Aerosol generating device, its heat generating structure, heat generating element, and method for manufacturing heat generating element

Abstract

The present invention relates to an aerosol generator, its heat-generating structure, heat-generating element, and a method for manufacturing the heat-generating element. The heat-generating structure includes a heat-generating element and a tube body, and the heat-generating element includes a heat-generating base and an infrared-emitting layer provided on the outer surface of the heat-generating base. The heat-generating base is electrically heated to excite the infrared-emitting layer and emit infrared light waves, and the heat-generating element is installed at least partially spaced from the tube wall of the tube. The tube wall is transparent to the infrared light waves and is used to heat an aerosol-forming substrate. This heat-generating structure has the advantages of a simple structure, high atomization efficiency, high atomization stability, a long lifespan, and significantly improved flavor.

Description

[Technical Field]

[0001] The present invention relates to the field of thermal non-combustion atomization, and more particularly to an aerosol generating device and its heat generating structure, heat generating element, and method for manufacturing the heat generating element. [Background technology]

[0002] In the field of HNB (heat-not-burn) atomization, heating methods such as central heating and peripheral heating are commonly used. Typically, a heating element generates heat, which is then transferred directly to the aerosol-forming substrate or other medium via thermal conduction. The medium is typically atomized at temperatures below 350°C. A drawback of this heating method is that because the heating element transfers heat directly or indirectly via a solid material, the operating temperature of the heating element must not be too high; otherwise, the medium may burn excessively or the solid material may emit an unpleasant odor, affecting the flavor of the e-cigarette. Furthermore, existing e-cigarettes require a long pre-heating time before inhalation. Current e-cigarettes typically require a pre-heating time of 15 seconds or more, significantly impacting the consumer experience. Summary of the Invention

[0003] SUMMARY OF THE INVENTION It is an object of the present invention to provide an improved heat generating structure and aerosol generating device, as well as an improved heat generating element and method for manufacturing the same.

[0004] The present invention provides a heating structure as a technical solution to solve the technical problem. The heating structure includes a heating element and a tube. The heating element includes a heating base and an infrared emitting layer disposed on the outer surface of the heating base. The heating base is electrically heated to excite the infrared emitting layer and emit infrared light waves. The heating element and a tube wall of the tube are at least partially spaced apart, and the tube wall is transparent to the infrared light waves. The infrared light waves are used to heat an aerosol-forming substrate.

[0005] In some embodiments, the tube is infrared transparent glass, transparent ceramic, or diamond.

[0006] In some embodiments, the heating element has a maximum operating temperature of 500°C to 1300°C.

[0007] In some embodiments, the operating temperature range of the heating element includes at least a first operating temperature range and a second operating temperature range, the maximum temperature of the first operating temperature range being 700°C to 1300°C, and the maximum temperature of the second operating temperature range being 500°C to 800°C.

[0008] In some embodiments, the heating element is spaced apart from the entire wall of the tube.

[0009] In some embodiments, the heating element and the tube are not in direct contact.

[0010] In some embodiments, the tube wall thickness of the tube is 0.15 mm to 0.6 mm.

[0011] In some embodiments, the distance between the tube wall of the tube and the heating element is 0.05 mm to 1 mm.

[0012] In some embodiments, the heat generating base is strip-shaped with a circular cross section, and the radial dimension of the heat generating base is 0.15 mm to 0.8 mm.

[0013] In some embodiments, the heat generating base has a flat strip-like cross section, and the thickness of the heat generating base is 0.15 mm to 0.8 mm.

[0014] In some embodiments, the heat generating base is in the form of a sheet, mesh, or film, and the thickness of the heat generating base is 10 μm to 500 μm.

[0015] In some embodiments, the infrared emitting layer has a thickness of 10 μm to 300 μm.

[0016] Some embodiments further include an antioxidant layer disposed between the heat-generating substrate and the infrared-emitting layer.

[0017] In some embodiments, the thickness of the antioxidant layer is between 1 μm and 150 μm.

[0018] Some embodiments further include a tie layer disposed between the antioxidant layer and the infrared emissive layer.

[0019] In some embodiments, the bonding layer has a thickness of between 10 μm and 70 μm.

[0020] In some embodiments, the infrared emitting layer includes an infrared layer and / or a composite infrared layer, and the composite infrared layer is formed by combining an infrared layer-forming substrate with a binder for bonding to the antioxidant layer.

[0021] In some embodiments, the heating substrate comprises a metal substrate, and the metal substrate comprises a nichrome alloy substrate or an iron chromium aluminum alloy substrate.

[0022] In some embodiments, the tube is a hollow tube having a first receiving cavity formed therein for receiving the heating element.

[0023] In some embodiments, the heating elements are longitudinally oriented.

[0024] In some embodiments, the heating element is in the form of a column, strip, sheet, spiral, or mesh.

[0025] In some embodiments, the heating element is positioned in at least a partial fold.

[0026] In some embodiments, the heating element forms a heating portion having at least one fold after folding, and the heating portion has a columnar, spiral, or mesh shape.

[0027] In some embodiments, the heating elements are spaced apart from one another around the circumference of a tube, the interior of which is hollow and defines a second receiving cavity for receiving an aerosol medium.

[0028] In some embodiments, the tube includes a first tube that transmits light waves and a second tube that is disposed around the first tube. A gap is provided between the second tube and the first tube, and the gap defines a first cavity that accommodates the heating element. The heating element is disposed around the first tube and spaced apart from the first tube.

[0029] The present invention also provides an aerosol generating device comprising the heat generating structure of the present invention and a power supply component for supplying power to the heat generating structure.

[0030] The present invention also provides a heating element including a heating base and an infrared emitting layer provided on the outer surface of the heating base, wherein the heating base is electrically heated to excite the infrared emitting layer to emit infrared light waves, thereby heating an aerosol-forming substrate placed in a receiving cavity of an aerosol generating device, the heating base being placed at a distance from a wall of the receiving cavity.

[0031] In some embodiments, the heat generating base is strip-shaped with a circular cross section, and the radial dimension of the heat generating base is 0.15 mm to 0.8 mm.

[0032] In some embodiments, the heat generating base is in a sheet shape, and the thickness of the heat generating base is 0.15 mm to 0.8 mm.

[0033] In some embodiments, the infrared emitting layer has a thickness of 10 μm to 300 μm.

[0034] Some embodiments further include an antioxidant layer disposed between the heat-generating substrate and the infrared-emitting layer.

[0035] In some embodiments, the thickness of the antioxidant layer is between 1 μm and 150 μm.

[0036] Some embodiments further include a tie layer disposed between the antioxidant layer and the infrared emissive layer.

[0037] In some embodiments, the bonding layer has a thickness of between 10 μm and 70 μm.

[0038] In some embodiments, the infrared emitting layer includes an infrared layer and / or a composite infrared layer, and the composite infrared layer is formed by combining an infrared layer-forming substrate with a binder for bonding to the antioxidant layer.

[0039] In some embodiments, the heating substrate comprises a metal substrate, and the metal substrate comprises a nichrome alloy substrate or an iron chromium aluminum alloy substrate.

[0040] In some embodiments, the heating element has a maximum operating temperature of 500°C to 1300°C.

[0041] In some embodiments, the operating temperature of the heating element includes at least a first operating temperature range and a second operating temperature range, the maximum temperature of the first operating temperature range being 700°C to 1300°C, and the maximum temperature of the second operating temperature range being 500°C to 800°C.

[0042] In some embodiments, the heating elements are longitudinally oriented.

[0043] In some embodiments, the heating element is in the form of a strip, sheet, spiral, or mesh.

[0044] The present invention also provides a method for producing a heating element, which comprises the following steps: Selecting a heat-generating substrate-forming substrate to form a heat-generating substrate; An infrared emitting layer-forming substrate is heat-treated on the outer surface of the heat generating base to form an infrared emitting layer on the outer surface of the heat generating base.

[0045] In some embodiments, the method further includes providing an antioxidant layer on an outer surface of the heat-generating substrate, and forming the infrared emitting layer on the side of the antioxidant layer away from the heat-generating substrate.

[0046] In some embodiments, the method further comprises applying a binder onto the antioxidant layer to bond the antioxidant layer and the infrared emitting layer to form a bonding layer.

[0047] In some embodiments, the infrared emitting layer includes an infrared layer and / or a composite infrared layer, and the composite infrared layer is formed by combining an infrared layer-forming substrate with a binder for bonding to the antioxidant layer.

[0048] In some embodiments, the heat generating substrate-forming substrate comprises a metal substrate, said metal substrate comprising a nichrome alloy substrate or an iron chromium aluminum alloy substrate.

[0049] In some embodiments, the heat generating base is strip-shaped with a circular cross section, and the radial dimension of the heat generating base is 0.15 mm to 0.8 mm.

[0050] In some embodiments, the heat generating base is in a sheet shape, and the thickness of the heat generating base is 0.15 mm to 0.8 mm.

[0051] In some embodiments, the infrared emitting layer has a thickness of 10 μm to 300 μm.

[0052] In some embodiments, the thickness of the antioxidant layer is between 1 μm and 150 μm.

[0053] In some embodiments, the bonding layer has a thickness of between 10 μm and 70 μm.

[0054] The aerosol-generating device, its heat-generating structure, its heat-generating element, and its manufacturing method for the heat-generating element of the present invention have the following beneficial effects. The heat-generating structure has an infrared-emitting layer on the outer surface of the heat-generating base. When the heat-generating base generates heat while powered on, the heat excites the infrared-emitting layer to emit infrared light waves, which then penetrate the tube and reach the aerosol-forming substrate, heating it. Because a gap is provided between the heat-generating element and the tube, even when the maximum operating temperature of the heat-generating element exceeds 500°C or even reaches 1000°C or higher within a short period of time (the operating temperature of a conventional HNB heating element typically does not exceed 400°C), the aerosol-forming substrate does not burn excessively, and the flavor during inhalation is significantly improved. At the same time, the preheating time is significantly shortened, and inhalation is possible simply by inserting the aerosol-forming substrate, significantly improving the consumer experience. [Brief explanation of the drawings]

[0055] The invention will now be further described with reference to the accompanying drawings and examples. [Figure 1] 1 is a structural schematic diagram of an aerosol generating device according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a structural schematic diagram of the heat generating structure of the aerosol generating device shown in FIG. [Figure 3] FIG. 3 is a cross-sectional view of the heat generating structure shown in FIG. [Figure 4] FIG. 3 is a structural exploded schematic diagram of the heat generating structure shown in FIG. 2. [Figure 5] 5 is a structural schematic diagram of a heat generating element of the heat generating structure shown in FIG. 4. [Figure 6] FIG. 6 is a cross-sectional view of the heating element shown in FIG. 5. [Figure 7] FIG. 2 is a temperature change curve diagram when the heating element shown in FIG. 1 is in operation. [Figure 8] FIG. 10 is a cross-sectional view of a heating element of an aerosol generating device according to a second embodiment of the present invention. [Figure 9] FIG. 10 is a cross-sectional view of a heating element of an aerosol generating device according to a third embodiment of the present invention. [Figure 10]FIG. 10 is a structural schematic diagram of the heat generating structure of the aerosol generating device according to the fourth embodiment of the present invention. [Figure 11] FIG. 11 is a structural schematic diagram of the heat generating structure shown in FIG. 10 from another angle. [Figure 12] FIG. 11 is a cross-sectional view of the heat generating structure shown in FIG. [Figure 13] FIG. 11 is a structural exploded schematic view of the heat generating structure shown in FIG. [Figure 14] FIG. 10 is a structural schematic diagram of a heating element of an aerosol generating device according to a fifth embodiment of the present invention. [Figure 15] FIG. 15 is a cross-sectional view of the heating element shown in FIG. [Figure 16] FIG. 10 is a cross-sectional view of a heating element of an aerosol generating device according to a sixth embodiment of the present invention. [Figure 17] FIG. 10 is a structural schematic diagram of a heating element of an aerosol generating device according to a seventh embodiment of the present invention. [Figure 18] FIG. 13 is a structural schematic diagram of a heating element of an aerosol generating device according to an eighth embodiment of the present invention. [Figure 19] FIG. 13 is a structural schematic diagram of a heating element of an aerosol generating device according to a tenth embodiment of the present invention. [Figure 20] FIG. 22 is a structural schematic diagram of a heating element of an aerosol generating device according to an eleventh embodiment of the present invention. [Figure 21] FIG. 22 is a structural schematic diagram of a heating element of an aerosol generating device according to the twelfth embodiment of the present invention. [Figure 22] FIG. 22 is a schematic exploded view of the structure of the heat generating element shown in FIG. 21. [Figure 23] FIG. 22 is a structural schematic diagram of a heating element of an aerosol generating device according to the thirteenth embodiment of the present invention. [Figure 24] FIG. 22 is a cross-sectional view of the heat generating structure of the aerosol generating device according to the fourteenth embodiment of the present invention. [Figure 25] FIG. 25 is a structural exploded schematic diagram of the heat generating structure of the aerosol generating device shown in FIG. 24. [Figure 26] FIG. 20 is a cross-sectional view of the heat generating structure of the aerosol generating device according to the fifteenth embodiment of the present invention. [Figure 27]FIG. 27 is a structural exploded schematic diagram of the heat generating structure of the aerosol generating device shown in FIG. 26. DETAILED DESCRIPTION OF THE INVENTION

[0056] In order to make the technical features, objects and effects of the present invention more clearly understandable, specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0057] FIG. 1 shows a first embodiment of an aerosol-generating device of the present invention. This aerosol-generating device 100 heats an aerosol-forming substrate 200 using a low-temperature heating, non-combustion method, resulting in high atomization stability and an excellent atomized flavor. In some embodiments, the aerosol-forming substrate 200 is removably installed in the aerosol-generating device 100, and the aerosol-forming substrate 200 may be cylindrical. Specifically, the aerosol-forming substrate 200 may be a thread- or sheet-like solid material made from plant leaves and / or stems, and a flavoring ingredient may be added to this solid material.

[0058] As shown in FIGS. 2 and 3 , in this embodiment, the aerosol-generating device 100 includes a heat-generating structure 11 and a power-supplying component 20. The heat-generating structure 11 is partially inserted into the aerosol-forming substrate 200, specifically, a portion of it is inserted into the medium portion of the aerosol-forming substrate 200. When energized, it generates infrared light waves to heat and atomize the medium portion of the aerosol-forming substrate 200, thereby generating an aerosol. The heat-generating structure 11 has the advantages of a simple structure, high atomization efficiency, high stability, and a long lifespan. The power-supplying component 20 is used to supply power to the heat-generating structure 11. Specifically, in some embodiments, the heat-generating structure 11 is detachably attached to the casing of the power-supplying component 20 and can be mechanically and / or electrically connected to the power source of the power-supplying component 20. The heat-generating structure 11 is detachably attached to the casing of the power-supplying component 20, allowing for easy replacement of the heat-generating structure 11.

[0059] 3 and 4 , in this embodiment, the heat-generating structure 11 includes a tube 111, a heating element 112, and a base 113. The tube 111 is disposed to cover at least a portion of the heating element 112 and is capable of transmitting light waves to the aerosol-forming substrate 200. Specifically, in this embodiment, the tube 111 is capable of transmitting infrared light waves, thereby facilitating the radiation of infrared light waves from the heating element 112 to heat the aerosol-forming substrate 200. The base 113 is disposed at an opening 1110 of the tube 111 and is used to fix the tube 111 or seal the opening 1110 of the tube 111.

[0060] In this embodiment, the tube 111 may be a quartz glass tube. Of course, it is understood that in other embodiments, the tube 111 is not limited to a quartz tube, and may be a window material capable of transmitting light waves, such as infrared-transmitting glass, transparent ceramics, or diamond.

[0061] In this embodiment, the tubular body 111 is hollow and has two ends distributed along the axial direction. Specifically, the tubular body 111 includes a tubular body 1111 having a circular cross section and a tip structure 1112 provided at one end of the tubular body 1111. Of course, it should be understood that in other embodiments, the cross section of the tubular body 1111 is not limited to a circular shape. The tubular body 1111 is a hollow structure having an opening 1110 at one end. The tip structure 1112 is located at the end of the tubular body 1111 away from the opening 1110, and the provision of the tip structure 1112 makes it easy to insert at least a portion of the heat-generating structure 111 into and remove from the aerosol-forming substrate 200. In this embodiment, a first accommodating cavity 1113 is formed inside the tubular body 111, and the first accommodating cavity 1113 is a cylindrical cavity body. In another embodiment, the heating element 112 may be spaced apart from one another around the periphery of the tube 111, and a second receiving cavity for receiving the aerosol-forming substrate 200 may be formed inside the tube 111.

[0062] In this embodiment, the entire wall of the tube 111 and the heating element 112 are spaced apart. For example, a gap 1114 is provided between the tube 111 and the heating element 112, and the gap 1114 can be filled with air. Of course, it is understood that in other embodiments, the gap 1114 can be filled with a reducing gas or an inert gas. By providing the gap 1114, direct contact between the tube 111 and the heating element 112 can be prevented. In some embodiments, the heating element 112 can be partially spaced apart from the wall of the tube 111. Specifically, the radial dimension of a portion of the heating portion 1120 is larger than the radial dimension of the other portion, and the radial dimension of the portion of the heating portion 1120 is equal to the inner diameter of the tube 111, thereby achieving a positioning function. Of course, it is understood that in some embodiments, the inner surface of the tube wall 111 partially protrudes toward the heating element 112 and comes into contact with the heating element 112, thereby achieving a positioning function. Of course, it should be understood that in other embodiments, an isolation positioning structure may be installed on the heating element 112 or the wall of the tube 111, so that there is no direct contact between the heating element 112 and the wall of the tube 111. For example, a ceramic ring may be attached to a part of the heating element 112. Note that the gap mentioned above may refer to a gap through which air can enter, but does not necessarily mean that air or other gases are present; a vacuum state is also one form of gap. To obtain a better flavor during inhalation and to extend the service life of the heating element, the tube 111 may be evacuated or installed with its open end sealed.

[0063] By adjusting the thickness of the tube wall and the distance between the heating element 112 and the tube wall, the heating temperature of the aerosol-forming substrate 200 throughout the heat-generating structure 11 can be adjusted. Under the same temperature conditions, as the thickness of the tube wall increases, the overall irradiance tends to decrease. Optionally, in some embodiments, the thickness of the tube wall of the tube 111 is 0.15 mm to 0.6 mm. In some embodiments, as the distance between the heating element 112 and the tube wall increases, the temperature of the heat-generating structure 11 tends to gradually decrease. Preferably, in some embodiments, the distance between the tube wall of the tube 111 and the heating element 112 may be 0.05 mm to 1 mm.

[0064] As shown in FIGS. 5 and 6 , in this embodiment, the heating element 112 may be a single piece, be disposed longitudinally, and have a first free end 112d and a second free end 112e. In this embodiment, the heating element 112 is strip-shaped with a circular cross section. The heating element 112 is at least partially folded to form a columnar heating portion 1120 as a whole. Specifically, it may be folded into a spiral columnar heating portion 1120. As should be understood, in other embodiments, the heating element 112 is not limited to a strip shape and may be a longitudinal sheet or mesh shape. The heating portion 1120 is not limited to a columnar shape and may be a sheet, mesh, or strip shape. In some embodiments, the heating element 112 may be wound into a single spiral, double spiral, M-shaped, N-shaped, or other shaped heating portion 1120. Of course, as should be understood, in other embodiments, the heating element 112 is not limited to a single piece, but may be two or more pieces. In other embodiments, the heating element may be a metal plate or a metal needle.

[0065] In this embodiment, the heating portion 1120 includes a first heating portion 112a and a second heating portion 112b. The first heating portion 112a and the second heating portion 112b are connected at one end. In this embodiment, the first heating portion 112a and the second heating portion 112b are integrally formed and can be formed by bending a single heating element 112. It should be understood that in other embodiments, the first heating portion 112a and the second heating portion 112b can be separate structures, and the first heating portion 112a and the second heating portion 112b can each be two heating elements 112. It should be understood that in other embodiments, the second heating portion 112b can be omitted or replaced with a non-heat-generating conductive rod.

[0066] In this embodiment, a conductive part 1121 is provided at one end of the heating part 1120, and the conductive part 1121 is connected to the heating part 1120 and can be drawn out from one end of the tube 111, penetrating the base 113 to be conductively connected to the power supply component 20. There may be two conductive parts 1121, which are spaced apart, connected to the heating part 1120 respectively, and penetrating the tube 111 from the same end. In this embodiment, the conductive part 1121 may be fixed to the heating part 1120 by welding. Of course, it should be understood that in other embodiments, the heating part 1120 may be integrally formed with the conductive part 1121, and the first free end 112d and the second free end 112e of the heating element 112 may each form two conductive parts 1121. That is, the first free end 112d of the first heating portion 112a forms one conductive portion 1121, and the second free end 112e of the second heating portion 112b forms the other conductive portion 1121. In other embodiments, the conductive portion 1121 may be a lead wire or may be welded to the heating portion 1120. Of course, it should be understood that in other embodiments, the conductive portion 1121 is not limited to a lead wire and may have other conductive structures.

[0067] In this embodiment, the heating element 112 includes a heating base 1122 and an infrared radiation layer 1124. The heating base 1122 is capable of generating heat when energized. The infrared radiation layer 1124 is disposed on the outer surface of the heating base 1122. When energized and heated, the heating base 1122 excites the infrared radiation layer 1124, which generates and radiates infrared light waves. In this embodiment, the heating base 1122 and the infrared radiation layer 1124 are concentrically distributed on the cross section of the heating part 1120.

[0068] In this embodiment, the heating base 1122 is generally strip-shaped and has a circular cross section. Specifically, the heating base 1122 may be a heating wire. Of course, it is understood that in other embodiments, the heating base 1122 may be sheet-shaped, i.e., the heating base 1122 may be a heating sheet. The heating base 1122 includes a metal base having oxidation resistance at high temperatures, and the metal base may be a metal wire. Specifically, the heating base 1122 may be a metal material having excellent oxidation resistance at high temperatures, high stability, and resistance to deformation, such as a nichrome alloy base (e.g., nichrome alloy wire) or an iron-chromium-aluminum alloy base (e.g., iron-chromium-aluminum alloy wire). In this embodiment, the radial dimension of the heating base 1122 may be 0.15 mm to 0.8 mm. The metal wire can be folded or wound to form various shapes, such as a spiral, a mesh, an M-shape, or an N-shape, and the heating element after being folded or wound can have an overall shape of a column, a spiral segment, a mesh, and other folded three-dimensional or planar shapes.

[0069] In this embodiment, the heating element 112 further includes an anti-oxidation layer 1123. The anti-oxidation layer 1123 is formed between the heating base 1122 and the infrared emitting layer 1124. Specifically, the anti-oxidation layer 1123 may be an oxide film, in which the heating base 1122 undergoes high-temperature heat treatment to form a dense oxide film on its surface, which then forms the anti-oxidation layer 1123. Of course, it should be understood that in other embodiments, the anti-oxidation layer 1123 is not limited to including a self-formed oxide film, and may also be an anti-oxidation coating applied to the outer surface of the heating base 1122. The formation of the anti-oxidation layer 1123 ensures that the heating base 1122 is not oxidized or is barely oxidized when heated in an air environment, thereby improving the stability of the heating base 1122. This eliminates the need to evacuate or fill the first containing cavity 1113 with a reducing gas, simplifying the assembly process of the entire heating structure 11 and reducing manufacturing costs. In this embodiment, the thickness of the antioxidant layer 1123 can be selected within the range of 1 μm to 150 μm. If the thickness of the antioxidant layer 1123 is less than 1 μm, the heat generating base 1122 is easily oxidized. If the thickness of the antioxidant layer 1123 exceeds 150 μm, the heat conduction between the heat generating base 1122 and the infrared emitting layer 1124 is seriously affected.

[0070] In this embodiment, the infrared emitting layer 1124 may be an infrared layer. The infrared layer may be formed on the side of the antioxidant layer 1123 away from the heat-generating substrate 1122 by subjecting an infrared-layer-forming substrate to high-temperature heat treatment. In this embodiment, the infrared-layer-forming substrate may be a silicon carbide, spinel, or composite substrate thereof. Of course, it should be understood that in other embodiments, the infrared emitting layer 1124 is not limited to an infrared layer. In other embodiments, the infrared emitting layer 1124 may be a composite infrared layer. In this embodiment, the infrared layer may be formed on the side of the antioxidant layer 1123 away from the heat-generating substrate 1122 by a method such as dip coating, spray coating, or brush coating. The thickness of the infrared emitting layer 1124 may be 10 μm to 300 μm. When the thickness of the infrared emitting layer 1124 is 10 μm to 300 μm, the infrared light wave effect is good, and the atomization efficiency of the aerosol-forming substrate 200 and the flavor during atomization are good. Of course, it should be understood that in other embodiments, the thickness of the infrared emitting layer 1124 is not limited to 10 μm to 300 μm.

[0071] In this embodiment, unlike heating elements in existing electronic cigarettes, the maximum operating temperature range of the heating element 112 may be 500°C to 1300°C. That is, the maximum operating temperature of the heating element 112 may be any temperature between 500°C and 1300°C throughout its entire operating period, specifically determined according to temperature control requirements. In contrast, the maximum operating temperature of heating elements in conventional technologies is generally within 400°C. Specifically, in this embodiment, the operating temperature of the heating element 112 includes a first operating temperature range and a second operating temperature range. The first operating temperature range may be the operating temperature range during preheating, and its maximum temperature may be 700°C to 1300°C. At this temperature, the aerosol-forming substrate 200 is preheated by infrared heat in an extremely short time, thereby ensuring the desired aerosol vapor volume and flavor for the first three or so puffs. Specifically, when powered on, the heating element 112 can rapidly heat up from room temperature to approximately 1000°C in 1 to 3 seconds. The second operating temperature range may be the operating temperature range when the aerosol-forming substrate is preheated and normally generates aerosol, and when the user inhales, and the maximum temperature may be 500°C to 800°C. Of course, it should be understood that in other embodiments, the operating temperature range of the heating element 112 is not limited to two, and may include, for example, a cooling stage after the second operating temperature range. Due to the presence of the gap 1114, the surface temperature of the tube 111 is controlled to 350°C or less, and the atomization temperature of the entire aerosol-forming substrate is controlled to 300°C to 350°C, thereby achieving accurate atomization of the aerosol-forming substrate 200, mainly in the infrared wavelength band of 2 to 5 μm.

[0072] Specifically, as shown in FIG. 7, FIG. 7 is a temperature change curve diagram of the heating element 112 of this embodiment during operation. The vertical axis represents temperature, and the horizontal axis represents the number of samplings, with approximately 15 points corresponding to 1 second. The peak portion corresponds to the preheating time, which lasts approximately 1 to 5 seconds (note that the preheating time can be significantly shortened from the conventional 15 seconds by controlling the output power as needed). In this solution, the preheating time is preferably 2 to 3 seconds. As shown in FIG. 7, after the aerosol generator is turned on, the heating element can heat up to 1000°C or higher in approximately 2 seconds, meaning that the first puff can be taken in approximately 1 second. This rapid temperature rise allows the medium to heat up quickly, shortening the waiting time and almost achieving the condition where the user can simply insert a cigarette and take a puff, greatly improving the consumer experience. Furthermore, even with such a rapid temperature rise, even when the temperature reaches 1000°C or higher, the medium does not burn and affect the flavor; rather, the flavor is improved, resolving the contradiction between the burning of the aerosol-forming substrate due to high-temperature operation of the heating element and the requirement for improved flavor during inhalation. In one embodiment, when the temperature reaches about 1200°C, the output power (or voltage) is reduced, lowering the temperature of the heating element to about 600°C, and maintaining this temperature or applying a short temperature pulse for about 5 minutes, after which the power is turned off and suction is terminated. Note that the main heating method in both the preheating stage and the stable output stage is infrared light waves, and although the wavelength bands of the infrared light waves corresponding to the high temperature stage and the stable output temperature are different, they are both wavelength bands that are easily absorbed by the medium.

[0073] The manufacturing method of the heating element 112 includes the following steps: Select a heating base-forming substrate to form the heating base 1122. Specifically, select a metal wire for infrared light waves (e.g., nichrome alloy wire or iron-chromium-aluminum alloy wire) to form the heating base 1122, and then wind the metal wire around the single-spiral heating portion 1120. Of course, it should be understood that in other embodiments, the heating element 112 is not limited to being wound around the single-spiral heating portion 1120, and the heating element 112 may adopt different winding methods, such as double spiral, M-shaped, or N-shaped.

[0074] Next, an oxidation-resistant layer 1123 is provided on the outer surface of the heat generating base 1122. Specifically, the wrapped heat generating part 1120 is placed in a heating furnace (for example, a muffle furnace) and heat treated, and then cooled to room temperature in the furnace, thereby forming an oxide film with a thickness of 1 μm to 150 μm on the outer surface of the heat generating base 1122, and a heat generating body preform having the oxidation-resistant layer 1123 is produced.

[0075] Thereafter, the infrared emitting layer-forming substrate is heat-treated on the side of the antioxidant layer 1123 away from the heat generating substrate 1122, and the infrared emitting layer 1124 is formed on the outer surface of the heat generating substrate 1122. Specifically, an infrared emitting layer-forming substrate (e.g., silicon carbide or spinel) is applied to the side of the antioxidant layer 1123 away from the heat generating substrate 1122 by dip coating, spray coating, brush coating, or other method, and the applied thickness of the infrared emitting layer-forming substrate is controlled to 10 μm to 300 μm. The heat generating element preform with the infrared emitting layer-forming substrate applied thereto is first heat-treated in a tunnel furnace, then placed in a heating furnace (e.g., a muffle furnace) and heat-treated at a temperature higher than the treatment temperature in the tunnel furnace, and then cooled to room temperature in the furnace. Note that in another embodiment, the infrared emitting layer 1124 may be formed directly on the outer surface of the heat generating substrate 1122 without previously forming an oxide film.

[0076] FIG. 8 shows a second embodiment of the aerosol generator of the present invention. The difference from the first embodiment is that the infrared radiation layer 1124 is a composite infrared layer. The composite infrared layer may be formed by combining an infrared layer-forming substrate with a binder for bonding the antioxidant layer 1123. Specifically, the binder may be glass powder, and the composite infrared layer may be a glass powder composite infrared layer. The reason for using glass powder is that it melts at high temperatures, thereby bonding the antioxidant layer 1123 to the infrared layer-forming substrate and sealing gaps in the infrared layer-forming substrate, further improving the dielectric breakdown resistance. The glass powder is then added to the infrared layer-forming substrate (e.g., silicon carbide or spinel) to form a composite. The composite is then applied to the side of the antioxidant layer 1123 away from the heat-generating substrate 1122 by methods such as dip coating, spray coating, or brush coating, followed by heat treatment. The resulting product is then placed in a heating furnace and heat-treated at a temperature higher than the treatment temperature in a tunnel furnace. The resulting product is then cooled to room temperature in the furnace, thereby producing the glass powder composite infrared layer.

[0077] 9 shows a third embodiment of the aerosol generating device of the present invention, which differs from the first embodiment in that the heating element 112 further includes a bonding layer 1125 disposed between the anti-oxidation layer 1123 and the infrared emitting layer 1124. The bonding layer 1125 may be used to prevent localized dielectric breakdown of the heating base 1122 and further improve the bonding strength between the anti-oxidation layer 1123 and the infrared emitting layer 1124. In some embodiments, the binder in the bonding layer 1125 may be glass powder, i.e., the bonding layer 1125 may be a glass powder layer.

[0078] In some embodiments, a binder may also be added to the infrared-emitting layer 1124, and the glass powder selected for the binder layer 1125 may have a higher melting point than the melting point of the glass powder in the infrared-emitting layer 1124.

[0079] 10 to 13 show a fourth embodiment of the aerosol-generating device of the present invention. The difference from the first embodiment is that the heat-generating structure 11 is not limited to being partially inserted into the aerosol-forming substrate 200 to heat the aerosol-forming substrate 200. In this embodiment, the heat-generating structure 11 is attached to the outer periphery of the medium portion of the aerosol-forming substrate 200, thereby heating the aerosol-forming substrate 200 in a peripheral heating manner. In this embodiment, the tubular body 111 includes a first tubular body 111a and a second tubular body 111b. The first tubular body 111a has a hollow structure with both ends penetrated. The first tubular body 111a may be cylindrical, and its inner diameter may be slightly larger than the outer diameter of the aerosol-forming substrate 200. A second receiving cavity 1115 is formed inside the first tubular body 111a to receive the aerosol-forming substrate 200 and form a heating space for heating the medium portion of the aerosol-forming substrate 200. The axial length of the first tube 111a may be greater than the axial length of the second tube 111b. The second tube 111b may be attached to the outer periphery of the first tube 111a, and the second tube 111b may be cylindrical. The radial dimension of the second tube 111b may be greater than the radial dimension of the first tube 111a, i.e., a gap is provided between the second tube 111b and the first tube 111a, and the gap forms a first accommodating cavity 1113, which is used to accommodate the heating element 112. In some embodiments, the heating element 112 is wrapped around the outer periphery of the first tube 111a, and a gap 1114 is formed between the inner wall of the second tube 111b and the outer wall of the first tube 111a as a whole, thereby creating a temperature difference between the inner wall of the first receiving cavity 1113 and the heating element 112, thereby providing a thermal insulation effect. In some embodiments, a reflective layer may be installed on the inner wall of the second tube 111b, which is used to reflect the heat of the heating element 112 and radiate it to the aerosol-forming substrate 200, thereby improving heating efficiency.

[0080] In other embodiments, the heating element 112 is not limited to being spaced apart from the entire first tube 111a or the second tube 111b. In other embodiments, the heating element 112 may be partially spaced apart from the first tube 111a, and the radial dimension of a portion of the heating part 1120 may be equal to the outer diameter of the first tube 111a, which can serve as a positioning function. In some embodiments, the heating element 112 may be partially spaced apart from the second tube 111b, and the radial dimension of a portion of the heating part 1120 may be equal to the radial dimension of the second tube 111b.

[0081] 14 and 15 show a fifth embodiment of the aerosol generator of the present invention. This embodiment differs from the first embodiment in that the heating element 112 is in the form of a sheet that is wound around to form a columnar heating portion 1120. The heating base 1122, the antioxidant layer 1123, and the infrared emitting layer 1124 can be arranged in a stacked configuration to form a structure similar to a "sandwich."

[0082] 16 shows a sixth embodiment of the aerosol generating device of the present invention. The difference from the fifth embodiment is that a bonding layer 1125 is provided between the infrared emitting layer 1124 and the anti-oxidation layer 1123.

[0083] 17 shows a seventh embodiment of the aerosol generating device of the present invention. The difference from the fifth embodiment is that the heating element 112 is bent to form a spring-loaded heating portion 1120.

[0084] 18 shows an eighth embodiment of the aerosol generator of the present invention. The difference from the fifth embodiment is that the heat generating element 112 is folded and arranged, and the heat generating part 1120 is sheet-shaped as a whole.

[0085] Figure 19 shows a ninth embodiment of the aerosol generator of the present invention. The difference from the first embodiment is that the first heating element 112a and the second heating element 112b may have a separate structure. The first heating element 112a and the second heating element 112b are two independent heating elements 112. Of course, it will be understood that the second heating element 112b may be replaced by a non-heat-generating conductive rod.

[0086] Figure 20 shows a tenth embodiment of the aerosol generating device of the present invention. The difference from the first embodiment is that the heating element 112 is wound in a double-helix manner to form a heating section 1120 having a double-helix structure. The heating section 1120 has a hollow structure. Of course, it should be understood that in other embodiments, a support rod may be installed in the center of the heating section 1120.

[0087] 21 and 22 show an eleventh embodiment of the aerosol generating device of the present invention. The difference from the first embodiment is that the heating element 112 forms a heating section 1120 using an M-winding method. Specifically, the heating structure 11 may include a winding frame 114, which may be two winding frames 114 spaced apart, with the heating element 112 wound around the two winding frames 114. The two winding frames 114 have the same structure and radial dimensions, so that the radial dimensions of the winding frames 114 throughout the heating section 1120 are uniformly distributed in the axial direction of the heating section 1120. In this embodiment, the heating structure 11 further includes a support rod 115, which is installed between the two winding frames 114 and serves as a support.

[0088] 23 shows a twelfth embodiment of the aerosol generator of the present invention. The difference from the second embodiment is that the radial dimension of one winding frame 114 is smaller than the radial dimension of the other winding frame 114, which makes the entire heat-generating part 1120 conical, and allows the conductive part 1121 to pass through the winding frame 114, which has a larger radial dimension.

[0089] 24 and 25 show a thirteenth embodiment of the aerosol generating device of the present invention. The difference from the fourth embodiment is that the heating element 112 forms a heating portion 1120 by a double spiral winding method.

[0090] 26 and 27 show a 14th embodiment of the aerosol generating device of the present invention. The difference from the 14th embodiment is that the heating element 112 forms a heating portion 1120 using an M-shaped winding method.

[0091] It should be understood that the above examples illustrate preferred embodiments of the present invention, and although the descriptions are specific and detailed, they should not be understood to limit the scope of the claims of the present invention. Those skilled in the art can freely combine the above technical features and make several modifications and improvements without departing from the spirit of the present invention, and all of these fall within the scope of protection of the present invention. Therefore, all equivalent changes and modifications made within the scope equivalent to the claims of the present invention are intended to be encompassed in the scope of the claims of the present invention.

Claims

1. A heating structure comprising a heating element (112) and a tube (111), wherein the heating element (112) comprises a heating base (1122) and an infrared radiation layer (1124) provided on the outer surface of the heating base (1122), wherein the heating base (1122) is heated by electrical current, exciting the infrared radiation layer (1124) to emit infrared light waves, the heating element (112) being positioned at least partially spaced from the tube wall of the tube (111), the tube wall of the tube (111) being transparent to the infrared light waves, and the infrared light waves being used to heat an aerosol-forming substrate.

2. The heating structure according to claim 1, wherein the tube (111) is made of infrared-transmitting glass, transparent ceramic, or diamond.

3. The heating structure according to claim 1, wherein the maximum operating temperature of the heating element (112) is 500°C to 1300°C.

4. The heating structure of claim 1, wherein the operating temperature range of the heating element (112) includes at least a first operating temperature range and a second operating temperature range, the maximum temperature of the first operating temperature range being 700°C to 1300°C, and the maximum temperature of the second operating temperature range being 500°C to 800°C.

5. The heating structure according to claim 1, wherein the heating element (112) is spaced apart from the entire wall of the tube (111).

6. The heat generating structure according to claim 1, wherein the heat generating element (112) and the tube (111) are not in direct contact with each other.

7. The heat generating structure according to claim 1, wherein the thickness of the wall of the tube body (111) is 0.15 mm to 0.6 mm.

8. 2. The heating structure according to claim 1, wherein the distance between the wall of the tube (111) and the heating element (112) is 0.05 mm to 1 mm.

9. The heat generating structure according to claim 1, wherein the heat generating base (1122) is a strip having a circular cross section, and the radial dimension of the heat generating base (1122) is 0.15 mm to 0.8 mm.

10. The heat generating structure according to claim 1, wherein the heat generating base (1122) has a flat strip-like cross section, and the thickness of the heat generating base (1122) is 0.15 mm to 0.8 mm.

11. The heat generating structure according to claim 1, wherein the heat generating base (1122) is in the form of a sheet, a mesh, or a film, and the thickness of the heat generating base (1122) is 10 μm to 500 μm.

12. The heat generating structure according to claim 1, wherein the thickness of the infrared radiation layer (1124) is 10 μm to 300 μm.

13. The heat generating structure according to claim 1, further comprising an anti-oxidation layer (1123) disposed between the heat generating base (1122) and the infrared emitting layer (1124).

14. The heat generating structure according to claim 13, wherein the thickness of the anti-oxidation layer (1123) is 1 μm to 150 μm.

15. 14. The heat generating structure of claim 13, further comprising a bonding layer (1125) disposed between the anti-oxidation layer (1123) and the infrared emitting layer (1124).

16. The heat generating structure according to claim 15, wherein the thickness of the bonding layer (1125) is between 10 μm and 70 μm.

17. The heat generating structure of claim 13, wherein the infrared radiation layer (1124) includes an infrared layer and / or a composite infrared layer, and the composite infrared layer is formed by combining an infrared layer forming substrate with a binder for bonding to the antioxidant layer (1123).

18. The heat generating structure of claim 1, wherein the heat generating substrate (1122) comprises a metal substrate, the metal substrate comprising a nichrome alloy substrate or an iron chromium aluminum alloy substrate.

19. The heating structure according to claim 1, wherein the heating element (112) is installed in a longitudinal direction.

20. The heat generating structure according to claim 1 , wherein the heat generating element is in the form of a column, a strip, a sheet, a spiral, or a mesh.

21. The heating structure according to claim 1, wherein the heating element (112) is at least partially bent.

22. The heating structure of claim 21, wherein the heating element (112) forms a heating portion (1120) having at least one bent portion after bending, and the heating portion (1120) is columnar, spiral, or mesh-shaped.

23. The heat generating structure according to claim 1, wherein the tube (111) is hollow and has a first accommodating cavity (1113) formed therein for accommodating the heat generating element (112).

24. The heating structure of claim 1, wherein the heating elements (112) are spaced apart from one another around the periphery of the tube (111), and the inside of the tube (111) is hollow, forming a second containing cavity (1115) for containing the aerosol medium.

25. The heating structure of claim 1, wherein the tube (111) includes a first tube (111a) that transmits light waves and a second tube (111b) that is arranged on the outer periphery of the first tube (111a), and a gap is provided between the second tube (111b) and the first tube (111a), and the gap forms a first accommodating cavity (1113) that accommodates the heating element (112). The heating structure of claim 1, wherein the heating element (112) is arranged on the outer periphery of the first tube (111a) and is installed at a distance from the first tube (111a).

26. 26. An aerosol generating device, comprising a heat generating structure (11) according to any one of claims 1 to 25 and a power supply component for supplying power to said heat generating structure (11).

27. A heating element comprising a heating base (1122) and an infrared emitting layer (1124) provided on the outer surface of the heating base (1122), wherein the heating base (1122) is heated by electrical current, exciting the infrared emitting layer (1124) to emit infrared light waves, which are used to heat an aerosol-forming substrate placed in a storage cavity of an aerosol generating device, and wherein the heating base is placed at a distance from the wall of the storage cavity.

28. 28. The heating element according to claim 27, wherein the heating base (1122) is strip-shaped with a circular cross section, and the radial dimension of the heating base (1122) is 0.15 mm to 0.8 mm.

29. The heating element according to claim 27, wherein the heating base (1122) is in a sheet form and the thickness of the heating base (1122) is 0.15 mm to 0.8 mm.

30. The heating element according to claim 27, characterized in that the thickness of the infrared radiation layer (1124) is between 10 μm and 300 μm.

31. 28. The heating element of claim 27, further comprising an anti-oxidation layer (1123) disposed between the heating base (1122) and the infrared emitting layer (1124).

32. The heating element according to claim 31, characterized in that the thickness of the anti-oxidation layer (1123) is between 1 μm and 150 μm.

33. 33. The heating element of claim 32, further comprising a bonding layer (1125) disposed between the anti-oxidation layer (1123) and the infrared emitting layer (1124).

34. A heating element according to claim 33, characterized in that the thickness of the bonding layer (1125) is between 10 μm and 70 μm.

35. The heating element of claim 33, characterized in that the infrared radiation layer (1124) includes an infrared layer and / or a composite infrared layer, and the composite infrared layer is formed by combining an infrared layer-forming substrate with a binder for bonding to the antioxidant layer (1123).

36. 28. The heating element of claim 27, wherein the heating substrate (1122) comprises a metal substrate, the metal substrate comprising a nichrome alloy substrate or an iron-chromium-aluminum alloy substrate.

37. A heating element according to claim 27, characterized in that the maximum operating temperature of the heating element (112) is between 500°C and 1300°C.

38. The heating element of claim 27, wherein the operating temperature of the heating element (112) includes at least a first operating temperature range and a second operating temperature range, the maximum temperature of the first operating temperature range being 700°C to 1300°C, and the maximum temperature of the second operating temperature range being 500°C to 800°C.

39. 28. Heating element according to claim 27, characterized in that the heating element (112) is installed longitudinally.

40. 28. The heating element according to claim 27, wherein the heating element is in the form of a strip, a sheet, a spiral, or a mesh.

41. The method includes the following steps: Selecting a heat generating substrate forming substrate to form a heat generating substrate (1122); A method for manufacturing a heating element, characterized in that an infrared emitting layer-forming substrate is heat-treated on the outer surface of the heating base (1122) to form an infrared emitting layer (1124) on the outer surface of the heating base (1122).

42. A method for manufacturing a heating element as described in claim 41, further comprising providing an anti-oxidation layer (1123) on the outer surface of the heating base (1122), and forming the infrared radiation layer (1124) on the side of the anti-oxidation layer (1123) away from the heating base (1122).

43. 43. The method for manufacturing a heating element according to claim 42, further comprising applying a binder onto the anti-oxidation layer (1123) to bond the anti-oxidation layer (1123) and the infrared radiation layer (1124) to form a bonding layer (1125).

44. The method for manufacturing a heating element described in claim 43, characterized in that the infrared radiation layer (1124) includes an infrared layer and / or a composite infrared layer, and the composite infrared layer is formed by combining an infrared layer-forming substrate with a binder for bonding to the antioxidant layer (1123).

45. 42. The method for manufacturing a heating element according to claim 41, wherein the heating element forming substrate includes a metal substrate, and the metal substrate includes a nichrome alloy substrate or an iron-chromium-aluminum alloy substrate.

46. The method for manufacturing a heating element according to claim 41, characterized in that the heating base (1122) is a strip-shaped body having a circular cross section, and the radial dimension of the heating base (1122) is 0.15 mm to 0.8 mm.

47. The method for manufacturing a heating element according to claim 41, wherein the heating base (1122) is in a sheet form and has a thickness of 0.15 mm to 0.8 mm.

48. The method for manufacturing a heating element according to claim 41, characterized in that the thickness of the infrared radiation layer (1124) is 10 μm to 300 μm.

49. The method for manufacturing a heating element according to claim 42, characterized in that the thickness of the anti-oxidation layer (1123) is 1 μm to 150 μm.

50. The method for manufacturing a heating element according to claim 43, characterized in that the thickness of the bonding layer (1125) is between 10 μm and 70 μm.

Images