 18 and shielding microporous insulating material 38. When a heating element is present, the film 40 shielding the microporous insulating material 38 may be in contact with the heating element.

[0218] Figure 4Another embodiment of the film 40 is used to make the shielded microporous insulating material 38. Figure 2 The comments apply accordingly to Figure 4 of film 40. However, with Figure 2 Compared with the membrane 40, Figure 4 The arms 44 and 48 of the membrane 40 are constructed identically. Figure 4 The membrane 40 has a symmetrical cross shape. Adhesive can be applied to at least a portion of the central portion 50 of the membrane 40. The microporous insulating material 38 can be attached to the membrane 40 via the adhesive. Adhesive can be applied to at least a portion of one or more of the arms 42, 44, 46, and 48. The arms 42, 44, 46, and 48 can be folded over the microporous insulating material 38 attached to the membrane 40 to completely enclose the microporous insulating material 38. The arms 42, 44, 46, and 48 can be attached to the microporous insulating material 38 via the adhesive applied to the arms 42, 44, 46, and 48. The membrane 40 completely covers the microporous insulating material 38 to form a shielded microporous insulating material 38. The shielded microporous insulating material 38 can be inserted into the heater housing 22.

[0219] Figure 5 A shows a heater housing 22 having a Figure 4 The film 40 of the shielding microporous insulating material 38 is in contact with the inner surface of the heater shell 22. Figure 5 A) can be inserted into the shielding microporous insulating material 38.

[0220] Figure 5 B shows a diagram including Figure 4 Schematic cross-section of heater assembly 12 with a membrane shielding element and a shielding microporous insulating material 38. The heating chamber 18 is centrally arranged around a cavity 52. The cavity 52 is configured to receive an aerosol-forming substrate. An air gap 54 is arranged radially outward from the heating chamber 18. The air gap 54 is coaxially aligned around the heating chamber 18. The shielding microporous insulating material 38 is arranged radially outward from the air gap 54. The shielding microporous insulating material 38 is coaxially aligned around the air gap 54. The heater shell 22 is arranged radially outward from the shielding microporous insulating material 38. The heater shell 22 is coaxially aligned around the shielding microporous insulating material 38. The shielding microporous insulating material 38 is arranged adjacent to the heater shell 22. The shielding microporous insulating material 38 is arranged in contact with the heater shell 22. A heating element (not shown) may be arranged around the heating chamber 18. The heating element may be arranged between the heating chamber 18 and the air gap 54.

Claims

1. A heater assembly for an aerosol generating device, comprising a heating chamber for heating the aerosol-forming substrate; a heater housing arranged around the heating chamber, wherein the heater housing is arranged radially spaced from the heating chamber, wherein the heater housing includes an airtight space, and wherein the airtight space includes a microporous insulating material, The airtight space includes a shielding element, wherein the shielding element is configured to cover at least a portion of the microporous insulating material.

2. The heater assembly of claim 1, wherein the shielding element is configured to at least partially, and preferably completely, enclose the microporous insulation material.

3. The heater assembly of any one of the preceding claims, wherein the shielding element is configured to abut at least a portion of the microporous insulation material.

4. A heater assembly according to any one of the preceding claims, wherein the heater assembly comprises a heating element, wherein the heating element is preferably arranged at least partially around the heating chamber. The heater assembly of claim 4 , wherein the shielding element is arranged radially outwardly of the heating element.

6. A heater assembly according to any preceding claim, wherein one or more of the heating chamber, the heater housing, the microporous insulation material and the heating element according to claim 4 or claim 5 are configured as hollow tubes.

7. A heater assembly according to any one of the preceding claims, wherein the shielding element comprises a membrane.

8. The heater assembly of claim 7, wherein the microporous insulating material is configured to be wrapped by the film.

9. The heater assembly of any one of claims 1 to 6, wherein the shielding element is configured as a coating on the microporous insulating material, preferably wherein the coating is a paint.

10. An aerosol-generating device comprising a heater assembly according to any preceding claim.

11. An aerosol generating system comprising an aerosol generating device according to claim 10 and an aerosol-forming substrate configured to be at least partially received in the heating chamber.

12. A method for manufacturing a heater assembly according to claim 7 or claim 8, comprising the steps of: a) providing a shielding element configured as a membrane, b) applying an adhesive to at least a portion of the film, c) coupling the microporous insulating material to at least a portion of the membrane via the adhesive, d) folding at least a portion of the membrane over at least a portion of the microporous insulating material to at least partially enclose the microporous insulating material, and e) Arranging the at least partially enclosed microporous insulating material in the airtight space.

13. The method according to claim 12, wherein in step a), the membrane provided is a cross-shaped membrane having at least four arms connected by a central portion, wherein in step b), the adhesive is applied to at least a portion of the central portion of the film, wherein in step c), the microporous insulating material is coupled to at least a portion of the central portion of the cross-shaped membrane via the adhesive, and wherein in step d), at least three arms of the cross-shaped membrane are folded over at least a portion of the microporous insulating material to at least partially close the microporous insulating material.

14. The method according to claim 13, wherein in step a), a cross-shaped membrane is provided having a first arm that is elongated compared to an arm arranged opposite the first arm, wherein in step d), the second arm, the third arm and the fourth arm are folded over at least a portion of the central portion of the membrane to at least partially enclose the microporous insulating material, wherein in step e), the at least partially enclosed microporous insulating material is wrapped around the heating chamber and assembled to the heating chamber by wrapping the first arm at least partially around the microporous insulating material.

15. The method according to claim 13, wherein in step a), a cross-shaped membrane is provided having opposite arms configured identically, wherein in step d), all four arms are folded towards the central portion of the membrane to completely enclose the microporous insulating material, and Therein, in step e), the closed microporous insulation material is preferably arranged adjacent to the heater shell.

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