Aerosol provision device

Abstract

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

Description

Technical Field

[0001] This invention relates to an aerosol supply device and an aerosol supply system. Background Technology

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

[0003] According to a first aspect of the present invention, an aerosol supply device is provided, comprising: Multiple electrical components; and A plastic body includes at least one conductive track configured to provide an electrical connection between at least two of the plurality of electrical components, wherein the at least one conductive track is formed by laser direct forming technology.

[0004] Using a plastic body comprising at least one conductive track formed by laser direct forming technology can reduce the number of cables required within the device, which provides electrical connections between at least two electrical components within the aerosol supply device. This can reduce the space required for laying such cables, potentially allowing the aerosol supply device to be manufactured more compactly. Using conductive tracks formed by laser direct forming technology also simplifies the manufacturing and assembly of the aerosol supply device.

[0005] The plastic body can be configured to support at least one of a plurality of electrical components.

[0006] The plastic body can be configured to house at least one of a plurality of electrical components.

[0007] The aerosol supply device may include a housing, and a plastic body may be housed within the housing or at least partially define the housing.

[0008] The plastic body can be formed from modified polyetheretherketone (PEEK).

[0009] Multiple electrical components may include at least one of the following: an electrical power source (e.g., a battery), a heating device, a temperature sensor, a controller, a light source, a tactile device, and a speaker.

[0010] The aerosol supply device may include at least one electrical connector arranged to connect a conductive rail to at least one of a plurality of electrical components.

[0011] At least one conductive track may include multiple conductive tracks.

[0012] Furthermore, at least two of the multiple conductive tracks can be electrically insulated from each other.

[0013] The plastic body can be made of a plastic material that can withstand temperatures of at least 200°C, for example, at least 220°C, or at least 250°C for a period of time.

[0014] This duration can include at least 60 seconds, for example at least 2 minutes, or at least 5 minutes.

[0015] The plastic body can be electrically insulated.

[0016] The plastic body can have high chemical resistance.

[0017] At least one conductive track can extend in multiple different planes.

[0018] According to a second aspect of the present invention, an aerosol supply system is provided, comprising: An aerosol supply device according to any one of the embodiments described above; and Products, including aerosol-generating materials.

[0019] According to a third aspect of the present invention, a method for forming a component for use in an aerosol supply device is provided, the method comprising: Forming a plastic matrix; Use a laser to illuminate the tracks on the plastic body; The track is coated with a conductive material.

[0020] The step of coating the irradiated track with a conductive material may include coating the track multiple times with the conductive material.

[0021] The step of forming a plastic body may include forming a plastic body with a three-dimensional shape, the plastic body having support features for mounting electrical components to the plastic body.

[0022] The step of forming a plastic body may include forming the plastic body from a material containing additives, the additives including a metallic inorganic compound configured to be activated by a laser. Attached Figure Description

[0023] The implementation will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 A side view of an aerosol supply system according to an embodiment of the present invention is shown; Figure 2A perspective view of the plastic body of an aerosol supply device according to an embodiment of the present invention is shown; Figure 3 A plan view of a portion of a plastic body including a conductive track, the conductive track including an electrical connector at its end is shown; and Figure 4 This is a flowchart of a method according to an embodiment of the present invention. Detailed Implementation

[0024] As used herein, the term "aerosol-generating material" is, for example, a material capable of generating aerosols when supplied with energy by heating, radiation, or any other means. Aerosol-generating materials can be, for example, in solid, liquid, or gel form, and may or may not contain active substances and / or flavorings. Aerosol-generating materials can include any plant-based material (such as materials containing tobacco), and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-generating materials may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. Aerosol-generating materials can be, for example, in solid, liquid, gel, wax, etc. Aerosol-generating materials can also be, for example, combinations or mixtures of materials. Aerosol-generating materials may also be referred to as "inhalable materials."

[0025] The aerosol-generating material may include a binder and an aerosol forming agent. Optionally, activators and / or fillers may also be present. Optionally, a solvent (such as water) may also be present, and one or more other components of the aerosol-generating material may be soluble or insoluble in that solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In some embodiments, the aerosol-generating material is substantially free of tobacco.

[0026] Aerosol-generating materials may include or may be "amorphous solids". Amorphous solids may be "monolithic solids". In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that can retain some fluid (such as a liquid) within it. In some embodiments, the aerosol-generating material may, for example, include from about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of amorphous solids.

[0027] Aerosol-generating materials may include aerosol-generating membranes. Aerosol-generating membranes may include or be sheets, which may optionally be shredded to form fragments. Aerosol-generating sheets or fragments may be substantially tobacco-free.

[0028] According to this disclosure, a "non-flammable" aerosol supply system is an aerosol supply system in which the aerosol generating material is non-flammable or non-ignitable, and can deliver at least one substance to a user. Any aerosol supply system described herein can be a non-flammable aerosol supply system.

[0029] In some implementations, the delivery system is a non-flammable aerosol supply system, such as a powered non-flammable aerosol supply system.

[0030] In some implementations, the non-flammable aerosol supply system is an electronic cigarette, also known as a vapor device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not necessary.

[0031] In some implementations, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a heated non-combustible system. An example of such a system is a tobacco heating system.

[0032] In some embodiments, the non-flammable aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, one or more of which can be heated. Each of these aerosol-generating materials can be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the mixing system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0033] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0034] In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-flammable aerosol supply devices. These consumables are sometimes referred to as articles in this disclosure.

[0035] In some embodiments, a non-flammable aerosol supply system (such as its non-flammable aerosol supply device) may include a power source and a controller. For example, the power source may be an electrical power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon matrix that can be powered to distribute power in the form of heat to the aerosol generating material or heat transfer material adjacent to the exothermic power source.

[0036] In some embodiments, a non-flammable aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, nozzles, filters, and / or aerosol modifiers.

[0037] In some embodiments, consumables for use with a non-flammable aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material delivery component, aerosol generator, aerosol generating area, housing, packaging paper, filter, nozzle and / or aerosol modifier.

[0038] An aerosol supply device can receive articles comprising aerosol-generating material for heating. In this context, "article" refers to a component that includes or contains aerosol-generating material (which is heated to cause the aerosol-generating material to volatilize) in use, and optionally other components in use. A user may first insert the article into the aerosol supply device, then heat the article to generate an aerosol, which the user then inhales. The article may, for example, have a predetermined or specific size, and is configured to be placed within a heating chamber of the device, the heating chamber being sized to receive the article.

[0039] refer to Figure 1 An aerosol supply system 2 according to an embodiment of the present invention is shown. The aerosol supply system 2 includes an aerosol supply device 4 for generating aerosols from aerosol generating materials. The aerosol supply system 2 also includes a replaceable article 6 containing aerosol generating materials. In general, the aerosol generating device 4 can be used to heat the article 6 to generate an aerosol or other inhalable medium to be inhaled by a user of the device 4.

[0040] The aerosol forming apparatus 4 includes a main body 8. This main body can be considered as forming a shell that surrounds and houses the various components of the apparatus 4. An article orifice 10 is formed at one end of the main body 8, through which an article 6 can be inserted for heating by the aerosol generator 12.

[0041] Device 4 may also include a user-operable control element 14, such as a button or switch, which operates device 4 when pressed. For example, a user can turn on device 4 by operating switch 14.

[0042] The aerosol generator 12 is positioned along a longitudinal axis aligned with the axis of the product 6.

[0043] In use, the article 6 can be fully or partially inserted into the aerosol generator 12, and the article can be heated in the aerosol generator 12 by one or more components of the aerosol generator 12.

[0044] Apparatus 4 includes a device for heating the aerosol-generating material, namely an aerosol generator 12. This device includes an aerosol-generating assembly, a controller (control circuitry), and a power source. This device forms part of the main body 8. The aerosol-generating assembly is configured to heat the aerosol-generating material of the article 6 inserted through the article aperture 10, such that an aerosol is generated from the aerosol-generating material. The power source supplies electrical power to the aerosol-generating assembly, and the aerosol-generating assembly converts the supplied electrical energy into heat energy for heating the aerosol-generating material. The power source can be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (e.g., lithium-ion batteries), nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries.

[0045] A power source can be electrically connected to the aerosol generating assembly to supply electrical power to heat the aerosol generating material when needed and under the control of the controller. The control circuitry can be configured to enable and disable the aerosol generating assembly based on user input. User input can be via pressing a button or opening a door of the device (e.g., a door covering a consumable receiving container). The control circuitry can be configured to enable and disable the assembly automatically, for example, when an article is inserted.

[0046] Aerosol generation assemblies may include various components that heat aerosol-generating materials via an induction heating process. Induction heating is a process of heating a conductive heating element (such as a sensor) through electromagnetic induction. An induction heating assembly may include a sensing element (e.g., one or more induction coils) and means for passing a changing current (such as alternating current) through the sensing element. The changing current in the sensing element generates a changing magnetic field. The changing magnetic field passes through a sensor (heating element) appropriately positioned relative to the sensing element and generates eddy currents within the sensor. The sensor has resistance to the eddy currents, and the flow of the eddy currents against this resistance causes the sensor to be heated by Joule heating. In cases where the sensor contains a ferromagnetic material (such as iron, nickel, or cobalt), heat can also be generated through hysteresis losses in the sensor, i.e., through the changing orientation of magnetic dipoles in the magnetic material due to their alignment with the changing magnetic field. Compared to heating, for example, by conduction, in induction heating, heat is generated within the sensor, thus allowing for rapid heating. Furthermore, no physical contact is required between the sensing element and the sensor, thus allowing for increased freedom in construction and application. In some embodiments, the aerosol generating apparatus may include a resistance heating device.

[0047] Figure 1 The aerosol supply system 2 shown may include any features of the various embodiments discussed below.

[0048] Figure 2 A perspective view of a plastic body 116 is shown, which can be formed Figure 1Part of the body 8 of the aerosol generating device 4 shown. The plastic body 116 may house / support multiple electrical components, including but not limited to: an electric power source 118 (e.g., a battery), a heating device 120 (e.g., a resistive or induction heating device), a controller 122 (e.g., including a processor), a temperature sensor 124 (e.g., a thermistor), a tactile device 126, a speaker 126, and / or a light source 128 (e.g., an LED).

[0049] Multiple electrical components may be housed within the plastic body 116. In some embodiments, the aerosol supply device may include a housing, and the plastic body 116 may at least partially define the housing of the aerosol supply device. For example, the plastic body 116 may be formed Figure 1 This is a portion of the main body 8 shown. In some embodiments, the plastic body 116 may be housed within a housing. Thus, the plastic body 116 may be an internal component of the aerosol supply device. In this embodiment, the plastic body 116 may, for example, form part of an internal support structure that defines the internal structure of the aerosol supply device.

[0050] In some embodiments, multiple electrical components may be supported by a plastic body 116. For example, the plastic body 116 may include a first support 130A and a second support 130B arranged to support a heating device 120. Similarly, the plastic body may include a third support 130C arranged to support a power source 118 and a fourth support 130D arranged to support a temperature sensor 124. Any number of the first support 130A, second support 130B, third support 130C, and fourth support 130D may be integrally formed with the plastic body 116. The form of the support may depend on the component being supported. The support may be integrally formed with the plastic body 116, for example, during integral body molding. In some embodiments, the plastic body 116 may include supports attached or mounted to the plastic body 116 during the manufacture / assembly of the device. Supporting components by the plastic body 116 can advantageously provide a simple and effective means for supporting electrical components within a device.

[0051] As in Figure 2As can be seen, the plastic body 116 includes multiple conductive tracks (hereinafter referred to as "electrical tracks"), including, for example, a first electrical track 132A, a second electrical track 132B, a third electrical track 132C, and a fourth electrical track 132D. The first electrical track 132A provides an electrical connection between the controller 122 and the heating device 120. The second electrical track 132B provides an electrical connection between the power source 118 and the controller 122. The third electrical track 132C provides an electrical connection between the controller 122 and the tactile component 126. The fourth electrical track 132D provides an electrical connection between the controller 122 and the temperature sensor 124. Although not shown, additional electrical tracks may be provided to provide an electrical connection between the light source 128 and the speaker 126. Each of the first electrical track 132A, the second electrical track 132B, the third electrical track 132C, and the fourth electrical track 132D is formed using laser direct forming technology. The applicant has recognized that using conductive tracks formed on the plastic body 116 via laser direct forming technology can provide a convenient means of achieving electrical connections between various electrical components without the need for cabling within the device. This reduces the amount of space required for cabling within the device, which can minimize the device's size or provide more space for other components, such as more battery space.

[0052] As in Figure 2 As depicted, in some embodiments, at least two of the conductive tracks 132A-132D are electrically insulated from each other. The electrical insulation of the conductive tracks 132A-132D can be achieved by appropriately arranging electrical components relative to the plastic body 116.

[0053] The specific form of the electrical track can depend on the plastic body or the portion of the plastic body that forms the electrical track. In some embodiments, such as in... Figure 2 As depicted, at least one electrical track (e.g., first electrical track 132A, second electrical track 132B, third electrical track 132C, or fourth electrical track 132D) extends in multiple (e.g., at least two) different planes. This can advantageously allow electrical connections between electrical components in the device that are not arranged in a single plane. Therefore, compared to other possible arrangements, this arrangement can facilitate more complex arrangement of electrical components within the device while still providing electrical connections to conductive tracks. In some embodiments, the plastic body 116 may be non-planar. In other words, the plastic body 116 may not be a flat plastic sheet but may have a more complex three-dimensional form. The exact form can be determined depending on the intended use of the plastic body 116 as part of the device.

[0054] Although the various electrical components and conductive tracks shown have been depicted and described above, it is understood that any number of different electrical components and any suitable number of electrical tracks may be included.

[0055] The plastic body 116 can be made of any suitable plastic material. In some embodiments, the plastic body is formed from modified polyetheretherketone (PEEK), i.e., made of modified polyetheretherketone (PEEK).

[0056] At least some parts of the aerosol supply device may reach relatively high temperatures during use. Therefore, it may be desirable for the plastic body 116 to withstand such temperatures. Furthermore, the plastic body 116 may be exposed to such temperatures for extended periods during use of the aerosol supply device. Therefore, in some embodiments, the plastic body 116 may be made of a plastic material capable of withstanding temperatures of at least 200°C (e.g., at least 220°C, or at least 250°C) for a duration. This helps ensure that the plastic body 116 can withstand the elevated temperatures it may be exposed to during use, thereby ensuring that it properly performs its function, such as as part of the housing of the aerosol supply device or as a support component within the device. A duration may include at least 60 seconds, such as at least 2 minutes, or at least 5 minutes.

[0057] The plastic body 116 may be electrically insulating, which ensures that the electrical rails 132A-132D can properly perform their functions. In some embodiments, the plastic body 116 has high chemical resistance. High chemical resistance can advantageously ensure that the plastic body 116 does not deteriorate in the presence of chemicals, such as those that are part of or formed from aerosol-generating articles that can be inserted into an aerosol supply device, wherein the plastic body 116 forms part of the aerosol supply device.

[0058] In any of the embodiments discussed above, electrical components 118-128 can be electrically connected to their respective electrical rails 132A-132D by any suitable means. For example, in some embodiments, electrical components 118-128 can be soldered to their respective electrical rails 132A-132D. However, this is not necessary, and in some embodiments, electrical components 118-128 can be connected via electrical connectors. This embodiment will be described in more detail below.

[0059] Figure 3A plan view of a portion of a plastic body 216 according to an embodiment of the invention is shown. As depicted, the plastic body 216 includes a conductive track 232. An electrical connector 234 is mounted to the conductive track 232, for example, at one end of the conductive track 232. The electrical connector 234 may be arranged to connect the conductive track 232 to an electrical component (e.g., any of the electrical components discussed above). The electrical connector 234 thus facilitates the connection of an electrical component to the conductive track 232. The electrical component may include a corresponding electrical connector configured to mate with the electrical connector 234. In some embodiments, at least one of these electrical tracks may include an electrical connector. The presence of the electrical connector can improve the ease of mounting the electrical component into the aerosol supply device 4. The presence of such an electrical connector 234 also makes it easier to remove and replace electrical components within the device 4.

[0060] The electrical connector 234 can take any suitable form. In some embodiments, the electrical connector 234 includes at least one connector pin 236, such as two connector pins 236, which provides an electrical connection to an electrical component attached thereto.

[0061] Figure 4 This is a flowchart depicting a method for forming components for use in an aerosol supply device according to an embodiment of the present invention. (Refer to...) Figure 2 The plastic body 116 shown illustrates the method, but it should be understood that the method can be used to form any suitable component having any suitable form for use in an aerosol supply device. In step S1, the method includes forming a plastic body, such as the plastic body 116 described above. Step S1 of forming the plastic body may include forming a plastic body having a three-dimensional shape, the plastic body having support features for mounting electrical components to the plastic body. The support features may include, for example, in… Figure 2 The support members 130A-130D shown are three-dimensional shapes that can be any non-planar shape.

[0062] Step S1 of forming the plastic body 116 may include forming the plastic body 116 from a material containing additives, the additives including a metal inorganic compound configured to be activated by a laser.

[0063] In step S2, the method includes using a laser to irradiate tracks, such as at least one of tracks 132A-132D, onto the plastic body 116. Any suitable laser can be used, such as an infrared laser.

[0064] In step S3, the method includes coating the irradiated track with a conductive material (e.g., a conductive metal). Step S3 may include coating the track multiple times with the conductive material.

[0065] At least steps S2 and S3 can be performed multiple times to form multiple conductive tracks.

[0066] The above-described method of forming components can advantageously form components for use in aerosol supply devices, the components including at least one conductive track that can provide electrical connections between various electrical components within the device. This method of forming components can be incorporated into a larger method of manufacturing / assembling the device. By forming components according to this method, further manufacturing / assembly steps (e.g., those related to the production and arrangement of cables for use in the device) can be minimized or even completely omitted. Therefore, this can make the manufacturing / assembly process more efficient.

[0067] The various embodiments described herein are provided only to aid in understanding and teaching the claimed features. These embodiments are provided merely as representative examples of various embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or on the equivalents of the claims, and other embodiments may be used and variations may be made without departing from the scope of the claimed invention. In addition to the elements, components, features, portions, steps, devices, etc. specifically described herein, various embodiments of the invention may suitably include, consist of, or substantially consist of suitable combinations of the disclosed elements, components, features, portions, steps, devices, etc., or suitable combinations of the disclosed elements, components, features, portions, steps, devices, etc. Furthermore, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An aerosol supply device, comprising: Multiple electrical components; as well as A plastic body includes at least one conductive track, the at least one conductive track being configured to provide an electrical connection between at least two of the plurality of electrical components, wherein at least one conductive track is formed by laser direct forming technology.

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

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

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

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

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

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

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

9. The aerosol supply device according to any one of the preceding claims, wherein, The plastic body is made of a plastic material capable of withstanding temperatures of at least 200°C, for example, at least 220°C, or at least 250°C for a period of time.

10. The aerosol supply device according to any one of the preceding claims, wherein, At least one of the conductive tracks extends in multiple different planes.

11. An aerosol supply system, comprising: Aerosol supply device according to any one of the preceding claims; as well as Products, including aerosol-generating materials.

12. A method of forming a component for use in an aerosol supply device, the method comprising: Forming a plastic matrix; The track is irradiated onto the plastic body using a laser; The irradiated track is coated with a conductive material.

13. The method according to claim 12, wherein, The step of coating the irradiated track with a conductive material includes coating the track multiple times with the conductive material.

14. The method according to claim 12 or 13, wherein, The step of forming the plastic body includes forming the plastic body having a three-dimensional shape, the plastic body having support features for mounting electrical components to the plastic body.

15. The method according to any one of claims 12 to 14, wherein, The step of forming the plastic body includes forming the plastic body from a material containing additives, the additives including a metal-inorganic compound configured to be activated by a laser.

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