Heating assembly for aerosol-generating device

Abstract

A heating assembly for an aerosol-generating device is disclosed, the heating assembly (100) comprising: an outer tube (102) having a first end and a second end; a heating cup (104) disposed radially inward of the outer tube, the heating cup comprising a heating element (106) disposed on an outwardly facing surface of the heating cup, the heating cup having an opening at a first end of the outer tube for receiving an aerosol-forming substrate; electrical connectors (112) configured to supply electrical power to the heating element; a base portion (114) disposed at the closed end of the heating cup, the base portion comprising one or more slots in which the electrical connectors may be received; and an end wall (110) disposed at the second end of the outer tube from which the electrical connectors extend, where the base portion is configured to bias at least a portion of each of the electrical connectors radially inward toward the heating element when the electrical connectors are received in the slots, in this way, the electrical connectors are pressed towards the heating element.

Description

Technical Field

[0001] This invention relates to a heating device for an aerosol generating apparatus and an aerosol generating apparatus including the heating device. This disclosure is particularly applicable to portable aerosol generating apparatuses, which may be stand-alone and cryogenic. Specifically, this invention relates to an aerosol generating apparatus having a heater disposed within a vacuum or insulated chamber. Background Technology

[0002] Aerosol generating devices (such as heat-without-burning devices) generate aerosols or vapors by heating an aerosol-forming matrix or consumable, typically comprising moist tobacco leaves or other suitable materials, to a temperature typically in the range of 150°C to 300°C. Heating the aerosol-forming matrix without burning or burning it releases the desired aerosol in a manner that does not include undesirable combustion byproducts. For example, aerosols generated by heating tobacco typically do not include the burnt or bitter taste that might result from combustion.

[0003] In such aerosol generating devices, it is desirable to improve the efficiency of heating operations, thereby extending the device's battery life. To this end, insulation materials have been incorporated into the aerosol generating device to thermally insulate the cavity in which the aerosol matrix is ​​heated, thereby limiting heat loss to the external environment.

[0004] However, heating assemblies including vacuum insulation are difficult to manufacture. A specific problem to overcome in producing this type of heating equipment is how to provide an effective electrical connection between the power source outside the insulation chamber and the heating element inside the insulation chamber, while maintaining an effective vacuum or insulation space within the heater assembly. The object of this invention is to solve this problem. Summary of the Invention

[0005] According to one aspect of the invention, a heating assembly for an aerosol generating apparatus is provided, the heating assembly comprising: an outer tube having a first end and a second end; a heating cup disposed radially inside the outer tube, the heating cup including a heating element disposed on an outwardly facing surface of the heating cup, the heating cup having an opening at the first end of the outer tube for receiving an aerosol forming matrix; electrical connectors configured to supply power to the heating element; a base portion disposed at a closed end of the heating cup, the base portion including one or more slots in which the electrical connectors can be received; and an end wall disposed at the second end of the outer tube, the electrical connectors extending from the end wall, wherein the base portion is configured to radially inwardly bias at least a portion of each of the electrical connectors toward the heating element when the electrical connectors are received in the slots, so as to press the electrical connectors toward the heating element.

[0006] In this way, a direct electrical connection is effectively formed between the electrical connector and the heating element without the need for brazing (as is done in known heating assemblies). Typically, this soldered connection between the electrical connector and the heating element is performed in a vacuum, which presents various obstacles during the design and manufacturing phases. For example, surfaces must be kept clean before brazing and require cleaning afterward. By avoiding the use of solder and flux, the risk of degassing and any undesirable pressure increase in the insulating space between the heating cup and the outer tube is reduced, which would otherwise diminish the insulation capacity of the vacuum insulation.

[0007] The base portion of this invention is configured to push the electrical connector toward the center of the outer tube, such that a direct electrical connection is formed when the heating cup (and heating assembly) is pressed or inserted into the space between the electrical connectors. The radially inward bias of the base portion toward the electrical connector ensures a reliable and good electrical connection throughout the operating life of the heating assembly. It should be understood that the electrical connection between the heating element and the electrical connector may undergo more than ten thousand heating and cooling cycles during its operating life, which may lead to undesirable loss of material flexibility / elasticity or material wear of the electrical connector and / or the heating element, resulting in an unreliable electrical connection. Advantageously, this base portion provides a biased physical constraint on the electrical connector to maintain a reliable electrical connection with the heating element.

[0008] Preferably, one or more slots are open in the radially inward section of the base portion. In this way, the base portion can radially bias at least a portion of the corresponding electrical connector into the heating element of the heating cup and ensure good electrical connection is maintained throughout the life of the heating assembly.

[0009] Preferably, the one or more slots include one or more corresponding surfaces disposed radially outward of at least a portion of each received electrical connector. The electrical connectors may each include a predetermined length extending from a base portion and a second end of an outer tube, and the base portion may bias the entire predetermined length of the electrical connector or only a portion of the predetermined length. In some cases, certain portions of the biased electrical connector may flex radially outward away from the heating cup. Therefore, the base portion may be configured to ensure that any radial outward bias of the electrical connector is limited to ensure a good electrical connection is maintained between the electrical connector and the heating element. The base portion may be annular in shape, providing a single surface surrounding the electrical connector. Alternatively, the slot may include separate surfaces for the respective electrical connectors.

[0010] Preferably, the base portion is configured to be removably attached to the heating cup and / or end wall. In this way, the base portion can be easily attached or removed to the heating cup and / or end wall during assembly of the heating assembly. It should be understood that when the electrical connector is received in one or more slots of the base portion, the base portion provides a radially inward biasing force to the electrical connector.

[0011] To ensure proper alignment between the electrical connector and the heating assembly, the heating assembly may further include a form-fit connection configured to substantially align the electrical contacts of the electrical connector and the heating element. The form-fit connection may be between the base portion and a sub-assembly of the heating cup, or between the base portion and the end wall. Alternatively, the heating cup and the end wall (attached to the base portion) may each have a form-fit connection to the outer tube. For example, the outer tube may include a notch or groove at each end, and the heating cup and the end wall may each include a corresponding tongue to fit into the corresponding notch / groove. In this way, the form-fit connection effectively ensures alignment between the electrical connector and the corresponding electrical contacts in the heating element. It will be apparent to those skilled in the art that the form-fit connection can be designed or suitable materials can be selected to minimize any undesirable heat loss.

[0012] One or more slots in the base portion may be shorter than the length of the electrical connector, such that the electrical connector is axially compressed within the slot, thereby biasing the electrical connector radially inward. The base portion may include a boss or chamfered surface configured to axially compress the electrical connector to bias it radially inward. The electrical connector may each include an end portion that presses against the boss or is biased by the chamfered surface to flex, bend, or wrinkle the electrical connector radially inward. In this way, axial compression reliably causes the electrical connector to extend or expand radially.

[0013] Electrical connectors can have a bent or zigzag shape to facilitate radial inward biasing of at least a corresponding portion of the received electrical connector. In this way, each of the electrical connectors can be axially compressed to form a contact point with the heating element. Electrical connectors can be shaped or designed to be corrugated or folded into a zigzag or wavy arrangement. This arrangement allows the electrical connector to have multiple radial inward extensions, which in turn provides multiple contact points between the electrical connector and the heating element.

[0014] Preferably, the base portion comprises a non-degassed material, such as ceramic or polyetheretherketone (PEEK). In this way, when the heating element generates heat, the base portion will not cause any pressure increase in the insulating space between the heating cup and the outer tube. Additionally, the material (such as ceramic or PEEK) can provide effective insulation properties.

[0015] Preferably, a vacuum is sealed between the outer tube, the heating cup, and the end wall. In this way, a vacuum is provided when the base portion is connected to the outer tube to provide a vacuum insulation. Alternatively, an insulating material can be used to seal between the outer tube, the heating cup, and the end wall. Examples of insulating materials that can be provided include, but are not limited to, air, aerogel materials, powdered or fibrous insulating materials.

[0016] Preferably, the end wall completely covers the second end of the outer tube. In this way, the manufacturing of the heating assembly can be simplified, wherein the attachment of the end wall to the outer tube connects the electrical connector to the heating element while also sealing the outer tube.

[0017] Preferably, the end wall is welded or brazed to the outer tube. In this way, the integrity of the insulating space (e.g., vacuum) between the outer tube and the heating cup is improved.

[0018] Preferably, the inner surface of the heating cup is electrically insulating. This improves the electrical safety of the heating assembly. The electrical insulation can be provided as a separate layer, or the heating cup material can be selected as an electrically insulating material.

[0019] Preferably, the end wall further includes a connection point. The connection point may include a through-hole leading to the space between the outer tube and the heating cup, through which a vacuum can be created in the space. The through-hole can be sealed after the vacuum is created. As an example, a conduit may be connected to the through-hole to create a vacuum in the space, and the conduit may be clamped or otherwise sealed to close the through-hole, thereby maintaining the vacuum in the space. In another example, a vacuum in the heating assembly can be created by manufacturing the heating assembly in a vacuum chamber and then sealing the through-hole after a vacuum is created in the space.

[0020] The connection point can be configured to allow structural elements to connect the heating assembly to the aerosol generating device. Since the connection point is part of the end wall, the structural element extending from the base portion to the device will limit any conductive heat loss or heat transfer from the heating cup to the device. Preferably, the heating assembly further includes a structural member arranged to secure the heating assembly to the aerosol generating device.

[0021] Preferably, the heating element is a resistance heater. In this way, a compact, simple, and easy-to-power heater form is provided.

[0022] According to another aspect of the invention, an aerosol generating device is provided, the aerosol generating device being configured to generate an aerosol for inhalation by a user, the aerosol generating device comprising: a heating component according to the first aspect; and a power source that supplies power to the heating component via an electrical connector.

[0023] According to another aspect of the invention, a method for manufacturing a heating assembly for an aerosol generating apparatus is provided, the method comprising the steps of: providing an outer tube having a first end and a second end; arranging a heating cup radially inward of the outer tube, the heating cup including a heating element disposed on an outwardly facing surface of the heating cup and having an opening at the first end of the outer tube for receiving an aerosol forming matrix; providing an end wall to be disposed at the second end of the outer tube; extending electrical connectors from the end wall, the electrical connectors being configured to supply power to the heating element; providing a base portion to be disposed at a closed end of the heating cup, the base portion including one or more slots in which the electrical connectors can be received; inserting the electrical connectors into the one or more slots of the base portion, wherein the base portion is configured to radially inwardly bias at least a portion of each of the electrical connectors toward the heating element when the electrical connectors are received in the slots, so as to press the electrical connectors toward the heating element; and attaching the end wall to the second end of the outer tube. Attached Figure Description

[0024] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which:

[0025] Figure 1 This is a perspective view of an aerosol generating apparatus including a heating device according to an embodiment of the present invention;

[0026] Figure 2 This is a cross-sectional view of aerosol-forming consumables;

[0027] Figure 3A , Figure 3B and Figure 3C This is a schematic diagram of a heating assembly according to an embodiment of the present invention; and

[0028] Figure 4 This is a cross-sectional schematic diagram of the base portion and end wall of a heating device according to another embodiment of the present invention. Detailed Implementation

[0029] As described herein, vapor should generally be understood as a substance that is in the gaseous phase at temperatures below its critical temperature. This means that vapor can condense into a liquid by increasing its pressure without lowering the temperature, while aerosols are fine solid particles or droplets suspended in air or another gas. However, it should be noted that the terms "aerosol" and "vapor" are used interchangeably in this specification, particularly with respect to the form of the inhalable medium produced for the user to inhale.

[0030] Figure 1An aerosol generating device 2 according to an embodiment of the present invention is shown. The aerosol generating device 2 is shown in an assembled configuration, with exemplary internal components visible. The aerosol generating device 2 is a heated but not burned device, also referred to as a tobacco-vapor device, and includes a heating device 4 configured to receive an aerosol matrix such as an aerosol generating material (e.g., tobacco) rod. The aerosol generating device 2 may include a power source (e.g., a battery) and a control circuitry system for controlling the power supply to the heating device 4. The heating device 4 is operable to heat but not burn the aerosol generating material rod to generate vapor or aerosol for inhalation by a user. Of course, those skilled in the art will understand that… Figure 1 The depicted aerosol generating device 2 is merely an exemplary aerosol generating device according to the present invention. Other types and configurations of tobacco-vapor products, vaporizers, or electronic cigarettes may also be used as aerosol generating devices according to the present invention.

[0031] Figure 2 A schematic diagram is shown for inserting an aerosol forming consumable 6 into a heating device 4 of an aerosol generating apparatus 2. The aerosol forming consumable 6 has a cylindrical body 8 in which a filter 10 is disposed facing a first end and an aerosol forming substance 12 is disposed at a second end of the body 8. The aerosol forming substance 12 may be a solid or semi-solid aerosol forming matrix comprising tobacco. The aerosol forming consumable 6 further includes an empty space 14 positioned within the body 8, between the filter 10 and the aerosol forming substance 12. This space 14 collects aerosols formed or generated by the aerosol forming substance 12 when heated before the generated aerosol is inhaled by the user through the filter 10.

[0032] The aerosol forming consumable 6 also includes a wrapping material 16 that holds the filter 10 and the aerosol forming material 12 in place and provides a space 14 between the filter 10 and the aerosol forming material 12. The wrapping material 16 has suitable properties to ensure the integrity of the aerosol forming consumable 6, for example, preventing it from wrinkling and collapsing into the space 14 when inserted into the heating device, or from tearing when removed from the heating device. The space 14 may be formed by a tubular member made of cardboard material, providing a degree of rigidity while allowing the generated aerosol to flow easily through the space 14 to the filter 10. The length of the aerosol forming material 12 in the body 8 may be similar to the length of the heating region in the longitudinal direction of this heating assembly.

[0033] Figure 3A , Figure 3B and Figure 3CA heating assembly 100 at different manufacturing stages according to an embodiment of the invention is shown. The heating assembly 100 includes an outer tube 102 and a heating cup 104 radially disposed within the outer tube 102. The heating cup 104 is connected to the outer tube 102 at a first end of the heating assembly 100 by welding or any other means obvious to a person skilled in the art.

[0034] The heating cup 104 defines a cavity in which aerosol-generating consumables (such as tobacco sticks or aerosol-forming consumables 6) can be received. The heating cup 104 further includes a heating element 106 disposed on its outer surface. The heating element 106 is configured to generate heat when an electric current flows through it, and wherein the generated heat is transferred by conduction through the heating cup wall to heat the air and consumables received in the cavity. The heating element 106 can be powered by a battery or other form of power source in the aerosol-generating device.

[0035] When viewed along one end parallel to its longitudinal axis, the outer tube 102 and the heating cup 104 have a generally elliptical or circular cross-section to provide a substantially cylindrical heating assembly 100. However, in alternative embodiments, the heating assembly 100 may be formed in other cross-sectional shapes, such as generally square or polygonal shapes.

[0036] The heating cup 104 and the outer tube 102 are radially spaced apart to define an enclosed, insulating space 108 between them, in which a vacuum can be formed. Those skilled in the art will understand that the term "vacuum" refers to a space in which the pressure is significantly lower than atmospheric pressure due to the removal of free matter (particularly air). The vacuum quality formed between the heating cup 104 and the outer tube 102 can be low, medium, or high.

[0037] In an alternative embodiment, instead of a vacuum, an insulating material, such as powder, fibrous material (e.g., aerogel), and / or air, can be placed between the heating cup 104 and the outer tube 102.

[0038] Heating element 106 is a resistance heating element that generates heat through resistance heating. In this disclosure, heating element 106 is a track around the heating cup 104, preferably around the entire circumference of the heating cup 104. Different patterns or arrangements of heating element 106 will be apparent to those skilled in the art. For example, heating element 106 may comprise a heating sheet partially or completely surrounding the heating cup 104. In another example, heating element 106 may be printed, coated, or otherwise attached to the outer surface of the heating cup 104. Heating element 106 further includes a first electrical contact and a second electrical contact (not shown) positioned toward the bottom end of the heating cup 104 for electrical connection to a power source.

[0039] The heating assembly 100 further includes an end wall 110 formed to cover the bottom end of the outer tube 102 and to enclose a vacuum or insulating space 108 between the heating cup 104 and the outer tube 102. The outer tube 102 and the end wall 110 may each be made of metal (such as stainless steel), allowing the two components to be welded or brazed together for a sealed connection.

[0040] The heating assembly 100 further includes electrical connectors 112 configured to connect the heating element 106 to a power source or battery in the aerosol generating device. The electrical connectors 112 may be wires or strips made of a conductive material, such as a metal (e.g., spring steel, stainless steel, or copper). The material of the electrical connectors 112 is configured to flex, wrinkle, or otherwise biased to a desired degree without breaking. The electrical connectors 112 extend from the end wall 110 into the space 108 between the heating cup 104 and the outer tube 102 to contact the electrical contacts of the heating element 106. As those skilled in the art will understand, the electrical connectors 112 can be electrically insulated from the end wall 110 and the outer tube 102 by using a non-conductive seal (not shown).

[0041] The heating assembly 100 further includes an annular base portion 114, which includes one or more slots configured to mate around an electrical connector 112 such that the electrical connector 112, extending from the end wall 110, is received in the slots of the base portion 114. The base portion 114 is made of a non-conductive material, such as ceramic or a non-degassed plastic (e.g., polyetheretherketone, PEEK).

[0042] As in Figure 3A and Figure 3B As can be seen, the base portion 114 is fitted around the electrical connector 112 such that the surface of one or more slots radially and inwardly biases the electrical connector 112 toward the center of the insulating space 108, and then the end wall 110 and the base portion 114 are inserted into the outer tube 102. It is understood that when the heating cup 104 is lowered into the base portion 114 (or when the end wall 110 and the base portion are inserted into the outer tube 102 and onto the heating cup 104), an electrical connection 116 is formed between the electrical connector 112 and the electrical contacts of the heating assembly 106, as... Figure 3C As shown. Since the electrical connector 112 is radially inwardly biased into the space of the heating cup 104, the electrical connector 112 directly presses against the heating element 106 when the heating cup 104 is received in the base portion 114.

[0043] In this specific example, the base portion 114 includes a boss 118 or a chamfered surface against which the electrical connector 112 is pushed to axially compress the electrical connector 112. The axial compression causes the electrical connector 112 to wrinkle into a zigzag shape and extend radially toward the center of the outer tube 102 / heating assembly 100.

[0044] End wall 110 further includes an orifice 120 that serves as a connection point for vacuum generating tube 122, which can be used during assembly to create a vacuum in the insulating space 108, after which the orifice 120 or vacuum generating tube 122 is sealed. Orifice 120 can also be used to allow one or more sensors to be attached to end wall 110, such as temperature or pressure sensors for heating assembly 100. In yet another example, orifice 120 can be used to connect heating assembly 100 to an aerosol generating device by providing a rigid structural element, and to secure heating assembly 100 in place.

[0045] Figure 4 A schematic cross-sectional view of the end wall 210 and base portion 212 according to another example of this disclosure is shown. The end wall 210 largely corresponds to the example shown in FIG3. However, in this specific example, the electrical connector 214 is shown as radially inwardly flexing into a single curved bow when axially compressed by the boss 216 of the base portion 212.

[0046] As shown in Figure 3 and Figure 4 As should be understood from the examples, the electrical connector may wrinkle to form a zigzag shape when the boss abutting the base portion is axially compressed, or it may bend or flex radially inward. This may depend on the initial shape and size of the electrical connector and the design of the base portion. Other designs for the base portion that allow the electrical connector to be radially biased inward to form a direct electrical connection with the heating cup during assembly will be readily apparent to those skilled in the art.

Claims

1. A heating assembly for an aerosol generating apparatus, the heating assembly comprising: An outer tube having a first end and a second end; A heating cup is disposed radially inside the outer tube, the heating cup includes a heating element disposed on the outward-facing surface of the heating cup, and the heating cup has an opening at a first end of the outer tube for receiving an aerosol-forming matrix; Electrical connectors, which are configured to supply power to the heating element; The base portion, which is disposed at the closed end of the heating cup, includes one or more slots in which electrical connectors can be received; as well as An end wall is disposed at the second end of the outer tube, from which these electrical connectors extend. The base portion is configured to radially inward bias at least a portion of each of the electrical connectors toward the heating element when the electrical connectors are received in the slots, so as to press the electrical connectors toward the heating element.

2. The heating assembly as claimed in claim 1, wherein, The one or more slots are open in the radially inward section of the base portion.

3. The heating assembly as described in claim 1 or 2, wherein, The slot or slot includes one or more corresponding surfaces arranged radially outward of at least a portion of each received electrical connector.

4. The heating assembly as described in claim 1, 2, or 3, wherein, The base portion is configured to be removably attached to the heating cup and / or the end wall.

5. The heating assembly as claimed in any of the preceding claims, wherein, The length of one or more slots in the base portion is less than the length of the electrical connectors, such that the electrical connectors are axially compressed within the slots, thereby causing the electrical connectors to be radially inwardly biased.

6. The heating assembly as claimed in any of the preceding claims, wherein, These electrical connectors have a bent or zigzag shape to facilitate radial inward bias of at least a corresponding portion of the received electrical connector.

7. The heating assembly as claimed in any of the preceding claims, wherein, The base portion includes non-degassed materials, such as ceramics or polyetheretherketone (PEEK).

8. The heating assembly as claimed in any of the preceding claims, wherein, A vacuum is formed between the outer tube, the heating cup, and the end wall.

9. The heating assembly as claimed in any of the preceding claims, wherein, The end wall is welded or brazed to the outer tube.

10. The heating assembly as claimed in any of the preceding claims, wherein, The inner surface of the heating cup is electrically insulated.

11. The heating assembly as claimed in any of the preceding claims, wherein, The end wall includes the connection point.

12. The heating assembly as claimed in claim 11, wherein, The heating assembly further includes a structural member arranged to secure the heating assembly to the aerosol generating device.

13. The heating assembly as claimed in any of the preceding claims, wherein, The heating element is a resistance heater.

14. An aerosol generating device configured to generate an aerosol for inhalation by a user, the aerosol generating device comprising: The heating assembly according to any one of claims 1 to 13, and A power source that supplies power to the heating element through these electrical connectors.

15. A method for manufacturing a heating assembly for an aerosol generating apparatus, the method comprising the steps of: An outer tube is provided, the outer tube having a first end and a second end; A heating cup is arranged radially inside the outer tube. The heating cup includes a heating element disposed on the outward-facing surface of the heating cup and has an opening at the first end of the outer tube for receiving an aerosol-forming matrix. Provide an end wall to be disposed at the second end of the outer tube; Electrical connectors extend from the end wall and are configured to supply power to the heating element. A base portion is provided to be disposed at the closed end of the heating cup, the base portion including one or more slots in which electrical connectors can be received; The electrical connectors are inserted into one or more slots in the base portion, wherein the base portion is configured to radially inwardly bias at least a portion of each of the electrical connectors toward the heating element when the electrical connectors are received in the slots, so as to press the electrical connectors toward the heating element; and Attach the end wall to the second end of the outer tube.

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