Aerosol generation device

Abstract

To provide a device improved in safety and / or reliability.SOLUTION: An aerosol generation device includes: an electrical power source (221); a heating chamber; a heater arranged to supply heat to the heating chamber; control circuitry configured to control the supply of electrical power from the electrical power source to the heater; a frame (223, 224); and a housing having an internal volume containing the electrical power source, the heating chamber, the heater, the control circuity and the frame. The frame is arranged between a first volume of the internal volume containing the heater and the heating chamber, and a second volume of the internal volume containing the electrical power source.SELECTED DRAWING: Figure 4C

Description

[Technical field]

[0001] The present disclosure relates to aerosol generating devices. The disclosure is particularly applicable to portable aerosol generating devices that may be self-contained and low-temperature. Such devices may heat tobacco or other suitable aerosol substrate material by conduction, convection, and / or radiation, rather than by combustion, to generate an aerosol for inhalation. [Background technology]

[0002] The popularity and use of risk reduction or risk modification devices (also known as vaporizers) has grown rapidly in recent years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. A variety of devices and systems are available that heat or warm an aerosolizable substance, as opposed to burning tobacco in traditional tobacco products.

[0003] A commonly available risk reduction or risk modification device is the heated substrate aerosol generating device or heat-not-burn device. This type of device generates an aerosol or vapor by heating an aerosol substrate, which typically includes moist tobacco or other suitable aerosolizable material, to a temperature typically ranging from 150°C to 300°C. By heating, rather than burning or combusting, the aerosol substrate releases an aerosol that includes the ingredients desired by the user, but without the toxic and carcinogenic by-products of combustion and burning. Furthermore, aerosols generated by heating tobacco or other aerosolizable material typically do not include the burnt or bitter taste that can result from combustion and burning, which can be unpleasant to the user. Thus, the substrate does not require sugars and other additives that are typically added to such materials to make the smoke and / or vapor more palatable to the user.

[0004] It is desirable to provide devices with improved safety and / or reliability.

[0005] In particular, in such aerosol generating devices, the aerosol substrate must be heated by a heater, and it is inevitable that some heat will leak from the heater to the rest of the aerosol generating device. This heat can damage other components, such as the heater's power supply or heat-sensitive electronics. In some cases, components that are not designed to be heated can become dangerous, even posing a risk of fire or explosion, if they become too hot.

[0006] In addition, the power supply may experience leakage or outgassing events that result in the release of fluids (liquid or gas) from the power supply. These events are within the normal behavior of the power supply and do not necessarily impair the functionality of the aerosol generating device. However, fluids released from such events may indirectly impair functionality, for example, by damaging sensitive components of the control circuitry or by contaminating the heating chamber. Summary of the Invention [Means for solving the problem]

[0007] According to a first aspect of the present disclosure, there is provided an aerosol generating device comprising a power source, a heating chamber, a heater arranged to provide heat to the heating chamber, a control circuit configured to control a supply of power from the power source to the heater, a frame, and a housing having an interior volume that accommodates the power source, the heating chamber, the heater, the control circuit, and the frame. The frame has a first volume of the interior volume that accommodates the heater and the heating chamber, and a second volume that accommodates the power source. The second volume is disposed between the inner volume.

[0008] By placing a frame between a first volume housing the heater and a second volume housing the power supply, the power supply can be thermally shielded from any heat leaking from the heater and heating chamber, and the heater and heating chamber can be physically shielded from leakage or outgassing events from the power supply.

[0009] Optionally, the housing is an elongated housing for hand holding, the first volume, the frame and the second volume being each disposed along a longitudinal direction of the housing.

[0010] Optionally, the first volume contains a region of air or vacuum adjacent the heating chamber.

[0011] Optionally, the heating chamber and heater are held by a frame so that they do not contact the housing.

[0012] By keeping the heating chamber and heater out of contact with the housing, heat transfer to the housing (which could otherwise cause the housing to become excessively or even dangerously hot) is prevented, and the heater and heating chamber are protected from external damage, for example if the aerosol generating device is dropped.

[0013] Optionally, the power supply and control circuitry are carried by the frame.

[0014] Optionally, the control circuitry comprises components mounted on a first PCB disposed within the second volume along the frame.

[0015] By locating the first PCB on the second volume side of the frame, the first PCB may be thermally shielded from the heater and the heating chamber by the frame, thereby reducing the effect of any heat escaping from the heating chamber on the components mounted on the first PCB.

[0016] Optionally, the first PCB is a double-sided PCB.

[0017] Optionally, the aerosol generating device further comprises a second PCB disposed along the frame between the first volume and the second volume.

[0018] The substrate of the second PCB acts as an additional heat shield to protect the control circuitry in the second volume.

[0019] Optionally, the second PCB is a single-sided PCB, and the control circuitry further comprises components mounted on the second PCB and within the second volume.

[0020] Since one side of the second PCB may be exposed to heat leaking from the heater and heating chamber in the first volume, it is convenient for the second PCB to be a single-sided PCB and for the control circuit components to be mounted on at most the side of the second PCB that is in the second volume.

[0021] Optionally, the first PCB and the second PCB are connected by a flexible PCB portion, and the first PCB, the second PCB and the flexible PCB portion are arranged around a frame.

[0022] This use of flexible PCB sections not only means that when one of the first and second PCBs is fixed, the other is easily guided into position, but also makes it easier to fit into irregular spaces. This also means that a larger area for the control circuitry can be easily printed at once to fit the control circuitry within the printed circuit board and reduce the area required for the control circuitry, while also allowing it to be split across multiple surfaces, helping to reduce the volume of the aerosol generating device.

[0023] According to a second aspect of the present disclosure, there is provided an aerosol generating device comprising a power source, a heating chamber, a heater arranged to provide heat to the heating chamber, a control circuit configured to control a supply of power from the power source to the heater, a frame, and a housing having an interior volume accommodating the power source, the heating chamber, the heater, the control circuit, and the frame, wherein the frame is disposed between a third volume of the interior volumes accommodating the heater, the heating chamber, and the control circuit, and a fourth volume of the interior volumes accommodating the power source.

[0024] Optionally, the frame is positioned to prevent fluid flow from the fourth volume to the third volume.

[0025] This protects the heater, heating chamber, and control circuitry from possible damage or contamination due to outgassing or leakage from the power supply.

[0026] Optionally, the housing is an elongated housing for hand holding, the third volume, the frame and the fourth volume being each disposed along a longitudinal direction of the housing.

[0027] Optionally, the power supply is carried by the frame.

[0028] Optionally, the first and second aspects may be combined to provide an aerosol generating device comprising a first frame disposed between a first volume housing a heater and a heating chamber and a fifth volume housing a control circuit, and a second frame disposed between the fifth volume of the internal volume housing the control circuit and a fourth volume housing a power source.

[0029] This arrangement has the advantage that the control circuitry is protected from heat leakage from the heater subassembly and from fluids generated by the power supply.

[0030] Optionally, the control circuitry comprises components mounted on a PCB held between the first frame and the second frame. [Brief description of the drawings]

[0031] [Figure 1A] FIG. 1 is a schematic diagram of an aerosol generating device. [Figure 1B] FIG. 1 is a schematic diagram of an aerosol generating device. [Figure 2A] FIG. 2 is a schematic diagram of an intermediate subassembly. [Figure 2B] FIG. 2 is a schematic diagram of a housing subassembly. [Figure 3A] FIG. 2 is a schematic diagram of a portion of the intermediate subassembly. [Figure 3B] FIG. 2 is a schematic diagram of a portion of the intermediate subassembly. [Figure 4A] FIG. 13 is a schematic diagram of another portion of the intermediate subassembly. [Figure 4B] FIG. 13 is a schematic diagram of another portion of the intermediate subassembly. [Figure 4C] FIG. 13 is a schematic diagram of another portion of the intermediate subassembly. [Figure 4D] FIG. 13 is a schematic diagram of another portion of the intermediate subassembly. [Figure 5A] FIG. 2 is a schematic diagram of a heater subassembly. [Figure 5B] FIG. 2 is a schematic diagram of a heater subassembly. [Figure 5C] FIG. 2 is a schematic diagram of a heater subassembly. [Figure 6A] FIG. 2 is a schematic diagram of a portion of an intermediate subassembly. [Figure 6B] FIG. 2 is a schematic diagram of a portion of an intermediate subassembly. [Figure 7A] FIG. 2 is a schematic diagram of an access subassembly. [Figure 7B] FIG. 2 is a schematic diagram of an access subassembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] 1A, 1B, 2A, and 2B show a series of modular subassemblies assembled into an aerosol generating device as an overview of an aerosol generating device according to one embodiment of the present invention. Figures 3A-6B show additional details of each of the subassemblies. It will be understood that many details of the embodiments are not relevant to explaining the claimed aspects of the present device, and therefore, for the sake of brevity, some of the illustrated features have not been described in detail, and, for simplicity, some features have been omitted entirely in certain figures in order to better explain features relevant to understanding and practicing the present invention.

[0033] Referring to FIG. 1A, according to one embodiment of the present invention, an aerosol generating device 1 comprises an access subassembly 11 and a housing subassembly 12.

[0034] The aerosol generating device 1 has an overall elongated, pebble-like shape with an upper end from which the aerosol is provided, a lower end opposite the upper end, and four sides in a generally rectangular configuration with two opposing larger sides and two opposing smaller sides between the lower end and the upper end.

[0035] The access subassembly 11 is at the top end and provides means for opening and closing access to the heating chamber within the aerosol generation device 1, for example for a user to supply an aerosol substrate such as tobacco to be heated in the heating chamber, to take the generated aerosol and to clean the heating chamber. In this embodiment the access means comprises a lid 111 attached to a slider mechanism.

[0036] The housing subassembly 12 provides a housing for the internal components of the aerosol generating device 1, including the power supply, heating chamber, heater, control circuitry, and frame, and provides at least a portion of the sides and the bottom end of the aerosol generating device 1. In this embodiment, the housing is an elongated housing for hand-holding, although the benefits of the present invention can also be achieved in aerosol generating devices 1 that are not designed to be hand-held. Additionally, as shown in the central linear region 121 of the housing subassembly 12 in FIG. 1A, in this embodiment, the aerosol generating device 1 includes one or more indicators (e.g., lights) and one or more inputs (e.g., buttons) for controlling the aerosol generating device. In embodiments with indicators or inputs, the housing subassembly may include transparent or tactile portions, or may simply include gaps that allow access to the internal indicators and inputs.

[0037] Referring to Figure 1B, in this schematic diagram, the access subassembly 11 and the housing subassembly 12 are represented as "transparent" (indicated by dashed edges), and it can be seen that the aerosol generating device 1 further comprises an intermediate subassembly 13 housed within the access subassembly 11 and the housing subassembly 12.

[0038] Details of the intermediate subassembly 13 are shown diagrammatically in FIG. 2A, and the interior volume of the housing subassembly is shown diagrammatically in FIG. 2B.

[0039] Referring to FIG. 2A, the intermediate subassembly 13 includes a heater subassembly 21 fixed relative to a power and control subassembly 22 .

[0040] The heater subassembly 21 includes a heater and a heating chamber, the heater being disposed in the heater subassembly to supply heat to the heating chamber. Next, the heater subassembly will be described in more detail.

[0041] The power and control subassembly 22 comprises a power source 221, in this case a battery. The power and control subassembly 22 further comprises control circuitry 222 configured to control the delivery of power from the power source to the heater. In this embodiment, the control circuitry 222 is implemented on multiple PCBs, as described below.

[0042] The power supply 221 and control circuitry 222 are supported by a heater subassembly support frame 223 and a power supply support frame 224 .

[0043] The heater subassembly support frame 223 is arranged to divide the interior volume of the housing subassembly 12 into a first volume and a second volume. The first volume houses the heater subassembly 21, which includes a heater and a heating chamber. The second volume houses the power supply 221. As shown in Figures 2A and 1B, in this embodiment, the first volume, the heater subassembly support frame 223, and the second volume are each arranged along the longitudinal direction of the housing of the housing subassembly 12, but as mentioned above, not all embodiments of the invention are elongated, and in such non-elongated embodiments, the heater subassembly support frame 223 may be arranged in any manner that divides the interior volume of the housing into a first volume and a second volume. This division is shown diagrammatically in Figure 2A using a dashed line A, with the first volume being to the left of the line A in the figure and the second volume being to the right of the line A in the figure. With this configuration, heater subassembly support frame 223, in addition to supporting heater subassembly 21, has the effect of shielding power supply 221 from any heat escaping from heater subassembly 21. Heater subassembly support frame 223 is optionally made of an insulating material to insulate control circuitry 222 and power supply 221 from heater subassembly 21, although the combined effect of the frame and shield is achieved with only moderately insulating materials such as plastic. Heater subassembly support frame 223 and power supply support frame 224 may comprise, for example, PA (polyamide) and / or PEEK (polyetheretherketone).

[0044] Additionally, in this embodiment, the heater subassembly 21, which includes the heating chamber and heater, is held by the heater subassembly support frame 223 such that neither the heating chamber nor the heater contacts the housing of the housing subassembly 12. Means for holding the heater subassembly 224 are described below with reference to Figures 3 and 4. This prevents heat transfer from the heater subassembly to the housing (which may otherwise cause the handheld housing to become excessively or even dangerously hot). This also protects the heater subassembly 21 from external damage, for example if the aerosol generating device is dropped. However, these advantages are separate from the volumetric feature, and in some embodiments, the heater subassembly support frame 223 feature of holding and suspending the heater and / or heating chamber can be omitted.

[0045] The power supply support frame 224 is arranged to divide the interior volume of the housing subassembly 12 into a third volume and a fourth volume. The third volume houses the heater subassembly 21, which includes the heater and heating chamber, and also houses the control circuitry 222. The fourth volume houses the power supply 221. As shown in Figures 2A and 1B, in this embodiment, the third volume, the power supply support frame 224, and the fourth volume are each arranged along the length of the housing of the housing subassembly 12, but as mentioned above, not all embodiments of the invention are elongated, and in such non-elongated embodiments, the power supply support frame 224 may be arranged in any manner that divides the interior volume of the housing into a third volume and a fourth volume. This division is shown diagrammatically in Figure 2A using dashed line B, with the third volume being to the left of line B in the figure. The fourth volume is to the right of line B in the diagram. With this configuration, the power supply support frame 224, in addition to supporting the power supply 221, has the effect of preventing fluid flow from the fourth volume to the third volume. This protects the heater, heating chamber, and control circuitry from damage or contamination due to outgassing or leakage by the power supply 221.

[0046] Additionally, in this embodiment, the power source 221 is held in the power source support frame 224 such that the power source 221 does not contact the housing of the housing subassembly 12. The power source 221 is held, for example, by an adhesive such as glue, a soldered bond that also forms an electrical contact, or by a mechanical connection such as a snap fit. The lack of contact with the housing ensures that there is space for outgassing or leakage to occur during normal operation of the power source 221, even though the power source support frame 224 prevents such leakage from expanding or entering the third volume. This also protects the power source 221 from external damage, for example if the aerosol generating device is dropped. However, these advantages are separate from the volume dividing feature, and in some embodiments, the feature of the power source support frame 224 holding and suspending the power source 221 can be omitted.

[0047] 1B , an intermediate fifth volume is defined across the aerosol generation device 1 as an overlap between the second and third volumes, such that a first volume housing the heater and heating chamber is on one side of the heater subassembly support frame 223, a fifth volume housing the control circuitry 222 is between the heater subassembly support frame 223 and the power supply support frame 224, and a fourth volume housing the power supply 221 is on the other side of the power supply support frame 224. However, it should be noted that while both are present in this embodiment, only one of the heater subassembly support frame 223 and the power supply support frame 224 is required, and the other may be omitted in alternative embodiments.

[0048] As additionally shown in Figure 2A, the power and control subassembly 22 may include an indicator array 225 of one or more indicators (e.g., LEDs) for indicating the status of the device, and one or more inputs 226 (e.g., tactile switches) corresponding to the central linear region 121 of the housing subassembly 12 of Figure 1A. The power and control subassembly 22 may further include a vibrator subassembly 227 for providing a further indication of the status of the device. Additionally, the power and control subassembly 22 may include an external electrical connector 228 for charging the power source 221, or optionally for data communication with the control circuitry 222.

[0049] Furthermore, as shown in FIG. 2A, in this embodiment, a space is left beside the heater subassembly 21 in the first volume. This space corresponds to the part of the aerosol generating device 1 that is most vulnerable to heat leaking from the heater subassembly 21, and is left empty to avoid exposing the vulnerable part to the leaking heat. To limit convective heat transfer from the heater subassembly 21, this empty space may be kept as a vacuum (where "vacuum" here includes air at substantially lower pressure than standard pressure). Alternatively, this empty space may be filled with air. In that case, air may be allowed to flow between the empty space and the outside of the aerosol generating device 1 to reduce the effect of heat leaking from the inside of the heater subassembly 21.

[0050] As shown in FIG. 2B, the housing subassembly 12 is generally hollow to accommodate at least a portion of the intermediate subassembly 13. As seen in FIG. 1B, in this embodiment, the intermediate subassembly 13 extends out from the housing subassembly 12 and is partially accommodated by the access subassembly 11. In other embodiments, the intermediate subassembly 13 may be configured as a casing. The entire bridge 13 may be contained within the housing subassembly 12 .

[0051] 3A and 3B, a portion of the power supply and control subassembly of one embodiment is shown, which may or may not actually represent a stage in the manufacture of the corresponding aerosol generating device, but is included here specifically to show the details of the power supply and control subassembly of this embodiment. In the view of FIG. 3A, the heater subassembly support frame 223 and the power supply support frame 224 are represented as "transparent" using dashed lines, allowing the first PCB 31 to be seen between the two frames and disposed along the length of the heater subassembly support frame 223. Meanwhile, FIG. 3B is a three-dimensional view showing the first PCB 31 partially encapsulated between the heater subassembly support frame 223 and the power supply support frame 224. In this embodiment, the heater subassembly support frame 223 and the power supply support frame 224 flank either side of the first PCB 31. This arrangement has the advantage that the first PCB 31 is in a second volume (protected from heat leaking from the heater subassembly 21) and in a third volume (protected from fluids generated by the power source 221). Thus, one or more sensitive components of the control circuit 222 (i.e., components sensitive to heat or fluids that may be generated by the power source) may be located on one or both sides of the first PCB 31. To maximize the surface area of ​​the first PCB 31, this PCB may be a double-sided PCB. For example, the first PCB 31 may have a processor chip or a memory chip mounted thereon.

[0052] To aid in the alignment of the heater subassembly support frame 223 and the power supply support frame 224, in this embodiment the heater subassembly support frame 223 and the power supply support frame 224 include respective first guide members 32 and 32' that fit together when the frames are properly aligned. For example, the first guide members 32 and 32' may be protrusions or pins and corresponding recesses or holes. In other embodiments, additionally or alternatively, the first PCB 31 may include a first guide member for aligning the first PCB 31 with the respective first guide members of the heater subassembly support frame 223 and / or the power supply support frame.

[0053] To assist in aligning the power supply and control subassembly 22 with the heater subassembly 21, the heater subassembly support frame also includes second guide members 33, 35 adapted to fit into corresponding second guide members on the heater subassembly 21.

[0054] Additionally, in this embodiment, the power supply and control subassembly is formed using snap fit connectors 34 which attach the heater subassembly support frame 223 to the power supply support frame 224, thereby holding the first PCB 31 in place.

[0055] 4A, 4B, 4C, and 4D, another portion of the power supply and control subassembly is shown from various perspectives around the assembly. This may or may not actually represent a stage in the manufacture of the corresponding aerosol generating device, as with FIGS. 3A and 3B, but is included here specifically to show the details of the power supply and control subassembly in this embodiment. The power supply support frame 224 is shown in FIGS. 4C and 4D, but is omitted in FIGS. 4A and 4B. To understand the comparison of these figures, it should be noted that FIG. 4B is horizontally reflected with respect to FIGS. 4A, 4C, and 4D to more effectively show the flexible PCB portion 41.

[0056] 4A to 4D, the power supply and control subassembly 22 of the present embodiment includes a first PCB 31, a second PCB 42, and a flexible PCB portion 41, and the first PCB 31 and the second PCB 42 are connected to each other by the flexible PCB portion 41. Each of the first PCB 31 and the second PCB 42 has one or more components of the control circuitry 222 mounted thereon. The power and control subassembly 22 may comprise further PCBs, which in this embodiment host, for example, the indicator array 225 and the inputs 226 shown in Figures 2A and 4C.

[0057] The flexible PCB portion 41 is wrapped around the heater subassembly support frame 223, and the second PCB 42 is attached to the heater subassembly support frame 223 such that the heater subassembly support frame 223 is between the first PCB 31 and the second PCB 42. This use of the flexible PCB portion not only means that when one of the first PCB 31 and the second PCB 42 is fixed, the other can be easily guided into the correct position, but also means that a large area for the control circuit 222 can be easily printed at once and at the same time split up into multiple surfaces in order to fit the control circuit 222 in an irregular space and reduce the area required for the control circuit 222, which helps to reduce the volume of the aerosol generating device 1.

[0058] FIG. 4A also illustrates an example of a first guiding member 32 ″ of the first PCB 31 described above in addition to or as an alternative to the first guiding members 32 and 32 ′ of the heater subassembly support frame 223 and the power supply support frame 224 .

[0059] As shown in Figures 4B, 4C, and 4D, the second PCB 42 is disposed along the heater subassembly support frame 223 to form part of the division between the first volume and the second volume. In other words, one side of the second PCB 42 is exposed to the first volume that may be exposed to heat leaking from the heater subassembly 21, and the other side of the second PCB 42 faces the heater subassembly support frame 223 or faces a gap in the heater subassembly support frame 223. Since one side of the second PCB 42 may be exposed to the leaking heat, it is convenient to make the second PCB 42 a single-sided PCB and mount the components of the control circuit 222 on the side of the second PCB 42 that is in the second volume at best. In this way, the substrate of the second PCB 42 functions as a heat shield to protect the control circuit 222 in the second volume. Nonetheless, to utilize some of the surface of the second PCB 42 facing the first volume, this surface may be provided with electrical contacts 44 for testing and / or connection to the heater subassembly 21. These contacts 44 remain exposed when the power and control subassembly 22 is completed, facilitating testing of the power and control subassembly and making electrical connections between the heater subassembly 21 and the power and control subassembly 22. The heater subassembly support frame 223 may further include snap fit connectors 43 for mounting the second PCB 42 to the frame.

[0060] 4C shows a gap in the heater subassembly support frame 223 where the components of the control circuit 222 implemented on the first PCB 31 can be seen before the second PCB 42 is attached to the heater subassembly support frame. Nevertheless, at this stage of assembly, the first PCB 31 is attached to the second PCB 42 by the flexible PCB portion 41. FIG. 4C also shows the components of the control circuit 222 implemented on the second PCB 42. When the second PCB 42 is attached to the heater subassembly support frame 223, the components of the control circuit 222 implemented on the first and second PCBs are protected by the substrate of the second PCB 42, and the heater subassembly support frame 223 separates a first volume exposed to heat from the heater subassembly 21 from a second volume housing the control circuit 222 and the power supply 221. Meanwhile, the opposite face of the second PCB 42, which includes electrical contacts 44, is exposed to the first volume, as shown in FIG. 4D.

[0061] 5A, 5B, and 5C show some additional features of the heater subassembly 21, which will be described later. The following provides some detailed information:

[0062] Figures 5A and 5B are end and side views, respectively, of the complete heater subassembly 21. Referring to Figures 5A and 5B, heater end frames 51 are provided on both ends of the heater subassembly 21 for supporting, aligning and mounting the heater subassembly. The heater end frames 51 include second guide members 33' and 35', respectively, to aid in alignment between the heater subassembly 21 and the power and control subassembly 22.

[0063] Between the heater end frames 51, a thermal insulation sheath 52 is provided. The thermal insulation sheath 52 surrounds the heating chamber 53 and the heater 54, which are shown separately in FIG. 5C. The heating chamber is an elongated chamber open at one end corresponding to the access subassembly 11, and includes a thermally conductive material, such as a metal, for conducting heat from the heater 54 wrapped around the outside of the heating chamber 53 to the aerosol substrate material in the heating chamber 53. The thermal insulation sheath 52 is provided to insulate and contain the heat generated by the heater 54, so that the heat is delivered to the heating chamber 53 more efficiently and other components of the aerosol generating device 1 are less exposed to the heat from the heater 54. In this embodiment, the heater subassembly 21 further includes a temperature sensor for measuring the temperature in the heater subassembly.

[0064] The heater 54 and temperature sensor each have electrical contacts or connections for receiving power and obtaining measurements.

[0065] 6A and 6B show diagrammatically how the mounting cap 23 can be used to complete the intermediate subassembly 13. As shown in FIG.

[0066] As shown in Figure 6A, the second guide members 33, 33', 35, and 35' of the heater subassembly 21 and the power and control subassembly 22, respectively, are aligned and mated together. Like the first guide members, the second guide members may be protrusions or pins and corresponding recesses or holes. As a result of this alignment and mating, the heater subassembly 21 and the power and control subassembly 22 are properly positioned but are not yet attached.

[0067] As shown in FIG. 6B, the mounting cap 23 (shown "transparent" in dashed lines) is arranged to fit snugly vertically over the ends of the aligned heater subassembly 21 and power and control subassembly 22, at least partially covering the heater subassembly 21 and power and control subassembly 22. The mounting cap 23 may form the top of a generally T-shaped frame assembly incorporating the heater subassembly support frame 223 and the power supply support frame 224, and may be arranged to close the tops of the first to fifth volumes when the intermediate subassembly 13 is housed in the housing subassembly 12 (where the orientation of "top" is defined based on the device orientation as shown in FIG. 1A). Thus, when the components of the intermediate subassembly 13 are suspended in the housing without contacting the housing, they may be directly or indirectly attached to the mounting cap 23.

[0068] The heater subassembly 21, the power and control subassembly 22, and the mounting cap 23 are adapted to interlock with one another such that the heater subassembly 21 and the power and control subassembly 22 cannot be separated from one another when the mounting cap 23 is placed over the ends. In particular, in this embodiment, the mounting cap 23 longitudinally surrounds the ends of the aligned heater subassembly 21 and power and control subassembly 22. and adapted to partially cover, the second guide members 33, 33', 35, and 35' are arranged to prevent relative movement in the vertical direction between the heater subassembly 21 and the power and control subassembly 22, since they are orthogonal to the direction of the second guide members. Thus, by attaching the mounting cap 23 to one or both of the heater subassembly 21 and the power and control subassembly 22, relative movement between the heater subassembly 21 and the power and control subassembly 22 is prevented in the vertical direction, since it is transverse to the direction of the second guide members, and also in the vertical circumferential direction, since it is prevented by being transverse to the direction of the second guide members or by covering and surrounding the mounting cap. Thus, the heater subassembly 21 is fixed relative to the power and control subassembly 22.

[0069] In this embodiment, the mounting cap 23 is attached to the power supply support frame 224 of the power and control subassembly 22 at mounting cap attachment points 61. Attachment may be made using one or more reversible fastening means, such as screws. By making this attachment using reversible fastening means, the heater subassembly 21 can be more easily removed for cleaning, although other embodiments use a snap-fit ​​or press-fit connection at the mounting cap attachment points 61.

[0070] It should be noted that the mounting cap 23 is not required to secure the heater subassembly 21 to the power and control subassembly 22, and in other embodiments, such securing can be achieved by further providing a snap-fit ​​or press-fit connector instead of or in addition to the second guide members 33, 33', 35, 35'. This alternative embodiment further reduces the number of components and steps required to manufacture the aerosol generating device. Nevertheless, even if the mounting cap 23 is not used to secure the heater subassembly 21 to the power and control subassembly 22, the inclusion of the mounting cap 23 is convenient for attaching the access subassembly 11 and the housing subassembly 12. In particular, the mounting cap 23 provides a modular mounting interface that is independent of the other components of the intermediate subassembly 13 and can be adapted for convenient attachment to the device housing separately from the adaptation of the heater subassembly 21 and the power and control subassembly 22 for other purposes.

[0071] As shown in FIG. 6B, when the heater subassembly 21 is fixed relative to the power supply and control subassembly 22, electrical connections such as wires can be easily installed between the heater subassembly 21 and the power supply and control subassembly 22 using the exposed electrical contacts 44 of the power supply and control subassembly 22 and the electrical contacts or connections of the heater 54 and temperature sensor of the heater subassembly 21.

[0072] 7A and 7B, some additional details of the access subassembly 11 will now be described.

[0073] FIG. 7A shows a view of the access sub-assembly 11 with the access housing 71 "transparent" (shown in dashed lines) so that the internal features of the access sub-assembly 11 can be more easily seen.

[0074] The lid 111 is attached to a slider cart 73. The slider cart is configured to slide along slider guides 74 so that the lid 111 slides between an open position and a closed position. In the closed position, the opening of the access housing 71 is blocked by the lid 111. In the open position, the opening of the access housing 71 is open. When the aerosol generating device 1 is assembled and the lid 111 is in the open position, the opening of the access housing 71 is closed by the lid 111. provides access to the heating chamber 53.

[0075] As shown in Figure 7A, the access housing 71 includes snap-fit ​​connectors 75 for attaching the access subassembly 11 to the intermediate subassembly 13. In this embodiment, two opposing snap-fit ​​connectors 75 are provided corresponding to the two smaller opposing sides of the aerosol generating device 1, although any effective arrangement of connectors can be used. As with the snap-fit ​​connectors discussed above, the snap-fit ​​connectors may alternatively be press-fit connectors.

[0076] Additionally, access housing 71 includes a stepped rim along its bottom edge (as shown). Inner rim 77 extends downwardly beyond outer rim 76. This stepped rim helps secure access subassembly 11 together with housing subassembly 12 and can divert impact stresses away from snap fit connector 75, thereby helping to prevent structural weakness at the joint between access subassembly 11 and intermediate subassembly 13.

[0077] 7B, the slider guide 74 is hidden in this view to better illustrate the slider biasing mechanism 78 which acts to return the slider cart 73 and lid 111 to the closed position, thereby ensuring that the heating chamber 53 is covered when not in use.

[0078] Definitions and Alternative Embodiments It will be appreciated from the above description that many of the features of the above embodiments perform independent functions having independent advantages, and thus each of these independent features may be independently selected for inclusion or omission in the embodiments of the invention defined in the claims.

[0079] For example, the embodiments described above use a specific design of the power and control subassembly 22 that includes multiple PCBs. Alternatively, in other embodiments, the control circuitry 222 may be provided without the use of PCBs, particularly in cases where the control is very simple, such as a switch to turn a heater on and off and an impedance setting circuit. Alternatively, embodiments of the invention may have only one of the first PCB 31 and second PCB 42 described above.

[0080] The term "heater" should be understood to mean any device for outputting sufficient thermal energy to form an aerosol from an aerosol substrate. The transfer of thermal energy from the heater 54 to the aerosol substrate can be conductive, convective, radiative, or any combination of these means. As a non-limiting example, a conductive heater may directly contact and press against the aerosol substrate, or may contact a separate component, such as a heating chamber, that itself causes heating of the aerosol substrate by conduction, convection, and / or radiation.

[0081] The heater may be electrically powered, combustion powered, or powered by any other suitable means. Electrically powered heaters may include resistive track elements (optionally including insulating packaging), inductive heating systems (including, for example, electromagnets and high frequency oscillators), and the like. The heater 54 may be disposed around the outside of the aerosol substrate, may penetrate partway or completely into the aerosol substrate, or any combination thereof. For example, instead of the heaters of the above-described embodiments, the aerosol generating device may include a blade-type heater that extends into the aerosol substrate in the heating chamber.

[0082] The term “temperature sensor” refers to the absolute or relative temperature of a portion of the aerosol generating device 1. It is used to describe an element capable of determining the temperature. This may include a thermocouple, a thermopile, a thermistor, etc. The temperature sensor may be provided as part of another component or may be a separate component. In some examples, multiple temperature sensors may be provided, for example to monitor the heating of various parts of the aerosol generating device 1, for example to measure a thermal profile. Alternatively, some examples do not include a temperature sensor. This is possible, for example, when a thermal profile has already been reliably established and the temperature can be assumed based on the operation of the heater 54.

[0083] The control circuitry 222 in the drawings is shown as having a single user operable button for triggering on the aerosol generating device 1. This keeps the controls simple and reduces the possibility of a user misusing or failing to properly control the aerosol generating device 1. However, in some cases the input controls available to the user may be more complex than this, for example to control the temperature, for example within pre-set limits, to vary the flavor balance of the vapor, or to switch between, for example, a power saving mode and a quick heating mode.

[0084] The aerosol substrate includes tobacco, e.g., in dried or cured form, and optionally has additional ingredients for flavor or to provide a smoother or otherwise more satisfying effect. In some examples, the aerosol substrate, such as tobacco, may be treated with a vaporizer. The vaporizer may improve the generation of vapor from the aerosol substrate. The vaporizer may include, for example, a polyol, such as glycerol, or a glycol, such as propylene glycol. In some cases, the aerosol substrate may not even include tobacco or nicotine, but instead may include natural or artificially derived ingredients for flavoring, volatility, improved smoothness, and / or other satisfying effects. The aerosol substrate may be provided as a solid or paste-type material in shredded, pelleted, powdered, granular, strip or sheet form, optionally a combination thereof. Similarly, the aerosol substrate may be liquid or gel. Indeed, in some examples, it may include both solid and liquid / gel portions.

[0085] Thus, the aerosol generating device 1 may equally be referred to as a "heated tobacco device," a "heated non-combustion tobacco device," a "device for vaporizing tobacco products," etc., and is to be construed as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol substrate.

[0086] The aerosol generating device 1 may be configured to house the aerosol substrate in a pre-packaged substrate carrier. The substrate carrier may be generally similar to a cigarette with a tubular region having the aerosol substrate configured in a suitable form. Some designs may also include filters, vapor collection regions, cooling regions, and other structures. An outer layer of paper or other flexible planar material such as foil may also be provided, for example, to hold the aerosol substrate in place, further enhancing the similarity to a cigarette or the like. The substrate carrier may fit within the heating chamber 53 or may be longer than the heating chamber 53 such that the lid 111 remains open while the substrate carrier is provided to the aerosol generating device 1. In such an embodiment, the aerosol may be provided directly from the substrate carrier, which functions as the mouthpiece of the aerosol generating device.

[0087] As used herein, the term "fluid" shall be construed as generically describing a type of non-solid material that is capable of flowing, including, but not limited to, liquids, pastes, gels, powders, and the like. Accordingly, a "fluidized material" shall be construed as a material that is inherently fluid, or a material that has been modified to behave as a fluid. Fluidization may include, but is not limited to, powdering, dissolving in a solvent, gelling, thickening, thinning, and the like. The present invention is not limited to these.

[0088] As used herein, the term "volatile" refers to a substance that can be easily changed from a solid or liquid state to a gaseous state. As a non-limiting example, a volatile substance may have a boiling or sublimation temperature near room temperature at ambient pressure. Thus, "volatilize" or "volatilise" shall be interpreted to mean to cause (a material) to volatilize and / or to evaporate or disperse into a vapor.

[0089] As used herein, the term "vapour" (or "vapor") means: (i) the form into which a liquid is transformed spontaneously by the action of a sufficient degree of heat; or (ii) liquid / moisture particles suspended in the atmosphere and visible as a cloud of steam / smoke; or (iii) a fluid that fills space like a gas, but can be liquefied by pressure alone when below a critical temperature.

[0090] Consistent with this definition, the term "vaporize" (or "vaporize") means: (i) to change into or cause to change into a vapor, and (ii) when a particle changes physical state (i.e., from a liquid or solid to a gaseous state).

[0091] As used herein, the term "atomise" (or "atomize") shall mean: (i) the conversion (of a substance, especially a liquid) into very small particles or droplets, and (ii) where the particles remain in the same physical state (liquid or solid) as they were before atomization.

[0092] As used herein, the term "aerosol" shall mean a system of particles dispersed in air or gas, such as mist, fog, or smoke. Accordingly, the term "aerosolize" (or "aerosolize") means to make into an aerosol and / or to disperse as an aerosol. It is noted that the meaning of aerosol / aerosolize is consistent with each of volatilization, atomization, and vaporization defined above. For the avoidance of doubt, aerosol is used to consistently describe mist or droplets that include atomized, volatilized, or vaporized particles. Aerosol also includes mist or droplets that include any combination of atomized, volatilized, or vaporized particles.

Claims

1. Power supply, A heating chamber; a heater positioned to supply heat to the heating chamber; a control circuit configured to control a supply of power from the power source to the heater; A frame, a housing having an interior volume that accommodates the power supply, the heating chamber, the heater, the control circuitry, and the frame; An aerosol generating device comprising: An aerosol generating device, wherein the frame is disposed between a first volume of the interior volume that houses the heater and the heating chamber and a second volume of the interior volume that houses the power source.

2. The aerosol generating device of claim 1 , wherein the housing is an elongated housing for hand holding, and the first volume, the frame, and the second volume are each arranged along the longitudinal direction of the housing.

3. 3. The aerosol generating device of claim 1 or 2, wherein the first volume contains a region of air or vacuum adjacent the heating chamber.

4. An aerosol generating device according to any one of claims 1 to 3, wherein the heating chamber and the heater are held by the frame so as not to contact the housing.

5. The aerosol generating device of claim 4 , wherein the power source and the control circuitry are carried by the frame.

6. An aerosol generating device as described in any one of claims 1 to 5, wherein the control circuit comprises components mounted on a first PCB arranged within the second volume along the frame.

7. The aerosol generating device of claim 6 , wherein the first PCB is a double-sided PCB.

8. An aerosol generating device according to any one of claims 1 to 7, further comprising a second PCB arranged along the frame between the first volume and the second volume.

9. The aerosol generating device of claim 8 , wherein the second PCB is a single-sided PCB, and the control circuit further comprises components mounted on the second PCB and within the second volume.

10. An aerosol generating device as described in claim 6 or 7 and claim 8 or 9, wherein the first PCB and the second PCB are connected by a flexible PCB portion, and the first PCB, the second PCB and the flexible PCB portion are arranged around the frame.

11. The aerosol generating device of claim 1 or 2, wherein the first volume of the internal volume houses the control circuitry.

12. 12. The aerosol generating device of claim 11, wherein the frame is positioned to prevent fluid flow from the second volume to the first volume.

13. 13. The aerosol generating device of claim 11 or 12, wherein the power source is carried by the frame.

14. An aerosol generating device described in any one of claims 11 to 13, further comprising a second frame arranged between a first portion of the second volume that houses the control circuit and a second portion of the second volume that houses the power source.

15. The aerosol generating device of claim 14 , wherein the control circuit comprises components mounted on a PCB held between the frame and the second frame.

Images