Aerosol generating device heating element

Abstract

An aerosol generating device heating member (102, 602, 702) is provided. The heating member is configured to generate an aerosol from an aerosol-generating substrate (120, 620), and includes a heating chamber (116, 616, 716) configured to receive the aerosol-generating substrate. The supercapacitor module (106, 606, 706) is configured to power a heater (118, 618, 718) associated with the heating chamber. The supercapacitor module is adjacent to the heating chamber. A phase change material (122, 622, 722) is disposed between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module.

Description

Technical Field

[0001] The present invention relates to an aerosol generating device, and more particularly to a heating component and a power system of an aerosol generating device. Background Art

[0002] Aerosol-generating devices, such as e-cigarettes and other aerosol inhalers or vaporizers, are becoming increasingly popular consumer products.

[0003] Heating devices for vaporization or aerosolization are known in the art. Such devices typically include a heating chamber and a heater. In operation, an operator inserts the product to be aerosolized or vaporized into the heating chamber. The product is then heated using an electric heater, vaporizing its components for inhalation. In some examples, the product is a tobacco product similar to a traditional cigarette. Such devices are sometimes referred to as "heat-not-burn" devices because the product is heated to the point of aerosolization without burning.

[0004] Problems faced by known aerosol-generating devices include providing efficient power management and heating. Summary of the Invention

[0005] In a first aspect, there is provided an aerosol-generating device heating component, the aerosol-generating device heating component being configured to generate an aerosol from an aerosol-generating substrate, the heating component comprising:

[0006] a heating chamber configured to receive the aerosol-generating substrate;

[0007] an ultracapacitor module configured to power a heater associated with the heating chamber, wherein the ultracapacitor module is adjacent to the heating chamber; and

[0008] A phase change material is disposed between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module.

[0009] Aerosol-generating devices configured to heat without burning the aerosol-generating material need to deliver relatively high thermal energy to the aerosol-generating material given the size of the aerosol-generating device. Furthermore, to meet operator or consumer expectations, these devices need to have a small form factor, which presents challenges for heat management within the device. One approach is to isolate the heat source from the rest of the device as much as possible using insulating materials with very low thermal conductivity, directing heat transfer toward the consumables. However, during the longer aerosolization process (e.g., approximately 5 minutes), heat is conducted to other parts of the device. Therefore, to protect other components (such as the supercapacitor module or battery module), a sufficient amount of insulation and thermal mass needs to be built into the device. This inherently increases size.

[0010] By positioning the supercapacitor module adjacent to the heating chamber, rather than separately from it, the size of the heating component can be reduced, thereby providing a compact aerosol-generating device heating component. This makes it easier for the operator to hold and use, as well as to store and transport, thereby improving the user experience.

[0011] Providing a phase change material between the heating chamber and the supercapacitor module protects the supercapacitor module from the heat of the heating chamber, allowing the supercapacitor module to be placed closer to the heating chamber and helping to reduce the size of the device. The phase change material also inhibits heat transfer from the heating chamber to the device's housing, thereby improving the device's usability.

[0012] The use of phase change materials can reduce the size of the device compared to using only thermal insulation materials. Components such as supercapacitor modules can then be protected from excessive temperatures, despite the device having a small form factor. Additionally, the housing temperature of the aerosol-generating device can be reduced, or the same housing temperature can be achieved with smaller heating components.

[0013] In this way, a compact aerosol-generating device heating component with an integrated supercapacitor module is provided.

[0014] Preferably, the phase change material at least partially surrounds the heating chamber.

[0015] In this way, thermal energy from the heating chamber is effectively absorbed by the phase change material to provide protection to the ultracapacitor module and inhibit heat flow to the housing on the device.

[0016] Preferably, the supercapacitor module at least partially surrounds the heating chamber.

[0017] In this way, a compact arrangement of the heating chamber and supercapacitor module is achieved, allowing for a reduction in device size.

[0018] Preferably, the supercapacitor module conforms to the shape of the heating chamber.

[0019] In this way, a compact arrangement of the heating chamber and supercapacitor module is achieved, allowing for a reduction in device size.

[0020] Preferably, the supercapacitor module includes two supercapacitors, and the two supercapacitors are arranged on opposite sides of the heating chamber to at least partially surround the heating chamber.

[0021] In this way, a compact arrangement of the heating chamber and supercapacitor module is achieved, allowing for a reduction in device size.

[0022] Preferably, the heating chamber is planar in shape and is configured to receive a planar aerosol-generating substrate.

[0023] In this way, a compact aerosol-generating substrate can be used, thereby reducing the overall size of the device.

[0024] Preferably, the heating chamber is cylindrical in shape and is configured to receive a rod-shaped aerosol-generating substrate.

[0025] In this way, a stick-shaped aerosol generating substrate can be used for the aerosolization process to provide the operator with an experience similar to traditional smoking.

[0026] Preferably, the rod-shaped aerosol-generating substrate is a tobacco rod.

[0027] In this way, a tobacco rod can be used for the aerosolization process to provide the operator with an experience similar to traditional smoking.

[0028] Preferably, the heater is integrated into or onto a side wall of the heating chamber.

[0029] In this way, a compact and easy to use heating chamber is provided.

[0030] Preferably, the aerosol-generating device heating element further comprises control electronics integrated into the flexible circuit board.

[0031] In this way, the flexible circuit board can adapt to any changes in the shape of the phase change material as it undergoes a phase change. This allows for a more compact device. Furthermore, the circuit board can conform to better utilize the reduced space in the heating element, thereby helping to reduce the size of the device.

[0032] Preferably, the phase change material is substantially indium based.

[0033] In this way, the beneficial properties of indium based phase change materials may be exploited.Preferably, the phase change material is substantially or entirely indium.

[0034] Alternatively or additionally, the phase change material may be based on one or more of liquid ammonia, liquid hydrogen, acetic acid, paraffin wax.

[0035] Preferably, the phase change material comprises a hydrated salt phase change material.Preferably, the phase change material is or is essentially a hydrated salt phase change material.

[0036] Hydrated salt phase change materials have been found to have particularly beneficial heat storage capabilities in heating components of aerosol generating devices.

[0037] Preferably, the phase change material comprises an organic solution phase change material.Preferably, the phase change material is or is essentially an organic solution phase change material.

[0038] Organic solution phase change materials have been found to have particularly beneficial heat storage capabilities in heating components of aerosol generating devices.

[0039] Preferably, the phase change material comprises a solid-solid phase change material.Preferably, the phase change material is or is essentially a solid-solid phase change material.

[0040] Solid-solid phase change materials have been found to have particularly beneficial heat storage capabilities in heating components of aerosol generating devices.

[0041] Preferably, the aerosol-generating device heating component further comprises a heat-insulating layer disposed between the heating chamber and the phase-change material.

[0042] In this way, the insulating layer may improve the efficiency of the heating component of the aerosol-generating device by reducing heat loss from the heating chamber by directing heat towards the aerosol-generating substrate.

[0043] Preferably, the total thickness of the thermal insulation layer is approximately twice the total thickness of the phase change material in the radial direction of the heating component of the aerosol-generating device.

[0044] Preferably, the phase change material is approximately 1 mm thick and the insulation layer is at least 1 mm thick, or preferably the insulation layer is 1.5 mm thick, or more preferably the insulation layer is 2 mm thick, or wherein the insulation layer is up to 3 mm thick.

[0045] These arrangements of thermal insulation layer thickness and phase change material thickness have been found to be particularly beneficial in inhibiting heat flow to the ultracapacitor module.

[0046] Preferably, the thermal insulation layer comprises a plurality of thermal insulation layers.

[0047] Preferably, the thermal insulation layer comprises aerogel.

[0048] Preferably, the phase change material comprises a plurality of phase change material layers.

[0049] Preferably, the aerosol generating device heating component further comprises: a first temperature sensor configured to monitor the temperature of the heater of the heating chamber; and a second temperature sensor configured to monitor the temperature of the phase change material;

[0050] wherein the controller of the heating component of the aerosol generating device is configured to recalibrate the monitored heater temperature by determining that the phase change material has reached a melting temperature based on a predetermined relationship between the temperature of the heater and the melting temperature of the phase change material, at which melting temperature the monitored temperature of the phase change material is substantially stable.

[0051] In this way, the phase change material can be used to provide a reference for continuously recalibrating the control of the heating temperature during the aerosolization process. This ensures that the aerosol-generating substrate is heated to the correct temperature, thereby improving the quality of the aerosolization process. This improves the user experience.

[0052] In a second aspect, there is provided an aerosol-generating device comprising the aerosol-generating device heating component of the first aspect and further comprising an auxiliary power component, wherein the auxiliary power component comprises a battery module; and

[0053] The auxiliary power component is removably connected to the heating component, and when connected, the battery module is configured to charge the supercapacitor module through the electrical connection between the heating component and the auxiliary power component.

[0054] In this way, a modular system is provided in which the battery module can be replaced by removing the auxiliary power components. This provides increased flexibility by decoupling the power between the supercapacitor module and the battery module. In addition, the supercapacitor module can be charged from the battery module so that it has a sufficient charge level to power the preheating stage of the subsequent aerosolization process. The preheating stage is energy-intensive, and powering these stages solely with batteries can put stress on the batteries; in addition, the supercapacitor can power the heater for faster preheating. In this way, the higher charge storage capacity of the battery module can be used to ensure that the supercapacitor module is ready to power the heater for the subsequent aerosolization process.

[0055] Preferably, the battery module is configured to power a heater associated with the heating chamber when the auxiliary power component is connected to the heating component via an electrical connection between the heating component and the auxiliary power component.

[0056] In this way, the battery module can supplement the power supply to the heater. This can allow for a reduced size supercapacitor, resulting in a more compact heating component. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0058] Figure 1 is a conceptual cross-sectional view of a first aerosol generating device;

[0059] Figure 2 is a conceptual circuit diagram of a power and heating system for an aerosol generating device, the power and heating system including a supercapacitor module, a battery module, and a heater;

[0060] Figure 3A is a diagram of a planar aerosol-generating matrix;

[0061] Figure 3B is inserted into the heating chamber Figure 3A A diagram of the aerosol generation matrix;

[0062] Figure 3C is a diagram of a heating component of an aerosol-generating device equipped with a mouthpiece;

[0063] Figure 4 is used for Figure 1 A conceptual cross-sectional view of a heating component of an aerosol generating device;

[0064] Figure 5 is a graph of phase change material temperature relative to heater temperature;

[0065] Figure 6A is a conceptual cross-sectional view of a second aerosol generating device;

[0066] Figure 6B is used for Figure 6A A conceptual cross-sectional view of a heating component of an aerosol generating device;

[0067] Figure 6C is used for Figure 6A A conceptual cross-sectional view of an alternative heating component of an aerosol generating device;

[0068] Figure 7 is a diagram of a heating component of an exemplary aerosol-generating device;

[0069] Figure 8A is a perspective view of an exemplary layout of a heating track;

[0070] Figure 8B is enclosed in an electrically insulating layer Figure 8A A perspective view of the heating track;

[0071] Figure 8C is enclosed in Figure 8B a cross-sectional view of a portion of a heating track in an electrically insulating layer;

[0072] Figure 8D It is a three-dimensional diagram of the heating chamber and the combination of the heating track and the suction nozzle;

[0073] Figure 8E is a diagram of where temperature probes may be positioned on a heated component;

[0074] Figure 9 It is a consistent diagram of a heating element having six insulation layers;

[0075] Figure 10is a graph showing the temperature changes over time recorded at the temperature probes T1, T2, T3, and T4 during the aerosolization process of a heating element having six insulation layers;

[0076] Figures 11A to 11E Shown with Figure 9 FIG. 1 is a diagram of an aerosol-generating device heating component consistent with an aerosol-generating device heating component of FIG. 1 but wherein one or more thermal insulation layers are replaced with a phase change material layer(s);

[0077] 12A to 12E Shown Figures 11A to 11E A graph of the temperature of the heating component of the aerosol generating device at the first temperature probe T1, the second temperature probe T2, the third temperature probe T3 and the fourth temperature probe T4 relative to time during the aerosolization process;

[0078] 13A to 13F Shown in accordance with Figure 11E Graphs of temperature versus time at the first temperature probe T1, the second temperature probe T2, the third temperature probe T3, and the fourth temperature probe T4 during aerosolization in a structured thermal insulation layer and a phase change material layer, and a heating element of different phase change materials;

[0079] Figure 14 shows different phase change materials as in reference Figure 11E A graph showing the temperature change over time of the described structured heating element recorded at the fourth temperature probe T4 during the aerosolization process;

[0080] Figure 15 Is as reference Figure 11E a simulated thermal map of a heating component of the described structured thermal insulation layer and phase change material layer; and

[0081] Figure 16 Is as reference Figure 11E Cross-sectional view of a heating component of the described structured thermal insulation layer and phase change material layer having a supercapacitor module adjacent to and at least partially surrounding a heating chamber. DETAILED DESCRIPTION

[0082] Figure 1 is a conceptual cross-sectional view of an aerosol-generating device 100 (also referred to as a vapor-generating device or an electronic cigarette). The cross-section is viewed perpendicular to the axial direction of the aerosol-generating device 100; that is, a cross-sectional view along the length of the aerosol-generating device 100.

[0083] For the purposes of this application, it should be understood that the terms "vapor" and "aerosol" are interchangeable. The aerosol-generating device 100 is configured to heat an aerosol-generating material without burning the aerosol-generating material to generate an aerosol. The aerosol-generating material may include tobacco, or a combination of tobacco and other ingredients (such as one or more humectants). Alternatively or additionally, the aerosol-generating material may include other non-tobacco materials suitable for generating an aerosol, such as an aerosol-generating liquid.

[0084] The aerosol generating device 100 comprises a heating component 102 (also referred to as a heating module) and an auxiliary power component 104 (also referred to as an auxiliary power module). The heating component 102 comprises a heating cavity or chamber ( Figure 1 (Not shown, but discussed in greater detail later), an aerosol-generating substrate 120 (also referred to as an aerosol-generating consumable) is inserted into the heating cavity or chamber. The aerosol-generating substrate 120 may include or itself be an aerosol-generating material. A heater 118 in the heating chamber 116 is configured to heat the aerosol-generating substrate 120 to generate an aerosol that can be inhaled by a consumer through the mouthpiece 110 of the heating element 102.

[0085] The supercapacitor module 106 is arranged in the heating component 102 to power the heater 118. The battery module 108 is arranged in the auxiliary power component 104. When the heating component 102 and the auxiliary power component 104 are connected, the battery module 108 can be operated to charge the supercapacitor module 106 and / or power the heater 118. Figure 2 for a more detailed discussion.

[0086] The supercapacitor module 106 may include one or more supercapacitors. The battery module 108 may include one or more batteries. In an example, the supercapacitor module 106 may be implemented as two supercapacitors connected in series, such as in a 2s1p stack. In such an example, the supercapacitors may be conventional supercapacitors and each may have a voltage of 2.5 V, thereby providing a total voltage of 5 V to the supercapacitor module 106. In another such example, the supercapacitors may each have a voltage of 3 V, thereby providing a total voltage of 6 V to the supercapacitor module 106. In another such example, the supercapacitors may each have a voltage of 3.3 V, thereby providing a total voltage of 6.6 V to the supercapacitor module 106. More generally, the supercapacitors may each have a voltage of 2.5 V to 3.3 V, thereby providing a total voltage of 5 V to 6.6 V to the supercapacitor module 106.

[0087] In other examples, multiple ultracapacitors may be connected in series to meet the voltage requirements needed to power the heater 118. Connecting multiple smaller ultracapacitors in series rather than using a single larger ultracapacitor is advantageous in allowing for greater design flexibility.

[0088] The life expectancy of a supercapacitor depends on the maximum operating voltage and temperature. In some cases, a trade-off in life expectancy can be made when using a supercapacitor with a higher operating voltage to achieve smaller device size and better energy density.

[0089] In an example, battery module 108 may be implemented as a single battery. The single battery may be a high-energy battery, such as a battery using lithium-ion technology, aluminum-ion technology, zinc-ion technology, or any other suitable type of battery. Alternatively, battery module 108 may include multiple batteries. In a specific example, the battery is a lithium-ion battery having a voltage of 3.7 V. As such, the voltage of battery module 108 may be 3.7 V.

[0090] The heating component 102 and the auxiliary power component 104 may each have a corresponding electrical connector 112 so that power may flow from the battery module 108 to the components of the heating component 102 when the heating component 102 and the auxiliary power component 104 are connected to each other.

[0091] The heating component 102 may include a controller configured to control the operation of the aerosol-generating device 100, including controlling the flow of power from the ultracapacitor module 106 to the heater 118, and controlling the flow of power from the battery module 108 to the ultracapacitor module 106 and / or the heater 118. The controller may be implemented as a microcontroller unit (or any other suitable control unit) comprising a memory having stored thereon instructions for operating the aerosol-generating device 100 and one or more processors configured to execute the instructions. The controller may be part of a circuit board 114 (such as a printed circuit board) that includes control electronics for the aerosol-generating device 100.

[0092] During operation, the controller can control the aerosol-generating device 100 to perform an aerosolization process, in which the aerosol-generating substrate 120 is heated to generate an aerosol for inhalation by the user. The aerosolization process may include a preheating mode and a heating mode. In the preheating mode, the controller controls the power flow to the heater 118 so that the heater 118 is heated to a predetermined temperature to generate an aerosol from the aerosol-generating substrate 120. The preheating phase can be considered the time during which the preheating mode is executed, for example, the time it takes for the heater 118 to reach the predetermined temperature. The preheating mode occurs during a first time period of the aerosolization process. In one example, the first time period can be a fixed predetermined time period. In other examples, the first time period can vary, corresponding to the length of time required to heat the heater 118 to the predetermined temperature. When the heater 118 reaches the predetermined temperature, the controller ends the preheating mode and controls the aerosol-generating device 100 to perform the heating mode. In the heating mode, the controller controls the power flow to substantially maintain the heater 118 at the predetermined temperature, thereby generating an aerosol for inhalation by the user. The heating phase can be considered to be the time during which the heating mode is being performed, for example, the time during which the heater 118 aerosolizes an aerosol-generating substrate 120 (or at least a portion thereof) after the preheating phase. The controller can control the power system to operate the heating mode for a second period of time during the aerosolization process. The second period of time can be predetermined and stored at the controller.

[0093] Figure 2 A conceptual circuit diagram of the ultracapacitor module 106 , the battery module 108 , and the heater 118 is shown.

[0094] The supercapacitor module 106 can be connected to the battery module 108. Optionally, a DC / DC voltage converter 134 can be arranged between the two. The DC / DC voltage converter can be used to increase the battery module voltage when the supercapacitor module 106 is charged by the battery module 108.

[0095] A first switching device 128 is arranged between the battery module 108 and the ultracapacitor module 106. The ultracapacitor module 106 may be connected to a heater 118 (represented as a load), and a second switching device 130 is arranged between the ultracapacitor module and the heater. In an example, the first switching device 128 and the second switching device 130 may be transistors ( Figure 2 not shown).

[0096] The ultracapacitor module 106 and the battery module 108 may be configured to operate in a number of different ways to power the heater 118 and recharge the ultracapacitor module 106 .

[0097] In a first example, during preheat mode, only the ultracapacitor module 106 is controlled to power the heater 118. Then, during heating mode, only the battery module 108 is configured to power the heater 118. This arrangement is beneficial because the higher discharge rate from the ultracapacitors allows for faster preheating than using batteries. It also prevents stress on the battery during the preheat phase, which may require higher current. The lower and more constant discharge rate from the battery module 108 can then be used for a longer heating mode, which requires less power than the preheat mode.

[0098] In a second example, similar to the first example, both the supercapacitor module 106 and the battery module 108 can be controlled to power the heater 118 during the preheating mode. Then, during the heating mode, only the battery module 108 is configured to power the heater 118. This arrangement is beneficial because the supercapacitor module 106 can support the battery module 108 during the preheating mode. However, because the supercapacitor module 106 only supports the battery module 108 during the preheating mode, rather than only powering the heater 118, a smaller supercapacitor module 106 can be used, thereby reducing the size of the device.

[0099] In a third example, during the preheating mode, only the ultracapacitor module 106 is controlled to power the heater 118. Then, during the heating mode, both the battery module 108 and the ultracapacitor module 106 are configured to power the heater 118. In this way, the ultracapacitor module 106 can support the battery module 108 during the heating phase.

[0100] In a fourth example, both the ultracapacitor module 106 and the battery module 108 can be controlled to power the heater 118 during the preheating mode. Then, during the heating mode, both the battery module 108 and the ultracapacitor module 106 are configured to power the heater 118. In this way, the ultracapacitor module 106 can support the battery module 108 during both the preheating phase and the heating phase.

[0101] The preheating phase, in particular, may require a high discharge rate to power the heater 118 for rapid preheating. This high discharge rate can stress the battery, shortening its lifespan. Using the supercapacitor module 106 during preheating reduces / eliminates stress on the battery module 108 compared to using batteries alone for heating, thereby increasing the battery's lifespan. Furthermore, the higher discharge rate available from the supercapacitor module 106 allows for faster preheating, thereby improving the user experience.

[0102] In these aforementioned examples, the battery module 108 can be controlled by the controller to direct power flow to the ultracapacitor module 106 between aerosolization processes, thereby recharging the ultracapacitor module 106 for the subsequent aerosolization process. In this way, the ultracapacitor module 106 can be fully charged for the preheating phase of the subsequent aerosolization process.

[0103] The power flow between the battery module 108 and the ultracapacitor and / or heater 118, and between the ultracapacitor and / or heater 118, can be controlled using the first switching device 128 and the second switching device 130. For example, opening the first switching device 128 and closing the second switching device 130 can be used to direct power flow from the ultracapacitor module 106 to the heater 118. Opening the second switching device 130 and closing the first switching device 128 can be used to direct power flow from the battery module 108 to the ultracapacitor module 106 to charge the ultracapacitor module 106. Closing both the first switching device 128 and the second switching device 130 can be used to direct power flow from both the battery module 108 and the ultracapacitor module 106 to the heater 118.

[0104] The first switching device 128 and the second switching device 130 can be controlled by a controller to apply a pulse width modulated (PWM) power flow by rapidly switching the switching devices between an open state and a closed state. Varying the open and close switching rate to adjust the duty cycle can be used to adjust the power flow.

[0105] In further examples, in addition to or instead of charging the ultracapacitor module 106 between aerosolization processes, the battery module may be configured to charge the ultracapacitor module 106 during the aerosolization process.

[0106] In a first example in which the battery module 108 charges the supercapacitor module 106 during the aerosolization process, the battery module 108 charges the supercapacitor module 106 during both the preheat mode and the heating mode. In this example, the controller controls the PWM power flow, wherein the supercapacitor module 106 is controlled to power the heater 118 and the battery module 108 is controlled to recharge the supercapacitor module 106. In both the preheat mode and the heating mode, only the supercapacitor module 106 powers the heater 118; the battery module 108 recharges the supercapacitor module 106. During the on-period of the PWM cycle of the pulse-width modulated power flow from the supercapacitor module 106 to the heater 118, the supercapacitor module 106 powers the heater 118, and the battery module 108 recharges the supercapacitor module 106 during the off-period of the PWM cycle of the pulse-width modulated power flow from the supercapacitor module 106 to the heater 118. That is, during the preheat mode and the heating mode, the ultracapacitor module 106 switches between powering the heater 118 during the on portion of the duty cycle and being recharged by the battery module 108 during the off portion of the duty cycle. During the on portion of the duty cycle, the battery module 108 does not charge the ultracapacitor module 106.

[0107] In heating mode, the pulse-width modulated power flow from the ultracapacitor module 106 to the heater 118 can operate with a first duty cycle scheme comprising one or more PWM cycles having a first duty cycle D1. In preheat mode, the ultracapacitor module 106 can power the heater 118 with a pulse-width modulated power flow using a second duty cycle scheme comprising one or more PWM cycles having a second duty cycle D2. The relationship between D1 and D2 can be considered as D2 = D1 * K, where K is a coefficient that is >> 1 and can be selected as an implementation choice. In an example, the first duty cycle can be much less than 1, and the second duty cycle can be close to but less than 1. In other examples, the first duty cycle can be << 0.5, and the second duty cycle can be ≥ 0.5. In another example, the first duty cycle is configured such that < 3 W is applied in heating mode, and the second duty cycle is configured such that approximately 16 W is applied in preheat mode. More generally, 2 W to 6 W can be applied during heating mode, and 10 W to 30 W can be applied during preheating mode. This control of heating and charging is achieved by a controller, first switching device 128, and second switching device 130. During the on-period of the PWM cycle of the pulse-width modulated power flow, the controller controls the second switching device 130 to close and the first switching device 128 to open. In this way, during the PWM on-period, power flows from the supercapacitor module 106 to the heater 118, while the battery module 108 is isolated from both the supercapacitor module 106 and the heater 118. During the off-period of the PWM cycle of the pulse-width modulated power flow, the controller controls the second switching device 130 to open and the first switching device 128 to close. In this way, power flows from the battery module 108 to the supercapacitor module 106 to recharge the supercapacitor module 106, while the supercapacitor module 106 is isolated from the heater 118. As such, during pulse width modulated power flow, rapid switching occurs between powering the heater 118 during the on period of the PWM cycle and recharging the ultracapacitor module 106 during the off period of the PWM cycle. In some examples, there may be a small delay between opening the first switching device 128 and closing the second switching device 130. This prevents power flow from the battery module 108 from unintentionally reaching the heater 118 during the on period of the duty cycle of the pulse width modulated power flow.

[0108] In a second example in which the battery module 108 charges the ultracapacitor module 106 during the aerosolization process, the battery module 108 charges the ultracapacitor module 106 during the heating mode, as described in the previous example. However, the battery module 108 does not charge the ultracapacitor module 106 during the preheat mode. In such an example, the controller uses the second switching device 130 to control the PWM power flow from the ultracapacitor module 106 to the heater 118 during the preheat mode, and the first switching device 128 remains open throughout the preheat mode. Due to the higher duty cycle used in the preheat mode, not charging the ultracapacitor module 106 during the preheat mode reduces system complexity because the battery module 108 does not need to apply PWM switching at this higher duty cycle.

[0109] As about Figure 1 As discussed, the heating component 102 and the auxiliary power component 104 can each have corresponding electrical connectors 112 so that when the heating component 102 and the auxiliary power component 104 are connected to each other, power can flow from the battery module 108 to the components of the heating component 102. These electrical connectors 112 are Figure 2 denoted by connecting node 132 .

[0110] Figures 3A to 3C It is shown that the Figure 1 Figure 1 depicts an arrangement of a planar aerosol-generating substrate 120 implemented in a heating element 102 of an aerosol-generating device. Figure 3A is a diagram of a planar aerosol-generating substrate 120, and Figure 3B is a diagram of an aerosol generating substrate 120 inserted into a heating chamber 116, the aerosol generating substrate being suitable for use in reference Figure 1 The aerosol generating device described is implemented in Figure 3C is based on Figure 1 FIG2 is a diagram of the heating element 102 of the aerosol-generating device 100, with the mouthpiece 110 assembled. In this example, the heating chamber 116 is arranged within the housing 126 of the heating element 102. As can be seen, the mouthpiece 110 is assembled over the mouthpiece portion 138 of the aerosol-generating substrate 120 extending from the heating chamber 116, so that the opening in the mouthpiece 110 coincides with the end of the aerosol-generating substrate 120 through which the generated aerosol is drawn when the operator inhales on the mouthpiece 110.

[0111] refer to Figure 3AThe shape of the aerosol-generating substrate 120 can be planar or flat, for example, in the form of a flat cuboid. In a specific example, the length of the substrate 120 according to the substrate axis is substantially 33 mm, and the width and depth are substantially 12 mm and 1.2 mm, respectively. That is, the shape of the substrate 120 can be considered planar because its depth is much shorter than its length and width. However, in other examples, the aerosol-generating substrate 120 and the corresponding heating chamber 116 can have other suitable shapes or dimensions. For example, the aerosol-generating substrate 120 has a round tube shape similar to that of a traditional cigarette.

[0112] The aerosol-generating substrate 120 may include a heating portion 140 and a mouthpiece portion 138. The heating portion 140 is received in the heating chamber 116, and the mouthpiece portion 138 is received in the mouthpiece 110 of the aerosol-generating device 100. That is, the heating portion 140 defines an abutting end of the substrate 120, which may abut or be adjacent to the bottom 150 of the heating chamber 116, and the mouthpiece portion 138 defines a mouth end of the substrate 120.

[0113] The heating portion 140 is configured to be heated by the heater 118 in the heating chamber 116 and includes an aerosol-generating material. The aerosol-generating material may be, for example, a material including nicotine or tobacco and an aerosol-forming agent. The tobacco may take the form of a variety of different materials, such as cut tobacco, granulated tobacco, leaf tobacco, and / or reconstituted tobacco. Suitable aerosol-forming agents include: polyols such as sorbitol, glycerol, and diols (such as propylene glycol or triethylene glycol); non-polyols (such as monohydric alcohols); acids (such as lactic acid); glycerol derivatives; and esters (such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin, or vegetable glycerin). In some embodiments, the aerosol-generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The matrix 120 may further include at least one of a gelling agent, a binder, a stabilizer, and a humectant. When the aerosol-generating material is heated, an aerosol or vapor is formed.

[0114] The mouthpiece portion 138 is intended to be received within the mouthpiece 110 of the heating element 102 of the aerosol-generating device 100. The mouthpiece portion 138 includes a core 144 that can provide a filtering function. In some examples, the core 144 can be foam or filled with fiber strands. The mouthpiece portion 138 can have a plurality of vents 142 arranged on the wall of the substrate 120 to allow fresh air to enter the interior of the substrate 120 to achieve a specific inhalation / tasting effect.

[0115] refer to Figure 3CThe mouthpiece 110 has a through hole designed to receive the mouthpiece portion 138 of the aerosol-generating substrate 120. The through hole may have the same cross-sectional shape as the aerosol-generating substrate 120, with its inner dimension being slightly larger than the outer dimension of the mouthpiece portion 138 of the aerosol-generating substrate 120.

[0116] In some cases, the matrix 120 may not include vents 142; in such cases, air can flow into the matrix 120 by being drawn through the abutment end. For example, air can be drawn into the device through an inlet 146 in the nozzle 110 or a side wall of the device to offset the pressure drop caused by the operator sucking on the nozzle 110.

[0117] Steering Figure 3B The heating chamber 116 can be cup-shaped, having an open end 148 and an opposite sealed end 150, into which the aerosol-generating substrate 120 is inserted. The heating chamber 116 receives the heating portion 140 of the aerosol-generating substrate 120. The heating chamber 116 has substantially the same cross-sectional shape as the aerosol-generating substrate 120. The walls of the heating chamber 116 can include one or more heating elements of the heater 118 therein or thereon. Each or one or more of the walls of the heating chamber 116 may have a heating element therein or thereon.

[0118] The walls of the heating chamber 116 may be ceramic with the heating wire or track embedded therein or thereon. In an example, the heating element may be arranged to contact one of the heating chamber walls outside the heating chamber 116. Figure 3B As depicted in the example of , the heating element is arranged on the outer surface of the chamber wall. Similarly, a second heating element can be arranged on the outer surface of an opposing chamber wall (not shown). Thus, the chamber wall transfers heat from the heating element to the aerosol generating substrate 120. In other examples, the heating element can be embedded in the chamber wall. In another example, the heating element can be on the chamber wall, inside the heating chamber 116. As explained, the chamber wall can be a ceramic material with a heating track or heating wire therein or thereon. In an alternative, each heating element can include a polyimide film heater that extends substantially along the total area of ​​the outer surface of the corresponding heating wall or along only a portion of that surface.

[0119] In a preferred example, the heating chamber 116 has two major interior faces corresponding to the opposite wider faces of the planar aerosol-generating substrate 120, and two minor interior faces corresponding to the opposite narrower faces of the planar aerosol-generating substrate 120. The minor interior faces can be perpendicular to and connected to the major interior faces. The walls of the heating chamber 116 corresponding to the major interior faces can be arranged with heating wires or tracks embedded therein or thereon, thereby forming two ceramic heaters. In some examples, the walls of the heating chamber 116 corresponding to the minor interior faces can also be ceramic. Such ceramic heaters can provide a compact heating chamber 116 with well-distributed heat directed to the planar aerosol-generating substrate 120. However, such ceramic heaters can require significantly more power to heat (e.g., >>10 W and / or >>1600 J) than heaters of aerosol-generating devices configured to receive more traditional cigarettes or cigarette-like consumables. Therefore, such heaters greatly benefit from heating power management using one or more supercapacitors, as described herein.

[0120] In other examples, each wall can be made of a heat conducting material, such as metal, in particular stainless steel. Additionally, at least some or all of the walls can form a single piece.

[0121] The internal dimensions of the heating chamber 116 may be defined such that an airflow channel is formed between the walls of the heating chamber 116 and the aerosol-generating substrate 120 (when inserted therein). That is, when the heating portion 140 of the aerosol-generating substrate 120 is inserted into the heating chamber 116, an airflow channel is formed along the axial length of the substrate 120.

[0122] The heating element 102 may include Figures 3A to 3C Additional components not shown in FIG. Figure 4 These are discussed in more detail.

[0123] Figure 4 Shown according to reference Figure 1 The heating component 102 of the aerosol generating device 100 described and reference Figures 3A to 3C A conceptual cross-sectional view of the depicted heating chamber 116. The cross-section is viewed along the axial direction of the heating element 102; that is, in the direction in which the aerosol-generating substrate 120 is inserted into or removed from the heating chamber 116.

[0124] The heating component 102 includes a heating chamber 116 configured to receive an aerosol-generating substrate 120. In an example, the heating chamber 116 and the aerosol-generating substrate 120 may be a reference Figures 3A to 3CAlternative heating chambers and aerosol-generating substrates may alternatively be implemented in the heating element 102. For example, the heating chamber 116 may be configured to receive a non-planar aerosol-generating substrate, a rod-type aerosol-generating substrate (similar to a traditional cigarette), or a loose aerosol-generating material (such as loose tobacco).

[0125] The heating element 102 also includes an ultracapacitor module 106 configured to power a heater 118. The ultracapacitor module 106 is adjacent to (i.e., proximate to or near) the heating chamber 116 and can be configured to at least partially or completely surround the heating chamber 116. The ultracapacitor module 106 can be configured so that it conforms to the shape of the heating chamber 116. In this way, the heating element 102 can have a compact shape and size.

[0126] In some examples, the ultracapacitor(s) of the ultracapacitor module 106 may have a curved shape, rather than a flat ultracapacitor, so as to substantially (or at least partially) surround the heating chamber 116. This may provide a more compact heating element 102. In other examples, the ultracapacitor(s) of the ultracapacitor module 106 may be flat ultracapacitor cells; these may be easier to manufacture and arrange in the heating element 102, but this may be balanced by the need for a larger heating element 102 to accommodate such flat cells.

[0127] exist Figure 4 In the specific example of FIG, the supercapacitor module 106 includes two supercapacitors. The two supercapacitors are arranged on opposite sides of the heating chamber 116. In this way, the two supercapacitors partially (and almost completely) surround the heating chamber 116. Figure 4 In one example, the supercapacitors are arranged on the larger faces of the planar heating chamber 116 (i.e., the major faces of the heating chamber 116) and are curved around these larger faces so that the supercapacitors substantially surround the heating chamber 116. The supercapacitors can be arranged in a 2s1p configuration. In other examples, only one supercapacitor can be used, or more than two supercapacitors can be used. In some examples, the supercapacitor(s) can completely surround the heating chamber 116.

[0128] The phase change material 122 is disposed between the heating chamber 116 and the ultracapacitor module 106 to separate the heating chamber 116 from the ultracapacitor module 106 .

[0129] The phase change material 122 absorbs heat from the heating chamber 116 during the aerosolization process and changes from a solid phase to a liquid phase by melting. The temperature of the phase change material 122 stabilizes as it continues to absorb thermal energy during the melting period. When the phase change material 122 reaches its maximum absorbable energy content by absorbing thermal energy from the heating chamber 116, the temperature may increase again.

[0130] The phase change material 122 is configured to protect the ultracapacitor module 106 by absorbing heat from the heating chamber 116. The phase change material 122 acts as a heat storage component, whereby at the phase change temperature, the latent heat capacity absorbs thermal energy from the heat source and prevents excessive temperature spikes at the ultracapacitor module 106. This absorption of heat from the heating chamber 116 also suppresses heating of the housing 126 of the heating element 102, thereby protecting the consumer who is handling the heating element 102. After the aerosolization process, when the device is no longer in use, the absorbed heat is released from the phase change material 122. Upon cooling down, the phase change of the phase change material 122 releases the thermal energy back into the system. Thus, the phase change material 122 mitigates excessive temperatures that may occur, for example, during the initial heat-up period of the heater under high heat flux through the system.

[0131] The main thermal properties desired for a phase change material in such an aerosol-generating device 100 configured to heat without burning the aerosol-generating material are high latent heat capacity, high specific heat capacity of both phases, low thermal conductivity, high density, and a phase change temperature that is lower than the maximum temperature defined for the components requiring protection (e.g., a supercapacitor module).

[0132] The phase change material 122 may also at least partially or completely surround the heating chamber 116. This may be achieved, for example, by conforming a single piece of phase change material 122 around the heating chamber 116. Alternatively, this may be achieved by positioning multiple pieces of phase change material 122 around the chamber. In some examples, the phase change material 122 may be one or more pieces of material. In other examples, the phase change material 122 may be a filler material that is, for example, injected or inserted between the heating chamber 118 and the ultracapacitor module 106. In some examples, the phase change material 122 may be indium or an indium-based phase change material 122. Alternatively or additionally, the phase change material 122 may be based on one or more of liquid ammonia, liquid hydrogen, acetic acid, or paraffin wax. In further examples, as will be discussed later, the phase change material 122 may be a hydrated salt, an organic solution, or a solid-solid phase change material.

[0133] An optional insulation layer 124 surrounds the heating chamber 116 substantially or completely along its axial length (i.e., the direction of insertion / removal of the aerosol-generating substrate 120). In some examples, the insulation layer is a super fleece material or an aerogel-based material, such as in sheet form. The phase change material 122 surrounds the heating chamber 116 substantially or completely along its axial length and also surrounds the insulation layer 124 (if included). The supercapacitor module 106 then substantially or completely surrounds the phase change material 122 at least partially along the axial length of the heating chamber 116. This can be accomplished by arranging one or more supercapacitors adjacent to the heating chamber 116 that can be bent or conformed to follow the shape of the heating chamber 116 along its axial length. Alternatively, this can be accomplished by arranging a plurality of flat supercapacitors adjacent to the heating chamber 116 and at least partially along its axial length. Thus, a layered arrangement is formed in the heating element 102 with the heating chamber 116 at the center, followed in an outward direction by the insulation layer 124 (optional), then the phase change material 122, and then the ultracapacitor module 106, all within the housing 126 of the heating element 102.

[0134] The heating chamber 116 or heater unit can be housed in a heater unit housing. The phase change material 122 can be thermally connected to the outside of the heater unit for heat dissipation. The heater unit housing can be made of metal, such as aluminum. The phase change material 122 can be connected using metal tape (e.g., copper tape) and / or thermal paste.

[0135] Supercapacitors can operate at higher temperatures than battery technologies commonly used in portable electronic applications, such as lithium-ion, nickel-metal hydride, galvanic, and nickel-cadmium products. For example, the maximum operating temperature of a discharged lithium-ion battery is approximately 60°C. Therefore, supercapacitors are well-suited for use in the heating component 102 of the aerosol-generating device 100. However, for optimal operation, the supercapacitor module 106 should be protected from excessive heat conduction from the heating chamber 116. The phase-change material 122 can be selected so that it absorbs sufficient thermal energy so that the supercapacitor does not reach a temperature exceeding the threshold for proper operation. The combination of the supercapacitor module 106 and the phase-change material 122 further enhances these benefits, as the supercapacitor module 106 can be positioned very close to the heating chamber 116 but protected from excessive thermal energy by the phase-change material 122.

[0136] Supercapacitors are also well-suited for this application in the heating element 102 of an aerosol-generating device 100 with a phase change material 122 because, in the event of a device failure (e.g., if the phase change material 122 ruptures, the heating chamber 116 overheats, or the supercapacitor(s) rupture), supercapacitor technology is safe by design. Supercapacitors do not have swelling constraints, are not subject to thermal events, or breakdown. As such, the supercapacitor module 106 is safer to use in the heating element 102 than, for example, batteries. Supercapacitors can also be discharged to 0 V without risk and without the need for under-discharge protection, or, in the case of asymmetric supercapacitors, can be discharged to the minimum voltage to which they can be discharged without risk.

[0137] Furthermore, ultracapacitor cells are well suited for applications with phase change material 122 because they can flex as the phase change material 122 changes phase without negatively impacting the operation of the ultracapacitor module 106 .

[0138] The thickness and exact dimensions of the ultracapacitor(s) may depend on the power requirements of the heater 118. However, in an example, the thickness of the ultracapacitor(s) may be in the range of 1 to 5 mm. The thickness of the phase change material 122 may depend on the latent heat requirements and type of phase change material 122 used. However, in an example, the thickness of the phase change material 122 may be in the range of 0.2 to 2 mm.

[0139] The temperature of the phase change material 122 can be monitored and used to recalibrate the temperature of the heater 118. A first temperature sensor 136-1 can be used to monitor the temperature of the heater 118, and a second temperature sensor 136-2 can be used to monitor the temperature of the phase change material 122. In some examples, these temperature sensors can be temperature sensor subcircuits. In some examples, the second temperature sensor 136-2 that monitors the temperature of the phase change material 122 does not require a high level of accuracy, meaning that a low-cost or basic sensor can be used. This is because the saturation (phase change) temperature of the phase change material 122 is a known, fixed parameter, so only plateaus in the temperature reading need to be detected, rather than a clear, accurate temperature value.

[0140] Figure 5 A graph is depicted of phase change material temperature 502 relative to heater temperature 504. When the phase change material 122 is in the solid phase, the temperature of the phase change material 122 will increase as the temperature of the heater 118 increases. However, when the phase change material 122 reaches a melting point 506, the temperature of the phase change material 122 levels off and remains substantially constant even as the heater temperature continues to increase.

[0141] The melting temperature of the phase change material 122 is a known property. This temperature can be stored in the firmware of the aerosol-generating device 100, for example, in a memory device accessible to the controller. Because the melting temperature of the phase change material 122 is known and predetermined, a relationship can be established between the heater (or heating chamber) temperature and the melting temperature of the phase change material 122. For example, it is known that the phase change material 122 reaches its melting point (i.e., melting temperature) at X°C. It can be predetermined that the phase change material 122 reaches X°C when the heater 118 is at Y°C. In other words, Y°C is the expected heater temperature when the phase change material 122 melts in the device. Thus, when it is determined that the phase change material 122 has reached its melting temperature because its temperature has stabilized, it can be determined that the heater 118 should be at an expected temperature of Y°C. This can be used to correct for temperature measurement offsets or errors in the measured heater temperature. If the measured heater temperature deviates by ΔY°C from the desired temperature Y°C when the temperature of the phase change material 122 stabilizes, this ΔY°C offset in the measured heater temperature can be corrected by recalibrating the measured heater temperature. This can be performed continuously during the aerosolization process. In this way, the melting point of the phase change material 122 can be used to accurately calibrate and control the heater temperature. This enables more precise control of the heater temperature, allowing the heater 118 to be accurately heated to the desired temperature for the aerosolization process, thereby improving aerosol generation for the consumer.

[0142] Return to Figure 4 , the components of the heating element 102 may be contained within a heating element housing 126. The components of the heating element 102 may further include a circuit board 114 on which the control electronics of the aerosol generating device 100 are arranged. In some examples, this may be a flexible printed circuit board. A flexible circuit board is advantageous because it can be conformed to fit compactly around the heating chamber 116 and other components in the heating element housing 126, resulting in a compact heating element 102. Figure 4 In the example of FIG, the circuit board 114 is arranged along the axial direction of the heating component 102, in the insertion / removal direction of the aerosol-generating material, and adjacent to the minor surface of the heating chamber 116. In other examples, the circuit board 114 may be arranged along the axial direction of the heating component 102, in the insertion / removal direction of the aerosol-generating material, and adjacent to the major surface of the heating chamber 116. In another example, the circuit board 114 may be arranged below the heating chamber 116 in the insertion / removal direction of the aerosol-generating material (i.e., away from the nozzle 110 end of the heating component 102), as shown in FIG. Figure 1 shown.

[0143] As noted, an insulating layer 124 may optionally be disposed between the phase change material 122 and the heating chamber 116. For example, the insulating layer 124 may be an insulating material disposed around or partially around the heating chamber 116. This may improve the efficiency of the aerosol-generating device by reducing heat loss from the heating chamber 116.

[0144] As reference Figure 1 As depicted, the heating component 102 and the auxiliary power component 104 may each have a corresponding electrical connector 112 such that power may flow from the battery module 108 to the components of the heating component 102 when the heating component 102 and the auxiliary power component 104 are connected to one another. Figure 4 In an example, two sets of electrical connectors 112 are included. In such an example, a first set of electrical connectors 112-1 can be between a controller on a circuit board and a battery module 108 in the auxiliary power component 104; this first set of electrical connectors 112-1 can be used to control the battery module 108. A second set of electrical connectors 112-2 can be between the ultracapacitor module 106 and / or the heater 118 and the battery module 108 of the auxiliary power component. However, it should be understood that any suitable number of electrical connectors can be included. For example, a single set of electrical connectors can be used to control the auxiliary power component 104 using a controller in the heating component 102 and for power flow from the battery module 108 to the ultracapacitor module 106 and / or the heater 118.

[0145] These electrical connectors 112 allow for electrical separation between the ultracapacitor module 106 and the battery module 108 by disconnecting the heating component 102 from the auxiliary power component 104. This provides for a modular energy system design with increased flexibility when the battery module 108 and the ultracapacitor module 106 are decoupled. In this way, for example, the battery can be replaced by replacing the auxiliary power component 104 without having to replace the entire aerosol-generating device 100 or the entire power system (ultracapacitor module 106 and battery module 108).

[0146] The decoupling of the supercapacitor module 106 from the battery module 108 in the manner described helps simplify replacement of the battery module 108 in terms of flexibility. Using different battery sizes in an aerosol generating system can increase technical complexity. For example, if 20 W (5 A, 4 V) is required from the battery, a 2500 mAh battery would require a 2 C discharge rate. However, for a 1250 mAh battery, this would mean a 4 C discharge rate would be required, which is more challenging in terms of battery life cycle. However, the decoupled power system provided by the present invention allows the supercapacitor module 106 to be used to power the heater 118, which reduces battery stress and thereby improves battery life cycle, thereby enabling the use of lower capacity batteries while also providing a safer aerosol generating device 100. In this way, the battery module 108 can be easily replaced at the end of its life cycle, providing flexibility in battery selection.

[0147] In some examples, a connection can be made between the supercapacitor cells in a 2s1p configuration; this connection can also be to a controller to sense the voltage across each supercapacitor cell in the 2s1p configuration so that the controller can control power flow. In some examples, another connection to the controller can be made separately. Additional connections can be made between the heater and the circuit board through the controller, for example on the bottom of the heater cell.

[0148] exist Figure 4 In the example shown, there are essentially two supercapacitors on either side of the planar heating chamber 116. However, in other examples, a continuous supercapacitor may surround the heating chamber 116, or multiple supercapacitors may be arranged around the heating chamber 116. Figures 6A to 6C Such examples are described in more detail.

[0149] Figures 6A to 6C A second aerosol generating device 600 is depicted in FIG. The aerosol generating device 600 may be used in the same manner as in reference Figures 1 to 5 The aerosolization process is performed in the same manner as described in the examples of FIG. 1 (eg, in terms of how the preheating phase and the heating phase are powered by the supercapacitor module 106 and / or the battery module 108); therefore, for the sake of brevity, these will not be repeated here.

[0150] Figure 6A There is shown a conceptual cross-sectional view of an aerosol-generating device 600 configured to receive a substantially rod-shaped aerosol-generating substrate 620, such as a tobacco rod. Figure 6A The aerosol generating device 600 has a heating component 602 and an auxiliary power component 604. The heating component 602 and the auxiliary power component 604 can be used in a manner similar to that of the reference Figures 1 to 5The aerosol generating device 100 is removably connected in the same manner as described.

[0151] The auxiliary power component 604 includes a battery module 608 that can be connected to the components of the heating component 602 via a connector 612. The auxiliary power component 604, the battery module 608, and the connector 612 can be connected to the components of the heating component 602 in a manner similar to that of the reference Figures 1 to 5 The auxiliary power components 104 , battery module 108 and connector 112 of the aerosol-generating device 100 are implemented in the same manner as described, so for the sake of brevity, this description will not be repeated here.

[0152] The heating component 602 includes a heating chamber 616 configured to receive and heat a rod-shaped aerosol generating substrate 620. The heating component 602 includes a supercapacitor module 606 and a phase change material 622, which can be used in a manner similar to that of a reference Figures 1 to 5 The supercapacitor module 106 and the phase change material 122 are implemented in the same manner as described above, so for the sake of brevity, this description will not be repeated here.

[0153] The heating element 602 may further include a housing 626, a heat insulating layer 624, and a circuit board 614, which may be similar to the reference Figures 1 to 5 The housing 126, the insulation layer 124, and the circuit board 114 are implemented in the same manner as described above, so for the sake of brevity, this description will not be repeated here. The heating component 602 may also include a first temperature sensor (not shown) configured to monitor the temperature of the heater and a second temperature sensor (not shown) configured to monitor the temperature of the phase change material 622. These temperature sensors may be configured to monitor the temperature of the phase change material 622 in the same manner as described above. Figures 1 to 5 The temperature sensor of the aerosol-generating device 100 is implemented in the same way as described.

[0154] refer to Figures 1 to 5 The aerosol generating device 100 described in reference Figures 6A to 6C The main differences between the described aerosol generating devices 600 are that Figures 6A to 6C The aerosol-generating device 600 has a heating chamber 616 configured to receive a substantially rod-shaped aerosol-generating substrate 620, such as a tobacco rod.

[0155] A heating chamber 616 is arranged in the heating unit 602. The heating chamber 616 is accessed through an opening in the heating unit 602, into which opening an aerosol-generating substrate 620 is inserted.

[0156] The aerosol-generating substrate 620 can comprise an aerosol-generating material, such as a tobacco rod comprising tobacco. The tobacco rod can be similar to a conventional cigarette. The cross-section of the heating chamber 616 can be approximately equal to the cross-section of the aerosol-generating substrate 620. The heating chamber 616 can have a circular or substantially circular cross-sectional shape to match the cross-sectional shape of the tobacco rod aerosol-generating substrate 620.

[0157] The heating chamber 616 may have a depth such that when the associated aerosol-generating substrate 620 is inserted into the heating chamber 616, a first end portion of the aerosol-generating substrate 620 reaches the bottom of the heating chamber 616 (i.e., the end of the chamber 616 distal from the opening), and a second end portion of the aerosol-generating substrate 620 distal from the first end portion extends outward from the heating chamber 616. In this manner, when the aerosol-generating substrate 620 is inserted into the aerosol-generating device 600, a consumer can inhale onto the aerosol-generating substrate.

[0158] The heater 618 is arranged in the heating chamber 616 so that the aerosol-generating substrate 620 engages with the heater 618 when inserted into the heating chamber 616. Figure 6A In the example of FIG. 6 , the heater 618 is arranged as a tube defining the heating chamber 616 such that when the first end portion of the aerosol-generating substrate 620 is inserted into the heating chamber 616, the heater 618 substantially or completely surrounds the portion of the aerosol-generating substrate 620 within the heating chamber 616. The heater 618 can be a wire, such as a coiled wire heater, or a ceramic heater, or any other suitable type of heater. The heater 618 can be embedded in the wall of the heating chamber 616 or attached to the inner or outer surface of the heating chamber wall. The heater 618 can include a plurality of heating elements arranged sequentially along the axial length of the heating chamber 616, which can be independently activated (i.e., energized) in sequence.

[0159] In an alternative embodiment (not shown), the heater may be arranged to heat an elongated piercing member (e.g., in the form of a needle, rod, or blade) within the chamber 616; in such an embodiment, the heater may be arranged to penetrate the aerosol-generating substrate 620 and engage with the aerosol-generating material when the aerosol-generating substrate 620 is inserted into the cavity.

[0160] In another alternative embodiment (not shown), the heater can be in the form of an induction heater. In such an embodiment, a heating element (i.e., a susceptor) can be disposed in the aerosol-generating substrate 620 and, when the aerosol-generating substrate 620 is inserted into the heating chamber 616, the heating element inductively couples with an inductive element (i.e., an induction coil) in the heating chamber 616. The induction heater then heats the heating element by induction.

[0161] Heater 618 is configured to heat tobacco (or other aerosol-generating material) without burning the tobacco to generate an aerosol. That is, heater 618 heats the tobacco to a predetermined temperature below the tobacco's combustion point, thereby generating a tobacco-based aerosol. A skilled artisan will readily appreciate that aerosol-generating substrate 620 need not necessarily comprise tobacco, and any other substance suitable for aerosolization (or vaporization) (particularly by heating the substance without burning the substance) may be used in place of or in combination with tobacco.

[0162] In an alternative, the aerosol-generating substrate 620 may be a vaporizable liquid. The vaporizable liquid may be contained in a cartridge receivable in an aerosol-generating device, or may be deposited directly into the aerosol-generating device.

[0163] Figure 6B Shown is a reference Figure 6A A cross-sectional view of a heating element 602 of an aerosol-generating device 600 is depicted. The cross-section is viewed along the axial direction of the heating element 602; that is, in the direction in which the aerosol-generating substrate 620 is inserted into or removed from the heating chamber 616.

[0164] The supercapacitor module 606 is adjacent to and substantially surrounds the heating chamber 616. The heating chamber 616 is defined by a heater 618. A phase change material 622 is provided between the heating chamber 616 and the supercapacitor module 606 to separate the heating chamber 616 from the supercapacitor module 606. Optionally, a thermal insulation layer 624 is provided between the heating chamber 616 and the phase change material 622. These components have the same Figures 1 to 5 The corresponding components described have the same functionality and advantageous technical effects.

[0165] The thermal insulation layer 624 surrounds the heating chamber 616 (partially or completely) along its axial length (i.e., the direction of insertion / removal of the aerosol-generating substrate 620). The phase change material 622 surrounds the heating chamber 616 (partially or completely) along its axial length, and also surrounds the thermal insulation layer 624 (if included). The supercapacitor module 606 then substantially surrounds the phase change material 622 at least partially along the axial length of the heating chamber 616. This is achieved by a plurality of supercapacitors that can bend or conform to follow the shape of the heating chamber 616 along its axial length. Figure 6B In the example shown, five supercapacitors are included; however, any suitable number of supercapacitors may be used.

[0166] Thus, a layered arrangement is formed in the heating element 602 with the heating chamber 616 in the center, followed in an outward direction by the insulation layer 624 (optional), then the phase change material 622, and then the ultracapacitor module 606, all within the housing 626 of the heating element 602.

[0167] Figure 6C Shown is a reference Figure 6A A cross-sectional view of an alternative heating member 602 of an aerosol-generating device 600 is depicted. The cross-section is viewed along the axial direction of the heating member 602; that is, in the direction in which the aerosol-generating substrate 620 is inserted into or removed from the heating chamber 616. Figure 6C The heating component 602 corresponds to Figure 6B The heating element 602 is similar to the heating element 602, except that the supercapacitor module 606 is a single supercapacitor that completely (or substantially completely) surrounds the heating chamber 616, rather than being formed from a plurality of supercapacitors. The single supercapacitor can conform to the shape of the heating chamber 616 (e.g., a tubular shape), is adjacent to the heating chamber 616, and extends at least partially along the length of the heating chamber.

[0168] Now refer to Figures 7 to 16 To describe the reference Figures 1 to 4 The analysis of the phase change material and the thermal insulation layer considerations of the heating component of the described aerosol generating device 100 is configured to heat the aerosol generating material without burning it to generate an aerosol. For the sake of brevity, the above description will not be repeated here. Figures 1 to 4 However, it should be noted that the present teachings may also be applied to devices such as those described in reference Figures 6A to 6C The heating component of the aerosol-generating device 600 is described.

[0169] Figure 7 A diagram of an exemplary aerosol-generating device heating element 702 is shown; this configuration of the aerosol-generating heating element 702 was used to evaluate the effects of different phase change material 722 and insulation layer 724 arrangements.

[0170] The heating component 702 includes a heating chamber 716, an aerosol generating substrate (e.g., Figures 3A to 3C The aerosol generating substrate described herein is received into the heating chamber and aerosolized therein. In some examples, the heating chamber 716 is made of or includes stainless steel. The heating chamber 716 has a heating track 718, as shown in FIG. Figures 8A to 8EThe heating track 718 can be encased in a thermally conductive, electrically insulating layer 719 (e.g., Kapton) to provide electrical insulation while separating the heater from the heating track. This Kapton layer can electrically insulate the heating track from other metal or conductive parts. While Kapton itself may have poor heat transfer properties (thermal conductivity), this layer can be made very thin (e.g., less than 50 μm thick), which means that heat is conducted to other parts with relatively little loss.

[0171] Optionally, a heat sink layer 721 may be included. The heat sink layer 721 may be configured to help spread heat from the heating chamber 716 to the phase change material 722. In some examples, the heat sink layer 721 may be a conductive layer, such as graphite foil. In a specific example, the heat sink layer 721 may have a thickness of approximately 40 microns.

[0172] With reference Figures 1 to 4 and Figures 6A to 6C In a manner similar to that described, an ultracapacitor module 706 comprising one or more ultracapacitors is disposed adjacent to the heating chamber 716 and at least partially surrounds the heating chamber.

[0173] A plurality of layers may be arranged between the ultracapacitor module 706 and the heat sink layer 721 (if included) or the electrical insulation layer 719 (if no heat sink layer is included) or the heating track 718 (if neither the heat sink layer 721 nor the electrical insulation layer 719 is included). The plurality of layers surrounds or at least partially surrounds the heating chamber. The plurality of layers may include one or more insulation layers 724 and one or more phase change material layers 722. Figure 7 In the example shown, there are four insulation layers and one phase change material layer; two insulation layers (labeled 724-1, 724-2) are arranged between the phase change material layer 722 and the heating chamber 716, and two insulation layers (labeled 724-3, 724-4) are arranged between the phase change material layer 722 and the ultracapacitor module 706. However, it should be understood that other numbers of insulation layers 724 and phase change material layers 722 may be included, for example, referring to FIG. Figures 11A to 11E More generally, the phase change material 722 may include one or more phase change material layers between the heating chamber 716 and the ultracapacitor module 706, and the thermal insulation layer 724 may include one or more thermal insulation layers arranged in any suitable order between the heating chamber 716 and the ultracapacitor module 706.

[0174] In an example, the insulation layer(s) 724 may be an aerogel, such as a SiO2-based aerogel. In a specific example, the insulation layer(s) 724 may be Finesulight. In some examples, the phase change material 722 may be indium or indium-based, a hydrated salt, an organic solution, or a solid-solid phase change material.

[0175] The suction nozzle 710 can be attached to the heating element. The suction nozzle 710 can be configured for inhalation by a user. The suction nozzle 710 can be attached to other components of the heating element 702 at a first end of the heating element 702. In an example, the suction nozzle 710 can be made of PEEK. The suction nozzle 702 can be attached to the heating element via a top cover 711. In an example, the top cover 711 can be made of PEEK. A seal 713 can be positioned between the suction nozzle 710 and the top cover 711. In an example, the seal 713 can be made of silicone.

[0176] A plug cap 715 may be disposed at a second end, opposite the first end, of the heating component 702. In an example, the plug cap may be PEEK.

[0177] An adhesive material 717 , such as silicone or glue, may be used to hold the heating chamber 716 in place within the heating component 702 .

[0178] Figure 8A A perspective view showing an exemplary layout of a heating track 718 is shown, which is configured to substantially surround the heating chamber and can be connected to the heating track 718. Figure 7 In this particular example, the heating track 718 is configured to surround two opposing major faces of the heating chamber and a minor face connecting the two major faces. Figure 8B A perspective view of a heating track 718 encased in an electrically insulating layer 719 (eg, Kapton) is shown. Figure 8C is a cross-sectional view of a portion of a heating track 718 encased or potted in an electrically insulating layer 719. In this example, the heating track 718 has a cross-sectional thickness A, and the electrically insulating layer 719 has a cross-sectional thickness B. In a specific example, A may be 5 microns, and B may be 15 microns. Figure 8D A perspective view of the heating chamber 716 and heating track 718 in combination with the suction nozzle 710 is shown with other layers of the heating components removed. Figure 8E Figure 7 shows where the temperature probe 723 may be positioned on the heating element. Figures 9 to 14 The temperature probe is discussed in more detail.

[0179] Figure 9 Shown with reference Figure 7 The description of the heating component is consistent with the diagram of the heating component. Figure 9The heating element has six layers 930-1, 930-2, 930-3, 930-4, 930-5, 930-6, which can be phase change material layers or heat insulation layers. Figures 11A to 11E and 12A to 12E Discussion of different combinations of phase change material layers and thermal insulation layers. In order to demonstrate the effectiveness of different combinations of phase change material layers and thermal insulation layers, temperature probes T1, T2, T3, T4 can be positioned between every two of these layers.

[0180] The first layer 930-1 is the phase change material layer or thermal insulation layer closest to the heating chamber 716. In the direction outward from the heating chamber (i.e., in the radial direction within the heating element), the second layer 930-2 is the phase change material layer or thermal insulation layer closest to the heating chamber after the first layer 930-1. In the outward direction, the third layer 930-3 is the phase change material layer or thermal insulation layer closest to the heating chamber 716 after the second layer 930-2. In the outward direction, the fourth layer 930-4 is the phase change material layer or thermal insulation layer closest to the heating chamber 716 after the third layer 930-3. In the outward direction, the fifth layer 930-5 is the phase change material layer or thermal insulation layer closest to the heating chamber 716 after the fourth layer 930-4. In the outward direction, the sixth layer 930-6 is the phase change material layer or thermal insulation layer closest to the heating chamber 716 after the fifth layer 930-5. In other words, when there are six layers of phase change material or insulation, the sixth layer is farther from the heating chamber 716 in a direction outward from the heating chamber.

[0181] A first temperature probe T1 is positioned in the heating chamber 716. A second temperature probe T2 is positioned between the second layer 930-2 and the third layer 930-3. A third temperature probe T3 is positioned between the fourth layer 930-4 and the fifth layer 930-5. A fourth temperature probe T4 is positioned outside (outward from the heating chamber 716) the sixth layer 930-6. The temperature probes may be thermocouples. The first temperature probe may be displaced a distance X in the axial direction of the heating element into the heating chamber; in this example, X may be 11 mm. The second, third, and fourth temperature probes may then be aligned with this temperature probe so that all temperature measurements are taken at the same axial position on the heating element.

[0182] Figure 10Graph 1000 shows the temperature 1004 recorded at each of the temperature probes (T1, T2, T3, and T4) over time 1002 during the aerosolization process. In this example, all six layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 are insulation layers made of Finesulight, and each layer is shrink-wrapped in plastic. As can be seen, throughout the aerosolization process, lower temperatures are observed as the number of insulation layers between the heating chamber 716 and the temperature probes increases (zero layers at T1, two layers at T2, four layers at T3, and six layers at T4). The lowest temperature is observed on the outer surface of the sixth layer 930-6, indicating the suitability of placing the ultracapacitor module on this surface by utilizing the heat dissipation provided by the insulation layers.

[0183] Figures 11A to 11E Shown with Figure 9 Figure 1 shows an aerosol-generating device heating component consistent with the aerosol-generating device heating component of FIG, but in which one or more thermal insulation layers are replaced with phase change material layer(s). Using these different combinations of thermal insulation layers and phase change material layers, a parametric study was conducted to determine which combination of thermal insulation layer(s) and phase change material layer(s) provides the most beneficial thermal shielding for the supercapacitor module adjacent to and at least partially surrounding the heating chamber (and the thermal insulation layers and phase change material layers).

[0184] against Figures 11A to 11E Each example heating element, in 12A to 12E The temperature changes with time at each temperature probe (T1, T2, T3, T4) during the aerosolization process are presented in Figure 2.

[0185] In the example heating element used for the parameter study, the insulation layer(s) were SiO2-based aerogels (Finesulight), the parameters of which are presented in Table 1.

[0186]

[0187] Table 1

[0188] In the example heating element used for the parameter study, the phase change material layer(s) was indium, the parameters of which are presented in Table 2. Indium phase change material has a melting point of 156°C and a latent heat of fusion of 3.26 kJ / mol = 28.35 kJ / kg.

[0189]

[0190] Table 2

[0191] For this parametric study, the heater temperature of the aerosolization process was set to 280°C.

[0192] Figures 11A to 11E The heating elements presented in FIG. 7 have different combinations of insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6. In one of these examples, the layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 are stacked and arranged adjacent to one another, starting from the first layer 930-1 closest to the heating chamber 718 and outward in the order of first layer 930-1, second layer 930-2, third layer 930-3, fourth layer 930-4, fifth layer 930-5, and sixth layer 930-6. In these examples, each layer is 0.5 mm.

[0193] For reference Figures 11A to 11E Each of the heating components described, 12A to 12E Graphs of temperature 1204 at a first temperature probe T1, a second temperature probe T2, a third temperature probe T3, and a fourth temperature probe T4 relative to time 1202 during the aerosolization process are shown. The first temperature probe T1 is positioned in the heating chamber 716. The second temperature probe T2 is positioned between the second layer 930-2 and the third layer 930-3. The third temperature probe T3 is positioned between the fourth layer 930-4 and the fifth layer 930-5. The fourth temperature probe T4 is positioned on the outside of the sixth layer 930-6 (in a direction outward from the heating chamber 716). For comparison purposes, each graph additionally shows how the temperature of the fourth temperature probe T4 changes with time when the phase change material layer is not included (i.e., when there are six insulation layers), as shown in FIG. Figure 10 As shown. In this way, in the reference Figures 11A to 11E A comparison is made between the different heating elements described, using the same power at the heating track.

[0194] Figure 11A The combination of thermal insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a first exemplary heating element 1100A is shown. The first layer 930-1 and the second layer 930-2 are each thermal insulation layers. The third layer 930-3 is a phase change material layer. The fourth layer 930-4, the fifth layer 930-5, and the sixth layer 930-6 are each thermal insulation layers. In other words, from the heating chamber 718 outward, there are two thermal insulation layers, followed by a phase change material layer, and three additional thermal insulation layers. In this example, each thermal insulation layer is 0.5 mm, and the phase change material layer is 0.5 mm; therefore, the phase change material layer has an effective thickness of 0.5 mm and is separated from the heating chamber by a 1 mm thermal insulation layer. Figure 12A Shown Figure 11AFIG. 12 is a graph 1200A showing a temperature 1204 of each of the first temperature probe T1 , the second temperature probe T2 , the third temperature probe T3 , and the fourth temperature probe T4 in the heating component 1100A of FIG. 1 .

[0195] Figure 11B The combination of thermal insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a second exemplary heating element 1100B is shown. The first layer 930-1 and the second layer 930-2 are each thermal insulation layers. The third layer 930-3 and the fourth layer 930-4 are each phase change material layers. The fifth layer 930-5 and the sixth layer 930-6 are each thermal insulation layers. That is, from the heating chamber 718 outward, there are two thermal insulation layers, followed by two phase change material layers, and two more thermal insulation layers. In this example, each thermal insulation layer is 0.5 mm, and each phase change material layer is 0.5 mm; therefore, the phase change material layer has an effective thickness of 1 mm and is separated from the heating chamber by a 1 mm thermal insulation layer. Figure 12B Shown Figure 11B FIG. 12 is a graph 1200B showing the temperature 1204 of each of the first temperature probe T1 , the second temperature probe T2 , the third temperature probe T3 , and the fourth temperature probe T4 in the heating component 1100B of FIG. 1 .

[0196] Figure 11C The combination of thermal insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a third exemplary heating element 1100C is shown. The first layer 930-1 and the second layer 930-2 are each thermal insulation layers. The third layer 930-3, the fourth layer 930-4, the fifth layer 930-5, and the sixth layer 930-6 are each phase change material layers. That is, outward from the heating chamber 718, there are two thermal insulation layers, followed by four phase change material layers. In this example, each thermal insulation layer is 0.5 mm, and each phase change material layer is 0.5 mm; therefore, the phase change material layer has an effective thickness of 2 mm and is separated from the heating chamber by a 1 mm thermal insulation layer. Figure 12C Shown Figure 11C FIG. 12 is a graph 1200C showing the temperature 1204 of each of the first temperature probe T1 , the second temperature probe T2 , the third temperature probe T3 , and the fourth temperature probe T4 in the heating component 1100C of FIG. 1 .

[0197] Figure 11DThe combination of thermal insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a fourth exemplary heating element 1100D is shown. The first layer 930-1, the second layer 930-2, the third layer 930-3, and the fourth layer 930-4 are each thermal insulation layers. The fifth layer 930-5 is a phase change material layer. The sixth layer 930-6 is a thermal insulation layer. That is, from the heating chamber 718 outward, there are four thermal insulation layers, followed by a phase change material layer, and then an additional thermal insulation layer. In this example, each thermal insulation layer is 0.5 mm, and the phase change material layer is 0.5 mm; therefore, the phase change material layer has an effective thickness of 0.5 mm and is separated from the heating chamber by a 2 mm thermal insulation layer. Figure 12D Shown Figure 11D FIG. 12 is a graph 1200D showing the temperature 1204 of each of the first temperature probe T1 , the second temperature probe T2 , the third temperature probe T3 , and the fourth temperature probe T4 in the heating component 1100D of FIG. 12 with respect to time 1202 .

[0198] Figure 11E The combination of thermal insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a fifth exemplary heating element 1100E is shown. The first layer 930-1, the second layer 930-2, the third layer 930-3, and the fourth layer 930-4 are each thermal insulation layers. The fifth layer 930-5 and the sixth layer 930-6 are phase change material layers. That is, outward from the heating chamber 718, there are four thermal insulation layers, followed by two phase change material layers. In this example, each thermal insulation layer is 0.5 mm, and each phase change material layer is 0.5 mm; therefore, the phase change material layer has an effective thickness of 1 mm and is separated from the heating chamber by a 2 mm thermal insulation layer. Figure 12E Shown Figure 11E FIG. 12 is a graph 1200E showing the temperature 1204 of each of the first temperature probe T1 , the second temperature probe T2 , the third temperature probe T3 , and the fourth temperature probe T4 in the heating component 1100E of FIG. 1 .

[0199] See also 12A to 12E As would be expected, in each case, the fourth temperature probe T4 positioned on the outside of the sixth layer 930 - 6 (in a direction outward from the heating chamber 716 ) recorded the lowest temperature.

[0200] exist Figure 12A , for the first exemplary heating element 1100A, the temperature at the fourth temperature probe T4 reaches 98.88° C., which is higher than the highest temperature at the fourth temperature probe T4 of the control example having six insulation layers and no phase change material layer (i.e., Figure 10 ).

[0201] exist Figure 12B , for the first exemplary heating member 1100B, the temperature at the fourth temperature probe T4 reaches 102.28° C., which is higher than the highest temperature at the fourth temperature probe T4 of the control example having six insulation layers and no phase change material layer (i.e., Figure 10 ).

[0202] exist Figure 12C , for the first exemplary heating element 1100C, the temperature at the fourth temperature probe T4 reaches 107.10°C, which is higher than the highest temperature at the fourth temperature probe T4 of the control example having six insulation layers and no phase change material layer (i.e., Figure 10 ).

[0203] exist Figure 12D , for the first exemplary heating element 1100D, the temperature at the fourth temperature probe T4 reaches 98.06° C., which is higher than the highest temperature at the fourth temperature probe T4 of the control example having six insulation layers and no phase change material layer (i.e., Figure 10 ).

[0204] exist Figure 12E , for the fifth exemplary heating element 1100E, the temperature at the fourth temperature probe T4 reaches 89.72° C., which is substantially equal to the highest temperature at the fourth temperature probe T4 of the control example having six insulation layers and no phase change material layer (i.e., Figure 10 ). However, it is noteworthy that during the aerosolization process, the temperature recorded at temperature probe T4 was consistently lower than that of the control example described above. This demonstrates the benefits of placing insulation between the phase change material and the heating chamber, and between the insulation and the supercapacitor module, to protect the supercapacitor module, which at least partially surrounds the heating chamber, from heat flowing out of the heating chamber. Therefore, from this parametric study, it can be concluded that the insulation and phase change material arrangement in the fifth exemplary heating element 1100E provides the most beneficial thermal shielding.

[0205] That is, it was determined that the optimal configuration of the phase change material and insulation was when a phase change material layer with a total thickness of 1 mm was placed against the ultracapacitor module, and a thermal insulation layer with a total thickness of 2 mm was placed between the phase change material and the heating chamber. In other words, the total thickness of the thermal insulation layer was approximately twice the total thickness of the phase change material layer in the radial direction of the heating element.

[0206] In already about Figures 11A to 11EWhere multiple stacked adjacent layers of insulation or phase change material are described, these stacked layers may alternatively be configured as single layers of greater thickness; the important components are the total thermal mass of the phase change material and the total thickness of the insulation layers. For example, Figure 11E The fifth exemplary heating element 1100E may have one 2 mm insulation layer and one 1 mm phase change material layer, rather than four 0.5 mm insulation layers and two 0.5 mm phase change material layers.

[0207] The parametric studies presented in Figures 11 and 12 use indium as the phase change material. Indium as a phase change material has a high transition temperature and low latent heat capacity. Alternative phase change materials to indium exist; some include hydrated salts, organic solutions, and solid-solid phase change materials.

[0208] As discussed, Figure 11E The combination of the insulation layer and the phase change material layer of the fifth exemplary heating element 1105 provides an optimal thermal shield for the supercapacitor module that at least partially surrounds the heating chamber. As a next step in this study, different phase change materials were used according to Figure 11E The fifth exemplary heating element 1105 includes a structured thermal insulation layer and a phase change material layer to replace the indium in the heating element.

[0209] The different phase change materials explored as alternatives to indium are detailed in Table 3.

[0210]

[0211] Table 3

[0212] Further details on each PCM type can be found at:

[0213] https: / / www.pcmproducts.net / Phase_Change_Material_Products.htm

[0214] For each phase change material detailed in Table 3, 13A to 13F Shown in accordance with Figure 11EGraphs of temperature 1304 versus time 1302 at a first temperature probe T1, a second temperature probe T2, a third temperature probe T3, and a fourth temperature probe T4 during aerosolization in a heating component of a structured thermal insulation layer and a phase change material layer of a fifth exemplary heating component 1105 are shown. The first temperature probe T1 is positioned within the heating chamber 716. The second temperature probe T2 is positioned between the second layer 930-2 and the third layer 930-3. The third temperature probe T3 is positioned between the fourth layer 930-4 and the fifth layer 930-5. The fourth temperature probe T4 is positioned outside (outward from the heating chamber 716) of the sixth layer 930-6.

[0215] See also 13A to 13F As would be expected, in each case, the fourth temperature probe T4 positioned on the outside of the sixth layer 930 - 6 (in a direction outward from the heating chamber 716 ) recorded the lowest temperature.

[0216] exist Figure 13A For the hydrated salt type 1 phase change material, the temperature at the fourth temperature probe T4 reaches 32°C, which is lower than Figure 12E The highest temperature of the indium phase change material at the fourth temperature probe T4.

[0217] exist Figure 13B For the hydrated salt type 2 phase change material, the temperature at the fourth temperature probe T4 reaches 48°C, which is lower than Figure 12E The highest temperature of the indium phase change material at the fourth temperature probe T4.

[0218] exist Figure 13C For organic solution type 1 phase change material, the temperature at the fourth temperature probe T4 reaches 43°C, which is lower than Figure 12E The highest temperature of the indium phase change material at the fourth temperature probe T4.

[0219] exist Figure 13D For organic solution type 2 phase change material, the temperature at the fourth temperature probe T4 reaches 48°C, which is lower than Figure 12E The highest temperature of the indium phase change material at the fourth temperature probe T4.

[0220] exist Figure 13E For solid-solid type 1 phase change material, the temperature at the fourth temperature probe T4 reaches 54°C, which is lower than Figure 12E The highest temperature of the indium phase change material at the fourth temperature probe T4.

[0221] exist Figure 13F For solid-solid type 2 phase change material, the temperature at the fourth temperature probe T4 reaches 57°C, which is lower than Figure 12EThe highest temperature of the indium phase change material at the fourth temperature probe T4.

[0222] For each of the hydrated salt type 1, hydrated salt type 2, organic solution type 1, organic solution type 2, solid-solid type 1, and solid-solid type 2 phase change materials, the temperature recorded at the fourth temperature probe T4 located on the outside (in the direction outward from the heating chamber 716) of the sixth layer 930-6 is lower than that for the Figure 12E The temperature of the indium phase change material. This can be Figure 14 It is clear that the figure presents the Figure 11E The change in temperature 1404 recorded at the fourth temperature probe T4 over time 1402 during the aerosolization process of the structured heating component when using each of hydrated salt type 1, hydrated salt type 2, organic solution type 1, organic solution type 2, solid-solid type 1 and solid-solid type 2 phase change materials and indium phase change material.

[0223] In addition, the temperature recorded at the fourth temperature probe T4 is also lower than that of the control example using six insulation layers and no phase change material (ie, Figure 10 ).

[0224] Importantly, for all of these phase change materials, the maximum temperature recorded at the fourth temperature probe T4 is generally lower than the maximum operating temperature of the supercapacitor module.

[0225] These results emphasize that Figure 11E The described structured insulation layer and heating element of the phase change material layer, the use of hydrated salt phase change materials, organic solution phase change materials or solid-solid phase change materials as the phase change material layer(s) is particularly beneficial for hydrated salt type 1 phase change materials.

[0226] In some examples, the phase change material may include a hydrated salt phase change material, an organic solution phase change material, or a solid-solid phase change material, or a combination of one or more of the hydrated salt phase change material, the organic solution phase change material, or the solid-solid phase change material.

[0227] Figure 15 shows a reference Figure 11E A simulated thermal map 1500 of a heating component of the described structured thermal insulation layer and phase change material layer. It can be seen that by providing the thermal insulation layer and the phase change material layer, the temperature near the heating chamber 716 where the ultracapacitor module may be arranged is significantly reduced.

[0228] Figure 16 shows a reference Figure 11EA cross-sectional view of a heating component with a structured insulation layer and phase change material layer, having an ultracapacitor module 706 adjacent to and at least partially surrounding a heating chamber. The first layer 930-1, the second layer 930-2, the third layer 930-3, and the fourth layer 930-4 are insulation layers, and the fifth layer 930-5 and the sixth layer 930-6 are insulation layers. Beneficially, as discussed, the structure of the insulation layer and phase change material layer significantly reduces heat generation in the area where the ultracapacitor module is connected to the heating component. This heat reduction prevents the temperature of the ultracapacitor module from reaching above 55°C to 65°C. This allows the ultracapacitor module to be positioned adjacent to and at least partially surrounding the heating chamber without causing damage. By positioning the ultracapacitor module adjacent to the heating chamber, the size of the heating component can be reduced, thereby providing a compact aerosol-generating device heating component. This makes it easier for the operator to handle and use, as well as store and transport, thereby improving the user experience. Furthermore, providing a phase change material between the heating chamber and the supercapacitor module protects the supercapacitor module from the heat of the heating chamber, allowing the supercapacitor module to be placed closer to the heating chamber and helping to reduce the size of the device. The phase change material also inhibits heat transfer from the heating chamber to the device housing, thereby improving the device's usability.

[0229] The aerosol generating devices described herein have been described as two-piece devices having a heating component and an auxiliary power component. However, in an alternative, these aerosol generating devices can be configured as a one-piece device, in which the heating component and the auxiliary power component are formed as a single device. In such a device, the supercapacitor module is adjacent to the heating chamber and / or at least partially surrounds the heating chamber, and a phase change material is provided between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module. This allows for a compact device because the supercapacitor module can be positioned adjacent to the heating chamber, rather than remotely located from the heating chamber. The battery module can be positioned separately in the device, remotely located from the heating chamber, to avoid damage to the battery and maintain device safety.

[0230] The skilled person will readily appreciate that the aforementioned embodiments in the foregoing description are not limiting; the features of each embodiment may be incorporated into other embodiments as appropriate.

[0231] In the foregoing examples, the processing steps described herein, performed by the controller or control electronics, may be stored in a non-transitory computer-readable medium or storage device associated with the corresponding controller or control electronics. Computer-readable media may include non-volatile media and volatile media. Volatile media may include, in particular, semiconductor memory and dynamic memory. Non-volatile media may include, in particular, optical and magnetic disks.

Claims

1. An aerosol-generating device heating component, the aerosol-generating device heating component being configured to generate an aerosol from an aerosol-generating substrate, the heating component comprising: a heating chamber configured to receive the aerosol-generating substrate; an ultracapacitor module configured to power a heater associated with the heating chamber, wherein the ultracapacitor module is adjacent to the heating chamber; as well as A phase change material is disposed between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module.

2. The aerosol generating device heating component according to claim 1, wherein: The phase change material at least partially surrounds the heating chamber.

3. An aerosol-generating device heating element according to any preceding claim, wherein The supercapacitor module at least partially surrounds the heating chamber.

4. The heating component of the aerosol generating device according to claim 3, wherein: The supercapacitor module conforms to the shape of the heating chamber.

5. An aerosol-generating device heating element according to any preceding claim, wherein The supercapacitor module includes two supercapacitors, and the two supercapacitors are arranged on opposite sides of the heating chamber to at least partially surround the heating chamber.

6. An aerosol-generating device heating element according to any preceding claim, wherein The heating chamber is planar in shape and is configured to receive a planar aerosol-generating substrate.

7. The heating component of the aerosol generating device according to any one of claims 1 to 5, wherein: The heating chamber is cylindrical in shape and is configured to receive a rod-shaped aerosol-generating substrate.

8. The heating component of the aerosol generating device according to claim 7, wherein: The rod-shaped aerosol generating substrate is a tobacco rod.

9. An aerosol-generating device heating element according to any preceding claim, wherein The heater is integrated into or onto a side wall of the heating chamber.

10. An aerosol-generating device heating element according to any preceding claim, wherein The aerosol-generating device heating element further comprises control electronics integrated into the flexible circuit board.

11. An aerosol-generating device heating element according to any preceding claim, wherein The phase change material is substantially indium based.

12. The aerosol generating device according to any one of claims 1 to 10, wherein: The phase change material includes a hydrated salt phase change material.

13. The aerosol generating device according to any one of claims 1 to 10, wherein: The phase change material includes an organic solution phase change material.

14. The aerosol generating device according to any one of claims 1 to 10, wherein: The phase change material includes a solid-solid phase change material.

15. An aerosol-generating device heating element according to any preceding claim, wherein The aerosol-generating device heating component further comprises a thermal insulation layer disposed between the heating chamber and the phase change material.

16. The aerosol generating device according to claim 15, wherein: The total thickness of the thermal insulation layer is approximately twice the total thickness of the phase change material in the radial direction of the heating component of the aerosol-generating device.

17. An aerosol generating device according to claim 15 or claim 16, wherein: The phase change material is approximately 1 mm thick and the insulation layer is at least 1 mm thick, or preferably the insulation layer is 1.5 mm thick, or more preferably the insulation layer is 2 mm thick, or wherein the insulation layer is up to 3 mm thick.

18. An aerosol generating device according to any one of claims 15 to 17, wherein: The thermal insulation layer includes a plurality of thermal insulation layers.

19. An aerosol generating device according to any one of claims 15 to 18, wherein The thermal insulation layer comprises aerogel.

20. An aerosol-generating device according to any preceding claim, wherein The phase change material includes a plurality of phase change material layers.

21. An aerosol-generating device heating element according to any preceding claim, wherein The aerosol-generating device heating component further comprises: a first temperature sensor configured to monitor the temperature of the heater of the heating chamber; and a second temperature sensor configured to monitor the temperature of the phase change material; wherein the controller of the heating component of the aerosol generating device is configured to recalibrate the monitored heater temperature by determining that the phase change material has reached a melting temperature based on a predetermined relationship between the temperature of the heater and the melting temperature of the phase change material, at which melting temperature the monitored temperature of the phase change material is substantially stable.

22. An aerosol-generating device comprising an aerosol-generating device heating element as claimed in any preceding claim and further comprising auxiliary power elements, wherein The auxiliary power component includes a battery module; and The auxiliary power component is removably connected to the heating component, and when connected, the battery module is configured to charge the supercapacitor module through the electrical connection between the heating component and the auxiliary power component.

23. An aerosol generating device according to claim 22, wherein: The battery module is configured to power a heater associated with the heating chamber when the auxiliary power component is connected to the heating component through an electrical connection between the heating component and the auxiliary power component.

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