Aerosol provision device
The aerosol supply device addresses the challenge of maintaining a strong and durable connection between the heating element and the device by using an integrally formed heating element embedded in a polymer mount, enhancing durability and isolation, ensuring efficient aerosol generation and easy maintenance.
Patent Information
- Application Number
- JP2025075735
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2020-10-16
- Filing Date
- 2025-04-30
- Publication Date
- 2025-07-10
AI Technical Summary
Existing smoking alternatives that release compounds without combustion, such as heating devices for tobacco or non-tobacco products, face challenges in maintaining a strong and durable connection between the heating element and the device, as well as effective isolation of contaminants from the heating electronics.
The aerosol supply device incorporates a heating element with a fixing portion that is integrally formed and embedded in a mount, enhanced by insert molding, which improves the connection strength and isolation through mechanisms like through-holes or recesses, using polymer materials for the mount to enhance durability and thermal insulation.
This design ensures a robust attachment of the heating element, prevents contaminants from entering the electronics, and allows for efficient heating and aerosol generation while facilitating easy cleaning and replacement of the heating assembly.
Smart Images
Figure 2025105902000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to an aerosol supply device. The present invention also relates to an aerosol supply device heating assembly, a method of forming the same, and an aerosol supply system comprising an aerosol supply device and an article comprising an aerosol generating material.
Background Art
[0002] Smoking articles such as cigarettes and cigars burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion. Examples of such products are heating devices that release compounds by heating a material without burning it. This material can be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.
Summary of the Invention
[0003] According to one aspect of the present disclosure, an aerosol supply device is provided. The device comprises a receptacle defining a heating chamber configured to receive at least a portion of an article comprising an aerosol generating material, a heating element configured to heat a portion of the article received in the heating chamber, and a mount supporting the heating element. The heating element includes a heating portion and a fixing portion, and the fixing portion is insert-molded into the mount so as to be embedded therein.
[0004] The heating element may be configured as an integral component. In other words, the heating portion and the fixing portion may be integrally formed.
[0005] Also, it can be said that the fixing portion is wrapped by the mount.
[0006] In another embodiment of the above aspect, the heating portion extends from the fixing portion and extends from the mount.
[0007] The heating part may extend along the longitudinal axis of the heating assembly.
[0008] In another embodiment of any of the above, the fixing part includes a fixing mechanism.
[0009] The fixing mechanism is a mechanism that helps improve the strength of the connection between the mount and the fixing part by increasing the contact area therebetween.
[0010] In another embodiment of the above, the fixing mechanism includes a recess in the fixing part, and a part of the mount is received in the recess to couple the fixing part to the mount.
[0011] In another embodiment of the above, the recess includes a through-hole in the fixing part, and a part of the mount extends through the through-hole to couple the fixing part to the mount.
[0012] In another embodiment of the above, the through-hole is square-shaped. In other embodiments, the through-hole can be any suitable and alternative regular (e.g., circular) or irregular shape. Also, in other embodiments, there are a plurality of through-holes, and each of them may have the same shape or different shapes.
[0013] In another embodiment of any of the above, the heating part defines a longitudinal axis along which the heating part extends, and the fixing mechanism extends intersecting the longitudinal axis. In some embodiments, the fixing mechanism is a protrusion extending from the fixing part.
[0014] In another embodiment of any of the above, the heating element stands upright in the heating chamber.
[0015] In another embodiment of any of the above, the heating element is substantially blade-shaped. In another alternative embodiment of any of the above, the heating element is substantially pin-shaped.
[0016] In another embodiment of any of the above, the device further comprises a wall protruding from the mount so as to define a heating chamber surrounding the heating portion of the heating element.
[0017] In another embodiment of any of the above, the heating element alternatively comprises a peripheral wall defining at least a part of the heating chamber.
[0018] In another embodiment of any of the above, the heating element comprises a susceptor that can be heated by the penetration of a varying magnetic field.
[0019] In another embodiment of the above, the device further comprises an inductor coil extending around the susceptor, the inductor coil being configured to generate a varying magnetic field.
[0020] In another embodiment of any of the above, the device further comprises a heating assembly receiving chamber, and the heating assembly is removably fixed to the device in the heating assembly receiving chamber.
[0021] In another embodiment of any of the above, the fixing portion of the heating element has an axial cross-sectional area larger than the base of the heating portion of the heating element. In another alternative embodiment of any of the above, the fixing portion of the heating element may have an axial cross-sectional area substantially equal to the base of the heating portion of the heating element.
[0022] In another embodiment of any of the above, the mount may comprise a formable material. The formable material may be a polymer material (e.g., polyetheretherketone (PEEK)).
[0023] According to another aspect of the present disclosure, there is provided an aerosol supply device heating assembly comprising a heating element configured to heat at least a part of an article containing an aerosol-generating material, and a mount supporting the heating element. The heating element includes a heating portion and a fixing portion, and the fixing portion is insert-molded into the mount so as to be embedded therein.
[0024] Any of the features of the heating assembly of the embodiments discussed in relation to the aerosol supply device also equally apply to this aspect.
[0025] According to another aspect of the present disclosure, an aerosol supply system is provided. The system includes the aerosol supply device described in any of the above aspects or their superior embodiments, and an article containing an aerosol generating material. The article is dimensioned to be at least partially received within the heating assembly.
[0026] According to another aspect of the present disclosure, a method of forming a heating assembly by insert molding a fixing portion of a heating element onto a mount is provided.
[0027] According to another aspect of the present disclosure, a method of forming a heating assembly is provided. The method includes placing a heating element having a fixing portion in a mold, the mold including a cavity that wraps around the fixing portion, injecting a molten material into the mold, the mold guiding the molten material into the cavity, and solidifying the molten material in the cavity around the fixing portion.
[0028] In any of the aspects of the above method, the formed heating assembly may have any of the features of the embodiments discussed in relation to the aerosol supply device.
[0029] The reference to "axial direction" in the above discussion refers to the direction along the longitudinal axis of the heating assembly. Similarly, "axial cross-section" relates to a cross-section in a vertical plane that intersects the longitudinal axis.
[0030] Another feature and advantage of the present invention will become apparent from the following description of the preferred embodiments of the present invention, which is shown by way of example only with reference to the accompanying drawings.
Brief Description of the Drawings
[0031]
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Mode for Carrying Out the Invention
[0032] [Detailed Description] As used herein, the term "aerosol generating material" includes materials that typically provide volatile components when heated, in the form of an aerosol. The aerosol generating material includes any tobacco-containing material, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Also, other non-tobacco products are included as aerosol generating materials, and depending on the product, they may or may not contain nicotine. The aerosol generating material may be in the form of, for example, a solid, liquid, gel, wax, etc. Also, the aerosol generating material may be, for example, a combination or mixture of materials. Also, the aerosol generating material may be known as a "smoking material".
[0033] Devices are known that form an aerosol that can be inhaled, usually without burning (burn or combust) the aerosol - generating material, by heating the aerosol - generating material to volatilize at least one component of the aerosol - generating material. Such devices may be described as "aerosol - generating devices", "aerosol - supply devices", "non - combustible heating devices", "tobacco - heated product devices", or "tobacco - heating devices", among others. Similarly, there are so - called e - cigarette devices that vaporize an aerosol - generating material, usually in liquid form (which may or may not contain nicotine). The aerosol - generating material may be in the form of a rod, cartridge, or cassette that can be inserted into the device, or it may be provided as part of it.
[0034] An aerosol - supply device can receive and heat an article containing an aerosol - generating material. In this context, an "article" is a component that, in use, comprises or contains an aerosol - generating material and is heated to volatilize the aerosol - generating material and optionally other components in use. After the user inserts the article into the aerosol - supply device, the aerosol - generating device may be heated to generate an aerosol that the user can inhale later. The article may be of a predetermined size, for example, configured to be placed within a heating chamber of a device sized to receive the article, or it may be of a specific size.
[0035] FIG. 1 shows an example of an aerosol - supply device 100 that generates an aerosol from an aerosol - generating medium / material. Generally, the device 100 may be used to heat a replaceable article 110 containing an aerosol - generating medium to generate an aerosol or other inhalable medium that can be inhaled by a user of the device 100.
[0036] Device 100 includes a housing 102 that encloses and houses various components of the device 100 (including an outer cover 108). Device 100 has an opening 104 at one end through which an article 110 can be inserted and heated by a heating assembly 200 (see FIG. 2). In use, the article 110 may be fully or partially inserted into the heating assembly 200 and heated by one or more components of the heating assembly 200.
[0037] Also, device 100 may include a user-operable control element 112, such as a button or switch, that operates the device 100 when pressed. For example, the user may turn on device 100 by operating switch 112.
[0038] Device 100 defines a longitudinal axis 101.
[0039] FIG. 2 is an exploded view of device 100 of FIG. 1. Device 100 includes an outer cover 108, a first end member 106, and a second end member 116. Device 100 includes an aerosol generation assembly 111 that includes a housing 109, a power source 118, and a heating assembly 200. Device 100 further includes at least one electronic device module 122.
[0040] The outer cover 108 forms part of the device shell. The first end member 106 is disposed at one end of device 100, and the second end member 116 is disposed at the opposite end of device 100. The first and second end members 106, 116 close the outer cover 108. Also, the first and second end members 106, 116 form part of the shell. In an embodiment, device 100 includes a lid (not shown) that can close opening 104 by movement relative to the first end member 106 when article 110 is not in place.
[0041] In addition, the device 100 may include electrical components such as a connector / port 114 that can receive a cable and charge the battery of the device 100. For example, the connector may be a charging port such as a USB charging port. In some examples, the connector may be used for data transfer between the device 100 and another device such as a computer device as an addition or alternative to the above.
[0042] The device 100 includes a housing 109. The housing 109 is received by an outer cover 108. The aerosol generating assembly 111 includes a heating assembly 200, and an article 110 can be inserted into all or part of the article 110 during use and heated by one or more components of the heating assembly 200. The aerosol generating assembly 111 and the power source 118 are mounted on the housing 109. The housing 109 is an integrated component.
[0043] An integrated component represents a component of the device 100 that cannot be separated into two or more components after the device 100 is assembled. The integrated form is related to two or more features formed to be integrated components during the manufacturing stage.
[0044] The first and second end members 106, 116 integrally define at least partially the end face of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. Also, an edge of the outer cover 108 may define a part of the end face. The first end member and the second end member 116 close the open end of the outer cover 108. The second end member 116 is present at one end of the housing 109.
[0045] The end of the device 100 closest to the opening 104 is considered to be the proximal end (or mouth end) of the device 100 because it is closest to the user's mouth during use. During use, the user inserts the article 110 into the opening 104, operates the user control element 112 to start heating the aerosol-generating material, and utilizes the aerosol generated in the device. Thereby, the aerosol flows through the device 100 along the flow path towards the proximal end of the device 100.
[0046] The other end of the device farthest from the opening 104 is considered to be the distal end of the device 100 because it is the end farthest from the user's mouth during use. When the user utilizes the aerosol generated in the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal when applied to the features of the device 100 are explained by referring to the relative arrangement of such features with respect to each other in the proximal-distal direction along the axis 101.
[0047] The power source 118 is a battery such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the aerosol-generating assembly 111, supplies power as needed, and heats the aerosol-generating material under the control of the controller 121.
[0048] The power source 118 and the aerosol-generating assembly 111 are arranged in an axial arrangement such that the power source 118 is at the distal end of the device 100 and the aerosol-generating assembly 111 is at the proximal end of the device 100. Other arrangements are also conceivable.
[0049] The electronic device module 122 may include, for example, a printed circuit board (PCB) 123. The PCB 123 may support at least one controller 121 such as a processor and a memory. Also, the PCB 123 may include one or more electrical tracks that electrically and integrally connect various electronic components of the device 100. For example, a battery terminal may be electrically connected to the PCB 123 so that power can be distributed throughout the device 100. Also, the connector 114 may be electrically coupled to the battery 118 via an electrical track.
[0050] The aerosol generation assembly 111 is an induction heating assembly and includes various components that heat the aerosol generating material of the article 110 by an induction heating process. Induction heating is a process of heating a conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element (e.g., one or more inductor coils) and a device that passes a varying current such as an alternating current through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor suitably disposed with respect to the induction element and generates eddy currents inside the susceptor. Since the susceptor has an electrical resistance to the eddy currents, the susceptor is heated by Joule heating due to the flow of the eddy currents through this resistance. Also, when the susceptor contains a ferromagnetic material such as iron, nickel, or cobalt, heat is also generated by magnetic hysteresis loss in the susceptor, that is, by the varying orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. In induction heating, heat is generated inside the susceptor, for example, as compared with heating by conduction, so rapid heating is possible. Furthermore, since no physical contact is required between the induction heater and the susceptor, the degrees of freedom in configuration and application increase.
[0051] FIG. 3 is a cross-sectional view of the device 100 including the heating assembly 200 and the inductor coil assembly 127.
[0052] FIG. 4 is a cross-sectional view of an alternative embodiment of the heating assembly 300 and the inductor coil assembly 127.
[0053] For common elements between the heating assembly 200 shown in FIG. 3 and the heating assembly 300 shown in FIG. 4, the same reference numbers are maintained, but are designated in the format of 2xx and 3xx respectively. The description of these common elements applies equally to any of the heating assemblies 200, 300.
[0054] The aerosol generating assembly 111 includes an inductor coil assembly 127 and heating assemblies 200, 300. The inductor coil assembly 127 extends around the heating assemblies 200, 300. The inductor coil assembly 127 includes an inductor coil 124 that is wound around (i.e., surrounds) the heating assemblies 200, 300. At the distal ends of the heating assemblies 200, 300, an inlet tube 400 is provided. The inlet tube 140 includes a funnel portion 142 that receives the mounting hooks 202 of the heating assemblies 200, 300 that hold the heating assemblies 200, 300 in place internally. The mounting hooks 202 may be fixedly held in the funnel portion 142 by interference fit. An O-ring seal 144 is disposed in the recesses 206 of the heating assemblies 200, 300 and is used for sealing between the funnel portion 142 and the heating assemblies 200, 300. By using the inlet tube 140, it may be possible to draw in an air flow from the distal end of the device 100 to the heating assemblies 200, 300 and / or access the distal ends of the heating assemblies 200, 300 for cleaning purposes. The inlet tube 140 includes a flange 146 at its distal end to enable fixation into the device housing 102.
[0055] The heating assemblies 200, 300 include heating elements. In the exemplary embodiment of FIG. 3, this heating element is the susceptor structure 210 (referred to herein as the "susceptor"). The susceptor 210 of this example is a pin-shaped member having a circular cross-section along its axial length around which the aerosol-generating material can be disposed. For example, the article 110 can be inserted onto or around the susceptor 210. The susceptor 210 has a generally constant diameter along most of its axial length and tapers towards the pin tip 212. In other examples, the diameter of the susceptor 210 may vary continuously along the axial length of the susceptor 210 to the pin tip 212.
[0056] In another example, as shown in FIG. 4, the susceptor may be the blade-shaped susceptor 310. The blade-shaped susceptor 310 has a constant rectangular cross-section along most of its axial length and may taper towards the blade tip 312. Similar to the pin-shaped susceptor 210, the article 110 can be inserted onto or around the susceptor 310.
[0057] Although the pin-shaped and blade-shaped embodiments of the susceptors 210, 310 have been shown, it is to be understood that within the scope of the present disclosure, the susceptor can have any number of suitable shapes and configurations. For example, the susceptor may be in the form of a rod (e.g., a cylindrical rod or a square rod) with a constant or variable cross-section along its axial length omitting the tip or taper portion.
[0058] In another example, the susceptor 210 may be a tubular member in which the article 110 / aerosol-generating material is received. Such a susceptor is an outer susceptor. In such an example, the susceptor may define a peripheral wall (e.g., an annular wall) that defines at least a part of a heating chamber capable of receiving and heating the article 110. In such an example, instead of the article 110 surrounding the susceptor as in the above-described pin-shaped and blade-shaped embodiments, the susceptor surrounds the article 110. It is understood that the cross-sectional profile of the outer susceptor can be formed in a variety of profile shapes.
[0059] In other examples, a plurality of susceptors (e.g., two or more separate susceptors) may be provided, which may have different configurations or similar configurations as required (e.g., pin-shaped, blade-shaped, rod-shaped, or tubular, etc.).
[0060] The susceptors 210 and 310 are formed of a conductive material suitable for heating by electromagnetic induction. The susceptor in this example is formed of carbon steel. It is understood that other suitable materials (e.g., ferromagnetic materials such as iron, nickel, or cobalt) can also be used.
[0061] In other embodiments, the mechanism acting as the heating element may not be limited to induction heating. Therefore, the mechanism acting as the heating element may be heatable by electrical resistance. For this reason, the heating assembly 200 may include electrical contacts for electrically activating the heating element by passing electrical energy to the heating element through an electrical connection with the device. In such embodiments, the inductor coil assembly 127 can be omitted as required.
[0062] The inductor coil 124 is composed of a conductive material. In this example, the inductor coil 124 is composed of a litz wire / cable wound in a spiral to provide a helical inductor coil 124. The litz wire includes a plurality of individual wires that are individually insulated and form a single wire by an integral twist. The litz wire is designed to suppress the skin effect loss of the conductor. In the exemplary device 100, the inductor coil 124 is composed of a copper litz wire with a circular cross-section. In other examples, the litz wire may have a cross-section of other shapes, such as rectangular. The end 130 of the inductor coil 124 can control the activation of induction heating using the electronic device module 122 and the switch 112 by connection to the PCB 123 (see FIG. 2).
[0063] Also, the number of induction coils used may be different. For example, although the induction coil assemblies 127 of the heating assemblies 200, 300 shown in FIGS. 3 and 4 include only one coil 124, it is understood that any suitable number of coils may be featured. By using additional coils, different heating zones having different heating characteristics can be provided for the susceptors 210, 310 (for example, applying different heating conditions to different areas along the axial length of the susceptors 210, 310 and / or applying different heating conditions to the susceptors 210, 310 at different times or in different usage cases). Also, by providing additional coils, heat may be generated in an additional susceptor (not shown) that can be disposed in the heating assembly 200.
[0064] FIG. 5 is a perspective view of the heating assembly 200 separated from other parts of the device 100. The heating assembly 200 is defined by a body 220. The body 220 in FIG. 5 is shown as transparent to clarify the structure within the heating assembly 200 and facilitate the description of its features. However, in reality, the body is not transparent, and these features may not be visible.
[0065] In the illustrated example, the body 220 is a generally annular element that defines a longitudinal axis 201 that is aligned generally parallel to the longitudinal axis 101 in the case of use in the device 100. In some examples, it may be coaxial with the longitudinal axis 101, and in other examples, it may be offset from the longitudinal axis 101. The body 220 includes the aforementioned mounting hook 202 that extends distally and an O-ring recess 206 defined circumferentially at its distal end. The body 220 also includes a proximal opening 204 suitable for receiving the replaceable article 110 that contains the aerosol-generating material. The opening 204 is defined by two annular flanges 207a, 207b separated by an annular recess 208. The flanges 207a, 207b and the recess 208 can be used to assist in the fixed fit of the body 220 to the device 100.
[0066] The body 220 may be defined as a fixing part in the device 100 / housing 209, or may be removably attached to the device 100 / housing 209. In the latter case, the device 100 / housing 209 may define a heating assembly chamber (not shown) for receiving the body 220. The body 220 is removably fixed in the chamber, for example, by forming a removable engagement (e.g., a removable rotational engagement, a screw-in engagement, or an interference fit) with the inlet pipe 140 by using the mounting hook 202. Thus, the heating assembly 200 as a whole is removable from the device 100 itself, facilitating the cleaning of the heating assembly 200 after use and the replacement in case of a failure of the heating assembly 200 (e.g., breakage of the heating element 210, etc.).
[0067] In the illustrated example, the body 220 includes a mount 222 and a wall 224 that axially projects from the mount 222 along the shaft 201. The body 220 defines a receptacle for receiving the article 110. An aerosol-generating material is received in the receptacle. Further, the receptacle defines a heating chamber 226. The heating chamber 226 is configured to receive at least a part of the article 110 containing the aerosol-generating material during use. The mount 222 defines the base of the heating chamber 226. The wall 224 is substantially annular and surrounds the heating element 210. Thus, the wall 224 defines an annular space around the heating element 210, providing a space around the heating element 210 that heats the aerosol-generating material during use.
[0068] The heating element 210 includes a fixing portion 216 embedded in the mount 222. It can also be said that the fixing portion 216 is wrapped by the mount 222. The mount 222 supports the heating element 210 by fixing the fixing portion 216 in place inside. The use of the fixing portion 216 provides a fixing point for firmly holding the heating element 210 in place within the mount 222. Also, the mount 222 defines an air passage 223 inside that can be used for the communication of the air flow from the inlet pipe 140 to the heating chamber 226. However, in other examples, the air passage 223 may not be present in the mount 222 and may be present in other components of the main body 220. Also, the air passage 223 may have any suitable shape or air path configuration to enable the communication of the air flow from outside the device 100 to the heating chamber 226 when the user utilizes the device 100.
[0069] Also, the heating element 210 includes a heating portion 214 that extends from the fixing portion 216 and protrudes along the longitudinal axis direction 201 from the mount 222. Thus, since the extending portion of the heating element 210 is defined along the longitudinal axis direction 201, it stands upright in the heating chamber 226. The heating portion 214 is the portion of the heating element 210 where the aerosol-forming material is held around during use in the heating chamber 226. The heating portion 214 and the fixing portion 216 are integrally formed so that the heating element 210 has a single integral structure. In other words, the heating element 210 is an integral component.
[0070] The fixing portion 216 is insert-molded with the mount 222 during the manufacture of the heating assembly 200 so as to be embedded and wrapped in the mount 222.
[0071] As shown in FIG. 7, in such an insert molding process 400, before forming the mount 222, the fixing portion 216 is inserted into the mold cavity (step 401). Then, the mount 222 is formed by injecting the mount molten material into the cavity (step 402). The solidification of the mount molten material in the cavity thereafter (step 403) embeds and encloses the fixing portion 216. Thus, it can be said that the fixing portion 216 is integrally molded within the mount 222. Also, it is understood that for the other parts of the main body 220 (including the wall 224), by appropriately molding the mold to be used, they can be molded as part of the same process.
[0072] According to the thus insert-molded heating assembly 200, the bonding strength between the fixing portion 216 and the mount 222 can be improved, and as a result, the strength and durability of the attachment and arrangement of the heating element 210 in the heating chamber 226 can be improved. This can be important in the exemplary device 100 because it is necessary to repeatedly insert and remove the replaceable article 110 around the heating element 210 during use.
[0073] Also, the insert-molded heating assembly 200 can provide improvement measures related to the improvement of the isolation of fluids and contaminants between the heating chamber 226 of the device 100 and the heating electronics. For example, since the fixing portion 216 is embedded and the heating element 210 is integrally formed with the mount 222, it is possible to prevent aerosol-generating materials or other contaminants (such as water vapor, etc.) deposited during the use of the device 100 from unnecessarily entering the heating electronics of the device 100 (for example, from around the heating element 210).
[0074] The mount 222 (and the main body 220) is composed of any suitable moldable material for such an insert molding process. In one example, the moldable material is a non-metallic material such as a polymer material.
[0075] Non-metallic / polymer materials can help limit interference with magnetic induction for susceptor heating. They can also act as a thermal insulation material to insulate other components of the device 100 from the heat generated by the heating element 210.
[0076] It is understood that such non-metallic / polymer materials should have a melting point above the maximum temperature targeted for the heating element 210 during use. In some examples, during use, the inductor coil 124 is configured to heat the susceptor 210 to a temperature of approximately 200°C to approximately 350°C, such as approximately 240°C to approximately 300°C or approximately 250°C to approximately 280°C.
[0077] A particularly suitable polymer material is polyetheretherketone (PEEK), which is a good thermal insulation material, has a sufficiently high melting point of approximately 343°C, and can be used in an insert molding process. Nevertheless, other suitable materials will readily become apparent to those skilled in the art, and all of these are considered to be within the scope of the present disclosure.
[0078] In the illustrated example, the fixing portion 216 has a larger axial cross-sectional area than the base portion 215 of the heating portion 214 connected to the fixing portion 216. This can help provide a stronger base for the heating portion 214 to extend. The illustrated example has a circular cross-section with a diameter larger than that of the heating portion 214. In other examples, any other suitable cross-section of the fixing portion 216 (e.g., square, hexagonal, rectangular, etc.) can be used, and it may or may not match the base portion 215 of the heating portion. Nevertheless, in other examples or additional examples, it is also possible to make the fixing portion 216 smaller than the base portion 215 of the heating portion 214, or to have the same axial cross-sectional area.
[0079] Figure 6 is a perspective view of the heating assembly 300 separated from other parts of the device 100. Also in this case, the main body 320 in Figure 6 is shown as transparent in order to reveal the structure within the heating assembly 300 and facilitate the description of its features. However, in reality, the main body is not transparent, and these features may not be visible. Similarly, for the common elements of the heating assembly 300 when compared with the heating assembly 200, the same reference numbers are maintained. However, they are specified in the format of 3xx instead of 2xx. The description of these common elements related to Figure 5 also equally applies to Figure 6, so it will not be repeated below.
[0080] Also, the features regarding the fixed or removably fixed nature of the heating assembly 200 in the device 100 equally apply to the heating assembly 300 / main body 320 in Figure 6.
[0081] In Figure 6, the fixing portion 316 has the same axial cross-sectional area and shape (i.e., rectangular) as the heating portion 314.
[0082] Also, the fixing portion 316 further comprises a fixing mechanism that helps improve the strength of the connection between the two by increasing the contact area between the mount 222 and the fixing portion 316.
[0083] In the illustrated example, the fixing mechanism is the through-hole 318 passing through the fixing portion 316. The through-hole 318 intersects the longitudinal axis 301 and passes through the fixing portion 316. In the insert molding process, the mount material will flow through the through-hole 318 and solidify inside. This can further improve the strength and durability of the connection between the fixing portion 316 and the mount 222. In this example, the through-hole 318 is square-shaped. However, as the through-hole 318, any other suitable regular or irregular shape is possible. Also, in other examples, there may be a plurality of through-holes 318, and each may have the same shape or different shapes. Also, the size of the through-hole 318 can be changed or selected as necessary to meet specific design requirements.
[0084] Although the fixing mechanism in the illustrated example is the through hole 318, it is understood that the present disclosure is extended to cover any other suitable fixing function(s) effective to increase the contact area between the mount 22 and the fixing portion 316.
[0085] For example, as an alternative, the fixing mechanism may be a recess that only partially extends into the fixing portion 316. The recess receives an additional portion of the mount material. Such a recess can be of any suitable form, such as separate circular or square recesses, or a groove or channel extending around the fixing portion 316. Also, a plurality of recesses or their patterns may be provided.
[0086] In yet another example, the fixing mechanism may be one or more protrusions extending from the fixing portion 316 into the mount 222. The protrusions may extend from the fixing portion 316 at any suitable angle from the longitudinal axis 310 (e.g., intersecting the longitudinal axis 310), and may be of any suitable shape, such as a cylindrical or square rod.
[0087] In still another example, the fixing mechanism may be roughening of the surface of the fixing portion 316. According to such roughening of the surface, the contact surface area between the mount 222 and the fixing portion 316 becomes larger. Such roughening of the surface can be of any suitable form, such as a series of scratches / dents formed by polishing or other surface treatment of the fixing portion 316 before molding onto the mount 222.
[0088] In other examples, the fixing portion 316 may feature a combination of different types of fixing mechanisms.
[0089] Although the above-described through hole 318 and other exemplary fixing mechanisms are shown in relation to the blade-shaped heating element 310, they are equally applicable to the fixing portions of heating elements of any other suitable shape, such as the fixing portion 216 of the pin-shaped heating element 210.
[0090] In the case of the tubular susceptor as described above, a fixing portion formed on the mount 222 is defined by the base portion of the peripheral wall, but it is also possible to define (one or more) fixing mechanisms inside as required.
[0091] The above-described embodiments should be understood as examples useful for explaining the present invention. Other embodiments of the present invention are also conceivable. It is to be understood that any feature described with respect to any one embodiment can be used alone or in combination with other described features, and also in combination with any other one or more features of the embodiments, or any other arbitrary combination of the embodiments. Further, equivalents and improvements not described above defined in the appended claims can also be employed without departing from the scope of the present invention.
Explanation of Reference Numerals
[0092] 100... aerosol supply device, 110... article, 200... heating assembly, 210... heating element, 214... heating part, 216... fixing part, 222... mount, 226... heating chamber.
Claims
1. A receptacle defining a heating chamber configured to receive at least a portion of an article containing an aerosol-generating material; A heating element configured to heat a portion of the article received in the heating chamber; A mount supporting the heating element; An aerosol supply device comprising a heating assembly having: The aerosol supply device, wherein the heating element includes a heating portion and a fixing portion, and the fixing portion is insert-molded into the mount so as to be embedded in the mount.
2. The aerosol supply device according to claim 1, wherein the heating portion extends from the fixing portion and extends from the mount.
3. The aerosol supply device according to claim 1 or 2, wherein the fixing portion comprises a fixing mechanism.
4. The aerosol supply device according to claim 3, wherein the fixing mechanism comprises a recess in the fixing portion, and a part of the mount is received in the recess to couple the fixing portion to the mount.
5. The aerosol supply device according to claim 4, wherein the recess comprises a through-hole in the fixing portion, and a part of the mount extends through the through-hole to couple the fixing portion to the mount.
6. The aerosol supply device according to claim 5, wherein the through-hole is square-shaped.
7. The aerosol supply device according to any one of claims 3 to 6, wherein the heating portion defines a longitudinal axis along which the heating portion extends, and the fixing mechanism extends intersecting the longitudinal axis.
8. The aerosol supply device according to any one of claims 1 to 7, wherein the heating element stands upright in the heating chamber.
9. The aerosol supply device according to any one of claims 1 to 8, wherein the heating element is substantially blade-shaped.
10. The aerosol supply device according to any one of claims 1 to 9, further comprising a wall protruding from the mount so as to define the heating chamber surrounding the heating portion of the heating element.
11. The aerosol supply device according to any one of claims 1 to 7, wherein the heating element comprises a peripheral wall defining at least a part of the heating chamber.
12. The aerosol supply device according to any one of claims 1 to 11, wherein the heating element comprises a susceptor that can be heated by the intrusion of a variable magnetic field.
13. The aerosol supply device according to claim 12, further comprising an inductor coil extending around the susceptor, wherein the inductor coil is configured to generate the variable magnetic field.
14. The aerosol supply device according to any one of claims 1 to 13, further comprising a heating assembly receiving chamber, wherein the heating assembly is removably fixed to the device in the heating assembly receiving chamber.
15. The aerosol supply device according to any one of claims 1 to 14, wherein the fixing portion of the heating element has an axial cross-sectional area larger than a base portion of the heating portion of the heating element.
16. The aerosol supply device according to any one of claims 1 to 14, wherein the fixing portion of the heating element has an axial cross-sectional area substantially equal to a base portion of the heating portion of the heating element.
17. The aerosol supply device according to any one of claims 1 to 16, wherein the mount includes a moldable material.
18. The aerosol supply device according to claim 17, wherein the moldable material is a polymer material.
19. The aerosol supply device according to claim 18, wherein the polymer material is polyetheretherketone (PEEK).
20. A heating element configured to heat at least a portion of an article containing an aerosol-generating material, A mount supporting the heating element, An aerosol supply device heating assembly comprising: The heating element includes a heating portion and a fixing portion, and the fixing portion is insert-molded into the mount so as to be embedded in the mount. An aerosol supply device heating assembly.
21. A method of forming an aerosol supply device heating assembly by insert-molding a fixing portion of a heating element into a mount.
22. Placing a heating element having a fixing portion in a mold, the mold including a cavity surrounding the fixing portion; Injecting a molten material into the mold, the mold guiding the molten material into the cavity; Solidifying the molten material in the cavity around the fixing portion; A method of forming an aerosol supply device heating assembly, including:
23. The aerosol supply device according to any one of claims 1 to 19, and An article containing an aerosol-generating material and dimensioned to be at least partially received within the heating assembly, and An aerosol supply system comprising.