Heater assembly with microporous insulating foam

Abstract

The present invention relates to a heater assembly 10 for an aerosol-generating device. The heater assembly comprises a heating chamber 12 for heating the aerosol-forming substrate. The heater assembly includes a heater housing 16 disposed around the heating chamber. The heater housing is arranged radially spaced from the heating chamber. The heater housing includes an airtight space 22. The airtight space includes a microporous insulating foam. The invention also relates to an aerosol-generating device. The invention also relates to an aerosol-generating system.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a heater assembly for an aerosol-generating device. The present disclosure further relates to an aerosol-generating device. The present disclosure further relates to an aerosol-generating system comprising an aerosol-generating device and an aerosol-forming substrate. BACKGROUND

[0002] It is known to provide an aerosol-generating device for generating an inhalable vapour. Such devices can heat an aerosol-forming substrate contained in an aerosol-generating article without combusting the aerosol-forming substrate. The aerosol-generating article can have a rod shape for insertion of the aerosol-generating article into a heating chamber of the aerosol-generating device. A heating element is typically arranged in or around the heating chamber for heating the aerosol-forming substrate after insertion of the aerosol-generating article into the heating chamber of the aerosol-generating device.

[0003] Heat generated by the heating element can inadvertently dissipate from the heating chamber. Heat can dissipate to the environment or other components of the aerosol-generating system. Heat can inadvertently dissipate from the heating chamber via free air convection. Heat can inadvertently dissipate from the heating chamber via radiation. Heat can inadvertently dissipate from the heating chamber via heat conduction through components of the aerosol-generating device. Heat can inadvertently dissipate from the heating chamber via heat conduction through components of the aerosol-generating article, for example, via the aerosol-forming substrate. Dissipation of heat from the heating chamber can cause heating of device components that are not intended to be heated. For example, a housing of the device to be gripped by a user can become uncomfortably hot. Dissipation of heat from the heating chamber can cause heat loss within the heating chamber. Heat loss within the heating chamber can result in less efficient heating. Excessive energy can be required to heat the heating chamber to a desired temperature. SUMMARY

[0004] It is desirable to have an aerosol-generating device that can reduce heat loss from a heating chamber. It is desirable to thermally insulate a heating chamber relative to other components of an aerosol-generating device. It is desirable to have an aerosol-generating device that can reduce the warming of an outer housing of the device to be gripped by a user. It is desirable to have an aerosol-generating device that can provide effective thermal insulation. It is desirable to have an aerosol-generating device that can provide thermal insulation at low manufacturing cost. It is desirable to have an aerosol-generating device that can provide lightweight thermal insulation. It is desirable to have an aerosol-generating device that can have improved thermal insulation. It is desirable to have an aerosol-generating device that has temperature-resistant thermal insulation. It is desirable to have an aerosol-generating device that has thermal insulation that reduces or avoids the release of potentially toxic substances when heated. It is desirable to have an aerosol-generating device with thermal insulation that has good flame retardant properties. It is desirable to have an aerosol-generating device that has a long lifespan. It is desirable to have an aerosol-generating device that has thermal insulation that is resistant to multiple heating-cooling cycles. It is desirable to have an aerosol-generating device that can have a heater housing with a reduced outer diameter. It is desirable to have an aerosol-generating device that can have a more compact device size.

[0005] According to embodiments of the present application, a heater assembly for an aerosol-generating device is provided. The heater assembly can include a heating chamber for heating an aerosol-forming substrate. The heater assembly can include a heater housing arranged around the heating chamber. The heater housing can be arranged radially spaced apart from the heating chamber. The heater housing can include an air-tight space. The air-tight space can include a microcellular insulation foam.

[0006] According to embodiments of the present application, a heater assembly for an aerosol-generating device is provided. The heater assembly includes a heating chamber for heating an aerosol-forming substrate. The heater assembly includes a heater housing arranged around the heating chamber. The heater housing is arranged radially spaced apart from the heating chamber. The heater housing includes an air-tight space. The air-tight space includes a microcellular insulation foam.

[0007] Providing an air-tight space comprising microcellular insulating foam around the heating chamber can reduce or avoid heat loss due to air circulation between the interior of the heater housing and the exterior air. Providing an air-tight space comprising microcellular insulating foam around the heating chamber can also reduce or avoid heat loss due to convection of air within the air-tight space. Providing an air-tight space comprising microcellular insulating foam around the heating chamber can reduce radiative heat transfer. Advantageously, by providing an air-tight space comprising microcellular insulating foam around the heating chamber, the thermal insulation of the heating chamber relative to the outer surface of the heater housing can be improved. By providing an air-tight space comprising microcellular insulating foam around the heating chamber, a heater assembly for an aerosol-generating device can be provided that can reduce heat loss from the heating chamber. By providing an air-tight space comprising microcellular insulating foam around the heating chamber, a heater assembly for an aerosol-generating device can be provided that can reduce the warming of the outer housing of the device to be gripped by a user. By providing an air-tight space comprising microcellular insulating foam around the heating chamber, a heater assembly for an aerosol-generating device can be provided that can provide effective thermal insulation. By providing an air-tight space comprising microcellular insulating foam, improved thermal insulation at the operating temperature of the aerosol-generating device can be provided compared to an air-tight hollow space.

[0008] By including a heater assembly comprising microcellular insulating foam, an aerosol-generating device with temperature-resistant thermal insulation can be provided. By including a heater assembly comprising microcellular insulating foam, an aerosol-generating device with thermal insulation that reduces or avoids the release of potentially toxic substances when heated can be provided. By including a heater assembly comprising microcellular insulating foam, an aerosol-generating device with thermal insulation with good flame-retardant properties can be provided. By including a heater assembly comprising microcellular insulating foam, an aerosol-generating device with a long lifetime can be provided. By including a heater assembly comprising microcellular insulating foam, an aerosol-generating device with thermal insulation that is resistant to multiple heating-cooling cycles can be provided.

[0009] The microcellular insulating foam can be a polymeric microcellular insulating foam.

[0010] The microcellular insulating foam can comprise one or more of a polyaryletherketone (PAEK) foam, a polyamide 46 (PA46) foam, a polyamide 4T (PA4T) foam, a polyphenylsulfone (PPSU) foam, a polyethersulfone (PES) foam, and a polyetherimide (PEI) foam.

[0011] The microcellular insulating foam can comprise or consist of a polyaryletherketone (PAEK) foam. The polyaryletherketone (PAEK) foam can comprise or consist of one or more of a polyetherketone (PEK) foam, a polyether ether ketone (PEEK) foam, a polyether ketone ketone (PEKK) foam, a polyether ether ketone ketone (PEEKK) foam, and a polyether ketone ether ketone ketone (PEKEKK) foam.

[0012] The polyaryletherketone (PAEK) foam can comprise an ether to ketone ratio of about 2: 1, about 1: 1, about 2:3, or about 1:2.

[0013] The microcellular insulating foam can have an average pore diameter of greater than 1 micron, preferably greater than 10 microns. The microcellular insulating foam can have an average pore diameter of less than 500 microns, preferably less than 300 microns, more preferably less than 100 microns. The microcellular insulating foam can have an average pore diameter of between 1 micron and 500 microns, preferably between 1 micron and 300 microns, more preferably between 1 micron and 100 microns, more preferably between 1 micron and 50 microns. The average pore diameter can be determined using SEM (scanning electron microscopy). It is well known to measure the pore size distribution of a porous material by processing SEM images, and can be done, for example, with the computer program ImageJ.

[0014] The microcellular insulating foam can comprise an open porous structure. The microcellular insulating foam can comprise a closed porous structure. The microcellular insulating foam can comprise a partially open partially closed porous structure.

[0015] The microcellular insulating foam can be made of a material that can withstand temperatures of at least 100 degrees Celsius, preferably at least 200 degrees Celsius, more preferably between 100 degrees Celsius and 500 degrees Celsius, more preferably between 150 degrees Celsius and 400 degrees Celsius, more preferably between 200 degrees Celsius and 300 degrees Celsius, without substantial degradation.

[0016] The microcellular insulating foam can have a thermal conductivity at room temperature of less than 0.05 W / m K, preferably less than 0.04 W / m K, more preferably less than 0.03 W / m K, more preferably less than 0.02 W / m K, more preferably less than 0.01 W / m K, more preferably less than 0.005 W / m K, more preferably less than 0.002 W / m K. The microcellular insulating foam can have a thermal conductivity at room temperature of about 0.001 W / m K.

[0017] The microcellular insulating foam can have a thermal conductivity at a temperature of 280 degrees Celsius of less than 0.05 W / m K, preferably less than 0.04 W / m K, more preferably less than 0.03 W / m K.

[0018] The microcellular insulating foam can have a thermal conductivity of less than 0.05 W / m°K, for example about 0.025 W / m°K at a temperature of 150 degrees Celsius.

[0019] The thermal conductivity can be determined according to ASTM C177.

[0020] The microcellular insulating foam can have a glass transition temperature between 100 degrees Celsius and 250 degrees Celsius, preferably between 105 degrees Celsius and 235 degrees Celsius, more preferably between 110 degrees Celsius and 230 degrees Celsius. The glass transition temperature can be measured by DSC (Differential Scanning Calorimetry).

[0021] The microcellular insulating foam can have a melting point between 250 degrees Celsius and 450 degrees Celsius, preferably between 280 degrees Celsius and 400 degrees Celsius, more preferably between 280 degrees Celsius and 350 degrees Celsius.

[0022] The microcellular insulating foam comprising PEEK can have a glass transition temperature between 100 degrees Celsius and 200 degrees Celsius, preferably between 120 degrees Celsius and 180 degrees Celsius, more preferably between 130 degrees Celsius and 170 degrees Celsius.

[0023] The microcellular insulating foam comprising PEEK can have a melting point between 250 degrees Celsius and 450 degrees Celsius, more preferably between 280 degrees Celsius, more preferably between 300 degrees Celsius and 350 degrees Celsius.

[0024] The microcellular insulating foam can have a density of less than 700 kilograms per cubic meter, preferably less than 600 kilograms per cubic meter, more preferably less than 500 kilograms per cubic meter. The microcellular insulating foam can have a density between 400 kilograms per cubic meter and 700 kilograms per cubic meter. The microcellular insulating foam can have a density between 400 kilograms per cubic meter and less than 700 kilograms per cubic meter.

[0025] The microcellular insulating foam can form one or more thermal insulation layers. The one or more thermal insulation layers together can have a thickness between 0.005 millimeters and 10 millimeters, preferably between 0.01 millimeters and 5 millimeters, more preferably between 0.1 millimeters and 4 millimeters, more preferably between 0.2 millimeters and 2 millimeters.

[0026] The microcellular insulating foam can form one thermal insulation layer. The thermal insulation layer can have a thickness between 0.005 millimeters and 10 millimeters, preferably between 0.01 millimeters and 5 millimeters, more preferably between 0.1 millimeters and 4 millimeters, more preferably between 0.2 millimeters and 2 millimeters.

[0027] The heater assembly can comprise a packaging material arranged around the microcellular insulating foam.

[0028] The packaging material can be provided in the form of a film layer or a film. The film can be a multilayer film.

[0029] The packaging material can comprise or consist of one or more of polyether ether ketone (PEEK), polyaryletherketone (PAEK), polyimide (PI), polyphenylsulfone (PPSU), polyethersulfone (PES), or polyetherimide (PEI).

[0030] The heater assembly can comprise an aerogel. The aerogel can be added to the microporous insulating foam. The aerogel and the microporous insulating foam can form a mixture, for example a homogeneous mixture.

[0031] The aerogel can be a nanoporous aerogel.

[0032] The "operating temperature" depends on the type of the aerosol-generating device and the aerosol-forming substrate used. The operating temperature of the aerosol-generating device can be between 150 and 300 degrees Celsius. The operating temperature of the aerosol-generating device can be between 200 and 230 degrees Celsius. The operating temperature of the aerosol-generating device can not exceed 280 degrees Celsius.

[0033] The air-tight hollow space can comprise air as an insulating material. However, at higher temperatures, the thermal conductivity of air increases. The microporous insulating foam comprises small cavities or pores. Air or other gaseous compositions are encapsulated within these cavities, thus having a lower thermal conductivity at elevated temperatures compared to air. The microporous insulating foam can almost maintain its thermal conductivity at the operating temperature of the aerosol-generating device compared to the thermal conductivity at room temperature. The low thermal conductivity of the microporous insulating foam results in better thermal insulation.

[0034] Due to the better thermal insulation, the heater shell comprising the microporous insulating foam can have a reduced outer diameter. Providing the heater shell with the air-tight space comprising the microporous insulating foam can result in an aerosol-generating device that can have a more compact device size.

[0035] As used herein, the terms "upstream" and "downstream" are used to describe the relative positions of components or parts of components of an aerosol-generating device with respect to the direction in which an airflow passes through the aerosol-generating device during use of the aerosol-generating device. The aerosol-generating device according to the present application comprises a proximal end through which, in use, an aerosol exits the device. The proximal end of the aerosol-generating device can also be referred to as the mouth end or downstream end. The mouth end is downstream of the distal end. The distal end of the aerosol-generating article can also be referred to as the upstream end. Components or parts of components of the aerosol-generating device can be described as being upstream or downstream of each other based on their relative positions with respect to the airflow path of the aerosol-generating device.

[0036] The proximal end of the heater assembly according to the present application is configured to be arranged within the aerosol-generating device in a direction towards the mouth end or downstream end of the device. The distal end of the heater assembly according to the present application is configured to be arranged within the aerosol-generating device in a direction towards the distal end or upstream end of the device. The longitudinal axis of the heating chamber can extend between the proximal end of the heating chamber and the distal end of the heating chamber. The longitudinal axis of the heating chamber can extend between the proximal end of the heater assembly and the distal end of the heater assembly.

[0037] The heating chamber can be configured for at least partially receiving an aerosol-forming substrate. The heating chamber can comprise a cavity into which the aerosol-forming substrate can be inserted. The aerosol-forming substrate can be part of an aerosol-generating article. The cavity can have a shape corresponding to a shape of the aerosol-generating article to be received in the cavity. The cavity can have a circular cross-section. The cavity can have an elliptical or rectangular cross-section. The cavity can have an inner diameter corresponding to an outer diameter of the aerosol-generating article.

[0038] The heating chamber can comprise an opening at the proximal end of the heating chamber for receiving the aerosol-forming substrate. The opening can also act as an air outlet. The heating chamber can comprise an air inlet at the distal end of the heating chamber.

[0039] The heating chamber can have an elongated shape. The heating chamber can be a hollow tube. The hollow tube can be formed by a wall of the heating chamber. The wall of the heating chamber can comprise or can be made of a metal or an alloy. The wall of the heating chamber can comprise or can be made of stainless steel.

[0040] The heater shell can be arranged radially spaced apart from the heating chamber by a distance d. The distance d can be measured in a direction orthogonal to the longitudinal axis of the heating chamber. The heating chamber can comprise a wall of the heating chamber. The heater shell can comprise a wall of the heater shell. The distance d can be measured in a radial direction between the wall of the heating chamber and the wall of the heater shell. The distance d can be measured in a radial direction between an outer side of the wall of the heating chamber and an inner side of the wall of the heater shell.

[0041] The distance d between the heating chamber and the heater shell can be between 1.5 millimetres and 7 millimetres. The distance d between the heating chamber and the heater shell can be between 2 millimetres and 4 millimetres, preferably about 3.1 millimetres.

[0042] The heater shell can be coaxially aligned around the heating chamber. The heating chamber and the heater shell can have a matching shape. The matching shape can allow to provide a constant radial distance d between the heater shell and the heating chamber.

[0043] The wall of the heater shell can match the shape of the wall of the heating chamber along the longitudinal axis of the heating chamber, such that the distance d can be substantially constant. For example, the heating chamber can be a hollow tube, and the wall of the heater shell can be a cylindrical wall coaxially aligned around the heating chamber. The distance d can be measured in a radial direction between the outer diameter of the hollow tube of the heating chamber and the inner diameter of the cylindrical wall of the heater shell. For example, the heating chamber can be a hollow frustoconical shape, and the wall of the heater shell can be a conical wall coaxially aligned. The skilled person will understand that other types of matching shapes will be possible. For example, the matching shape can be curved or wavy, or can comprise a combination of different shapes along the longitudinal axis of the heating chamber.

[0044] The heating chamber and the heater shell can have a deviating shape. The shape of the wall of the heater shell can deviate from the shape of the wall of the heating chamber along the longitudinal axis of the heating chamber to some extent. The shape of the wall of the heater shell can deviate from the shape of the wall of the heating chamber along the longitudinal axis of the heating chamber such that the distance d varies along the longitudinal axis of the heating chamber by no more than 1 mm. For example, the heating chamber can be a hollow straight cylinder, and the wall of the heater shell can be a slightly conical hollow cylinder coaxially aligned around the heating chamber. Due to the conical shape of the wall of the heater shell, the distance d can vary along the longitudinal axis of the heating chamber by no more than 1 mm.

[0045] The outer diameter of the heater shell can be measured in a direction orthogonal to the longitudinal axis of the heating chamber. The outer diameter of the heater shell can be between 8 mm and 20 mm, preferably between 14 mm and 18 mm, and preferably about 16 mm.

[0046] The outer diameter of the heating chamber can be measured in a direction orthogonal to the longitudinal axis of the heating chamber. The ratio of the outer diameter of the heater shell to the outer diameter of the heating chamber can be between 1.3 and 3.5, preferably between 1.5 and 2.5, more preferably about 2.0. In particular, in one embodiment, the outer diameter of the heating chamber can be about 5.6 mm, and the outer diameter of the heater shell can be about 17 mm, resulting in a ratio of about 3.0. In one embodiment, the outer diameter of the heating chamber can be about 5.6 mm, and the outer diameter of the heater shell can be about 16.5 mm, resulting in a ratio of about 2.95. In one embodiment, the outer diameter of the heating chamber can be about 7.6 mm, and the outer diameter of the heater shell can be about 16.5 mm, resulting in a ratio of about 2.17.

[0047] The air-tight space is air-tightly sealed from the outside air. In other words, the interior of the air-tight space is not fluidically connected to the outside air. Thereby, heat losses due to gas circulation between the air-tight space and the air outside of the heater assembly can be avoided.

[0048] The air-tight space can be at ambient pressure. The air pressure within the air-tight space can be between 0.9 bar and 1.1 bar, preferably about 1.0 bar. The air-tight space can be filled with a gaseous composition at about ambient pressure at about 20 degrees Celsius. As known to the person skilled in the art, variations in the air pressure within the air-tight space depending on the temperature can occur. Providing the air-tight space at ambient pressure can be less costly to manufacture than providing an evacuated air-tight space under vacuum. Vacuum-based thermal insulation can be more costly to manufacture.

[0049] It has been found that an air-tight hollow space with a distance d between 1.5 millimetres and 7 millimetres sufficiently reduces heat loss. When providing such a distance d, the air or other gaseous composition enclosed within the air-tight space can be considered as stationary air. Stationary air or non-moving air additionally reduces air convection within the air-tight space. Heat loss due to air convection within the air-tight space can be reduced.

[0050] The thermal conductivity of air increases with increasing temperature. The thermal conductivity of air at 25 degrees Celsius is about 0.0262 W / m⋅K. At an operating temperature of 280 degrees Celsius, the thermal conductivity of air has already been about 0.043 W / m⋅K. Therefore, using only air as an insulating material in an air-tight hollow space would require a relatively large thickness of the air gap to provide sufficient thermal insulation.

[0051] Microcellular insulating foam can have a lower thermal conductivity than air at room temperature. At higher temperatures, the difference between the thermal conductivity of air and microcellular insulating foam can even be greater. The thermal conductivity of microcellular insulating foam can not increase as quickly as the thermal conductivity of air. Microcellular insulating foam can almost maintain its thermal conductivity even at elevated temperatures. For example, a microcellular insulating foam can have a thermal conductivity of 0.018 W / m⋅K at 20 degrees Celsius. At 200 degrees Celsius, the thermal conductivity is 0.022 W / m⋅K. At a temperature of 400 degrees Celsius, the thermal conductivity increases to 0.028 W / m⋅K according to ASTM C177. The thermal conductivity of this exemplary microcellular insulating foam is almost the same as the thermal conductivity of air at room temperature even at temperatures higher than the maximum working temperature of the aerosol-generating device. The lower thermal conductivity results in better thermal insulation.

[0052] An air-tight space including an insulating foam with a lower thermal conductivity can have a smaller thickness while still providing sufficient thermal insulation. An air-tight space including microcellular insulating foam instead of an air-tight hollow space including only air can have a smaller distance d. The smaller distance d can result in a smaller outer diameter of the aerosol-generating device.

[0053] Microcellular insulating foam can have a density below 500 kg / m 3 , preferably below 400 kg / m 3 , more preferably below 300 kg / m3 a nominal density of 0.1 g / cm3.

[0054] The microcellular insulating foam of the present invention can have a thermal conductivity of less than 0.05 W / m K, preferably less than 0.04 W / m K, more preferably less than 0.03 W / m K, more preferably less than 0.02 W / m K at 20 degrees Celsius and according to ASTM C177. The microcellular insulating foam can have a thermal conductivity of less than 0.05 W / m K, preferably less than 0.04 W / m K, more preferably less than 0.03 W / m K at a temperature of 280 degrees Celsius and according to ASTM C177. The thermal conductivity of the microcellular insulating foam at a temperature of 280 degrees Celsius can increase by at most 40%, preferably at most 30%, more preferably at most 20% compared to the thermal conductivity of the microcellular insulating foam at 20 degrees Celsius.

[0055] At the working temperature of the aerosol-generating device, the hermetic space comprising the microcellular insulating foam can have a lower thermal conductivity than the same hermetic hollow space comprising ambient air instead.

[0056] The hermetic space can be completely filled with the microcellular insulating foam.

[0057] Alternatively, the hermetic space can not be completely filled with the microcellular insulating foam. By not completely filling the hermetic space with the microcellular insulating foam, the weight of the aerosol-generating device can be reduced. However, the hermetic space can be at least partially filled with the microcellular insulating foam. The hermetic space can also be at least partially filled with a gaseous composition. The gaseous composition can be at ambient pressure. The gaseous composition can be air. The gaseous composition can comprise one or more of nitrogen, argon, carbon dioxide, oxygen, krypton, sulfur hexafluoride or mixtures thereof or other suitable gaseous compositions.

[0058] By additionally providing the hermetic space with a gaseous composition, the weight of the aerosol-generating device can be reduced. Providing the hermetic space with a gaseous composition can reduce manufacturing costs.

[0059] The volume of the hermetic space filled with the microcellular insulating foam can be 30%, 40%, 50%, 60%, 70%, 80% or 90% by volume. The ratio of the microcellular insulating foam and the gaseous composition can depend on the working temperature of the aerosol-generating device. Aerosol-generating devices with a higher working temperature can require more microcellular insulating foam.

[0060] The hermetic space can comprise at least one air gap. The gaseous composition can be provided in the air gap.

[0061] The air-tight space can comprise one air gap. The air-tight space can comprise two air gaps. The air-tight space can comprise three air gaps. The microcellular insulating foam can be sandwiched between two air gaps in a radial direction.

[0062] The air gap can have a thickness measured in a direction orthogonal to a longitudinal axis of the heating chamber. The thickness of the air gap can be between 0.5 mm and 4 mm, preferably between 1 mm and 3 mm, more preferably about 2 mm.

[0063] The one or more air gaps can be within the microcellular insulating foam. The one or more air gaps can extend in a direction parallel to a longitudinal axis of the aerosol-generating device. The one or more air gaps can have a longitudinal extension that is the same or shorter than a longitudinal extension of the microcellular insulating foam. The one or more air gaps can have a circular cross-section. Alternatively, the one or more air gaps can not extend around the entire perimeter of the microcellular insulating foam. The one or more air gaps can be completely surrounded by the microcellular insulating foam. The one or more air gaps can be in direct contact with the first and second connecting walls, as described in more detail below. The one or more air gaps can be in direct contact with the heating chamber. The one or more air gaps can be in direct contact with the heater shell.

[0064] Providing an air gap within the air-tight space can reduce the weight of the aerosol-generating device. By providing an air gap within the air-tight space, manufacturing costs can be reduced.

[0065] The microcellular insulating foam can be in direct contact with the heating chamber. The microcellular insulating foam can be surrounded by the air gap. The temperature around the heating chamber can decrease radially with increasing distance from the longitudinal axis of the heating chamber. The microcellular insulating foam can provide better thermal insulation at higher temperatures than, for example, air. The assembly in which the microcellular insulating foam is in direct contact with the heating chamber, surrounded by the air gap, can have improved thermal insulation than an assembly in which the components are arranged the other way around.

[0066] The heater assembly can further comprise a first connecting wall connecting the heating chamber and the heater shell and a second connecting wall connecting the heating chamber and the heater shell. The air-tight space can be defined between the heating chamber, the heater shell and the first and second connecting walls. The air-tight space can be limited by the walls of the heating chamber and the heater shell and the first and second connecting walls. The first and second connecting walls can provide for easy assembly of the air-tight space. The first and second connecting walls can provide for simple manufacturing of the air-tight space. Providing the first and second connecting walls can ensure a defined distance d of the heater shell from the heating chamber. By providing the first and second connecting walls, correct placement of the microcellular insulating foam can be ensured. The first and second connecting walls can be in contact with the microcellular insulating foam, thereby preventing heat loss via air convection on the proximal and distal ends of the microcellular insulating foam.

[0067] Each of the first and second connecting walls can extend between a wall of the heating chamber and a wall of the heater shell. The first and second connecting walls can sealingly connect the heater shell with the outer wall of the heating chamber. The connecting walls can be oriented perpendicular to the longitudinal axis of the heating chamber. The first connecting wall can be a proximal connecting wall. The second connecting wall can be a distal connecting wall.

[0068] The microporous insulating foam can be in direct contact with the heating chamber. The microporous insulating foam can be in direct contact with the heater shell. The microporous insulating foam can be in direct contact with the first and second connecting walls. The microporous insulating foam can be in direct contact with the heating chamber and the heater shell. The microporous insulating foam can be in direct contact with the heating chamber, the heater shell, and the first and second connecting walls. The microporous insulating foam can be mounted between the first and second connecting walls. The microporous insulating foam can be arranged to span a distance between the first and second connecting walls. The microporous insulating foam can be mounted between the first and second connecting walls while not contacting one or both of the heater shell and the heating chamber.

[0069] The microporous insulating foam can have an elongated extension. The microporous insulating foam can extend parallel to the longitudinal axis of the heating chamber. The microporous insulating foam can be a hollow tube extending around the heating chamber.

[0070] The microporous insulating foam can have a thickness measured in a direction orthogonal to the longitudinal axis of the heating chamber. The thickness of the microporous insulating foam can be equal to the distance d. The thickness of the microporous insulating foam can be between 1 and 7 millimeters, preferably between 2 and 6 millimeters, more preferably between 3 and 5 millimeters.

[0071] The microporous insulating foam can be formed from one single element. Alternatively, the microporous insulating foam can be formed from at least two insulating elements. The microporous insulating foam can be formed from two insulating elements. The microporous insulating foam can be formed from at least a first insulating element comprising at least a first connecting element and a second insulating element comprising at least a second connecting element. The first and second connecting elements can be configured as mating connecting elements. When connected, the mating connecting elements can enable the connection of the first and second microporous insulating elements. The connected first and second connecting elements can be such that the overall insulating foam forms a hollow tube. The hollow tube can have an inner diameter corresponding to the outer diameter of the heating chamber. Providing the microporous insulating foam from two insulating elements can provide for an easy assembly of the microporous insulating foam around the heating chamber. By forming the microporous insulating foam from two insulating elements, a perfect shape fit of the microporous insulating foam with the heating chamber can be provided. Providing a perfect shape fit of the microporous insulating foam with the heating chamber can ensure a better thermal insulation.

[0072] The first and second connecting elements can be configured as male and female connecting elements, form-fit connecting elements, snap-fit connecting elements, bayonet connecting elements or mixtures thereof, or other commonly used connecting elements known to the skilled person. The first connecting element can comprise a male connecting element and the second connecting element can comprise a female connecting element. The first and second connecting elements can comprise form-fit connecting elements. The first and second connecting elements can comprise snap-fit connecting elements. The first and second connecting elements can comprise bayonet connecting elements.

[0073] The microcellular insulating foam can be configured as a two-piece assembly. The two-piece assembly can comprise a first insulating element and a second insulating element. The first and second insulating elements can for example be in the form of hollow semi-cylindrical elements. The hollow semi-cylindrical elements can comprise matching first and second connecting elements. When connected, the hollow semi-cylindrical elements can form a single hollow tube. The inner diameter of the hollow tube can have the same size as the outer diameter of the heating chamber. Thereby, a convenient assembly can be ensured. However, a microcellular insulating foam formed as one element having an inner diameter identical to the outer diameter of the heating chamber can be more difficult to assemble around the heating chamber due to friction. The close proximity or direct contact of the microcellular insulating foam to the heating chamber can improve the thermal insulation of the heating chamber.

[0074] The heating chamber can comprise a temperature sensor. The temperature sensor can be on the top of the heating chamber. The microcellular insulating foam can have a shape matching the temperature sensor. The microcellular insulating foam can have a cavity facing the temperature sensor. The microcellular insulating foam can completely close around the heating chamber. The temperature sensor can be enclosed by the microcellular insulating foam. The temperature sensor can be sandwiched between the heating chamber and the microcellular insulating foam.

[0075] The heater assembly can further comprise a heating element. The heating chamber can comprise the heating element.

[0076] The heating element can be arranged at least partially around the heating chamber. The heating element can be arranged at least partially around a wall of the heating chamber. Preferably, the heating element is arranged to completely coaxially enclose an outer periphery of the wall of the heating chamber. The heating element can be arranged along at least a portion of a longitudinal axis of the heating chamber.

[0077] The heating element can comprise one or more electrically conductive tracks on an electrically insulating substrate. The one or more electrically conductive tracks can be electrically resistive heating tracks. The one or more electrically conductive tracks can be configured as an inductor to be inductively heated. The electrically insulating substrate can be a flexible substrate.

[0078] The heating element can be flexible and can be wrapped around the heating chamber. The heating element can be arranged between the heating chamber and the heater housing.

[0079] Microporous insulating foam can have a longitudinal extension that is the same as or greater than that of the heating element. This ensures proper thermal insulation of the heat generated by the heating element.

[0080] Microporous insulating foam can extend around the heating element. Microporous insulating foam can also be in direct contact with the heating element.

[0081] In all aspects of this disclosure, the heating element may include a resistive material. Suitable resistive materials include, but are not limited to: semiconductors (such as doped ceramics), “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics.

[0082] As described, in any aspect of this disclosure, the heating element may be part of a heating chamber of a heater assembly for an aerosol generation apparatus. The heater assembly may include an internal heating element, an external heating element, or both internal and external heating elements, wherein “internal” and “external” refer to the aerosol forming matrix. The internal heating element may take any suitable form. For example, the internal heating element may take the form of a heating blade. Alternatively, the internal heater may take the form of a sleeve or substrate with different conductive portions, or a resistance metal tube. Alternatively, the internal heating element may be one or more heating needles or rods extending through the center of the aerosol forming matrix. Other alternatives include heating wires or filaments, such as Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wires, or heating plates. Optionally, the internal heating element may be deposited in or on a rigid carrier material. In one such embodiment, the resistance heating element may be formed using a metal having a defined relationship between temperature and resistivity. In such exemplary devices, the metal may be formed as a track on a suitable insulating material (such as a ceramic material) and then sandwiched in another insulating material (such as glass). Heaters formed in this way can be used to both heat and monitor the temperature of the heating element during operation.

[0083] The external heating element can take any suitable form. For example, it can take the form of one or more flexible heating foils on a dielectric substrate (e.g., polyimide). The flexible heating foil can be shaped to conform to the periphery of the matrix receiving cavity. Alternatively, the external heating element can take the form of a metal mesh or multiple metal meshes, a flexible printed circuit board, a molded interconnect device (MID), a ceramic heater, a flexible carbon fiber heater, or can be formed on a suitable shaped substrate using coating techniques (e.g., plasma vapor deposition). The external heating element can also be formed using a metal with a defined relationship between temperature and resistivity. In such an exemplary device, the metal can be formed as a track between two layers of suitable insulating material. An external heating element formed in this way can be used to both heat and monitor the temperature of the external heating element during operation.

[0084] Advantageously, the heating element heats the aerosol-forming matrix by means of thermal conduction. The heating element may at least partially contact the matrix or a carrier on which the matrix is ​​placed. Alternatively, heat from an internal or external heating element may be conducted to the matrix by means of a thermally conductive element.

[0085] During operation, the aerosol-forming matrix can be completely contained within the aerosol-generating device. In this case, the user can inhale through the mouthpiece of the aerosol-generating device. Alternatively, during operation, a smoking product containing the aerosol-forming matrix can be partially contained within the aerosol-generating device. In this case, the user can inhale directly through the smoking product.

[0086] The heating element can be configured as an induction heating element. An induction heating element may include an induction coil and a sensor. Generally, the sensor is a material capable of generating heat when penetrated by an alternating magnetic field. According to the invention, the sensor may be conductive or magnetic, or both. The alternating magnetic field generated by one or more induction coils heats the sensor, which then transfers the heat to the aerosol-forming matrix, causing aerosol formation. Heat transfer can be primarily by thermal conduction. This heat transfer is optimal if the sensor is in close thermal contact with the aerosol-forming matrix. When an induction heating element is used, it can be configured as an internal heating element as described herein or as an external heater as described herein. If the induction heating element is configured as an internal heating element, the sensor element is preferably configured as a pin or blade for penetrating the aerosol-forming article. If the induction heating element is configured as an external heating element, the sensor element is preferably configured as a cylindrical sensor at least partially surrounding the sidewall of the cavity or forming cavity.

[0087] The heating chamber may include a central region comprising a heating element. The term "central region" refers to the longitudinal direction. The heating chamber may further include a proximal region and a distal region. The proximal and distal regions may be spaced apart from the heating element in the longitudinal direction. During use, the proximal and distal regions may be colder than the central region of the heating chamber. A first connecting wall may contact the heating chamber in the proximal region, and a second connecting wall may contact the heating chamber in the distal region. Therefore, during use, the first and second connecting walls may contact the heating chamber at its coldest point. This further reduces heat loss from the heating chamber to the connecting walls and the heater housing. It also further improves thermal insulation.

[0088] The walls of the heating chamber can be made of stainless steel. This can advantageously enhance the following effect: during use, the proximal and distal areas can be cooler than the central area of ​​the heating chamber.

[0089] The thickness of the heater housing wall can be less than about 2 mm. The thickness of the heater housing wall can be less than 1.2 mm, preferably about 0.8 mm. The thickness of one or both of the first and second connecting walls can be less than 1.2 mm, preferably about 0.8 mm. With such thin walls, the thermal mass of the heater housing can be minimized. This further reduces heat loss from the heating chamber.

[0090] The walls of the heater housing, as well as one or more of the first and second connecting walls, may be made of a material with low thermal conductivity. This further reduces heat loss from the heating chamber. The walls of the heater housing may comprise or be made of a plastic material. The first and second connecting walls may comprise or be made of a plastic material. The plastic material may comprise one or both of polyaryletherketone (PAEK), polyetheretherketone (PEEK), and polyphenylene sulfone (PPSU). Preferably, the plastic material comprises polyphenylene sulfone (PPSU).

[0091] The inner side of the heater housing wall may include a metallic coating. The inner side of one or both of the first and second connecting walls may include a metallic coating. The metallic coating can reduce the emissivity of the inner side of the wall. For example, the emissivity of a PEEK wall can be reduced from about 0.95 to about 0.4. The metallic coating can reflect thermal radiation emitted from the heating chamber. The metallic coating can provide additional thermal insulation for the heating chamber relative to the outside of the heater housing. The metallic coating may be a low-emissivity metallic coating. The metallic coating may include one or more of aluminum, gold, and silver.

[0092] The present invention further relates to an aerosol generating apparatus including a heater assembly as described herein.

[0093] Preferably, the aerosol generating apparatus includes a power supply device configured to supply power to the heating element. The power supply device preferably includes a power source. Preferably, the power source is a battery, such as a lithium-ion battery. Alternatively, the power source can be another form of charge storage device, such as a capacitor. The power source may require recharging. For example, the power source may have sufficient capacity to allow continuous aerosol generation for approximately six minutes, or multiples of six minutes. In another instance, the power source may have sufficient capacity to allow for a predetermined number of suction cycles or intermittent activation of the heater assembly.

[0094] The power supply may include control electronics. The control electronics may include a microcontroller. The microcontroller is preferably a programmable microcontroller. The circuitry may include additional electronic components. The circuitry can be configured to regulate the power supply to the heater assembly. Power may be supplied continuously to the heater assembly after system activation, or it may be supplied intermittently, such as on a per-inlet suction basis. Power may be supplied to the heater assembly in the form of current pulses.

[0095] The present invention also relates to an aerosol generation system comprising an aerosol generation apparatus as described herein and an aerosol forming matrix. The aerosol forming matrix may be configured to be at least partially received in a heating chamber. The aerosol forming matrix may be a solid aerosol forming matrix. The aerosol forming matrix may form part of an aerosol-generating article. The aerosol-generating article may be configured to be at least partially inserted into the heating chamber.

[0096] As used herein, the term "aerosol-forming matrix" refers to a matrix capable of releasing volatile compounds that can form aerosols. Volatile compounds can be released by heating or burning the aerosol-forming matrix. Alternatively, in some cases, volatile compounds can be released through chemical reactions or by mechanical stimulation, such as ultrasound. The aerosol-forming matrix can be solid or liquid, or may include both solid and liquid components. The aerosol-forming matrix can be part of an aerosol-generating article.

[0097] The aerosol forming matrix can be a solid aerosol forming matrix. It can include both solid and liquid components. The aerosol forming matrix can include tobacco-containing materials containing volatile tobacco flavor compounds released from the matrix upon heating. The aerosol forming matrix can also include non-tobacco materials. Furthermore, the aerosol forming matrix can include aerosol forming agents that contribute to the formation of dense and stable aerosols. Examples of suitable aerosol forming agents are glycerol and propylene glycol.

[0098] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming matrix capable of releasing volatile compounds that can form aerosols. Aerosol-generating articles may be disposable.

[0099] As used herein, the term "aerosol generating apparatus" refers to an apparatus that interacts with an aerosol forming matrix to generate an aerosol. An aerosol generating apparatus may interact with one or both of an aerosol generating article comprising an aerosol forming matrix and a cylinder comprising an aerosol forming matrix. In some instances, the aerosol generating apparatus may heat the aerosol forming matrix to promote the release of volatile compounds from the matrix. Electrically operated aerosol generating apparatus may include an atomizer, such as an electric heater, to heat the aerosol forming matrix to form an aerosol.

[0100] As used herein, the term "aerosol generation system" refers to the combination of an aerosol generation apparatus and an aerosol forming matrix. When the aerosol forming matrix forms part of an aerosol generation article, the aerosol generation system refers to the combination of the aerosol generation apparatus and the aerosol generation article. In an aerosol generation system, the aerosol forming matrix and the aerosol generation apparatus cooperate to generate aerosols.

[0101] The following is a non-exhaustive list of non-limiting examples. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0102] Example E1: A heater assembly for an aerosol generation apparatus, comprising

[0103] Heating chamber used to heat the aerosol formation matrix;

[0104] A heater housing arranged around the heating chamber, wherein the heater housing is arranged radially spaced from the heating chamber, wherein the heater housing includes an airtight space, and wherein the airtight space includes microporous insulating foam.

[0105] Example E2: The heater assembly according to Example E1, wherein the microporous insulating foam is a polymer microporous insulating foam.

[0106] Example E3: The heater assembly according to Example E2, wherein the microporous insulating foam comprises one or more of the following: polyaryletherketone (PAEK) foam, polyamide 46 (PA46) foam, polyamide 4T (PA4T) foam, polyphenylsulfone (PPSU) foam, polyethersulfone (PES) foam, and polyetherimide (PEI) foam.

[0107] Example E4: The heater assembly according to Example E3, wherein the microporous insulating foam comprises polyaryletherketone (PAEK) foam.

[0108] Example E5: The heater assembly according to Example E4, wherein the polyaryl ether ketone (PAEK) foam comprises one or more of the following: polyether ketone (PEK) foam, polyether ether ketone (PEEK) foam, polyether ketone ketone (PEKK) foam, polyether ether ketone ketone (PEEKK) foam, and polyether ketone ether ketone ketone (PEKEKK) foam.

[0109] Example E6: The heater assembly according to Example E4 or Example E5, wherein the polyarylether ketone (PAEK) foam comprises an ether to ketone ratio of about 2:1, about 1:1, about 2:3 or about 1:2.

[0110] Example E7: A heater assembly according to any of the foregoing examples, wherein the average pore diameter of the microporous insulating foam is between 1 micrometer and 500 micrometers, preferably between 1 micrometer and 300 micrometers, more preferably between 1 micrometer and 100 micrometers, and even more preferably between 1 micrometer and 50 micrometers.

[0111] Example E8: A heater assembly according to any of the preceding examples, wherein the microporous insulating foam comprises an open porous structure, a closed porous structure, or a partially open and partially closed porous structure.

[0112] Example E9: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam is made of a material capable of withstanding temperatures of at least 100 degrees Celsius, preferably at least 200 degrees Celsius, more preferably between 100 degrees Celsius and 500 degrees Celsius, more preferably between 150 degrees Celsius and 400 degrees Celsius, and more preferably between 200 degrees Celsius and 300 degrees Celsius without substantial degradation.

[0113] Example E10: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam has a thermal conductivity of less than 0.05 W / m⋅K at room temperature, preferably less than 0.04 W / m⋅K, more preferably less than 0.03 W / m⋅K, and / or

[0114] The microporous insulating foam described therein has a thermal conductivity of less than 0.05 W / m⋅K, preferably less than 0.04 W / m⋅K, and more preferably less than 0.03 W / m⋅K at a temperature of 280 degrees Celsius.

[0115] Example E11: A heater assembly according to any of the foregoing examples, wherein the thermal conductivity of the microporous insulating foam at a temperature of 280 degrees Celsius is increased by up to 40%, preferably up to 30%, and more preferably up to 20% compared to the thermal conductivity of the microporous insulating foam at room temperature.

[0116] Example E12: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam has a glass transition temperature between 100 degrees Celsius and 250 degrees Celsius, preferably between 105 degrees Celsius and 235 degrees Celsius, and more preferably between 110 degrees Celsius and 230 degrees Celsius.

[0117] Example E13: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam has a melting point between 250 degrees Celsius and 450 degrees Celsius, preferably between 280 degrees Celsius and 400 degrees Celsius, and more preferably between 280 degrees Celsius and 350 degrees Celsius.

[0118] Example E14: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam has a density of less than 700 kg / m³, preferably less than 600 kg / m³, more preferably less than 500 kg / m³.

[0119] Example E15: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam forms one or more thermal insulation layers, preferably wherein the microporous insulating foam forms a thermal insulation layer.

[0120] Example E16: The heater assembly according to Example E15, wherein the thermal insulation layer has a thickness between 0.005 mm and 10 mm, preferably between 0.01 mm and 5 mm, more preferably between 0.1 mm and 4 mm, and even more preferably between 0.2 mm and 2 mm.

[0121] Example E17: A heater assembly according to any of the foregoing examples, the heater assembly comprising packaging material arranged around the microporous insulating foam.

[0122] Example E18: A heater assembly according to Example E17, wherein the packaging material is provided in the form of a film layer or membrane.

[0123] Example E19: The heater assembly according to Example E17 or Example E18, wherein the packaging material comprises one or more of the following: polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyimide (PI), polyphenylsulfone (PPSU), polyethersulfone (PES), or polyetherimide (PEI).

[0124] Example E20: The heater assembly according to any of the foregoing examples further includes aerogel.

[0125] Example E21: The heater assembly according to Example E20, wherein the aerogel is a nanoporous aerogel.

[0126] Example E22: A heater assembly according to any of the foregoing examples, the heater assembly further includes a first connecting wall connecting the heating chamber and the heater housing and a second connecting wall connecting the heating chamber and the heater housing, wherein the airtight space is defined between the heating chamber, the heater housing and the first connecting wall and the second connecting wall.

[0127] Example E23: A heater assembly according to Example E22, wherein the connecting wall is oriented perpendicular to the longitudinal axis of the heating chamber.

[0128] Example E24: A heater assembly according to any of the preceding examples, wherein the airtight space is at ambient pressure.

[0129] Example E25: A heater assembly according to any of the preceding examples, wherein the airtight space is at least partially filled with the microporous insulating foam.

[0130] Example E26: A heater assembly according to any of the foregoing examples, wherein the airtight space is at least partially filled with a gaseous composition at ambient pressure.

[0131] Example E27: A heater assembly according to any of the preceding examples, wherein the airtight space includes at least one air gap.

[0132] Example E28: A heater assembly according to Example E27, wherein the microporous insulating foam is sandwiched between two air gaps in the radial direction.

[0133] Example E29: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam is in direct contact with the heating chamber.

[0134] Example E30: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam is in direct contact with the heater housing.

[0135] Example E31: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam is in direct contact with the first connecting wall and the second connecting wall of claim 22.

[0136] Example E32: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam is in direct contact with the heating chamber, the heater housing, and the first and second connecting walls of claim 22.

[0137] Example E33: A heater assembly according to any of the preceding examples, wherein the microporous insulating foam is formed of a first insulating element including at least one first connecting element and a second insulating element including at least one second connecting element, wherein the first connecting element and the second connecting element are configured as mating connecting elements.

[0138] Example E34: A heater assembly according to Example E33, wherein the first connecting element includes a convex connecting element and the second connecting element includes a concave connecting element.

[0139] Example E35: A heater assembly according to Example E33 or Example E34, wherein the first connecting element and the second connecting element include form-fitting connecting elements.

[0140] Example E36: ​​A heater assembly according to any one of Examples E33 to E35, wherein the first connecting element and the second connecting element include snap-fit ​​connecting elements.

[0141] Example E37: A heater assembly according to any one of Examples E33 to E36, wherein the first connecting element and the second connecting element include bayonet connecting elements.

[0142] Example E38: A heater assembly according to any of the preceding examples, wherein the microporous insulating foam has an elongated extension.

[0143] Example E39: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam extends parallel to the longitudinal axis of the heating chamber.

[0144] Example E40: A heater assembly according to any of the foregoing examples, wherein the distance between the heating chamber and the heater housing is between 1.5 mm and 7 mm, preferably between 2 mm and 4 mm, and more preferably about 3.1 mm.

[0145] Example E41: The heater assembly according to any of the foregoing examples further includes a heating element.

[0146] Example E42: A heater assembly according to Example E41, wherein the heating element is arranged at least partially around the heating chamber.

[0147] Example E43: A heater assembly according to Example E41 or Example E42, wherein the microporous insulating foam has the same or greater longitudinal extension as the heating element.

[0148] Example E44: A heater assembly according to any one of Examples E41 to E43, wherein the heating element is flexible and surrounds the heating chamber.

[0149] Example E45: A heater assembly according to any one of Examples E41 to E44, wherein the heating element is arranged between the heating chamber and the heater housing.

[0150] Example E46: A heater assembly according to any one of Examples E41 to E45, wherein the heating element comprises one or more conductive rails on an electrically insulating substrate.

[0151] Example E47: A heater assembly according to any of the foregoing examples, wherein the ratio of the outer diameter of the heater housing to the outer diameter of the heating chamber is between 1.3 and 3.5, preferably between 1.5 and 2.5, and more preferably about 2.0.

[0152] Example E48: A heater assembly according to any of the foregoing examples, wherein the heating chamber has an elongated shape, preferably wherein the heating chamber is a hollow tube.

[0153] Example E49: A heater assembly according to any of the preceding examples, wherein the heating chamber includes: a central region, the central region including the heating element of Example E41;

[0154] Proximal region; and

[0155] Distal region,

[0156] The proximal region and the distal region are spaced apart from the heating element in the longitudinal direction, and

[0157] In example E22, the first connecting wall contacts the heating chamber in the proximal region, and the second connecting wall of example E22 contacts the heating chamber in the distal region.

[0158] Example E50: A heater assembly according to any of the foregoing examples, wherein the inner side of the wall of the heater housing includes a metal coating, and optionally, wherein the wall of the heating chamber includes stainless steel.

[0159] Example E51: A heater assembly according to any of the foregoing examples, wherein the wall of the heater housing and one or more of the first connecting wall and the second connecting wall of claim 2 have a thickness of less than 2 mm, preferably less than 1.2 mm, more preferably about 0.8 mm.

[0160] Example E52: A heater assembly according to any of the preceding examples, wherein the hermetic space includes a polyimide layer.

[0161] Example E53: A heater assembly according to Example E52, wherein the polyimide layer is arranged around the microporous insulating foam, preferably wherein the polyimide layer is arranged to be in direct contact with the microporous insulating foam.

[0162] Example E54: A heater assembly according to Example E53, wherein a gap is provided between the polyimide layer and the heater housing.

[0163] Example E55: A heater assembly according to any of the foregoing examples, wherein the microporous insulating foam is arranged to be in direct contact with the heating chamber.

[0164] Example E56: A heater assembly according to any of the foregoing examples, wherein the heater assembly further includes a heat dissipation element arranged to at least partially surround the heating chamber, preferably wherein the heat dissipation element is a graphene layer, more preferably wherein the graphene layer is a coating.

[0165] Example E57: A heater assembly according to Example E56, wherein the heat dissipation element is arranged between the microporous insulating foam and the heating chamber and on the outer periphery of the heating chamber.

[0166] Example E58: An aerosol generating apparatus, comprising a heater assembly according to any one of the foregoing examples.

[0167] Example E59: An aerosol generation system comprising an aerosol generation apparatus according to Example E58 and an aerosol forming matrix configured to be at least partially received in the heating chamber, preferably wherein the aerosol forming matrix is ​​a solid aerosol forming matrix.

[0168] The features described with respect to one embodiment can also be applied to other embodiments of the invention. Attached Figure Description

[0169] The invention will be further described by way of example only with reference to the accompanying drawings, in which:

[0170] Figure 1 An embodiment of a heater assembly for an aerosol generation apparatus is shown;

[0171] Figure 2 An embodiment of the heating chamber of the heater assembly is shown;

[0172] Figure 3 An embodiment of a heater assembly for an aerosol generation apparatus is shown;

[0173] Figure 4 An embodiment of a heater assembly for an aerosol generation apparatus is shown;

[0174] Figure 5 An embodiment of a heater assembly for an aerosol generation apparatus is shown;

[0175] Figure 6 An embodiment of a heater assembly for an aerosol generation apparatus is shown;

[0176] Figure 7 An embodiment of a microporous insulating foam for a heater assembly of an aerosol generation apparatus is shown;

[0177] Figure 8 An embodiment of the aerosol generation apparatus is shown;

[0178] Figure 9 An embodiment of the aerosol generating apparatus is shown; and

[0179] Figure 10 An embodiment of an aerosol generating apparatus is shown. Detailed Implementation

[0180] Figure 1 A heater assembly 10 is schematically shown. The heater assembly 10 includes a heating chamber 12 for heating an aerosol-forming matrix. The heating chamber 12 has an elongated shape. The heating chamber 12 includes a wall 14 defining a cavity for insertion into the aerosol-forming matrix. The wall 14 of the heating chamber forms a hollow tube. The heater assembly 10 further includes a heater housing. The heater housing is arranged coaxially around the heating chamber 12. The heater housing includes a cylindrical wall 16. The heater housing is further arranged radially spaced from the heating chamber 12 by a distance d. The distance d is measured radially between the outer diameter of the hollow tube formed by the wall 14 of the heating chamber and the inner diameter of the cylindrical wall 16 of the heater housing. The wall 14 of the heating chamber and the wall 16 of the heater housing have matching shapes. Thus, the distance d is constant along the longitudinal axis of the heating chamber 12.

[0181] The heater assembly 10 further includes a first connecting wall 18 at its proximal end. The heater assembly 10 further includes a second connecting wall 20 at its distal end. The first connecting wall 18 and the second connecting wall 20 are oriented perpendicular to the longitudinal axis of the heating chamber 12. The heater assembly 10 further includes an airtight space 22. The airtight space 22 is defined between the wall 14 of the heating chamber, the wall 16 of the heater housing, and the first connecting wall 18 and the second connecting wall 20. The airtight space 22 comprises microporous insulating foam.

[0182] Figure 2 An embodiment of a heating chamber 12 is shown. The heating chamber 12 includes a central region comprising a heating element. The heating element is arranged partially around the heating chamber 12. The wall 14 of the heating chamber is a metal tube, preferably a stainless steel tube. The heating element is flexible and is wrapped around the metal tube. The heating element includes conductive heating rails 24 on an electrically insulating flexible substrate 26. In the illustrated embodiment, the proximal and distal edge portions of the flexible substrate 26 are not covered by the heating rails 24. In other embodiments, different areas or even the entire surface of the flexible substrate 26 may be covered by the heating rails 24. The proximal region 28 and distal region 30 of the heating chamber 12 are spaced apart from the heating element in the longitudinal direction.

[0183] Figure 3It shows including Figure 2 An embodiment of the heater assembly 10 of the heating chamber 12. The heating element is arranged between the heating chamber 12 and the heater housing.

[0184] The first connecting wall 18 and the second connecting wall 20 sealably connect the wall 16 of the heater housing to the wall 14 of the heating chamber, thereby airtightly surrounding the airtight space 22.

[0185] The first connecting wall 18 and the second connecting wall 20 contact the heating chamber 12 in the proximal region 28 and the distal region 30, respectively. The first connecting wall 18 and the second connecting wall 20 contact the heating chamber 12 at positions spaced apart from the heating element. Therefore, when the first connecting wall 18 and the second connecting wall 20 are heated during use, they contact the heating chamber 12 at the coldest point of the heating chamber 12. This further reduces heat loss due to heat transfer from the heating chamber 12 to the connecting walls 18, 20 and the heater housing via thermal conduction. Thermal insulation can also be further improved.

[0186] The airtight space 22 includes microporous insulating foam 32.

[0187] Microporous insulating foam 32 can be, for example, a polymeric microporous insulating foam. Microporous insulating foam 32 can include one or more of the following: polyaryl ether ketone (PAEK) foam, polyamide 46 (PA46) foam, polyamide 4T (PA4T) foam, polyphenylsulfone (PPSU) foam, polyethersulfone (PES) foam, and polyetherimide (PEI) foam. Microporous insulating foam 32 can include or be composed of polyaryl ether ketone (PAEK) foam. Polyaryl ether ketone (PAEK) foam can include or be composed of one or more of the following: polyether ketone (PEK) foam, polyether ether ketone (PEEK) foam, polyether ketone ketone (PEKK) foam, polyether ether ketone ketone (PEEKK) foam, and polyether ketone ether ketone ketone (PEKEKK) foam. Polyaryl ether ketone (PAEK) foam can contain an ether to ketone ratio of about 2:1, about 1:1, about 2:3, or about 1:2.

[0188] exist Figure 3 In the embodiment shown, the entire airtight space 22 is filled with microporous insulating foam 32. The microporous insulating foam 32 contacts the wall 14 of the heating chamber, the heating rail 24, the first connecting wall 18 and the second connecting wall 20, and the wall 16 of the heater housing. Although not shown, Figure 3 The microporous insulating foam 32 shown may also include one or more air gaps extending in a direction parallel to the longitudinal axis of the aerosol generating device. These air gaps may be in direct contact with the wall 14 of the heating chamber, the wall 16 of the heater housing, or the first connecting wall 18 and the second connecting wall 20. These air gaps may have a shorter longitudinal extension than the microporous insulating foam 32.

[0189] Figure 4 , 5 Figures 6 and 7 illustrate an alternative embodiment in which the airtight space 22 is only partially filled with microporous insulating foam 32. The main components are similar. Figure 3 The heater assembly. In Figure 4 , 5 In the embodiments shown in Figures 6 and 7, the airtight space 22 includes at least one additional air gap 34. In all these embodiments, the microporous insulating foam 32 contacts the first connecting wall 18 and the second connecting wall 20. However, the microporous insulating foam 32 may alternatively contact only one of the first connecting wall 18 and the second connecting wall 20. Preferably, the microporous insulating foam 32 contacts only the first (proximal) connecting wall 18. The microporous insulating foam 32 may be mounted on the first connecting wall 18 and the second connecting wall 20.

[0190] exist Figure 4 The image shows a heater assembly in which an air gap 34 extends around a heating chamber 12. A microporous insulating foam 32 extends radially spaced from the heating chamber 12 around the air gap 34. The microporous insulating foam 32 is in direct contact with the wall 16 of the heater housing.

[0191] Figure 5 An alternative embodiment is shown in which the microporous insulating foam 32 is in direct contact with the heating chamber 12. An air gap 34 extends radially spaced from the heating chamber 12 around the microporous insulating foam 32. The air gap 34 is in direct contact with the wall 16 of the heater housing.

[0192] Figure 6 An alternative embodiment is shown in which the airtight space 22 includes two air gaps 34. One air gap 34 extends around and is directly connected to the heating chamber 12. A microporous insulating foam 32 extends radially spaced from the air gap 34. A second air gap 34 follows, extending radially spaced from the microporous insulating foam 32. The microporous insulating foam 32 is sandwiched between the two air gaps 34 in the radial direction.

[0193] Figure 3 , 4 The airtight space 22 shown in Figures 5 and 6 can be filled with microporous insulating foam 32 in different ratios. For example, half the volume of the airtight space 22 can be filled with microporous insulating foam 32. However, other ratios are also possible. For example, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the volume of the airtight space 22 can be filled with microporous insulating foam 32.

[0194] Figure 7 A two-piece assembly of microporous insulating foam 32 is shown. Figure 3 ,4 The heater assembly 10 described in 5 and 6 may all include Figure 7 Two-piece components. However, two-piece components are particularly suitable for... Figure 3 and 5 Examples, such as... Figure 7 As can be seen, the microporous insulating foam 32 is formed by a first insulating element 36 having a first connecting element 40 and a second insulating element 38 having a second connecting element 42. The first connecting element 40 and the second connecting element 42 are configured as mating connecting elements. When the two first insulating elements 36 and the second insulating element 38 are connected, the first connecting element 40 and the second connecting element 42 are connected to each other. The connection of the first connecting element 40 and the second connecting element 42 provides direct contact between the first insulating element 36 and the second insulating element 38. The first insulating element 36 and the second insulating element 38 may have, for example, Figure 7 The hollow semi-cylindrical design is shown. However, other shapes and configurations are possible. When connected, the hollow semi-cylindrical design provides a hollow tube. The hollow tube can have an inner diameter that is substantially the same as the outer diameter of the heating chamber 12. The hollow tube can also have an inner diameter that is the same as the outer diameter of the combined heating chamber 12 and heating rail 24. With this two-piece assembly, the microporous insulating foam 32 can have a perfect fit with the heating chamber 12 and the heating rail 24 surrounding the heating chamber. Additionally, if the heating chamber includes a temperature sensor (not shown), the internal shape of the microporous insulating foam 32 can be configured to suit the temperature sensor. The microporous insulating foam 32 can include a cavity facing the sensor. This cavity can have the same volume and opposite shape as the temperature sensor. The microporous insulating foam 32 can be completely closed around the heating chamber 12 and heating rail 24. Using a hollow tube that consists only of a single element including the microporous insulating foam 32 may not provide this perfect fit with the heating chamber 12.

[0195] Figure 8 It shows including Figure 3 An embodiment of the heater assembly 10 is provided for an aerosol generating apparatus. The aerosol generating apparatus further includes a power supply device. The power supply device includes a power source 44 and control electronics 46. The power source 44 may be a rechargeable battery. Figure 8 In one embodiment, the wall 16 of the heater housing forms part of the outer housing 48 of the aerosol generating device.

[0196] At the opening 50, the aerosol forming matrix can be at least partially inserted into the heating chamber 12. The aerosol forming matrix can be part of the aerosol-generated article.

[0197] Figure 9 It shows including Figure 3 An embodiment of the aerosol generating apparatus of the heater assembly 10. (Compared to...) Figure 8 The implementation methods differ, inFigure 9 In one embodiment, the heater assembly 10 is arranged within a separate outer housing 48 of the aerosol generating device.

[0198] Figure 10 An embodiment of an aerosol generating apparatus is shown, comprising a heater assembly 10 arranged proximal to an aerosol generating device adjacent to the aerosol generating apparatus. A flexible substrate 26 and a heating rail 24 of the heating assembly 10 are arranged around a heating chamber 12. A microporous insulating foam 32 is arranged around and in contact with the flexible substrate 26 and the heating rail 24. The microporous insulating foam 32 may contain 1% to 99% aerogel and up to 30% polymer resin. Because of the provided polymer resin, the microporous insulating foam 32 can be configured as a flexible layer, allowing it to wrap around the flexible substrate 26 at the heating rail 24. To hold the microporous insulating foam 32 in place, a polyimide layer 52 may be arranged to wrap around the microporous insulating foam 32. The polyimide layer 52 is a flexible layer. Figure 10 As shown, the polyimide layer 52 can partially cover the microporous insulating foam 32. Figure 10 In the embodiment shown, a proximal overlap is provided between the polyimide layer 52 and the microporous insulating foam 32. In other words, the microporous insulating foam 32 extends beyond the polyimide layer 52 in the proximal direction. Similarly, a distal overlap is provided between the polyimide layer 52 and the microporous insulating foam 32, such that the microporous insulating foam 32 extends beyond the polyimide layer 52 in the distal direction. Alternatively, the polyimide layer 52 may completely cover the microporous insulating foam 32.

[0199] An air gap 54 is provided around the polyimide layer 52. Both the polyimide layer 52 and the air gap 54 are located within the airtight space 22. A heater housing wall 16 is provided radially outside the air gap 54.

[0200] The microporous insulating foam 32 is in direct contact with the first connecting wall 18 on its proximal side. The microporous insulating foam 32 is spaced apart from the second connecting wall 20 on its distal side. Alternatively, the microporous insulating foam 32 may also be spaced apart from the first connecting wall 18. As yet another alternative, the microporous insulating foam 32 may be in direct contact with both the first connecting wall 18 and the second connecting wall 20.

[0201] exist Figure 10 In the embodiment shown, the heater housing (more specifically, the wall 16 of the heater housing) is mounted on an internal frame 56 within the housing 48 of the aerosol generating apparatus. The internal frame 56 holds other components of the aerosol generating apparatus, such as the heating chamber 12.

Claims

1. A heater assembly for an aerosol generation apparatus, comprising: Heating chamber used to heat the aerosol formation matrix; A heater housing arranged around the heating chamber, wherein the heater housing is arranged radially spaced from the heating chamber, wherein the heater housing includes an airtight space, and wherein the airtight space includes microporous insulating foam.

2. The heater assembly according to claim 1, wherein the microporous insulating foam is a polymer microporous insulating foam.

3. The heater assembly of claim 2, wherein the microporous insulating foam comprises one or more of the following: polyaryletherketone (PAEK) foam, polyamide 46 (PA46) foam, polyamide 4T (PA4T) foam, polyphenylsulfone (PPSU) foam, polyethersulfone (PES) foam, and polyetherimide (PEI) foam.

4. The heater assembly of claim 3, wherein the microporous insulating foam comprises polyaryletherketone (PAEK) foam.

5. The heater assembly of claim 4, wherein the polyaryl ether ketone (PAEK) foam comprises one or more of the following: polyether ketone (PEK) foam, polyether ether ketone (PEEK) foam, polyether ketone ketone (PEKK) foam, polyether ether ketone ketone (PEEKK) foam, and polyether ketone ether ketone ketone (PEKEKK) foam.

6. The heater assembly according to claim 4 or claim 5, wherein the polyarylether ketone (PAEK) foam comprises an ether to ketone ratio of about 2:1, about 1:1, about 2:3, or about 1:

2.

7. The heater assembly according to any one of the preceding claims, wherein the average pore diameter of the microporous insulating foam is between 1 micrometer and 500 micrometers, preferably between 1 micrometer and 300 micrometers, more preferably between 1 micrometer and 100 micrometers, and even more preferably between 1 micrometer and 50 micrometers.

8. The heater assembly according to any one of the preceding claims, wherein the microporous insulating foam is made of a material capable of withstanding temperatures of at least 100 degrees Celsius, preferably at least 200 degrees Celsius, more preferably between 100 degrees Celsius and 500 degrees Celsius, more preferably between 150 degrees Celsius and 400 degrees Celsius, and more preferably between 200 degrees Celsius and 300 degrees Celsius without substantial degradation.

9. The heater assembly according to any one of the preceding claims, wherein the microporous insulating foam has a thermal conductivity of less than 0.05 W / m⋅K at room temperature, preferably less than 0.04 W / m⋅K, more preferably less than 0.03 W / m⋅K, and / or The microporous insulating foam described therein has a thermal conductivity of less than 0.05 W / m⋅K, preferably less than 0.04 W / m⋅K, and more preferably less than 0.03 W / m⋅K at a temperature of 280 degrees Celsius.

10. The heater assembly according to any one of the preceding claims, wherein the microporous insulating foam has a glass transition temperature between 100°C and 250°C, preferably between 105°C and 235°C, and more preferably between 110°C and 230°C.

11. The heater assembly according to any one of the preceding claims, wherein the microporous insulating foam has a melting point between 250 degrees Celsius and 450 degrees Celsius, preferably between 280 degrees Celsius and 400 degrees Celsius, and more preferably between 280 degrees Celsius and 350 degrees Celsius.

12. The heater assembly according to any one of the preceding claims, wherein the microporous insulating foam has a density of less than 700 kg / m³, preferably less than 600 kg / m³, more preferably less than 500 kg / m³.

13. The heater assembly according to any one of the preceding claims, wherein the microporous insulating foam forms a thermal insulation layer, and wherein the thermal insulation layer has a thickness between 0.005 mm and 10 mm, preferably between 0.01 mm and 5 mm, more preferably between 0.1 mm and 4 mm, and even more preferably between 0.2 mm and 2 mm.

14. An aerosol generating apparatus, the aerosol generating apparatus comprising a heater assembly according to any one of the preceding claims.

15. An aerosol generation system comprising the aerosol generation apparatus according to claim 14 and an aerosol forming matrix configured to be at least partially received in the heating chamber, preferably wherein the aerosol forming matrix is ​​a solid aerosol forming matrix.

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