Aerosol-forming unit, atomization assembly, manufacturing process, and heater

Abstract

An aerosol-forming unit, an atomization assembly, a manufacturing process, and a heater. An atomization assembly (11a) comprises a solid aerosol-forming substrate (111), a heating body (112), and an electrode (113); the solid aerosol-forming substrate (111) is a flexible sheet; the heating body (112) comprises a flexible first wire (1121) stitched on the solid aerosol-forming substrate (111), and the first wire (1121)is made of a conductive material; the electrode (113) comprises at least two conductive electrodes (1131) respectively electrically connected to the first wire (1121). According to the atomization assembly, the heating body is formed by stitching a wire, thereby facilitating the use of a thinner heating wire; since the cross-sectional area can be made smaller,the heating speed is high, heat diffusion is also fast, and a solid aerosol-forming substrate can be driven by means of a lower power, thereby facilitating energy conservation; forming the heating body by stitching a wire also facilitates large-scale production.

Description

FIELD

[0001] The present invention relates to the field of atomization, and more specifically, to an aerosol-forming unit, an atomization assembly, manufacturing processes, and a heater.BACKGROUND

[0002] Low-temperature Heat Not Burning, as a new atomization method, significantly reduces harmful substances compared to traditional burning atomization. As a result, it has gained acceptance from users both domestically and internationally in recent years. Currently, most Heat Not Burning atomization systems on the market use integrated heating elements and atomization devices, while the rod-shaped atomization medium being disposable. However, several issues remain during use, such as carbon deposition and dirt accumulation on the heating sheet of insert-type heating methods, as well as the fragility of the heating sheet, which is difficult to clean.

[0003] In addition, when heating the rod-shaped atomization medium externally, there are problems with poor contact between the heating element and the rod-shaped atomization medium, leading to uneven heating. A common issue is that the contact area between the heating element and the rod-shaped atomization medium is small, resulting in slower heat transfer from the heating element to the rod-shaped atomization medium. The part near the heating element tends to get scorched, while the area farther away from the heating element remains unheated. This results in low efficiency and long waiting times for users. Therefore, improvements are needed to address these issues.SUMMARY

[0004] The technical problem to be solved by the present invention is to provide an improved aerosol-forming unit, an atomization assembly, manufacturing processes, and a heater, addressing the defects such as uneven heating and slow speed in the prior art.

[0005] The technical solution adopted by the present invention to solve the technical problem is: constructing an atomization assembly, including a solid aerosol-forming substrate, a heating element and electrodes.

[0006] The solid aerosol-forming substrate is flexible and sheet-shaped.

[0007] The heating element includes a flexible first wire sewn onto the solid aerosol-forming substrate, where the first wire is made of a conductive material.

[0008] The electrodes include at least two conductive electrodes electrically connected to the first wire respectively.

[0009] In some embodiments, the first wire includes at least one seam portion passing from a first side to a second side, opposite to the first side, and then returning to the first side.

[0010] In some embodiments, the seam portion includes a first section, a third section, and a second section connected sequentially, with the third section located on the second side , and the first section and second section passing through the solid aerosol-forming substrate respectively; or, the seam portion includes a first section and a second section connected sequentially and arranged side by side, with the first section and the second section located within the same sewing hole.

[0011] In some embodiments, the first wire includes a connecting section located on the first side, and connecting between the first section and the second section of two adjacent seam portions.

[0012] In some embodiments, the heating element includes several first wires located on the same side of the solid aerosol-forming substrate, and each of the first wires is interwoven and / or arranged side by side; or, the wiring path of the first wire on the solid aerosol-forming substrate is bent or curved.

[0013] In some embodiments, the atomization assembly further includes a heat-conducting layer provided on at least one side of the solid aerosol-forming substrate and used for thermal conduction. The heat-conducting layer is made of an insulating material.

[0014] In some embodiments, at least one of the conductive electrodes is sewn onto the solid aerosol-forming substrate using a conductive wire.

[0015] In some embodiments, the conductive electrode is provided with a conductive layer.

[0016] In some embodiments, the conductive layer is formed from conductive paste or conductive adhesive.

[0017] In some embodiments, the conductive layer is a metal sheet.

[0018] In some embodiments, the metal sheet is sewn onto the solid aerosol-forming substrate.

[0019] In some embodiments, both ends of the first wire are electrically connected to the conductive electrodes respectively, and the electrodes further include at least one conductive electrode connected between the two ends of the first wire.

[0020] In some embodiments, the conductive electrode further includes an extending portion that extends out of the solid aerosol-forming substrate.

[0021] In some embodiments, the solid aerosol-forming substrate includes a heating section and a covering section. The heating element is arranged in the heating section, and the electrodes are located in the covering section.

[0022] In some embodiments, the heating element further includes a flexible second wire sewn onto the solid aerosol-forming substrate. The first wire and the second wire are located on opposite sides of the solid aerosol-forming substrate respectively, and the first wire and the second wire are interwoven with each other.

[0023] An aerosol-forming unit, including an atomization unit formed by winding and / or bending the aforementioned atomization assembly, with the electrodes exposed.

[0024] In some embodiments, the aerosol-forming unit is columnar or block-shaped.

[0025] In some embodiments, the solid aerosol-forming substrate further includes a covering section used to cover the outer periphery of the atomization unit, with the electrodes located in the covering section.

[0026] In some embodiments, the aerosol-forming unit includes a filter mouthpiece arranged at one end of the atomization unit.

[0027] In some embodiments, both the atomization unit and the filter mouthpiece are surrounded by a supporting cylinder.

[0028] In some embodiments, the supporting cylinder is rolled supporting paper.

[0029] In some embodiments, the aerosol-forming unit further includes a filter sheet arranged at the end of the atomization unit far away from the filter mouthpiece.

[0030] In some embodiments, the conductive electrodes are arranged along the circumferential direction of the aerosol-forming unit; or, the conductive electrodes are led out from the ends of the heating element and arranged at the end or sidewall of the aerosol-forming unit.

[0031] A manufacturing process of the atomization assembly, including the following steps: providing a flexible solid aerosol-forming substrate and a flexible first wire, and the first wire is made of a conductive material; sewing the first wire onto the solid aerosol-forming substrate, wherein the first wire is sewn onto the solid aerosol-forming substrate to form a heating element; and arranging a conductive electrode electrically connected to the heating element on the solid aerosol-forming substrate.

[0032] In some embodiments, the first wire passes from the first side to the second side and then returns to the first side through the same sewing hole; or, the first wire passes from the first side to the second side and then along the second side and back to the first side.

[0033] In some embodiments, it further includes the step of: providing a flexible second wire, and sewing the first wire and the second wire from both sides of the solid aerosol-forming substrate respectively, wherein the first wire and second wire is interwoven into the solid aerosol-forming substrate to form the heating element.

[0034] In some embodiments, at least one of the conductive electrodes is formed by sewing; or, at least one conductive electrode is formed by sewing and a conductive layer is provided on the sewn conductive electrode.

[0035] In some embodiments, the solid aerosol-forming substrate includes a heating section and a covering section, with the heating element arranged in the heating section and the electrodes arranged in the covering section.

[0036] In some embodiments, the solid aerosol-forming substrate is formed by slitting liquid-conducting raw material. After the heating element is sewn onto the liquid-conducting raw material and the conductive electrodes are arranged, the atomization assembly is formed by slitting.

[0037] In some embodiments, when sewing the first wire, at least one seam portion passing from the first side to the second side opposite to the first side and then returning to the first side is formed when sewing the first wire.

[0038] A manufacturing process of the aerosol-forming unit, including the following steps: winding and / or bending the atomization assembly to form the atomization unit, with the conductive electrodes exposed.

[0039] In some embodiments, a filter mouthpiece is provided at one end of the atomization unit.

[0040] In some embodiments, the solid aerosol-forming substrate includes a covering section, the electrodes are located on the covering section, and the covering section covers the outer periphery of the atomization unit.

[0041] In some embodiments, part or all of the conductive electrodes include an extending portion that extends out of the solid aerosol-forming substrate. The manufacturing process further includes the following steps: winding the extending portion along the circumferential direction of the aerosol-forming unit, or arranging the extending portion at the end or sidewall of the heating element after being led out from the end of the heating element.

[0042] A heater, including a working position for placing the aerosol-forming unit, wherein the working position is provided with a contact point corresponding to the position of the conductive electrode, to energize the heating element and make the heating element generate heat.

[0043] By implementing the aerosol-forming unit, atomization assembly, manufacturing processes, and heater of the present invention, it has following beneficial effects: the heating element formed by sewing wires, which is conducive to adopt finer heating wires. Since the cross-sectional area can be made smaller, the heat-up speed is fast, and heat dissipation is also rapid. The solid aerosol-forming substrate can be driven by means of a lower power, thereby facilitating energy conservation. Additionally, forming the heating element by the wire-sewing method is conducive to large-scale production.BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The present invention will be further explained in conjunction with the drawings and embodiments. In the drawings: Figure 1 is a perspective view of the aerosol-forming unit in an embodiment of the present invention. Figure 2 is a sectional view of the aerosol-forming unit in Figure 1. Figure 3 is an exploded view of the aerosol-forming unit in Figure 1. Figure 4 is a sectional view of the aerosol-forming unit in Figure 1 before it is inserted into the heater. Figure 5 is a sectional view of the atomization assembly formed by arranging the heating element and conductive electrodes on the solid aerosol-forming substrate. Figure 6 is a perspective view of the atomization assembly in Figure 4. Figure 7 is a cross-sectional view of the aerosol-forming unit formed by rolling the atomization assembly. Figure 8 is a cross-sectional view of the aerosol-forming unit formed by folding the atomization assembly. Figure 9 is a schematic view showing the seam portion in Figure 5 passing along the second side and then through the solid aerosol-forming substrate to the first side. Figure 10 is a schematic view of the first wire folded back. Figure 11 is a schematic view of a plurality of the first wires interwoven. Figure 12 is a schematic view showing the heating element including the first wire and the second wire formed by sewing on its both sides. Figure 13 is an unfolded schematic view of the solid aerosol-forming substrate when the heating element and two conductive electrodes are provided thereon. Figure 14 is an unfolded schematic view of the solid aerosol-forming substrate when the heating element and three conductive electrodes are provided thereon. Figure 15 is an unfolded schematic view of the conductive electrodes on the solid aerosol-forming substrate, including an extending portion extending out of the solid aerosol-forming substrate. Figure 16 is a schematic view of the conductive electrodes of the aerosol-forming unit when arranged on the sidewall surface. Figure 17 is a schematic view of the conductive electrodes of the aerosol-forming unit when arranged on the sidewall surface of the same end. Figure 18 is a schematic view of the conductive electrodes of the aerosol-forming unit when arranged on the sidewall surface and the end surface respectively. Figure 19 is a schematic view of the heat-conducting layer on one side of the solid aerosol-forming substrate of the atomization assembly. Figure 20 is a schematic view of the heat-conducting layers on both sides of the solid aerosol-forming substrate of the atomization assembly. DETAILED DESCRIPTION

[0045] In order to have a clearer understanding of the technical features, objectives, and effects of the present invention, the specific embodiments of the invention will be described in detail with reference to the drawings.

[0046] As shown in Figures 1 to 3, an aerosol-forming unit 10 in a preferred embodiment of the present invention includes an atomization unit 11 formed by winding the atomization assembly 11a, a filter mouthpiece 12 arranged at one end of the atomization unit 11, a filter sheet 13 arranged at one end of the atomization unit 11 far from the filter mouthpiece 12, and a supporting cylinder 14 covering the outer sides of the atomization unit 11 and the filter mouthpiece 12. The filter mouthpiece 12 is mainly in contact with the human body, filtering impurities and large particles, and cooling, ensuring that the temperature of the vapor entering the mouth is moderate. The function of the filter sheet 13 is to prevent large particles such as dust from entering, as well as to prevent tobacco shreds and other substances from leaking out of the aerosol-forming unit 10.

[0047] As shown in Figure 4, the supporting cylinder 14 can connect the atomization unit 11 and the filter mouthpiece 12 together. Preferably, the supporting cylinder 14 is rolled supporting paper, which provides the aerosol-forming unit 10 with a certain degree of hardness. This ensures that the aerosol-forming unit 10 can be smoothly inserted into the heater 20 and that the atomization unit 11 is supported, positioning the electrode 113 of the atomization unit 11. This allows for a good contact between the contact point 211 on the heater 20 and the electrode 113 on the aerosol-forming unit 10.

[0048] As shown in Figures 5 and 6, the atomization assembly 11a includes a solid aerosol-forming substrate 111, a heating element 112, and electrodes 113. The solid aerosol-forming substrate 111 is flexible and sheet-shaped. Preferably, the extracted fibers of the herbaceous plant can be made into a flexible, bendable paper-shaped or sheet-shaped solid aerosol-forming substrate 111. As shown in Figures 7 and 8, the atomization unit 11 can be rolled or folded to form a specific shape such as cylindrical or block shapes, and then assembled with the filter mouthpiece 12 and other components into a cylindrical or block-shaped aerosol-forming unit 10, which can be inserted into the heater 20.

[0049] The electrode 113 of the atomization unit 11 is exposed. After the aerosol-forming unit 10 is inserted into the heater 20, the electrode 113 makes contact with the contact points inside the heater 20, to supply power to the atomization unit 11 for atomization. It is understood that the atomization assembly 11a can also be bent to form the atomization unit 11, or a combination of rolling and bending can be used to form the atomization unit 11.

[0050] The heating element 112 includes a flexible first wire 1121 sewn onto the solid aerosol-forming substrate 111. The first wire 1121 is made of conductive material and is sewn and fixed onto the sheet-shaped solid aerosol-forming substrate 111. The electrodes 113 include two conductive electrodes 1131, which are electrically connected to the first wire 1121 respectively. The conductive electrodes 1131 can make contact with the contact points on the heater 20, such that the heater 20, after supplying power to the heating element 112, heats the solid aerosol-forming substrate 111 to generate the aerosol.

[0051] As shown in Figures 5 and 6, in some embodiments, the first wire 1121 includes a seam portion 1122 passing from a first side A to a second side B opposite to the first side A and then returning to the first side A. The seam portion 1122 allows the first wire 1121 to be sewn onto the solid aerosol-forming substrate 111, so that the first wire 1121 and the solid aerosol-forming substrate 111 are better adhered to each other, and the connection is stable and not easily loosened. According to the stitching length of the first wire 1121, one or other number of the seam portion 1122 can be arranged along the stitching direction and sewn onto the solid aerosol-forming substrate 111.

[0052] It is understood that, in some embodiments, the seam portion 1122 may include a first section 1122a and a second section 1122b connected sequentially. The first section 1122a and the second section 1122b are located in the same sewing hole. In other words, the seam portion 1122, after passing through the solid aerosol-forming substrate 111 from the first side A to the second side B, returns through the original sewing hole to the first side A. This arrangement buries the seam portion 1122 inside the solid aerosol-forming substrate 111, thereby heating the solid aerosol-forming substrate 111.

[0053] Generally, the first wire 1121 is sewn in a certain path to form the heating element 112, with several seam portions 1122, to ensure a stable connection with the solid aerosol-forming substrate 111 and a sufficient heating coverage. Additionally, the first wire 1121 further includes a connecting section 1123 located on the first side A and connected between two adjacent seam portions 1122, allowing the heating element 112 to extend over a longer length along the first side A, thus increasing the heating coverage. Of course, only one seam portion 1122 could be arranged, with both ends of the heating element 112 being fixed to the solid aerosol-forming substrate 111 by the electrode 113.

[0054] The heating element formed by sewing wires, which is conducive to adopt finer heating wires. Since the cross-sectional area can be made smaller, the heat-up speed is fast, and heat dissipation is also rapid. The solid aerosol-forming substrate can be driven by means of a lower power, thereby facilitating energy conservation. Forming the heating element by the wire-sewing method is conducive to mass and large-scale production. The manufacturing process for filamentous wire typically adopts die-hole drawing forming, ensuring precise size control and more stable resistance of the heating element 112.

[0055] The wire diameter is usually quite fine, which is typically a round wire with a cross-sectional area of ϕ 0.2mm. The heating element 112 formed by sewing the wire onto the solid aerosol-forming substrate 111 and the solid aerosol-forming substrate 111 are formed to an integrated structure. The heating element 112 is fixed onto the solid aerosol-forming substrate 111, allowing the solid aerosol-forming substrate 111 to serve as a carrier for the heating element 112, which prevents deformation of the heating element 112 formed by the wire, ensures good adhesion between the heating element 112 and the solid aerosol-forming substrate 111, and facilitates large-scale automated production.

[0056] The materials for the first wire 1121 can include: nickel-based alloys, stainless steel alloys, chromium-containing alloys, titanium-containing alloys, tungsten-containing alloys, molybdenum-containing alloys, iron-containing alloys, tin-containing alloys, and other metallic materials. It can also include non-metallic conductive materials such as carbon fiber strands, graphite fiber strands, or an ultra-fine conductive metal wire and conductive non-metal wire one or both of which are twisted or braided together to form a filament. The conductive metal wires and non-metal wires are relatively thin, with diameters ranging from a few micrometers to several dozen micrometers, and the specific diameters are not limited.

[0057] Further, as shown in Figure 9, in other embodiments, the seam portion 1122 includes a first section 1122a, a third section 1122c and a second section 1122b connected sequentially. The third section 1122c is located on the second side B, and the first section 1122a and the second section 1122b pass through the solid aerosol-forming substrate 111 respectively. During sewing, the first wire 1121 passes from the first side A through the solid aerosol-forming substrate 111 to the second side B, then a segment of the first wire 1121 is led out along the second side B, and then it passes through the solid aerosol-forming substrate 111 and back to the first side A, and loops the above steps. The first wire 1121 is sewn onto the solid aerosol-forming substrate 111, ensuring that both sides of the solid aerosol-forming substrate 111 are heated. When the heating element 112 heats up, it allows for the heating and atomization of the solid aerosol-forming substrate 111. Of course, the length of the third section 1122c can be shortened, and the wire may not necessarily pass through the second side B. It could slightly protrude from the second side B and return to the first side A along the sewing hole where the first section 1122a is located.

[0058] It can be understood that, as shown in Figure 10, the first wire 1121 can be bent. The bending can be performed in a back-and-forth manner, or in a wave-patterned manner. Additionally, the wire can be curved, and the specific curving method is not limited.

[0059] Furthermore, as shown in Figure 11, to increase the area of heat radiation, the heating element 112 includes several first wires 1121 located on the same side of the solid aerosol-forming substrate 111. Preferably, the number of the first wires 1121 may be two or more. Each of the first wires 1121 can be interwoven to form a mesh structure, or each of the first wires 1121 can be arranged side by side or in a combination of interwoven and side-by-side.

[0060] Preferably, in some embodiments, the heating element 112 also includes a flexible second wire 1124 sewn onto the solid aerosol-forming substrate 111. The first wire 1121 and the second wire 1124 are located on opposite sides of the solid aerosol-forming substrate 111 respectively. The first wire 1121 and the second wire 1124 are interwoven, making the connection between the heating element 112 and the solid aerosol-forming substrate 111 more stable. Typically, the second wire 1124 can be made of an insulating material, allowing the side where the first wire 1121 is located of the heating element 112 to heat up, thereby slowing the heating rate, ensuring uniform heat distribution, and preventing the generation of harmful substances due to localized high temperatures within the aerosol-forming unit 10. Of course, the second wire 1124 could also be made of conductive material, and the first wire 1121 and second wire 1124 can be selected to have a low resistance to avoid excessive temperature rise and rapid heating.

[0061] The sheet-shaped solid aerosol-forming substrate 111 is made from herbaceous plants by extracting flavor plant fibers, and processed through methods such as papermaking, resulting in a fabric-like or paper-like material. This material has certain hygroscopic properties. When heated, the material generates an aerosol with an herbaceous flavor. Additionally, by mixing smoke generating solvents such as propylene glycol, glycerol, and edible essence into a solvent that can be atomized, the solvent and other substances are absorbed into the herbaceous plant fibers. When the heating element 112 generates heat to the required temperature for solvent atomization, the aerosol is produced.

[0062] Since the first wire 1121 is relatively soft, the sheet-shaped solid aerosol-forming substrate 111 provides support strength for the wire. The heating element 112 and the aerosol-forming unit 10 form an integrated structure, which allows for higher thermal efficiency of the heating element 112, resulting in better utilization and sufficient heating of the heated solid aerosol-forming substrate 111. Additionally, the aerosol-forming unit 10 can be discarded after use, avoiding the need for cleaning and the risk of damage to the power supply equipment, comparing to piercing-type heating methods. At the same time, the stitching positions and depths are more uniform, ensuring that the generated heat is distributed evenly. This results in more uniform heating of the aerosol-forming unit 10 and prevents localized high temperatures within the unit, thus avoiding the generation of harmful substances.

[0063] Preferably, as shown in Figure 13, both ends of the first wire 1121 are electrically connected to conductive electrodes 1131. To allow the heating element 112 to heat in segments, further as shown in Figure 14, the electrode 113 may also include one or more conductive electrodes 1131 connected between the two ends of the first wire 1121. By connecting conductive electrodes 1131 at different positions, different sections of the heating element 112 can participate in heating. For example, the heating element 112 can be divided into an upper heating section and a lower heating section, achieving segmental heating during use by controlling circuit.

[0064] Further, as shown in Figure 15, the conductive electrode 1131 also includes an extending portion 1132 that extends out from the solid aerosol-forming substrate 111. The extending portion 1132 is a sheet-shaped conductor that can adhere to the conductive electrode 1131 and extend outward. The extending portion 1132 can also be sewn and fixed during the sewing process of the conductive electrode 1131. After the solid aerosol-forming substrate 111 is curled or folded into shape, the extending portion 1132 can be wound or bent onto the outer wall surface of the atomization assembly 11a, facilitating electrical connection with the contact points of the heater 20. Of course, the extending portion 1132 can be canceled, and when the solid aerosol-forming substrate 111 is curled or folded into shape, the region where the conductive electrode 1131 is located can be arranged on the outside.

[0065] As shown in Figures 3 and 16, when the conductive electrode 1131 extends out from the solid aerosol-forming substrate 111, the conductive electrode 1131 is led out from the sidewall of the aerosol-forming unit 10 and arranged along the circumferential direction of the aerosol-forming unit 10. This allows the electrode to make contact with the contact point 211 on the heater 20 when the aerosol-forming unit 10 is inserted or placed in the heater 20, no matter the direction it is facing.

[0066] Of course, as shown in Figures 17 and 18, in other embodiments, the conductive electrode 1131 can also be led out from the end of the aerosol-forming unit 10 and arranged at the end of the aerosol-forming unit 10. Alternatively, the conductive electrode 1131 can be led out from the end and bent to the sidewall of the aerosol-forming unit 10, making contact with the corresponding contact point 211 on the heater 20 to establish an electrical connection.

[0067] Preferably, as shown in Figures 13 and 14, in this embodiment, the solid aerosol-forming substrate 111 includes a heating section 1111 and a covering section 1112. The heating element 112 is located in the heating section 1111 and the electrode 113 is positioned in the covering section 1112. During winding or folding, the covering section 1112 is placed on the outermost layer, covering the internal wound or folded heating section 1111. The heat from the internal heating section 1111 can transfer to the external covering section 1112, heating and atomizing covering section 1112, without directly heating the covering section 1112 by the heating element 112, which prevents the external temperature from becoming too high. Of course, in other embodiments, the heating section 1111 and covering section 1112 may not be distinguished, and the heating element 112 can be distributed across various regions of the solid aerosol-forming substrate 111.

[0068] In some embodiments, the conductive electrode 1131 can be sewn from the first wire 1121 onto the solid aerosol-forming substrate 111, which facilitates mass and automated production of the atomization assembly 11a. It can also be understood that, in some cases, part of the conductive electrode 1131 can be woven onto the solid aerosol-forming substrate 111 using a different conductive wire.

[0069] Furthermore, the two conductive electrodes 1131 are positioned on the same side of the solid aerosol-forming substrate 111. Preferably, the conductive electrodes 1131 and the first wire 1121 are made from the same conductive wire. The conductive electrode 1131 and heating element 112 can be sewn in one process using a single conductive wire, improving production efficiency.

[0070] Of course, in other embodiments, one of the conductive electrodes 1131 can be positioned on the first side A, and the other conductive electrode 1131 can be positioned on the second side B. The conductive electrode 1131 on the first side A can be made from the same conductive wire as the first wire 1121, while the conductive electrode 1131 on the second side B can be sewn separately and make contact with the wire on the second side B of the heating element 112 to establish an electrical connection.

[0071] Furthermore, the conductive electrode 1131 formed by sewing can be provided with a conductive layer, which helps stabilize the resistance and facilitates the connection of external leads or contacts. In some embodiments, the conductive layer is formed from conductive paste or conductive adhesive which can be coated or printed onto the electrode.

[0072] It can be understood that, in other embodiments, the conductive layer can also be a metal sheet attached to the conductive electrode 1131. The metal sheet can be made of materials such as nickel, stainless steel, copper, or aluminum foil. The metal sheet is then sewn into the solid aerosol-forming substrate 111 by piercing through it, thereby fixing it together. The advantage of this arrangement is that the conductive electrode 1131 will have a certain degree of hardness for support, making it easier to connect with the contact points inside the heater 20.

[0073] As shown in Figures 19 and 20, in some embodiments, the atomization assembly 11a further includes a heat-conducting layer 114 positioned on at least one side of the solid aerosol-forming substrate 111 and used for thermal conduction. The heat-conducting layer 114 is made of an insulating material. The heat-conducting layer 114 is fixed together with the solid aerosol-forming substrate 111 by the heating element 112, so that the heat generated by the heating element 112 can be evenly distributed through the heat-conducting layer 114, rather than being concentrated in the portion near the heating element 112. This ensures that all parts of the solid aerosol-forming substrate 111 are evenly heated, avoiding the risk of localized heating and carbonisation while other parts remain unheated and wasted.

[0074] As shown in Figures 5 and 6, another embodiment of the present application also discloses a manufacturing process for the atomization assembly 11a, which includes the following steps: S11: Providing a flexible solid aerosol-forming substrate 111 and a flexible first wire 1121, and the first wire 1121 is made of a conductive material. S12: sewing the first wire 1121 onto the solid aerosol-forming substrate 111, with the first wire 1121 sewn into the solid aerosol-forming substrate 111 to form a heating element 112. S13: arranging conductive electrodes 1131 electrically connected to the heating element 112 on the solid aerosol-forming substrate 111.

[0075] In step S12, when sewing the first wire 1121, the first wire 1121 passes from the first side A to the second side B, and then returned to the first side A through the same sewing hole, so that the first wire 1121 forms a seam portion embedded within the solid aerosol-forming substrate 111.

[0076] At least one seam portion 1122 passing from the first side A to the second side B opposite to the first side A and then returning to the first side A is formed when sewing the first wire 1121.

[0077] Of course, as shown in Figure 9, when sewing the first wire 1121, the first wire 1121 can also pass from the first side A to the second side B and then along the second side B and back to the first side A. The sewing method of the first wire 1121 on the solid aerosol-forming substrate 111 is not limited, as long as the first wire 1121 can be fixed and combined with the solid aerosol-forming substrate 111.

[0078] Further, as shown in Figure 12, in some embodiments, step S12 also includes: providing a flexible second wire 1124, sewing the first wire 1121 and second wire 1124 from both sides of the solid aerosol-forming substrate 111, so that the first wire 1121 and second wire 1124 are interwoven into the solid aerosol-forming substrate 111 to form the heating element 112. The heating element 112 formed by interweaving the first wire 1121 and second wire 1124 has a more stable combination with the solid aerosol-forming substrate 111.

[0079] In some embodiments, in step S13, a single conductive electrode 1131 can be formed by sewing, or two conductive electrodes 1131 can be formed by sewing. Additionally, a conductive layer can be provided on the sewn conductive electrode 1131.

[0080] Further, as shown in Figures 13 and 14, the solid aerosol-forming substrate 111 includes a heating section 1111 and a covering section 1112. In step S12, the heating element 112 is arranged in the heating section 1111, and in step S13, the electrode 113 is arranged in the covering section 1112.

[0081] Preferably, the solid aerosol-forming substrate 111 is formed by slitting liquid-conducting raw material. To improve production efficiency, after sewing the heating element 112 on the liquid-conducting raw material according to the arrangement of the solid aerosol-forming substrate 111, and arranging the conductive electrode 1131, the atomization assembly 11a is formed by slitting. The heating elements 112 and electrodes 113 of multiple atomization assemblies 11a can be made in a single manufacturing, making it suitable for mass production and highly efficient.

[0082] As shown in Figures 7 and 8, another embodiment of this application also discloses a manufacturing process for the aerosol-forming unit 10, which includes the following steps: The aforementioned atomization assembly 11a is formed into the atomization unit 11 by winding, bending, or a combination of winding and bending, with the conductive electrode 1131 exposed.

[0083] Furthermore, as shown in Figures 1 to 3, the manufacturing process also includes the step of: providing a filter mouthpiece 12 at one end of the atomization unit 11.

[0084] Additionally, the electrode 113 is located in the covering section 1112, allowing the covering section 1112 to cover the outer periphery of the atomization unit 11.

[0085] When part or all of the conductive electrodes 1131 include an extending portion 1132 extending out of the solid aerosol-forming substrate 111, the manufacturing process further includes the following steps: As shown in Figures 16 to 18, winding the extending portion 1132 along the circumferential direction of the aerosol-forming unit 10, or arranging the extending portion 1132 at the end or sidewall of the heating element 112 after being led out from the end of the heating element 112, The extending portion 1132 is located on the outer side of the aerosol-forming unit 10, and is used to conduct electricity with the contact points of the heater 20.

[0086] As shown in Figure 4, another embodiment of the present application also discloses a heater 20, which includes a working position 21 for placing the aerosol-forming unit 10. The working position 21 is provided with a contact point 211 corresponding to the position of the conductive electrode 1131, to energize the heating element 112 and make the heating element 112 generate heat.

[0087] The working position 21 of the heater 20 is a socket for the aerosol-forming unit 10 to be inserted. In other embodiments, the working position 21 can also be a bayonet for the aerosol-forming unit 10 to be secured after being snapped into place.

[0088] The heater 20 may be provided with a battery 22, and a charging panel 23 for charging the battery 22 may also be provided. Meanwhile, the control board 24 can control the power supply from the battery 22 to the contact point 211 to control the heating of the aerosol-forming unit 10.

[0089] It is understood that the above technical features can be used in any combination without limitation.

[0090] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process modification made based on the content of this specification and the accompanying drawings, or any direct or indirect application in other related technical fields, is also included within the scope of protection of the present invention.

Claims

1. An atomization assembly, characterized by comprising a solid aerosol-forming substrate (111), a heating element (112), and electrodes (113); wherein the solid aerosol-forming substrate (111) is flexible and sheet-shaped; wherein the heating element (112) comprises a flexible first wire (1121) sewn onto the solid aerosol-forming substrate (111), and the first wire (1121) is made of a conductive material; and wherein the electrodes (113) comprise at least two conductive electrodes (1131) electrically connected to the first wire (1121) respectively.

2. The atomization assembly according to claim 1, characterized in that the first wire (1121) comprises at least one seam portion (1122) passing from a first side (A) to a second side (B) opposite to the first side (A) and then returning to the first side (A).

3. The atomization assembly according to claim 2, characterized in that the seam portion (1122) comprises a first section (1122a), a third section (1122c), and a second section (1122b) connected sequentially, with the third section (1122c) located on the second side (B), and the first section (1122a) and second section (1122b) passing through the solid aerosol-forming substrate (111) respectively; or, wherein the seam portion (1122) comprises a first section (1122a) and a second section (1122b) connected sequentially and side by side, with the first section (1122a) and second section (1122b) located in the same sewing hole.

4. The atomization assembly according to claim 3, characterized in that the first wire (1121) comprises a connecting section (1123) located on the first side (A), and connecting between the first section (1122a) and the second section (1122b) of two adjacent seam portions (1122).

5. The atomization assembly according to claim 1, characterized in that the heating element (112) comprises a plurality of the first wires (1121) located on the same side of the solid aerosol-forming substrate (111), and each of the first wires (1121) is interwoven and / or arranged side by side; or, the wiring path of the first wire (1121) on the solid aerosol-forming substrate (111) is bent or curved.

6. The atomization assembly according to claim 1, characterized in that the atomization assembly (11a) further comprises a heat-conducting layer (114) provided on at least one side of the solid aerosol-forming substrate (111) and used for thermal conduction, and the heat-conducting layer (114) is made of an insulating material.

7. The atomization assembly according to claim 1, characterized in that at least one of the conductive electrodes (1131) is sewn to the solid aerosol-forming substrate (111) using a conductive wire.

8. The atomization assembly according to claim 7, characterized in that a conductive layer is provided on the conductive electrode (1131).

9. The atomization assembly according to claim 8, characterized in that the conductive layer is formed from conductive paste or conductive adhesive.

10. The atomization assembly according to claim 8, characterized in that the conductive layer is a metal sheet.

11. The atomization assembly according to claim 10, characterized in that the metal sheet is sewn onto the solid aerosol-forming substrate (111).

12. The atomization assembly according to claim 1, characterized in that both ends of the first wire (1121) are electrically connected to the conductive electrodes (1131) respectively, and the electrodes (113) further comprise at least one conductive electrode (1131) connected between the two ends of the first wire (1121).

13. The atomization assembly according to claim 1 or 12, characterized in that the conductive electrode (1131) further comprises an extending portion (1132) extending out of the solid aerosol-forming substrate (111).

14. The atomization assembly according to claim 1, characterized in that the solid aerosol-forming substrate (111) comprises a heating section (1111) and a covering section (1112), and the heating element (112) is located in the heating section (1111), and the electrode (113) is located in the covering section (1112).

15. The atomization assembly according to any one of claims 1 to 12, characterized in that the heating element (112) further comprises a flexible second wire (1124) sewn onto the solid aerosol-forming substrate (111), the first wire (1121) and the second wire (1124) are located on opposite sides of the solid aerosol-forming substrate (111) respectively, and the first wire (1121) and the second wire (1124) are interwoven with each other.

16. An aerosol-forming unit, characterized by comprising an atomization unit (11) formed by winding and / or bending the atomization assembly according to any one of claims 1 to 15, with the electrode (113) exposed.

17. The aerosol-forming unit according to claim 16, characterized in that the aerosol-forming unit (10) is columnar or block-shaped.

18. The aerosol-forming unit according to claim 16 or 17, characterized in that the solid aerosol-forming substrate (111) further comprises a covering section (1112) for covering the outer periphery of the atomization unit (11), with the electrode (113) located in the covering section (1112).

19. The aerosol-forming unit according to claim 16, characterized in that the aerosol-forming unit (10) comprises a filter mouthpiece (12) arranged at one end of the atomization unit (11).

20. The aerosol-forming unit according to claim 19, characterized in that the atomization unit (11) and the filter mouthpiece (12) are externally covered with a supporting cylinder (14).

21. The aerosol-forming unit according to claim 20, characterized in that the supporting cylinder (14) is rolled supporting paper.

22. The aerosol-forming unit according to claim 19, characterized in that the aerosol-forming unit (10) further comprises a filter sheet (13) arranged at the end of the atomization unit (11) far away from the filter mouthpiece (12).

23. The aerosol-forming unit according to any one of claims 16, 17, 19 to 22, characterized in that the conductive electrode (1131) is arranged along the circumferential direction of the aerosol-forming unit (10); or the conductive electrode (1131) is led out from the end of the heating element (112) and arranged at the end or sidewall of the aerosol-forming unit (10).

24. A manufacturing process of the atomization assembly according to any one of claims 1 to 15, characterized by comprising the following steps: providing a flexible solid aerosol-forming substrate (111) and a flexible first wire (1121), and the first wire (1121) is made of a conductive material; sewing the first wire (1121) onto the solid aerosol-forming substrate (111), wherein the first wire (1121) is sewn onto the solid aerosol-forming substrate (111) to form a heating element (112); and arranging a conductive electrode (1131) electrically connected to the heating element (112) on the solid aerosol-forming substrate (111).

25. The manufacturing process of the atomization assembly according to claim 24, characterized in that the first wire (1121) passes from the first side (A) to the second side (B) and then returns to the first side (A) through the same sewing hole; or the first wire (1121) passes from the first side (A) to the second side (B) and then along the second side (B) and back to the first side (A).

26. The manufacturing process of the atomization assembly according to claim 24, characterized by further comprising the step of: providing a flexible second wire (1124), sewing the first wire (1121) and second wire (1124) from both sides of the solid aerosol-forming substrate (111) respectively, wherein the first wire (1121) and second wire (1124) are interwoven into the solid aerosol-forming substrate (111) to form the heating element (112).

27. The manufacturing process of the atomization assembly according to claim 24, characterized in that at least one of the conductive electrodes (1131) is formed by sewing; or at least one of the conductive electrodes (1131) is formed by sewing and a conductive layer is provided on the sewn conductive electrode (1131).

28. The manufacturing process of the atomization assembly according to claim 24, characterized in that the solid aerosol-forming substrate (111) comprises a heating section (1111) and a covering section (1112), with the heating element (112) arranged in the heating section (1111) and the electrode (113) arranged in the covering section (1112).

29. The manufacturing process of the atomization assembly according to claim 25, characterized in that the solid aerosol-forming substrate (111) is formed by slitting liquid-conducting raw material, and after sewing the heating element (112) on the liquid-conducting raw material and arranging the conductive electrode (1131), the atomization assembly (11a) is formed by slitting.

30. The manufacturing process of the atomization assembly according to claim 25, characterized in that at least one seam portion (1122) passing from the first side (A) to the second side (B) opposite to the first side (A) and then returning to the first side (A) is formed when sewing the first wire (1121).

31. A manufacturing process of the aerosol-forming unit according to any one of claims 16 to 23, characterized by comprising the following steps: winding and / or bending the atomization assembly (11a) according to any one of claims 24 to 30 to form the atomization unit (11), with the conductive electrode (1131) exposed.

32. The manufacturing process of the aerosol-forming unit according to claim 31, characterized in that a filter mouthpiece (12) is provided at one end of the atomization unit (11).

33. The manufacturing process of the aerosol-forming unit according to claim 32, characterized in that the solid aerosol-forming substrate (111) comprises a covering section (1112), the electrode (113) is located on the covering section (1112) and the covering section (1112) covers the outer periphery of the atomization unit (11).

34. The manufacturing process of the aerosol-forming unit according to claim 32, characterized in that part or all of the conductive electrodes (1131) comprise an extending portion (1132) extending out of the solid aerosol-forming substrate (111), and the manufacturing process further comprises the following steps: winding the extending portion (1132) along the circumferential direction of the aerosol-forming unit (10), or arranging the extending portion (1132) at the end or sidewall of the heating element (112) after being led out from the end of the heating element (112).

35. A heater, characterized by comprising a working position (21) for placing the aerosol-forming unit (10) according to any one of claims 16 to 23, wherein the working position (21) is provided with a contact point (211) corresponding to the position of the conductive electrode (1131), to energize the heating element (112) and make the heating element (112) generate heat.

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