Aerosol generation device and production method

Abstract

[PROBLEM] To provide an arrangement that enables proper detection of insertion of a substrate into an aerosol generating device. [SOLUTION] An aerosol generating device includes an accommodation portion for accommodating a substrate containing an aerosol source in an inner space thereof, a load for generating energy for heating the aerosol source of the substrate accommodated in the accommodation portion, and a capacitive sensor including a plurality of electrodes for detecting an electrostatic capacitance of the inner space in the accommodation portion, wherein the electrodes include a main body formed of a metal, and a first portion of a surface of the main body of the electrodes is covered by an insulating layer formed of a ceramic.

Description

Technical Field

[0001] This disclosure relates to an aerosol generating apparatus and a production method. Background Technology

[0002] Aerosol generating devices for producing aerosols for users to inhale are becoming increasingly common. For example, an aerosol generating device produces a flavored aerosol by using an aerosol source for generating the aerosol and a matrix including a flavor source to impart flavor components to the generated aerosol. Users can enjoy the flavor by inhaling the flavored aerosol produced by the aerosol generating device. The act of a user inhaling the aerosol will also be referred to below as "inhalation" or "inhalation action." Devices that can be categorized as aerosol generating devices include those used as alternatives to cigarettes, such as heated tobacco products. It should be noted that heated tobacco products are a type of aerosol generating device that produces aerosols by heating an aerosol source.

[0003] For aerosol generating devices that heat the inserted substrate, techniques are being developed for detecting the insertion of the substrate. For example, PTL 1 below describes a technique for detecting substrate insertion using a capacitive sensor. Furthermore, PTL 2 below describes a technique for a capacitive sensor in which the electrodes are formed of aluminum material treated with an alumina film.

[0004] Citation List

[0005] Patent documents

[0006] PTL 1: JP 6348985 B2

[0007] PTL 2: JP H04-037366 B2 Summary of the Invention

[0008] The problem to be solved by the present invention

[0009] However, there is still room for improvement in techniques such as those described in PTL 1, which use capacitive sensors to detect the matrix. The technique described in PTL 2 is designed to measure the liquid level, and therefore is far from suitable for aerosol generation devices in terms of size, making it difficult to apply the technique "as is" to the field of aerosol generation devices.

[0010] Therefore, this disclosure is made in view of the above-mentioned problems, and the purpose of this disclosure is to provide an arrangement that enables proper detection of matrix insertion into an aerosol generating device.

[0011] Solution to the problem

[0012] To address the aforementioned problems, one aspect of this disclosure provides an aerosol generating apparatus comprising: a containment portion for containing a matrix comprising an aerosol source within its internal space; a load for generating energy for heating the aerosol source contained in the matrix within the containment portion; and a capacitive sensor comprising a plurality of electrodes for detecting electrostatic capacitance of the internal space within the containment portion, wherein the electrodes comprise a body formed of metal, and a first portion of the surface of the body of the electrodes is covered by an insulating layer formed of ceramic.

[0013] The electrodes can be arranged such that a portion of the electrodes is exposed within the interior space of the receiving portion, and the portion of the electrodes exposed within the interior space of the receiving portion can be covered by an insulating layer.

[0014] The receiving portion may be a cylindrical body with an opening on its upper side that allows for vertical insertion / removal of the substrate, and an insulating layer covers 100% of the side of the electrode body on the central axis side of the receiving portion and at least 50% of the area above and below the central axis side of the receiving portion.

[0015] The relative permittivity of the insulating layer can be 3 or greater.

[0016] The electrode body can be made of aluminum, and the insulating layer can be an aluminum oxide film.

[0017] The insulating layer can be formed by coating silicon carbide or glass.

[0018] The thickness of the insulating layer can be 1 [µm] or greater than that but less than 20 [µm].

[0019] The thickness of the electrode body can be 0.1 mm or greater than that but less than 4 mm.

[0020] The second part of the surface of the electrode body can be covered by a flux layer, which is formed of a cladding material used to assist welding.

[0021] The area of ​​the second part can be 0.01 mm² or greater than that but less than 16 mm².

[0022] The electrodes can be formed in a ring shape, and the multiple electrodes can be spaced apart in the vertical direction.

[0023] A portion of the receiving portion may form an insulating layer made of ceramic, and the electrode may be arranged to contact the outer side of the receiving portion that forms the insulating layer made of ceramic.

[0024] The aerosol generating device may further include a control unit for controlling the operation of the load based on electrostatic capacitance detected by means of a capacitive sensor.

[0025] Furthermore, to address the aforementioned problems, another aspect of this disclosure provides a method for manufacturing electrodes constituting a capacitive sensor used in an aerosol generating apparatus. This method includes: a first step: using a sheet-like base material formed of aluminum as a workpiece, and machining the workpiece into the following shape: including a first annular member, a second annular member surrounding the exterior of the first annular member, and two connecting portions connecting the first annular member and the second annular member at different locations; a second step: after completing the first step, subjecting the workpiece to an alumina film treatment; a third step: after completing the second step, forming a through-hole in the second annular member of the workpiece and cutting one of the two connecting portions; a fourth step: after completing the third step, plating the inner surface of the through-hole and the cut surface of the cut connecting portion in the workpiece; and a fifth step: after completing the fourth step, cutting the uncut connecting portion in the workpiece.

[0026] Advantages of the present invention

[0027] As described above, this disclosure provides an arrangement that enables proper detection of matrix insertion into an aerosol generating apparatus. Attached Figure Description

[0028] [ Figure 1 [Illustrated diagram showing an example configuration of an aerosol generating device.]

[0029] [ Figure 2 [ ] is an end view of the receiving portion taken in the vertical direction according to this embodiment.

[0030] [ Figure 3 [This refers to the accommodating portion according to this embodiment, along...] Figure 2 The end face view taken by the cross section line AA is shown.

[0031] [ Figure 4 ] is to show Figure 2 and Figure 3 A perspective view of a specific example of the electrode shown.

[0032] [ Figure 5 [ ] is a diagram showing the first step in the method of producing electrodes.

[0033] [ Figure 6 [ ] is a diagram illustrating the second step in the method of producing electrodes.

[0034] [ Figure 7[This is a diagram illustrating the third step in the method of producing electrodes.]

[0035] [ Figure 8 [This is a diagram illustrating the fourth step in the method of producing electrodes.]

[0036] [ Figure 9 [This is a diagram illustrating the fifth step in the method of producing electrodes.]

[0037] [ Figure 10 [] is an end view taken vertically from the receiving portion of the first variant instance.

[0038] [ Figure 11 [Is along the containment portion of the first variant instance] Figure 10 The end face view taken by the cross-section line BB is shown.

[0039] [ Figure 12 [] is an end view taken vertically from the receiving portion of the second variant instance.

[0040] [ Figure 13 [Is along the containment portion of the second variant instance] Figure 12 The end face view taken by the cross-section line CC is shown. Detailed Implementation

[0041] Preferred embodiments of this disclosure will now be described in detail with reference to the accompanying drawings. It should be noted that the same reference numerals will be assigned to components having substantially the same functional configuration in the specification and drawings to avoid repetitive descriptions.

[0042] <1. Example of Aerosol Generating Device Configuration>

[0043] An aerosol generating device is a device used to generate aerosols for users to inhale.

[0044] Figure 1 This is a schematic diagram illustrating an example configuration of an aerosol generating device. For example... Figure 1 As shown, the aerosol generating device 100 according to this configuration example includes: a power supply unit 111, a sensor unit 112, a notification unit 113, a memory unit 114, a communication unit 115, a control unit 116, a heating unit 121, a housing portion 140, and a heat insulation portion 144.

[0045] The power supply unit 111 stores electricity. The power supply unit 111 then supplies power to each component of the aerosol generating device 100 based on the control executed by the control unit 116. For example, the power supply unit 111 may be configured with a rechargeable battery (such as a lithium-ion secondary battery).

[0046] Sensor unit 112 acquires various types of information related to aerosol generating device 100. As an example, sensor unit 112 is configured with a pressure sensor (such as a capacitive microphone, flow sensor, or temperature sensor) and acquires values ​​associated with user inhalation. As another example, sensor unit 112 is configured with an input device (such as a button or switch) for receiving information input from the user.

[0047] The notification unit 113 notifies the user of information. For example, the notification unit 113 may be configured with a light-emitting device that emits light, a display device that displays images, a sound output device that outputs sound, or a vibration device that can vibrate.

[0048] Memory unit 114 stores various types of information for the operation of aerosol generating device 100. Memory unit 114 is configured, for example, by a non-volatile storage medium (such as flash memory).

[0049] Communication unit 115 is a communication interface capable of performing communication conforming to any wired or wireless communication standard. Examples of communication standards that can be used include those employing Wi-Fi (registered trademark), Bluetooth (registered trademark), Bluetooth Low Energy (BLE) (registered trademark), Near Field Communication (NFC), or Low Power Wide Area (LPWA) standards.

[0050] The control unit 116 serves as an arithmetic processing device and a control device, thereby controlling all operations within the aerosol generating device 100 according to various programs. For example, the control unit 116 is implemented by a CPU (central processing unit) or electronic circuitry (such as a microprocessor).

[0051] The receiving portion 140 has an internal space 141 and holds the rod-shaped substrate 150, while also housing a portion of the rod-shaped substrate 150 within the internal space 141. The receiving portion 140 has an opening 142 that allows communication between the internal space 141 and the outside, and receives the rod-shaped substrate 150 inserted into the internal space 141 through the opening 142. For example, the receiving portion 140 is a cylindrical body including the opening 142 and a bottom portion 143 serving as a bottom surface, and this receiving portion defines the cylindrical internal space 141. An airflow path for supplying air to the internal space 141 is connected to the receiving portion 140. For example, an air inlet hole is provided in the side surface of the aerosol generating device 100, which serves as an inlet for air to enter the airflow path. For example, an air outlet hole is provided in the bottom portion 143, which serves as an outlet for air to exit from the airflow path to the internal space 141.

[0052] The stick-shaped matrix 150 includes a matrix portion 151 and a mouthpiece portion 152. The matrix portion 151 contains an aerosol source. The aerosol source includes tobacco-derived or non-tobacco-derived flavor components. If the aerosol generating device 100 is a medical inhaler (such as a nebulizer), the aerosol source may include a drug. The aerosol source may be, for example, a liquid containing tobacco-derived or non-tobacco-derived flavor components, such as polyols (such as glycerol or propylene glycol) or water, or it may be a solid containing tobacco-derived or non-tobacco-derived flavor components. With the stick-shaped matrix 150 held in the receiving portion 140, at least a portion of the matrix portion 151 is contained in the internal space 141, and at least a portion of the mouthpiece portion 152 protrudes from the opening 142. Thus, when a user holds the mouthpiece portion 152 protruding from the opening 142 in their mouth and inhales, air flows into the internal space 141 through an airflow path (not depicted) and reaches the user's mouth along with the aerosol generated by the matrix portion 151.

[0053] Heating unit 121 heats the aerosol source to atomize it, thereby generating an aerosol. Figure 1 In the illustrated example, the heating unit 121 has a membrane-like form and is arranged to cover the outer periphery of the receiving portion 140. Thus, when the heating unit 121 generates heat, the matrix portion 151 of the rod-shaped matrix 150 is heated from the outer periphery, thereby generating an aerosol. The heating unit 121 generates heat when powered by the power supply unit 111. For example, power can be supplied when the sensor unit 112 detects that the user has begun inhalation and / or has entered predetermined information. Then, power supply can be stopped when the sensor unit 112 detects that the user has completed inhalation and / or has entered predetermined information.

[0054] The heat insulation portion 144 prevents heat from being transferred from the heating unit 121 to other components. For example, the heat insulation portion 144 is made of vacuum insulation material or aerogel insulation material.

[0055] The above describes a configuration example of the aerosol generating device 100. The aerosol generating device 100 is, of course, not limited to the configuration described above, but can have various configurations shown below.

[0056] As an example, the heating unit 121 may be in the form of a blade and may be arranged to protrude from the bottom portion 143 of the receiving portion 140 into the internal space 141. In this case, the blade-shaped heating unit 121 is inserted into the matrix portion 151 of the rod-shaped matrix 150 and heats the matrix portion 151 of the rod-shaped matrix 150 from the inside. As another example, the heating unit 121 may be arranged to cover the bottom portion 143 of the receiving portion 140. Furthermore, the heating unit 121 may be configured by a combination of two or more heating units: a first heating unit covering the outer periphery of the receiving portion 140, a blade-shaped second heating unit, and a third heating unit covering the bottom portion 143 of the receiving portion 140.

[0057] As another example, the receiving portion 140 may include an opening and closing mechanism (such as a hinge) for opening and closing a portion of the housing forming the internal space 141. Thus, by opening and closing the housing, the receiving portion 140 can clamp and receive the rod-shaped substrate 150 that has been inserted into the internal space 141. In this case, a heating unit 121 may be disposed on the clamping portion of the receiving portion 140, and can heat the rod-shaped substrate while pressing it.

[0058] Furthermore, the means for atomizing the aerosol source is not limited to heating provided by the heating unit 121. For example, the means for atomizing the aerosol source can be induction heating. In this case, the aerosol generating device 100 includes at least an electromagnetic induction source (such as a coil) for generating a magnetic field, instead of the heating unit 121. A sensor for generating heat by means of induction heating can be provided in the aerosol generating device 100, or it can be included in the rod-shaped matrix 150.

[0059] <2. Technical Issues>

[0060] The technical issues of detecting the matrix using a capacitive sensor will be described below.

[0061] Preferably, the electrodes are positioned as close as possible to the object being detected to improve the sensitivity of the capacitive sensor. However, when the electrode body is brought close to the substrate while still exposed, short circuits may occur between the electrodes via aerosols generated by the substrate. For example, the wrapping paper forming the outermost shell of the substrate may be wetted by aerosols generated by the substrate, and short circuits may occur between the electrodes via the wrapping paper. In this case, it is difficult to accurately detect electrostatic capacitance.

[0062] Furthermore, in capacitive sensors installed in small devices such as aerosol generating device 100, electrode isolation is achieved by forming electrodes on an FPC (flexible printed circuit). However, the resins constituting the FPC (such as polyimide, polyethylene naphthalate (PEN), and polyethylene terephthalate (PET)) have low relative permittivity, which can lead to a decrease in the sensitivity of the capacitive sensor. Moreover, wrapping the FPC around a small cylindrical body, such as the receiving portion 140, is inherently difficult, and there is a risk that the sensitivity of the capacitive sensor may decrease depending on the accuracy of the wrapping.

[0063] <3. Technical Features>

[0064] <3.1. Configuration of Capacitive Sensor 10>

[0065] The following will refer to Figures 2 to 4 This describes the configuration used for the electrostatic capacitance-based detection rod matrix 150.

[0066] Figure 2 This is an end view of the receiving portion 140 taken in the vertical direction according to this embodiment. Figure 3 It is along the receiving portion 140 according to this embodiment Figure 2 The end face view taken by the cross section line AA is shown. Figure 4 It is shown Figure 2 and Figure 3 A perspective view of a specific example of electrode 11 shown.

[0067] In this embodiment, the insertion / extraction direction of the rod-shaped substrate 150 is also referred to hereinafter as the vertical direction. The rod-shaped substrate 150 is inserted in a downward direction and withdrawn in an upward direction. Furthermore, the receiving portion 140 includes an opening 142 on its upper side and a bottom portion 143 on its lower side.

[0068] like Figure 2 As shown, the receiving portion 140 is formed by connecting the upper first receiving portion 140a and the lower second receiving portion 140b. More specifically, the first receiving portion 140a is a cylindrical body with openings at both ends, while the second receiving portion 140b is a cylindrical body with a bottom. Then, the edges of the lower openings of the first receiving portion 140a and the edges of the openings of the second receiving portion 140b are connected to form the receiving portion 140.

[0069] The first housing portion 140a may be formed, for example, of a resin (such as polyetheretherketone (PEEK)) or of a material with low thermal conductivity. The second housing portion 140b may be formed, for example, of a metal (such as stainless steel (SUS)) or of a material with high thermal conductivity. (See reference) Figure 1The described heating unit 121 is arranged around the second receiving portion 140b and heats the rod-shaped substrate 150 through the second receiving portion 140b. The first receiving portion 140a may further include a shielding layer for blocking noise that may affect the electrode 11, the shielding layer covering the periphery of the electrode 11 (e.g., top, bottom, and outside).

[0070] like Figure 2 and Figure 3 As shown, the capacitive sensor 10 is arranged in the receiving portion 140 (particularly in the first receiving portion 140a). The process of constructing the receiving portion 140 by connecting the first receiving portion 140a and the receiving portion 140b, and the process of arranging the capacitive sensor 10 in the first receiving portion 140a, can be performed by means of insertion molding.

[0071] The capacitive sensor 10 detects the electrostatic capacitance of the internal space 141 in the receiving portion 140. The capacitive sensor 10 includes two electrodes 11 and detects the electrostatic capacitance of the space between the two electrodes 11, which partially overlaps with the internal space 141 in the receiving portion 140.

[0072] like Figures 2 to 4 As shown, electrode 11 is formed in a ring shape. Electrode 11 is then arranged such that the hollow portion of electrode 11 is located above the internal space 141 in the receiving portion 140, with the outer side of electrode 11 embedded in the receiving portion 140. In particular, the two electrodes 11 are spaced apart in the vertical direction. According to this configuration, capacitive sensor 10 is able to detect changes in electrostatic capacitance when rod-shaped substrate 150 passes through the hollow portion of electrode 11. Furthermore, according to this configuration, the step of wrapping FPC around the receiving portion 140 as is required for capacitive sensors formed by FPC, thus capacitive sensor 10 can be installed in aerosol generating device 100 without any loss of sensitivity.

[0073] The electrostatic capacitance detected by the capacitive sensor 10 varies depending on the presence of the rod-shaped matrix 150 between the electrodes 11. Specifically, the aerosol source contained in the rod-shaped matrix 150 has a high relative permittivity, thus the electrostatic capacitance varies significantly depending on the presence of the aerosol source between the electrodes 11. The control unit 116 can determine whether the rod-shaped matrix 150 has been inserted into the receiving portion 140 based on this change in electrostatic capacitance.

[0074] The control unit 116 can control the operation of the heating unit 121 based on the electrostatic capacitance detected by the capacitive sensor 10. For example, when the control unit 116 determines that the rod-shaped substrate 150 has been inserted into the receiving portion 140 based on the electrostatic capacitance detected by the capacitive sensor 10, it can activate the heating unit 121 to heat it. Such a function can also be referred to as an automatic start function.

[0075] like Figure 2 and Figure 3 As shown, electrode 11 includes a conductive body 12. A first portion 12a, constituting a part of the surface of the body 12 of electrode 11, is then covered by an insulating layer 13. For example, the body 12 of electrode 11 can be formed of any metal. For example, the insulating layer 13 can be formed of any ceramic.

[0076] like Figure 2 and Figure 3 As shown, electrode 11 is arranged such that a portion of electrode 11 is exposed within the interior space 141 of the receiving portion 140. This configuration allows the distance from electrode 11 to the detected rod-shaped substrate 150 to be minimized. Therefore, the sensitivity of the capacitive sensor 10 can be improved.

[0077] Here, as Figure 2 and Figure 3 As shown, the portion of electrode 11 exposed in the interior space 141 of the receiving portion 140 is covered by the insulating layer 13. That is, only the first portion 12a of electrode 11 covered by the insulating layer 13 is exposed in the interior space 141 of the receiving portion 140. With this configuration, short circuits between electrodes 11 via aerosols can be prevented.

[0078] The relative permittivity of the insulating layer 13 is preferably higher than that of the FPC formed from resin. Specifically, the relative permittivity of the insulating layer 13 is preferably 3 or greater. With this configuration, sensitivity can be improved compared to capacitive sensors formed from FPC.

[0079] For example, the body 12 of electrode 11 can be formed of aluminum (e.g., Al2O3). The insulating layer 13 can then be an alumina film (e.g., an alumina film) and can be formed by means of an alumina film treatment. Due to this configuration, electrode 11 can withstand the heat of insertion molding while also meeting the requirements for relative permittivity. Furthermore, alumina film treatment is more likely to produce a uniform film than other film formation methods (e.g., coating). That is, the sensitivity of capacitive sensor 10 can be improved by using an alumina film formed by means of an alumina film treatment as the insulating layer 13. The alumina film also has high abrasion resistance, and therefore can exhibit high durability to resist wear caused by the insertion / removal of the rod-shaped substrate 150.

[0080] The thickness of the insulating layer 13 is preferably 1 [µm] or greater but less than 20 [µm]. The insulating layer 13 exhibits suitable insulating properties provided its thickness is at least 1 [µm] or greater. However, if the insulating layer 13 is too thick, it becomes difficult to form properly (especially at the edges of the body 12), and cracks may form. These cracks can lead to reduced usability in several ways, such as reduced sensitivity of the capacitive sensor 10 due to dust accumulation in the cracks, and the generation of unpleasant odors. In this regard, by setting the thickness of the insulating layer 13 to less than 20 [µm], crack formation can be prevented, thereby preventing reduced usability.

[0081] Meanwhile, the thickness of the body 12 of electrode 11 can be 0.1 mm or greater than that but less than 4 mm. With this configuration, the capacitive sensor 10 can be made small enough to be installed in a device such as an aerosol generating device 100.

[0082] like Figure 4 As shown, the second portion 12b of the surface of the body 12 of the electrode 11 is covered by a flux layer 14, which is formed of a cladding material for assisting soldering. Examples of cladding materials constituting the flux layer 14 include Ni, Sn, and Au. A wire for supplying power to the electrode 11 is soldered to the flux layer 14. This configuration strengthens the connection between the electrode 11 and the wire.

[0083] Here, as Figure 4 As shown, electrode 11 may have a shank 26 protruding to the outside. A solder flux layer 14 may then be provided at the end of the shank 26. The solder flux layer 14 provided at the end of the shank 26 may protrude to the outside of the receiving portion 140, while electrode 11 is arranged within the receiving portion 140. With this configuration, electrode 11 and wires can be easily connected after insertion molding.

[0084] The thickness of the flux layer 14 is preferably 1 [µm] or greater than that but less than 10 [µm]. With this configuration, the connection between the electrode 11 and the wire can achieve the required strength.

[0085] The width of the second portion 12b covered by the flux layer 14 is preferably 0.1 mm or greater than that but less than 4 mm. Considering the thickness of the body 12 of the electrode 11, the area of ​​the second portion 12b covered by the flux layer 14 is preferably 0.01 mm² or greater than that but less than 16 mm². This configuration allows for a compact electrode 11 while achieving the required weld strength.

[0086] A third portion 12c, which belongs to neither the first portion 12a nor the second portion 12b, on the surface of the body 12 of electrode 11, can be exposed without being covered. This is because the third portion 12c is not exposed within the internal space 141 of the receiving portion 140, for example, because the third portion is embedded in and insulated by the first receiving portion 140a. Figure 4 As shown, the third part 12c can be disposed on the side opposite to the second part 12b on the outer circumferential surface of the electrode 11.

[0087] It should be noted that, Figure 4 In the illustrated example, a large portion of the body 12 of the electrode 11 is covered by the insulating layer 13, but this disclosure is not limited to this example. The portion of the body 12 of the electrode 11 that is at least exposed within the interior space 141 of the receiving portion 140 should be covered by the insulating layer 13. For example, 100% of the side surface (i.e., the inner circumferential surface) 12d of the body 12 of the electrode 11 on the central axis side of the receiving portion 140, and at least 50% of the area 12e on the upper and lower surfaces on the central axis side of the receiving portion 140, is preferably covered by the insulating layer 13. Here, the central axis of the receiving portion 140 is a vertically extending axis passing through the center of the interior space 141 of the receiving portion 140. With this configuration, when less than 50% of the interior of the electrode 11 is exposed within the interior space 141 of the receiving portion 140, the entire exposed portion is covered by the insulating layer 13.

[0088] <3.2. Method for manufacturing electrode 11>

[0089] The following will refer to Figures 5 to 9 Description for production Figure 4 The method of electrode 11 shown in the figure constitutes a capacitive sensor 10 used in aerosol generating device 100.

[0090] Figure 5 This is a diagram illustrating the first step S11 in the method for producing electrode 11. Figure 6 This is a diagram illustrating the second step S12 in the method for producing electrode 11. Figure 7 This is a diagram illustrating the third step S13 in the method for producing electrode 11. Figure 8 This is a diagram illustrating the fourth step S14 in the method for producing electrode 11. Figure 9 This is a diagram illustrating the fifth step S15 in the method for producing electrode 11.

[0091] Electrode 11 is used when a sheet-like base material is used as workpiece 20 by executing... Figures 5 to 9The process involves a series of steps. For example, the base material can be a sheet of uniform thickness formed from aluminum (e.g., A1050). Furthermore, the thickness of the base material can correspond to the thickness of the body 12 of the electrode 11, for example, 0.1 mm or greater than that but less than 4 mm.

[0092] In the first step S11, as Figure 5 As shown, a sheet-like base material is used as the workpiece 20, and the workpiece 20 is machined into the following shape: including a first annular member 21, a second annular member 22 surrounding the outside of the first annular member 21, and two connecting portions 23 (23a and 23b) connecting the first annular member 21 and the second annular member 22 at different locations. The first annular member 21 corresponds to the body 12 of the electrode 11. For example, cutting, pressing, or laser processing can be used as the machining method in the first step S11.

[0093] In the second step S12, as Figure 6 As shown, after completing the first step S11, the workpiece 20 is subjected to an alumina film treatment, and the surface of the workpiece 20 is covered with an alumina film. For example, this alumina film can be formed from an alumina film of oxalate. This alumina film corresponds to the insulating layer 13 of the electrode 11. That is, the thickness of the alumina layer corresponds to the thickness of the insulating layer 13 of the electrode 11, and is preferably, for example, 1 [µm] or greater than that value and less than 20 [µm]. The portion of the body 12 of the electrode 11 covered by the insulating layer 13 corresponds to the first portion 12a of the surface of the body 12 of the electrode 11.

[0094] In the third step S13, as Figure 7 As shown, after completing the second step S12, a through hole 24 is formed in the second annular member 22 in the workpiece 20, and one of the two connecting portions 23, 23a, is cut. A portion of the connecting portion 23a remains connected to the first annular member 21 and serves as a shank 26 protruding to the outside of the first annular member 21. This exposes the base material on the inner surface 25 of the through hole 24 and on the two cut surfaces 27 (27a and 27b) of the connecting portion 23a. It should be noted that the cut surface 27a on the shank 26 side of the two cut surfaces 27 of the connecting portion 23a corresponds to the second portion 12b of the surface of the body 12 of the electrode 11 described above. For example, cutting, pressing, or laser processing can be used as the machining method in the third step S13.

[0095] In the fourth step S14, as Figure 8As shown, after completing the third step S13, the inner surface 25 of the through hole 24 and the cut surface 27 of the cut connecting portion 23a are plated in the workpiece 20. Specifically, the plating can be electroplating, and can be, for example, Ni-Sn plating. A base material formed of aluminum is exposed on the inner surface 25 of the through hole 24 and the cut surface 27 of the connecting portion 23a. Therefore, current flows between the inner surface 25 of the through hole 24 and the cut surfaces 27 (27a and 27b) of the connecting portion 23a, allowing a flux layer 14, serving as a plating layer, to be formed on these surfaces. Specifically, the plating layer formed on the cut surface 27a at the end of the shank 26 corresponds to the flux layer 14 of the second portion 12b of the surface of the body 12 covering the electrode 11. That is, the thickness of the plating layer corresponds to the thickness of the flux layer 14, and is preferably, for example, 1 [µm] or greater than that value but less than 10 [µm].

[0096] In step S15, as Figure 9 As shown, after completing the fourth step S14, the uncut connecting portion 23b is cut in the workpiece 20. After completing the fifth step S15, the first annular member 21 constitutes the electrode 11. The cutting surface 28a on the first annular member 21 side of the two cutting surfaces 28 (28a and 28b) of the connecting portion 23b corresponds to the exposed, uncovered third portion 12c of the surface of the body 12 of the electrode 11. For example, cutting, pressing, or laser processing can be used as the machining method in the fifth step S15.

[0097] It should be noted that the above steps can be implemented by a computer that controls each machining equipment.

[0098] According to the above-described manufacturing method, electrodes 11 constituting the capacitive sensor 10 according to this embodiment can be appropriately manufactured.

[0099] According to the above-described production method, an alumina film, used as the insulating layer 13, is formed by alumina film treatment. Since the thickness of the insulating layer 13 is easily controlled, it can be formed thinner and more uniformly compared to forming the insulating layer 13 by coating. Furthermore, the relative permittivity of the alumina film is higher than that of the FPC, and therefore the sensitivity of the capacitive sensor 10 can be improved compared to a capacitive sensor formed by an FPC. The alumina film also has high abrasion resistance, thus exhibiting higher durability to resist wear caused by the insertion / removal of the rod-shaped substrate 150.

[0100] Alumina films are difficult to solder and possess insulating properties. Therefore, it is difficult to form a flux layer 14 on an alumina film. As another method for forming the flux layer 14, the desired area can be masked before alumina film treatment and then plated after the alumina film treatment. However, with this method, it is difficult to ensure production accuracy, for example, the mask may peel off during alumina film treatment.

[0101] In this regard, in the third step S13 and the fourth step S14, the flux layer 14 is formed by plating the aluminum portion exposed on the cut surface 27a at the end of the base material, which is formed by cutting the connecting portion 23a. Therefore, conductivity in the area required for the welding electrode 11 and the wire can be ensured, and the flux layer 14 can be formed with high precision.

[0102] Electroless plating is also a viable alternative plating method. However, it is difficult to ensure the insulation properties of electrode 11 through electroless plating because the entire structure will be plated, including the aluminum oxide layer.

[0103] In this regard, in the third step S13, the exposed surface of the base material used as the plated electrode contact is formed by forming the through hole 24 and cutting the connecting portion 23a. Therefore, plating can be performed, and the flux layer 14 can be formed in a small area (such as the cut surface 27a at the end of the shank 26).

[0104] <4. Supplementary Information>

[0105] The preferred embodiments of this disclosure have been described in detail above with reference to the accompanying drawings; however, this disclosure is not limited to these examples. It is obvious that those skilled in the art to which this disclosure pertains will conceive of various modifications or variations within the scope of the technical concept set forth in the claims, and such modifications and variations will naturally be understood to fall within the technical scope of this disclosure.

[0106] (1) First variant instance

[0107] In the examples described above, the electrodes 11 are formed in an annular shape and vertically spaced apart; however, this disclosure is not limited to this example. Two electrodes 11 can also be formed in a plate shape and arranged such that the plate surfaces face each other. (Refer to...) Figure 10 and Figure 11 Describe this variant instance.

[0108] Figure 10 It is an end view taken vertically from the receiving portion 140 of the first variant instance. Figure 11 It is along the receiving portion 140 of the first variant instance. Figure 10 The end face view taken by the cross-section line BB is shown. Figure 10 and Figure 11 As shown, the two electrodes 11 can be formed as curved plates bent along the inner circumferential shape of the receiving portion 140, and can be arranged facing the internal space 141 of the receiving portion 140, wherein the internal space 141 is located between the two electrodes. The electrodes 11 are formed, for example, by covering the body 12 (aluminum curved plate) with an insulating layer 13 (alumina film). A portion of the electrodes 11 may be exposed in the internal space 141 of the receiving portion 140, and all exposed portions should be covered by the insulating layer 13. The aforementioned technical problem can also be solved in the same manner as in the embodiments by the above-described variant examples.

[0109] (2) Second variant instance

[0110] The foregoing has described in detail the case where the receiving portion 140 and the electrode 11 are integrally formed, but this disclosure is not limited to this example. The electrode 11 can be formed on the FPC and can be arranged on the receiving portion 140. (See reference...) Figure 12 and Figure 13 Describe this variant instance.

[0111] Figure 12 It is an end view taken vertically from the receiving portion 140 of the second variant instance. Figure 13 It is along the accommodating portion 140 of the second variant instance. Figure 12 The end face view shown is taken from the cross-section line CC. Figure 12 and Figure 13 As shown, the two electrodes 11 are formed as curved plates that bend along the outer circumference of the receiving portion 140. The two electrodes 11 are then positioned facing the receiving portion 140, which is disposed between the two electrodes such that the inner side of the electrodes 11 is located on the outer side of the receiving portion 140. In particular, the two electrodes 11 are spaced apart in a direction orthogonal to the vertical direction (i.e., the radial direction of the receiving portion 140).

[0112] For example, electrode 11 is attached to FPC substrate 15 formed of resin (such as polyimide or liquid crystal polymer), and then secured to the outside of first receiving portion 140a by, for example, wrapping electrode 11 (including FPC substrate 15) around first receiving portion 140a. Here, first receiving portion 140a is formed of ceramic, particularly high dielectric and insulating ceramic (such as alumina or zirconium oxide).

[0113] That is, in this variant example, the first receiving portion 140a constitutes an insulating layer 13 formed of ceramic. The electrode 11 is then arranged to contact the outside of the first receiving portion 140a constituting the insulating layer 13 formed of ceramic. In particular, the electrode 11 and the high-dielectric and insulating first receiving portion 140a are preferably arranged to adhere tightly.

[0114] With this configuration, when the electrodes 11 are also formed on the FPC substrate 15, the capacitive sensor 10 can detect changes in electrostatic capacitance as the rod-shaped matrix 150 passes through the space between the two electrodes 11. In particular, with this configuration, the capacitive sensor 10 can be mounted in the aerosol generating device 100 in a way that suppresses any decrease in sensitivity that might occur if the first receiving portion 140a is formed of a resin material.

[0115] Furthermore, in this configuration, a shielding layer for blocking noise that would affect electrode 11 in the manner described above can be integrally formed on the FPC substrate 15 along with electrode 11. This configuration is effective when electrode 11 is susceptible to noise, and it is important to block noise through the shielding layer.

[0116] Radiated noise from heating unit 121 can be cited as an example of noise. To block radiated noise, it is preferable to... Figure 12 A tortuous metal shielding layer is arranged below the electrode 11 (i.e., between the electrode 11 and the heating unit 121 arranged on the outer circumference of the second receiving portion 140b).

[0117] Another example of noise that can be exemplified is noise from a person on the side of opening 142, which is generated during insertion of the rod-shaped matrix 150 or during inhalation. To block noise from a person, it is preferable to... Figure 12 A tortuous surface metal shielding layer is arranged above the electrode 11 (i.e., between the electrode 11 and the opening 142).

[0118] In order to block the above-mentioned type of noise, in addition to the shielding layers above and below the electrode 11, a cylindrical metal shielding layer is more preferably arranged to cover the outside of the electrode 11.

[0119] (3) Other matters

[0120] In the example described above, a capacitive sensor 10 is formed using two electrodes 11; however, this disclosure is not limited to this example. The number of electrodes 11 constituting the capacitive sensor 10 may be three or more.

[0121] In the examples described above, the body 12 of electrode 11 is formed of aluminum, but this disclosure is not limited to this example. The body 12 of electrode 11 may be formed of another metal, such as stainless steel (SUS). Alternatively, the body 12 of electrode 11 may be formed of indium tin oxide or a non-metal (such as a conductive polymer).

[0122] In the examples described above, the insulating layer 13 is an alumina film formed by an alumina film treatment; however, this disclosure is not limited to this example. The insulating layer 13 can be formed by coating with silicon carbide or glass.

[0123] In the examples described above, the heating unit 121 is a load for generating heat, which is energy used to heat the aerosol source housed in the housing portion 140 of the rod-shaped matrix 150. The load is not limited to the heating unit 121. When the means of heating the aerosol source is induction heating, the load may be an induction coil for generating a magnetic field, which is energy used to inductively heat the sensor adjacent to the aerosol source.

[0124] In the example described above, the automatic startup function is triggered by detecting the insertion of the rod-shaped substrate 150; however, this disclosure is not limited to this example. The wake-up function (recovery from low-power standby mode) can also be triggered by detecting the insertion of the rod-shaped substrate 150.

[0125] In the above example, the control unit 116 detects the insertion of the rod-shaped matrix 150 based on changes in electrostatic capacitance; however, this disclosure is not limited to this example. The control unit 116 can also detect the state of the rod-shaped matrix 150 or its aspiration based on changes in electrostatic capacitance during aspiration.

[0126] It should be noted that the series of processes performed by each device described in this specification can be implemented using software, hardware, or any combination of software and hardware. For example, the program constituting the software is pre-stored on a recording medium (more specifically, a non-transitory computer-readable storage medium) located internally or externally to each device. Then, when these programs are executed, for example, by a computer used to control each device described in this specification, these programs are read into random access memory (RAM) and executed by means of processing circuitry such as a central processing unit (CPU). This recording medium is, for example, a magnetic disk, optical disk, magneto-optical disk, or flash memory. Furthermore, the computer program can be distributed, for example, via a network without using a recording medium. Additionally, the computer can be an application-specific integrated circuit (ASIC), a general-purpose processor that performs functions by reading software programs, or a computer on a server used for cloud computing. Furthermore, the series of processes performed by each device described in this specification can be centrally processed by a single computer or processed in a distributed manner by multiple computers. Additionally, in the above embodiments, two or more communication means existing in a single device can be physically implemented using a single medium.

[0127] Furthermore, the processes described using flowcharts or sequence diagrams in this specification do not necessarily have to be implemented in the order depicted. Some processing steps can be implemented in parallel. In addition, additional processing steps can be used, and some processing steps can be omitted.

[0128] It should be noted that configurations such as the following also fall within the scope of this disclosure. (1)

[0130] An aerosol generating apparatus, the aerosol generating apparatus comprising:

[0131] A containment section for containing a matrix containing an aerosol source within its internal space;

[0132] A load, which generates energy for heating an aerosol source contained within the containment portion; and

[0133] A capacitive sensor comprising multiple electrodes for detecting the electrostatic capacitance of the internal space within the housing portion.

[0134] in,

[0135] These electrodes comprise a body formed of metal, and

[0136] The first part of the surface of the main body of these electrodes is covered by an insulating layer formed of ceramic. (2)

[0138] As disclosed in (1) above, the aerosol generating device,

[0139] These electrodes are arranged such that a portion of them is exposed within the interior space of the receiving portion, and

[0140] The portions of these electrodes exposed within the interior space of the housing are covered by the insulating layer. (3)

[0142] As disclosed in (2) above, the aerosol generating device,

[0143] The receiving portion is a cylindrical body with an opening on its upper side, allowing for vertical insertion / removal of the substrate.

[0144] The insulating layer covers 100% of the body of these electrodes on the side of the central axis of the receiving portion and at least 50% of the area above and below the central axis of the receiving portion. (4)

[0146] As disclosed in any of (1) to (3) above, the aerosol generating device,

[0147] The relative permittivity of the insulating layer is 3 or greater. (5)

[0149] As disclosed in (4) above, the aerosol generating device,

[0150] The main body of these electrodes is made of aluminum, and

[0151] The insulating layer is an aluminum oxide film. (6)

[0153] As disclosed in (4) above, the aerosol generating device,

[0154] The insulating layer is formed by coating silicon carbide or glass. (7)

[0156] As disclosed in any of (1) to (6) above, the aerosol generating device,

[0157] The thickness of the insulating layer is 1 [µm] or greater than that value but less than 20 [µm]. (8)

[0159] As disclosed in any of (1) to (7) above, the aerosol generating device,

[0160] The thickness of the main body of these electrodes is 0.1 mm or greater than that but less than 4 mm. (9)

[0162] As disclosed in any of (1) to (8) above, the aerosol generating device,

[0163] The second part of the surface of the main body of these electrodes is covered by a flux layer, which is formed of a cladding material used to assist welding. (10)

[0165] As disclosed in (9) above, the aerosol generating device,

[0166] The area of ​​the second part is 0.01 mm² or greater than that but less than 16 mm². (11)

[0168] As disclosed in any of (1) to (10) above, the aerosol generating device,

[0169] These electrodes are formed in a ring shape, and

[0170] The multiple electrodes are spaced apart in the vertical direction. (12)

[0172] As disclosed in (1) above, the aerosol generating device,

[0173] A portion of the receiving portion constitutes an insulating layer formed of ceramic, and

[0174] These electrodes are arranged to contact the outside of the receiving portion that constitutes the insulating layer formed of ceramic. (13)

[0176] As disclosed in any of (1) to (12) above, the aerosol generating device,

[0177] The aerosol generating device further includes a control unit for controlling the operation of the load based on the electrostatic capacitance detected by the capacitive sensor. (14)

[0179] A method for manufacturing electrodes constituting a capacitive sensor used in an aerosol generating apparatus, the method comprising:

[0180] First step: Use a sheet of aluminum as the workpiece and machine the workpiece into the following shape: including a first annular member, a second annular member surrounding the outside of the first annular member, and two connecting portions connecting the first annular member and the second annular member at different locations;

[0181] The second step: After completing the first step, the workpiece is treated with an aluminum oxide film.

[0182] Third step: After completing the second step, a through hole is formed in the second annular member of the workpiece and one of the two connecting parts is cut.

[0183] Fourth step: After completing the third step, plate the inner surface of the through hole and the cut surface of the cut connecting portion in the workpiece; and

[0184] Fifth step: After completing the fourth step, cut the uncut connecting parts in the workpiece.

[0185] List of reference numerals

[0186] 100 Aerosol Generating Device

[0187] 111 Power Supply Unit

[0188] 112 Sensor Unit

[0189] 113 Notification Unit

[0190] 114 memory cells

[0191] 115 Communication Unit

[0192] 116 Control Unit

[0193] 121 Heating Unit

[0194] 140 Retaining sections (140a: first retaining section, 140b: second retaining section)

[0195] 141 Interior Space

[0196] 142 Opening

[0197] 143 Bottom section

[0198] 144 Thermal Insulation Components

[0199] 150 rod-shaped substrate

[0200] 151 Matrix Part

[0201] 152 Suction nozzle section

[0202] 10. Capacitive Sensor

[0203] 11 electrodes

[0204] 12 main body

[0205] 12a Part 1

[0206] 12b Part Two

[0207] 12c Part 3

[0208] 13 Insulation layer

[0209] 14. Solder flux layer

[0210] 15 FPC substrate

[0211] 20 workpieces

[0212] 21 First Annular Component

[0213] 22 Second Ring Component

[0214] 23. Linking section

[0215] 24 through holes

[0216] 25 inside

[0217] 26 handles

[0218] Cut surfaces 27 and 28.

Claims

1. An aerosol generating device, the aerosol generating device comprising: A containment portion for containing a matrix containing an aerosol source within its internal space; The load is used to generate energy for heating the aerosol source contained in the containment portion; as well as A capacitive sensor comprising multiple electrodes for detecting the electrostatic capacitance of the internal space within the housing portion. in, These electrodes comprise a body formed of metal, and The first part of the surface of the main body of these electrodes is covered with an insulating layer made of ceramic.

2. The aerosol generating device as described in claim 1, in, These electrodes are arranged such that a portion of these electrodes is exposed within the interior space of the housing, and The portions of these electrodes exposed within the interior space of the housing are covered by the insulating layer.

3. The aerosol generating device as described in claim 2, in, The receiving portion is a cylindrical body with an opening on its upper side, which allows for the vertical insertion / removal of the substrate. The insulating layer covers 100% of the body of these electrodes on the side of the central axis of the receiving portion and at least 50% of the area above and below the central axis of the receiving portion.

4. The aerosol generating apparatus according to any one of claims 1 to 3, in, The relative permittivity of the insulating layer is 3 or greater.

5. The aerosol generating apparatus as described in claim 4, in, The main body of these electrodes is made of aluminum, and The insulating layer is an aluminum oxide film.

6. The aerosol generating apparatus as described in claim 4, in, The insulating layer is formed by coating silicon carbide or glass.

7. The aerosol generating apparatus according to any one of claims 1 to 6, in, The thickness of the insulating layer is 1 [µm] or greater than that value but less than 20 [µm].

8. The aerosol generating apparatus according to any one of claims 1 to 7, in, The thickness of the main body of these electrodes is 0.1 mm or greater than that but less than 4 mm.

9. The aerosol generating apparatus according to any one of claims 1 to 8, in, The second part of the surface of the main body of these electrodes is covered by a flux layer, which is formed of a cladding material used to assist welding.

10. The aerosol generating apparatus as described in claim 9, in, The area of ​​the second part is 0.01 mm² or greater than that but less than 16 mm².

11. The aerosol generating apparatus according to any one of claims 1 to 10, in, These electrodes are formed in a ring shape, and The multiple electrodes are spaced apart in the vertical direction.

12. The aerosol generating apparatus as described in claim 1, in, A portion of the housing constitutes an insulating layer formed of ceramic, and These electrodes are arranged to contact the outside of the receiving portion that constitutes the insulating layer formed of ceramic.

13. The aerosol generating apparatus according to any one of claims 1 to 12, in, The aerosol generating device further includes a control unit for controlling the operation of the load based on the electrostatic capacitance detected by the capacitive sensor.

14. A method for producing electrodes constituting a capacitive sensor used in an aerosol generating apparatus, the method comprising: First step: Use a sheet of aluminum as the workpiece and machine it into the following shape: It includes a first annular member, a second annular member surrounding the outside of the first annular member, and two connecting portions connecting the first annular member and the second annular member at different locations; The second step: After completing the first step, the workpiece is treated with an aluminum oxide film. Third step: After completing the second step, a through hole is formed in the second annular member of the workpiece and one of the two connecting parts is cut. Fourth step: After completing the third step, plate the inner surface of the through hole and the cut surface of the cut connecting part in the workpiece. as well as Fifth step: After completing the fourth step, cut the uncut connecting parts in the workpiece.

Images