Heating assembly with side extensions

Abstract

The present invention relates to a heating assembly for an aerosol generating device, the heating assembly comprising a first substrate layer. The first substrate layer is an electrically insulating substrate layer. The aerosol generating device further comprises a heating element. The heating element is disposed on the first substrate layer. The aerosol generating device further comprises a second substrate layer. The second substrate layer is an electrically insulating substrate layer. The second substrate layer is disposed so as to cover the heating element and the first substrate layer. The aerosol generating device further comprises a temperature sensor. The temperature sensor is disposed on the second substrate layer. The aerosol generating device further comprises a third substrate layer. The third substrate layer is an electrically insulating substrate layer. The third substrate layer may be disposed so as to at least partially cover the temperature sensor and to cover the second substrate layer. One or more of the first substrate layer, second substrate layer, and third substrate layer comprise side extensions on short edge portions of the respective substrate layers. The present invention further relates to an aerosol generating device and a method of manufacturing a heating assembly for an aerosol generating device.

Description

[Technical field]

[0001] The present invention relates to a heating assembly for an aerosol generating device. The present invention further relates to an aerosol generating device, and to a method for manufacturing the heating assembly. [Background technology]

[0002] It is known to provide an aerosol-generating device for producing an inhalable vapor. Such a device may heat an aerosol-forming substrate to a temperature at which one or more components of the aerosol-forming substrate volatilize without burning the aerosol-forming substrate. The aerosol-forming substrate may be provided as part of an aerosol-generating article. The aerosol-generating article may have a rod shape for insertion of the aerosol-generating article into a cavity (e.g., a heating chamber, etc.) of the aerosol-generating device. A heating assembly may be disposed in or around the heating chamber to heat the aerosol-forming substrate when the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device. Summary of the Invention [Problem to be solved by the invention]

[0003] It would be desirable to have a heating assembly for an aerosol generating device that has improved reliability.It would be desirable to have a heating assembly for an aerosol generating device that has improved manufacturing quality.It would be desirable to have a heating assembly for an aerosol generating device that has improved robustness during manufacturing. [Brief description of the drawings]

[0004] [Figure 1] 1 shows a heating assembly. [Diagram 2] 1 shows the layers that make up the heating assembly. [Diagram 3] 1 shows the layers that make up the heating assembly, including the third insulating layer. [Figure 4] 1 shows different perspective views of the heating assembly, in particular the electrical connections. [Diagram 5] 1 shows a substrate layer of a heating assembly having side extensions. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0005] According to one aspect of the present invention, there is provided a heating assembly for an aerosol generating device, the heating assembly comprising a first substrate layer. The first substrate layer may be an electrically insulating substrate layer. The aerosol generating device may further comprise a heating element. The heating element may be disposed on the first substrate layer. The aerosol generating device may further comprise a second substrate layer. The second substrate layer may be an electrically insulating substrate layer. The second substrate layer may be disposed to cover the heating element and the first substrate layer. The aerosol generating device may further comprise a temperature sensor. The temperature sensor may be disposed on the second substrate layer. The aerosol generating device may further comprise a third substrate layer. The third substrate layer may be an electrically insulating substrate layer. The third substrate layer may be disposed to at least partially cover the temperature sensor and to cover the second substrate layer. One or more of the first substrate layer, the second substrate layer and the third substrate layer may comprise a side extension at a short edge of the respective substrate layer.

[0006] According to one aspect of the present invention, there is provided a heating assembly for an aerosol generating device, the heating assembly comprising a first substrate layer. The first substrate layer is an electrically insulating substrate layer. The aerosol generating device further comprises a heating element. The heating element is disposed on the first substrate layer. The aerosol generating device further comprises a second substrate layer. The second substrate layer is an electrically insulating substrate layer. The second substrate layer is disposed to cover the heating element and the first substrate layer. The aerosol generating device further comprises a temperature sensor. The temperature sensor is disposed on the second substrate layer. The aerosol generating device further comprises a third substrate layer. The third substrate layer is an electrically insulating substrate layer. The third substrate layer may be disposed to at least partially cover the temperature sensor and to cover the second substrate layer. One or more of the first substrate layer, the second substrate layer and the third substrate layer comprise a side extension at a short edge of the respective substrate layer.

[0007] The term "covering" or "covering" may mean that the first layer has substantially the same size as the second layer, such that the first layer can be placed on the second layer such that the surface area of ​​the second layer facing the first layer is overlapped by the first layer. When the first layer is placed to cover the second layer, the surface size of the first layer may be at least 90% of the surface area of ​​the second layer, preferably, the surface size of the first layer may be at least 80% of the surface area of ​​the second layer, more preferably, the surface size of the first layer may be at least 70% of the surface area of ​​the second layer, and most preferably, the surface size of the first layer may be at least 60% of the surface area of ​​the second layer.

[0008] The heating element may be sandwiched between the first and second substrate layers. The heating element may cover only a portion of the surface of the first substrate layer. When the second substrate layer is disposed on the first substrate layer and on the heating element, the second substrate layer preferably covers the heating element and the remaining portion of the surface of the first substrate layer on which the heating element is disposed and that is not covered by the heating element.

[0009] Similarly, the temperature sensor may be sandwiched between the second and third substrate layers. The temperature sensor may cover only a portion of the surface of the second substrate layer. When the third substrate layer is disposed over the second substrate layer and the temperature sensor, the third substrate layer preferably covers the temperature sensor and the remaining portion of the surface of the second substrate layer on which the temperature sensor is disposed and that is not covered by the temperature sensor.

[0010] In the final heating assembly, the heating element and the temperature sensor are preferably located on opposing surfaces of the second substrate layer, such that the heating element is electrically insulated from the temperature sensor by the second substrate layer.

[0011] The heating element may be protected by a first substrate layer and by a second substrate layer.

[0012] The temperature sensor may be protected by a second substrate layer and by a third substrate layer.

[0013] Providing side extensions may improve the attachment of the heating assembly. The heating assembly may be rolled to attach it to the aerosol generating device. Rolling the heating assembly may result in a tubular heating assembly. The heating assembly may be wrapped around a cavity of the aerosol generating device, as described in more detail below. The cavity may be a stainless steel tube. The heating assembly may be attached to the tube, illustratively by adhesive. However, in the absence of side extensions, the only adhesion between the rolled heating assembly and the tube is adhesive. This may not be sufficient to securely fix the heating assembly to the tube. Providing side extensions may allow the rolled heating assembly to remain in a rolled state by the side extensions. More specifically, the side extensions may be attached to the opposite short edge of each layer after rolling the heating assembly to ensure that the heating assembly remains in a rolled state. This may be done in addition to or as an alternative to providing adhesive to attach the rolled heating assembly to the tube of the aerosol generating device that forms the cavity.

[0014] The side extensions may be flexible, which may allow for placement of the side extensions on opposite short edges of each layer after the heating assembly is rolled.

[0015] The side extensions may be provided with an adhesive layer or coating that allows attachment of the side extensions to the opposing short edges of the respective layers.

[0016] "Attachment to the opposite short edge of each layer" refers to attachment of the side extensions in a region adjacent the opposite short edge of each layer. This region may abut the short edge. This region may have a surface of similar dimensions to the surface of the side extension. This region may have a surface area of ​​similar dimensions to the surface area of ​​the side extension. This region may have a surface area corresponding to the surface area of ​​the side extension. After the side extensions are attached to the opposite short edges of each layer, the short edges of each layer may abut one another. The heating assembly may thus have a tubular shape after rolling the heating assembly and attaching the side extensions to the opposite short edges of each layer.

[0017] Two or three of the first substrate layer, the second substrate layer, and the third substrate layer may include a side extension at a short edge of the respective substrate layer.

[0018] All three of the first substrate layer, the second substrate layer, and the third substrate layer may include lateral extensions at the short edge of the respective substrate layer.

[0019] In all of these cases, the respective side extensions may be attached to opposing short edges of the respective layers described herein.

[0020] Illustratively, the first substrate layer may include a first side extension at a first short edge of the first substrate layer. The first side extension may be configured to be attached to a second short edge of the first substrate layer opposite the first short edge of the first substrate layer. The second substrate layer may include a second side extension at a first short edge of the second substrate layer. The second side extension may be configured to be attached to a second short edge of the second substrate layer opposite the first short edge of the second substrate layer. The third substrate layer may include a third side extension at a first short edge of the third substrate layer. The third side extension may be configured to be attached to a second short edge of the third substrate layer opposite the first short edge of the third substrate layer.

[0021] As described herein, providing two or more side extensions, and preferably three side extensions, can improve attachment of the substrate layer after rolling of the heating assembly.

[0022] The side extensions of the substrate layers may have the same dimensions, which may facilitate attachment of the side extensions to the opposing short edges of each substrate layer.

[0023] The side extensions may be stacked on top of one another.

[0024] The lateral extensions may be integrally formed with their respective substrate layers, i.e., a first lateral extension may be integrally formed with a first substrate layer, a second lateral extension may be integrally formed with a second substrate layer, and a third lateral extension may be integrally formed with a third substrate layer.

[0025] One or more of: the first side extension may be disposed at a first short side edge of the first substrate layer; the second side extension may be disposed at a first short side edge of the second substrate layer; and the third side extension may be disposed at a first short side edge of the third substrate layer.

[0026] One or more of the first substrate layer, the second substrate layer, and the third substrate layer may have a rectangular shape.

[0027] The term "short edge" refers to an edge of one or more of the first substrate layer, the second substrate layer, and the third substrate layer that is shorter than the further edge of the respective layer.

[0028] In the case of a rectangular layer, two opposing short edges are connected via two opposing long edges, the length of the short edges being less than the length of the long edges.

[0029] The lateral extensions may extend over at least 70%, may extend over at least 80%, more preferably may extend over at least 90%, and more preferably may extend over the entire length of the short side edge of each substrate layer.

[0030] Each substrate layer including the side extensions may include an attachment region at an opposing short edge of the respective substrate layer.

[0031] The surface area of ​​the attachment region may be essentially the same, preferably the same, as the surface area of ​​the side extensions.

[0032] The attachment regions may abut a short edge of the respective substrate layer, in other words, the attachment regions may be disposed directly adjacent to the respective substrate layer.

[0033] The length of the side extension may be 1.5 times, preferably 2.0 times, more preferably 2.5 times, and most preferably at least 3 times greater than the width of the side extension.

[0034] The lateral extensions may have an elongated shape.

[0035] The side extensions may have a rectangular shape.

[0036] The side extensions may be longer than they are wide.

[0037] The side extensions may be thinner than they are wide.

[0038] The side extensions may be thinner than the length.

[0039] The lateral extensions may have a length of from 5mm to 20mm, preferably from 8mm to 15mm, more preferably from 10mm to 14mm, and most preferably 12mm.

[0040] The lateral extensions may have a width of from 2mm to 6mm, preferably from 3mm to 5mm, more preferably 4mm.

[0041] The long side edge of one or more of the first substrate layer, the second substrate layer, and the third substrate layer may have a length of 16 mm to 32 mm, preferably 19 mm to 29 mm, more preferably 22 mm to 26 mm, and most preferably 24 mm.

[0042] Only one of the first substrate layer, the second substrate layer, and the third substrate layer may include a side extension. This may facilitate attachment of the side extension to the opposite short edge, since only one side extension needs to be attached. This may also be sufficient, since the first, second, and third substrate layers may be attached to each other as described herein, preferably by an adhesive layer. Thus, one side extension may be sufficient to attach the first substrate layer, the second substrate layer, and the third substrate layer together in a tubular shape.

[0043] The heating assembly may further include a fastening leg, the fastening leg may be disposed on a long edge of one or more of the first substrate layer, the second substrate layer, and the third substrate layer.

[0044] The fastening legs may serve to mount the heating assembly to a cavity in the aerosol-generation assembly.

[0045] The heating element may include heater contacts, which may be disposed on the fixation legs.

[0046] The fixing legs may form a support for the heater contacts. The fixing legs may be arranged to allow attachment of the heater contacts to electrical components of the aerosol generating device. The electrical components may include a controller and a power supply.

[0047] The heating element may be a resistive heater. The heating element may comprise a heating track. The heating element may be a heating track. The heating track may be configured to generate heat. The heating track may be an electrical resistive heating track. The heating element may comprise electrical contacts for electrically contacting the heating track. The electrical contacts may be attached to the heating track by any known means, for example by soldering or welding. A first electrical contact may be attached to a first end of the heating track and a second electrical contact may be attached to a second end of the heating track. The first end of the heating track may be a proximal end of the heating track and the second end of the heating track may be a distal end of the heating track or vice versa.

[0048] The heating track may be made of stainless steel. The heating track may be made of stainless steel with a thickness of about 50 μm. The heating track may preferably be made of stainless steel with a thickness of about 25 μm. The heating track may be made of Inconel with a thickness of about 50.8 μm. The heating track may be made of Inconel with a thickness of about 25.4 μm. The heating track may be made of copper with a thickness of about 35 μm. The heating track may be made of constantan with a thickness of about 25 μm. The heating track may be made of nickel with a thickness of about 12 μm. The heating track may be made of brass with a thickness of about 25 μm.

[0049] The heating elements may be printed onto the first substrate layer. The heating tracks may be photoprinted onto the substrate layer. The heating tracks may be chemically etched onto the substrate layer.

[0050] The term "heat track" encompasses a single heating track. The heating element or heating track may be printed on the first substrate layer.

[0051] The heating track may be centrally located on the first substrate layer. The heating track may have a bent shape. The heating track may have a curved shape. The heating track may have a zigzag shape. The heating track may have a serpentine shape.

[0052] The heating assembly may be rolled into a tube. The heating track may be flat before the substrate layer is rolled into a tube. The heating track or heating element may be flexible. The heating track or heating element may conform to the tubular shape of the substrate layer when the substrate layer is rolled into a tube.

[0053] The temperature sensor may have two contacts.

[0054] The third substrate layer may include at least two openings. The two openings are provided to allow electrical contacts of the temperature sensor to be contacted through the third substrate layer.

[0055] The two openings can be aligned such that the two contacts are not covered by the third substrate layer. The two openings can be located adjacent opposite ends of the third substrate layer. The two openings can correspond to the location of the electrical contacts on the temperature sensor.

[0056] In addition to the two openings, a further opening may be provided in the third substrate layer. The third opening may be centrally located in the third substrate layer. This third opening may improve the mechanical strength of the third substrate layer in this region. In particular, the central opening in the third substrate layer may enhance the fixation of the wires in contact with the electrical contacts of the temperature sensor, since in this region the wires contact the adhesive layer underlying the second substrate layer.

[0057] The electrical contacts of the temperature sensor may be attached to the temperature sensor by any known means, illustratively by soldering or welding. A first electrical contact may be attached to a first end of the temperature sensor and a second electrical contact may be attached to a second end of the temperature sensor. The first end of the temperature sensor may be the proximal end of the temperature sensor and the second end of the temperature sensor may be the distal end of the temperature sensor, or vice versa.

[0058] The temperature sensor may include a temperature sensor track.

[0059] The heat shrink layer may be disposed around the heating assembly. The heat shrink layer may be made of PEEK. The heat shrink layer may be disposed around the heating assembly when the heating assembly is rolled into a tube. The heat shrink layer may be configured to shrink when heated. The heat shrink layer may hold the heating assembly securely. The heat shrink layer may be configured to apply a uniform inward pressure to the heating assembly. The heat shrink layer may improve contact between the tube and the first substrate layer and between the second substrate layer and the third substrate layer or both. The heat shrink layer may hold most or all of the components of the heating assembly securely together. The heat shrink layer may be used in place of the glue or adhesive layers described herein. Alternatively, the heat shrink layer may be used in addition to the glue or adhesive layers described herein.

[0060] The thickness of the heat shrink layer may be between 100 μm and 300 μm, preferably about 180 μm.

[0061] The heat shrink layer may be made of PEEK. The heat shrink layer may be made of or include one or more of Teflon and PTFE.

[0062] The heating assembly may include a tube, preferably a metal tube, around which the substrate layer is wrapped or wound. The metal tube is preferably a stainless steel tube. Alternatively, the tube may be a ceramic tube. The tube may define the tubular shape of the heating assembly. The outer diameter of the tube may correspond to the inner diameter of the first substrate layer after rolling of the substrate layer.

[0063] The heating assembly may further comprise a heating chamber that conforms to the tubular shape of the heating assembly. The substrate layer may be rolled with the heating element and temperature sensor to fit the tube that forms the heating chamber. In this configuration, the first substrate layer may form the inner layer facing the tube and the third substrate layer may be the outer layer. The first substrate layer may be adjacent to the metal tube that forms the innermost layer of the heating assembly.

[0064] The tube may be made of stainless steel. The tube may have a length of 10 mm to 35 mm, preferably 12 mm to 30 mm, preferably 13 mm to 22 mm. The tube may be a hollow tube. The hollow tube may have an inner diameter of 4 mm to 9 mm, preferably 5 mm to 6 mm, or 6.8 mm to 7.5 mm, preferably about 5.35 mm or about 7.3 mm. The tube may have a thickness of 70 μm to 110 μm, preferably 80 μm to 100 μm, preferably about 90 μm. The tube may have a cylindrical cross section. The tube may have a circular cross section.

[0065] The length of the first substrate layer can be equal to or less than the circumference of the tube. The first substrate layer can wrap completely around the tube. The first substrate layer can be wrapped once around the tube such that after the first substrate layer is wrapped around the tube, the surface of the tube is covered by the first substrate layer.

[0066] The tube of the heating chamber may have a thickness of 70 μm to 110 μm, preferably 80 μm to 100 μm, preferably about 90 μm.

[0067] The temperature sensor can be an NTC, Pt100, or preferably a Pt1000 temperature sensor. The temperature sensor can be attached to the second substrate layer by an adhesive layer. The temperature sensor can be photoprinted onto the second substrate layer. Chemical etching can be utilized to form one or both of the heating element heating track and the temperature sensor track. The contacts of the temperature sensor can then be welded onto the temperature sensor track through the openings in the third substrate layer.

[0068] The temperature sensor may be disposed on the second substrate layer such that when the heating assembly is rolled, the temperature sensor may be located in an area corresponding to the center of the first substrate layer. By positioning the temperature sensor in this manner, the heating element may be mapped such that the temperature sensor is located adjacent the hottest portion of the heating element. The hottest portion adjacent the temperature sensor may be the center of the first substrate layer. The heating element may be disposed at the center of the first substrate layer. The temperature sensor may be disposed directly adjacent the heating element, spaced from the heating element by the thickness of the second substrate layer.

[0069] One or more of the substrate layers may have a thickness of from 10 μm to 50 μm, preferably from 20 μm to 30 μm, more preferably about 25 μm.

[0070] The heating element, preferably when made from stainless steel, may have a thickness of 20 μm to 60 μm, preferably 30 μm to 50 μm, more preferably about 40 μm. The heating track, preferably when made from stainless steel, may have a thickness of 20 μm to 60 μm, preferably 30 μm to 50 μm, more preferably about 40 μm.

[0071] One or more of the following:

[0072] A first adhesive layer may be provided between the first substrate layer and the heating element;

[0073] A second adhesive layer may be provided between the heating element and the second substrate layer.

[0074] A third adhesive layer may be provided between the second adhesive layer and the temperature sensor.

[0075] A fourth adhesive layer may be provided between the temperature sensor and the third substrate layer.

[0076] The first adhesive layer may facilitate attachment between the first substrate layer and the heating element. The first adhesive layer may further facilitate attachment between the first substrate layer and the second substrate layer in areas of the first substrate layer not covered by the heating element. The second adhesive layer may facilitate attachment between the heating element and the second substrate layer. The third adhesive layer may facilitate attachment between the second substrate layer and the temperature sensor. The third adhesive layer may further facilitate attachment between the second substrate layer and the third substrate layer in areas of the third adhesive layer not covered by the temperature sensor. The fourth adhesive layer may facilitate attachment between the temperature sensor and the third substrate layer.

[0077] One or more of the adhesive layers may have a thickness of from 2 μm to 10 μm, preferably from 3 μm to 7 μm, more preferably about 5 μm.

[0078] One or more of the adhesive layers may be a silicone-based adhesive layer. The adhesive layers may include one or both of a PEEK-based adhesive and an acrylic adhesive.

[0079] One or more of the first substrate layer, the second substrate layer, and the third substrate layer may include a polyamide film. Any of the substrate layers may be made of polyimide or polyamide. The substrate layers may be configured to withstand temperatures between 220° C. and 320° C., preferably between 240° C. and 300° C., preferably about 280° C. Any of the substrate layers may be made of Pyralux.

[0080] The present invention further relates to an aerosol generating device comprising a heating assembly as described herein.

[0081] The aerosol generating device may include a cavity for receiving the aerosol-generating article. The heating assembly may be disposed at least partially surrounding the cavity.

[0082] The sidewalls of the cavity may be formed of a stainless steel tube. A heating assembly may be mounted on the stainless steel tube. The heating assembly may form the cavity as described in more detail herein.

[0083] The present invention further relates to a method of manufacturing a heating assembly for an aerosol generating device, the method comprising the steps of: providing a first substrate layer, the first substrate layer being an electrically insulating substrate layer; disposing a heating element on the first substrate layer; disposing a second substrate layer over the heating element and the first substrate layer, the second substrate layer being an electrically insulating substrate layer; disposing a temperature sensor on the second substrate layer; disposing a third substrate layer at least partially covering the temperature sensor and over the second substrate layer, the third substrate layer being an electrically insulating substrate layer; providing one or more of the first substrate layer, the second substrate layer, and the third substrate layer with a side extension at a short edge of each substrate layer.

[0084] As used herein, the terms "upstream" and "downstream" are used to describe the relative location of components or parts of components of an aerosol generating device with respect to the direction in which air flows through the aerosol generating device during use. An aerosol generating device according to the invention comprises a proximal end through which the aerosol exits the device during use. The proximal end of the aerosol generating device may also be referred to as the mouth end or downstream end. The mouth end is downstream of the distal end. The distal end of the aerosol-generating article may also be referred to as the upstream end. Components or parts of components of an aerosol generating device may be described as being upstream or downstream of each other based on their relative location with respect to the airflow path of the aerosol generating device.

[0085] In all aspects of the present disclosure, the heating element may include an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics.

[0086] As described, in any of the aspects of the present disclosure, the heating element may comprise an external heating element, where "external" refers to the aerosol-forming substrate. The external heating element may take any suitable form. For example, the external heating element may take the form of one or more flexible heating foils or heating tracks on a dielectric substrate, such as polyimide. The dielectric substrate is a substrate layer. The flexible heating foils or heating tracks may be shaped to fit the periphery of the heating chamber. Alternatively, the external heating element may take the form of a metal grid, a flexible printed circuit board, a molded integrated circuit device (MID), a ceramic heater, a flexible carbon fiber heater, or may be formed using a coating technique such as plasma deposition on a substrate layer of suitable shape. The external heating element may also be formed using a metal with a defined temperature-resistivity relationship. In such an exemplary device, the metal may be formed as a track between a first substrate layer and a second substrate layer. The external heating element thus formed may be used for both heating and temperature monitoring of the external heating element during operation.

[0087] The heating element advantageously heats the aerosol-forming substrate by means of conduction. Alternatively, heat from either an internal or external heating element may be conducted to the substrate by a thermally conductive element.

[0088] In operation, the aerosol-forming substrate may be completely contained within the aerosol-generating device, in which case the user may puff on the mouthpiece of the aerosol-generating device. Alternatively, in operation, the smoking article containing the aerosol-forming substrate may be partially contained within the aerosol-generating device, in which case the user may puff on the smoking article directly.

[0089] The heating element may be configured as an induction heating element. The induction heating element may comprise an induction coil and a susceptor. Generally, the susceptor is a material that has the ability to generate heat when penetrated by an alternating magnetic field. According to the present invention, the susceptor may be conductive, or magnetic, or both conductive and magnetic. The alternating magnetic field generated by one or several induction coils heats the susceptor, which then transfers the heat to the aerosol-forming substrate so that the aerosol is formed. The heat transfer may be mainly by thermal conduction. Such heat transfer is best when the susceptor is in intimate thermal contact with the aerosol-forming substrate. When an induction heating element is employed, the induction heating element may be configured as an external heater as described herein. When the induction heating element is configured as an external heating element, the susceptor element is preferably configured as a cylindrical susceptor that at least partially surrounds the heating chamber. The heating track described herein may be configured as a susceptor. The susceptor can be disposed between the first substrate layer and the second substrate layer. The second portion of the substrate layer can be surrounded by an induction coil. The susceptor and the induction coil can be part of a heating assembly.

[0090] Preferably, the aerosol generating device comprises a power supply configured to provide power to one or both of the heating element and the heating assembly. Preferably, the power supply comprises a power source. The power source is preferably a battery, such as a lithium ion battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging. For example, the power source may have a capacity sufficient to allow continuous generation of aerosol for approximately six minutes, or a multiple of six minutes. In another example, the power source may have a capacity sufficient to allow a predetermined number of puffs, or discontinuous activation of the heating assembly.

[0091] The aerosol generating device may comprise control electronics. The control electronics may comprise a microcontroller. The microcontroller is preferably a programmable microcontroller. The electrical circuit may comprise further electronic components. The electrical circuit may be configured to regulate the supply of power to the heating assembly. Power may be supplied to the heating assembly continuously after activation of the system, or may be supplied intermittently (e.g., between puffs). Power may be supplied to the heating assembly in the form of pulses of current.

[0092] The control electronics may include a printed circuit board. The control electronics may be configured as a printed circuit board.

[0093] The temperature sensor may be electrically connected to the control electronics. The length of the electrical connection between the temperature sensor and the control electronics may be longer than the distance between the temperature sensor and the control electronics. This may have the beneficial effect of preventing detrimental effects on the electrical contacts between the temperature sensor and the control electronics due to thermal expansion of the contacts during operation of the aerosol generating device. The electrical connection is preferably configured as an electrical wire.

[0094] Similarly, the length of the electrical connection between the heating element and the control electronics may be longer than the distance between the heating element and the control electronics, which can have the beneficial effect of preventing detrimental effects on the electrical contacts between the heating element and the control electronics due to thermal expansion of the contacts during operation of the aerosol generating device. The electrical connection is preferably configured as an electrical wire.

[0095] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating or burning the aerosol-forming substrate. As an alternative to heating or burning, in some cases the volatile compound may be released by a chemical reaction or by mechanical stimulation such as ultrasound. The aerosol-forming substrate may be solid or liquid, or may include both solid and liquid components. The aerosol-forming substrate may be part of an aerosol-generating article.

[0096] As used herein, the term "aerosol-generating article" refers to an article that includes an aerosol-forming substrate capable of emitting a volatile compound capable of forming an aerosol. The aerosol-generating article may be disposable.

[0097] The term "aerosol-generating device" as used herein refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-generating device may interact with one or both of an aerosol-generating article that includes an aerosol-forming substrate and a cartridge that includes an aerosol-forming substrate. In some examples, the aerosol-generating device may heat the aerosol-forming substrate to facilitate the release of volatile compounds from the substrate. An electrically operated aerosol-generating device may include an atomizer, such as an electric heater, for heating the aerosol-forming substrate to form an aerosol.

[0098] The term "aerosol-generating system" as used herein refers to the combination of an aerosol-generating device with an aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol-generating article, the aerosol-generating system refers to the combination of an aerosol-generating device with an aerosol-generating article. In an aerosol-generating system, the aerosol-forming substrate and the aerosol-generating device work together to generate an aerosol. EXAMPLES

[0099] The following provides a non-exhaustive list of non-limiting examples, any one or more of the features of which may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0100] Example 1. 1. A heating assembly for an aerosol generating device, the heating assembly comprising: a first substrate layer, the first substrate layer being an electrically insulating substrate layer; a heating element disposed on the first substrate layer; a second substrate layer, the second substrate layer being an electrically insulating substrate layer disposed to cover the heating element and the first substrate layer; a temperature sensor disposed on the second substrate layer; a third substrate layer, the third substrate layer being an electrically insulating substrate layer at least partially covering the temperature sensor and disposed over the second substrate layer; A heating assembly, wherein one or more of the first substrate layer, the second substrate layer, and the third substrate layer include a side extension at a short edge of the respective substrate layer. Example 2. The heating assembly of example 1, wherein two or three of the first substrate layer, the second substrate layer, and the third substrate layer include a side extension at a short edge of each substrate layer. Example 3. The heating assembly of any one of claims 1 to 2, wherein all three of the first substrate layer, the second substrate layer, and the third substrate layer include a side extension at a short edge of the respective substrate layer. Example 4. The heating assembly of any one of Examples 2 to 3, wherein the lateral extensions of the substrate layer have the same dimensions. Example 5. The heating assembly of any one of Examples 2-4, wherein the side extensions overlap one another. Example 6. The heating assembly of any of Examples 1-5, wherein the side extensions are integrally formed with their respective substrate layers. Example 7. A heating assembly as described in any of Examples 1-6, wherein the side extensions extend across at least 70%, at least 80%, more preferably at least 90%, and more preferably the entire length of the short side edge of each substrate layer. Example 8. The heating assembly of any of Examples 1-7, wherein each substrate layer including the side extensions includes an attachment region on opposing short edge portions of the respective substrate layer. Example 9. 6. The heating assembly of example 5, wherein a surface area of ​​the attachment region is essentially the same as, and preferably the same as, a surface area of ​​the side extensions. Example 10. 10. The heating assembly of any of Examples 1-9, wherein the length of the side extension is 1.5 times, preferably 2.0 times, more preferably 2.5 times, and most preferably at least 3 times greater than the width of the side extension. Example 11. 11. The heating assembly according to any of Examples 1-10, wherein the lateral extensions have a length of 5 mm to 20 mm, preferably 8 mm to 15 mm, more preferably 10 mm to 14 mm, and most preferably 12 mm. Example 12. 12. The heating assembly according to any of Examples 1-11, wherein the lateral extensions have a width of 2 mm to 6 mm, preferably 3 mm to 5 mm, more preferably 4 mm. Example 13. The heating assembly of any one of Examples 1 to 12, wherein the long edge of one or more of the first substrate layer, the second substrate layer, and the third substrate layer has a length of 16 mm to 32 mm, preferably 19 mm to 29 mm, more preferably 22 mm to 26 mm, and most preferably 24 mm. Example 14. The heating assembly of any of Examples 1 and 3-13, wherein only the first substrate layer, the second substrate layer, or the third substrate layer includes a side extension. Example 15. A heating assembly as described in any one of Examples 1 to 14, wherein the heating assembly further comprises a fastening leg, the fastening leg being disposed on a long edge portion of one or more of the first substrate layer, the second substrate layer, and the third substrate layer. Example 16. The heating assembly of any one of Examples 1-15, wherein the heating element is a resistive heater. Example 17. 17. The heating assembly of examples 15 and 16, wherein the heating element comprises heater contacts, the heater contacts being disposed on the fixation legs. Example 18. The heating assembly of any of Examples 1-17, wherein the heating element comprises a heating track, preferably the heating element is a heating track. Example 19. The heating assembly of any of Examples 1-18, wherein the heating element is printed onto the first substrate layer. Example 20. The heating assembly of any of Examples 1-19, wherein the heating assembly is rolled into a tube. Example 21. 21. The heating assembly of any one of Examples 1-20, wherein the temperature sensor comprises two contacts. Example 22. The heating assembly of any of Examples 1-21, wherein the third substrate layer comprises at least two openings. Example 23. The heating assembly of Examples 21 and 22, wherein the two openings are aligned such that the two contacts are not covered by the third substrate layer. Example 24. The heating assembly of any of Examples 1-23, wherein a heat shrink layer is disposed around the heating assembly, the heat shrink layer preferably being made of PEEK. Example 25. Of the following: a first adhesive layer is provided between the first substrate layer and the heating element; a second adhesive layer is provided between the heating element and the second substrate layer; a third adhesive layer is provided between the second adhesive layer and the temperature sensor; - a fourth adhesive layer is provided between the temperature sensor and the third substrate layer. Example 26. The heating assembly of any of Examples 1-25, wherein one or more of the first substrate layer, the second substrate layer, and the third substrate layer comprises a polyamide film. Example 27. An aerosol generating device comprising a heating assembly according to any one of Examples 1 to 26. Example 28. 28. The aerosol generating device of Example 27, wherein the aerosol generating device comprises a cavity for receiving an aerosol-generating article, and the heating assembly is positioned to at least partially surround the cavity. Example 29. 29. The aerosol generating device of Example 28, wherein the sidewall of the cavity is formed from a stainless steel tube and the heating assembly is mounted on the stainless steel tube. Example 30. 1. A method of manufacturing a heating assembly for an aerosol generating device, the method comprising: providing a first substrate layer, the first substrate layer being an electrically insulating substrate layer; disposing a heating element on the first substrate layer; disposing a second substrate layer overlying the heating element and the first substrate layer, the second substrate layer being an electrically insulating substrate layer; disposing a temperature sensor on the second substrate layer; disposing a third substrate layer at least partially covering the temperature sensor and over the second substrate layer, the third substrate layer being an electrically insulating substrate layer; providing one or more of the first substrate layer, the second substrate layer, and the third substrate layer with a side extension at a short edge of each substrate layer.

[0101] Features described with respect to one embodiment may be equally applied to other embodiments of the invention.

[0102] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0103] 1 shows a heating assembly 10. The heating assembly 10 comprises a stainless steel tube 12. The stainless steel tube 12 forms an inner layer of the heating assembly 10. The stainless steel tube 12 is tubular. The stainless steel tube 12 forms a heating chamber 14 such that an aerosol-generating article comprising an aerosol-forming substrate can be placed within the heating chamber 14 to heat the aerosol-forming substrate and create an inhalable aerosol.

[0104] Figure 1 further shows a first substrate layer 16. A heating element 18 in the form of a heating track is disposed on the first substrate layer 16. Electrical heater contacts 20 of the heating element 18 are also shown in Figure 1. A first adhesive layer 22 is disposed on the first substrate layer 16 for attachment between the first substrate layer 16 and the heating element 18. Additionally, the surface area of ​​the first substrate layer 16 not covered by the heating element 18 may be attached to a second substrate layer 24 via the first adhesive layer 22.

[0105] FIG. 1 further shows a second substrate layer 24. A second adhesive layer 26 is disposed on the second substrate layer 24. The second adhesive layer 26 functions to enable attachment between the second substrate layer 24 and the temperature sensor 28. The second adhesive layer 26 further facilitates attachment between the second substrate layer 24 and the sensor contact 30 of the temperature sensor 28. Finally, the second adhesive layer 26 facilitates attachment between the second substrate layer 24 and a third substrate layer 38. The third substrate layer 38 is disposed on the temperature sensor 28, as will be described in more detail below with reference to FIG. 3. The third substrate layer 38 is not shown in FIG. 1. Finally, a heat shrink layer 32 is positioned on the heating assembly 10. Heating the heat shrink layer 32 facilitates secure retention of all components of the heating assembly 10.

[0106] 2 shows the layers of the heating assembly 10 in more detail. The inner layer is formed by the stainless steel tube 12. A tube adhesive layer 34 is utilized to connect the stainless steel tube 12 with the first substrate layer 16. As the next layer, the heating element 18 is placed on the first substrate layer 16 via a first adhesive layer 22. A heater adhesive layer 36 is placed between the heating element 18 and the second substrate layer 24. Finally, the temperature sensor 28 is placed on the second substrate layer 24 via a second adhesive layer 26.

[0107] FIG. 2 further illustrates the preferred thicknesses of all layers.

[0108] Figure 3 shows the additional placement of a third substrate layer 38 over the temperature sensor 28 via a fourth adhesive layer 40. The third substrate layer 38 is provided with at least two openings 42 to allow the sensor contacts 30 to be contacted through the third substrate layer 38. Figure 3 further shows the preferred thicknesses of all layers.

[0109] FIG. 4 shows a different view of the heating assembly 10 from the top, showing the heating assembly 10 before it is rolled into a tube.

[0110] The heating tracks of the heating element 18 are illustrated in Figure 4. Two heater contacts 20 are provided to allow the supply of electrical energy to the heating element 18. Furthermore, two sensor contacts 30 are provided to electrically contact the temperature sensor 28. An opening in the third substrate layer 38 is shown in Figure 4 to allow contact with the temperature sensor 28 via the sensor contacts 30. Furthermore, Figure 4 shows a third opening in the middle of the third substrate layer 38 to improve the mechanical strength of the connection of the temperature sensor 28, since the contacts can contact the sensor adhesive layer 40 through this opening.

[0111] FIG. 5 shows the first substrate layer 16, the second substrate layer 24 and the third substrate layer 38 prior to attachment of the layers and prior to attachment of the heating element 18 and temperature sensor 28.

[0112] FIG. 5 further illustrates a first lateral extension 44 of the first substrate layer 16 , a second lateral extension 46 of the second substrate layer 24 , and a third lateral extension 48 of the third substrate layer 38 .

[0113] The first side extension 44 is disposed at a first short edge 50 of the first substrate layer 16. The second side extension 46 is disposed at a first short edge 52 of the second substrate layer 24. The third side extension 48 is disposed at a first short edge 54 of the third substrate layer 38.

[0114] The first side extension 44 may be attached to a first attachment area 56 disposed adjacent the opposite short edge of the first substrate layer 16. The second side extension 46 may be attached to a second attachment area 58 disposed adjacent the opposite short edge of the second substrate layer 24. The third side extension 48 may be attached to a third attachment area 60 disposed adjacent the opposite short edge of the third substrate layer 38.

[0115] First side extension 44 is shorter than first attachment region 56. First side extension 46 is shorter than second attachment region 58. Third side extension 48 is shorter than third attachment region 60. As a result, step regions 62 are created where each short edge extends above each side extension.

[0116] 5 also shows mounting feet 64. The mounting feet are provided so that heater contacts of the heating element 18 can be placed on the mounting feet 64. The heater contacts can be attached to electrical components of the aerosol generating device, such as a controller or power supply.

Claims

1. 1. A heating assembly for an aerosol generating device, the heating assembly comprising: a first substrate layer, the first substrate layer being an electrically insulating substrate layer; a heating element disposed on the first substrate layer; a second substrate layer, the second substrate layer being an electrically insulating substrate layer and disposed to cover the heating element and the first substrate layer; a temperature sensor disposed on the second substrate layer; a third substrate layer, the third substrate layer being an electrically insulating substrate layer at least partially covering the temperature sensor and positioned over the second substrate layer; The heating assembly, wherein all three of the first substrate layer, the second substrate layer, and the third substrate layer include side extensions at short edges of each substrate layer.

2. The heating assembly of claim 1 , wherein the side extensions overlap one another.

3. 3. A heating assembly according to claim 1, wherein the side extensions extend over at least 70%, preferably at least 80%, more preferably at least 90%, and more preferably the entire length of the short side edge of each substrate layer.

4. 3. The heating assembly of claim 1, wherein each of the substrate layers including the side extensions includes an attachment area on an opposite short edge of the respective substrate layer.

5. 5. The heating assembly of claim 4, wherein the surface area of ​​the attachment area is essentially the same as, and preferably is the same as, the surface area of ​​the side extensions.

6. A heating assembly according to any of claims 1 or 2, wherein the lateral extensions have a length of from 5mm to 20mm, preferably from 8mm to 15mm, more preferably from 10mm to 14mm, most preferably 12mm.

7. A heating assembly according to any of claims 1 or 2, wherein the lateral extensions have a width of from 2 mm to 6 mm, preferably from 3 mm to 5 mm, more preferably 4 mm.

8. 3. The heating assembly of claim 1, further comprising fastening legs, the fastening legs being disposed on a long edge of one or more of the first substrate layer, the second substrate layer, and the third substrate layer.

9. 3. A heating assembly according to claim 1 or 2, wherein the heating element comprises a heating track, preferably the heating element is a heating track.

10. The heating assembly of claim 1 or 2, wherein the heating element is printed onto the first substrate layer.

11. 3. The heating assembly of claim 1, wherein the heating assembly is rolled into a tube.

12. An aerosol generating device comprising a cavity for receiving the heating assembly described in claim 11 and an aerosol-forming substrate, wherein the side walls of the cavity are formed from a stainless steel pipe and the heating assembly is mounted on the stainless steel pipe.

13. 1. A method of manufacturing a heating assembly for an aerosol generating device, the method comprising: providing a first substrate layer, said first substrate layer being an electrically insulating substrate layer; disposing a heating element on the first substrate layer; disposing a second substrate layer covering the heating element and the first substrate layer, the second substrate layer being an electrically insulating substrate layer; disposing a temperature sensor on the second substrate layer; disposing a third substrate layer at least partially covering the temperature sensor and overlying the second substrate layer, the third substrate layer being an electrically insulating substrate layer; and providing all three of the first substrate layer, the second substrate layer, and the third substrate layer with side extensions at a short edge of each of the substrate layers.

Images