Aerosol generating device with thermal insulator

Abstract

The aerosol generating device (1) comprises: an insulator (102) having an inner wall (104) and an outer wall (106) separated from each other; a cavity (110) defined in the inner wall (104) capable of receiving an aerosol-forming substrate; and a heater (112) positioned to heat the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity (110); a casing (10) surrounding the insulator (102); and electrical contacts (116) connected to the heater (112), at least one of the electrical contacts (116) being mechanically connectable to the casing (10) to hold the insulator (102) in place.

Description

[Technical Field]

[0001] The present invention relates to an aerosol generating device, and more particularly to an aerosol generating device equipped with an insulator such as a vacuum insulator. [Background technology]

[0002] The popularity and use of aerosol-generating devices and systems (also known as vaporizers) has grown rapidly in recent years as an alternative to traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling cigarettes. A variety of devices and systems are available that heat or warm an aerosolizable substance, which may or may not contain nicotine or other active substances, as opposed to burning tobacco in traditional tobacco products.

[0003] Commonly available aerosol generation systems are substrate-heated aerosol generation or heat-and-burn types. These types of systems generate aerosol or vapor by heating a consumable product (i.e., a "heat-and-burn stick") containing an aerosol-forming substrate, such as reconstituted tobacco, to temperatures typically ranging from 150°C to 350°C. By heating rather than burning or combusting the aerosol-forming substrate, an aerosol is released that contains the ingredients desired by the user but does not contain the undesirable by-products of combustion. In addition, aerosols generated by heating tobacco or other aerosolizable materials typically do not contain the burnt or bitter taste that can result from combustion, which can be unpleasant to users.

[0004] Typically, a heat-and-burn consumable product, for example in the form of a stick, is inserted into a cavity of the heat-and-burn device, with the end of the stick protruding from the device to form a mouthpiece for inhalation. A heater within the heat-and-burn device then supplies heat to the stick to aerosolize an aerosolizable material contained in an aerosol-forming substrate within the stick, and the resulting aerosol is delivered to the user from the protruding end of the stick.

[0005] Typically, not all of the heat generated by the heater is transferred to the consumable to generate the aerosol. This reduces the overall efficiency of the device and shortens battery life. Furthermore, losses can lead to heating of other components within the device, which can lead to damage and can cause discomfort to the user when holding the device. Summary of the Invention [Problem to be solved by the invention]

[0006] The purpose of the present invention is to address these problems. [Means for solving the problem]

[0007] According to one aspect of the present invention, there is provided an aerosol generation device comprising: an insulator having inner and outer walls separated from each other, a cavity defined in the inner wall capable of receiving an aerosol-forming substrate, and a heater positioned to heat the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity; a casing surrounding the insulator; and electrical contacts connected to the heater, at least one of the electrical contacts being mechanically connectable to the casing to hold the insulator in place.

[0008] Advantageously, the electrical contacts also provide a mechanical connection between the insulator and the casing, thereby reducing the number of heat conduction paths between them. By reducing the amount of heat conducted from the insulator to the casing, a greater proportion of the heat can be transferred to the aerosol-forming substrate, thereby increasing the efficiency of the heater. Furthermore, reduced heating of the casing may reduce damage to other components of the device installed within the casing, which may be desirable from the perspective of a user holding the casing.

[0009] The insulation and heater together may be referred to as a heating device. The heating device may be received within a chamber of the casing, such as a chamber defined by a side portion of the casing extending from a base portion of the casing. The heating device may be received within the chamber such that an air gap is provided between an outer wall of the insulation and the casing. The region between the inner and outer walls of the insulation may be referred to as an insulation region.

[0010] Preferably, the electrical contacts provide the only connection between the insulation and the casing. Advantageously, this reduces heat transferred between the insulation and the casing by minimizing the number of thermal conduction paths between the insulation and the casing. In other words, preferably, the only way heat can be transferred between the insulation and the casing is through the electrical contacts.

[0011] Preferably, the inner and outer walls of the insulation are separated from one another by a vacuum, thereby providing vacuum insulation. In this manner, heat conduction and / or convection between the inner and outer walls of the insulation is further inhibited, thereby further reducing heat transfer from the insulation to the casing. Alternatively, the inner and outer walls of the insulation may be separated from one another by an air gap, an aerogel, a foam material, a fibrous material, and / or any combination of the above.

[0012] Preferably, the insulation is removable from within the casing. In other words, at least one of the electrical contacts can be mechanically disconnected from the casing. For example, the insulation and the heating device providing the heater may be removable from the casing, such as from within the chamber. In this manner, the insulation can be replaced, cleaned, and / or repaired. Alternatively, the insulation may be permanently fixed within the casing, which may allow for a stronger connection between the insulation and the casing.

[0013] The cavity may have at least one opening where the inner wall is joined to the outer wall, and one or more electrical contacts may be located on the insulation at a location that minimizes heat flow between the at least one opening and the electrical contact. In this way, the electrical contact is made in the portion of the outer wall that remains coolest during use of the aerosol generating device. This reduces heat transfer between the insulation and the casing. For example, the electrical contact may be located at a location that maximizes the shortest distance between the at least one opening and the electrical contact. In other words, if there are multiple openings to the cavity, the electrical contact is not located close to any of them. The distance may be determined along a direct path between the opening and the electrical contact. Preferably, the distance is determined along a thermal path between the opening and the electrical contact. Because heat flow is suppressed through the insulating portion of the insulation, the distance may be measured along a thermal path through the air surrounding the insulation and / or along the outer wall of the insulation.

[0014] The insulation may be cup-shaped so that the cavity has a single opening where the inner wall is joined to the outer wall, and the electrical contact is located at the base of the insulation opposite the cavity opening. In other words, the insulation may be attached to the casing in a cantilevered configuration, with only one end of the insulation connected to the casing. By providing the electrical contact at the base of the insulation, the electrical contact is made at the coldest part of the outer wall during use, thereby reducing heat transfer from the insulation to the casing. In other words, the distance between the electrical contact and the cavity opening is maximized.

[0015] Alternatively, the insulation may be tubular so that the cavity has two openings where the inner wall is joined to the outer wall, and the electrical contact is located on a side of the insulation spaced from both of the openings. The electrical contact may be positioned equidistant from both openings to the cavity, thereby maximizing the shortest distance to both openings. Alternatively, if it is determined that one opening generates more heat than the other, the electrical contact may be moved farther from that opening. In this way, the electrical contact is made on the coolest portion of the outer wall during use, thereby reducing heat transfer from the insulation to the casing.

[0016] The electrical contacts may be mechanically connectable to the base portion of the casing. Connecting the electrical contacts to the base portion of the casing reduces heat transfer to a side portion of the aerosol generating device (which may be held by a user). Alternatively, the electrical contacts may be mechanically connectable to a side portion of the casing. The side portion of the casing may comprise an inner wall and an outer wall, and the electrical contacts may be mechanically connectable to the inner wall. Insulation may be installed between the inner and outer walls, thereby further reducing heat transfer from the insulation to the casing.

[0017] The electrical contacts may comprise a pair of pins which may be connectable to the casing by a lockable coupling, or which may be connectable to the casing using a bayonet connection or a screw thread.

[0018] The electrical contacts may include a pin and a threaded outer surface engageable with the casing to hold the insulator in place.

[0019] It will be understood by those skilled in the art that any device or apparatus feature described herein may be provided as a method feature. It will be understood that specific combinations of the various features described and defined in any aspect described herein may be implemented and / or provided and / or used independently. Moreover, it will be understood that the present invention is described herein merely by way of example, and that modifications in detail may be made within the scope of the present invention.

[0020] One or more embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0021] [Figure 1A] 1 shows a schematic cross-section of a first embodiment of an aerosol generating device comprising a heating device. [Figure 1B]1B shows a cross section of the heating device of the embodiment shown in FIG. 1A. [Figure 2A] 1 shows a schematic cross section of a second embodiment of an aerosol generating device comprising a heating device. [Figure 2B] 2B shows a cross section of the heating device of the embodiment shown in FIG. 2A. [Figure 3-4] 1 illustrates an alternative heating arrangement that may be used in an embodiment of the aerosol generating device. DETAILED DESCRIPTION OF THE INVENTION

[0022] In the following description and accompanying drawings, corresponding features may preferably be identified using corresponding reference numerals so that the common features need not be described in detail with respect to each and every embodiment.

[0023] 1A depicts a schematic cross-section of a first embodiment of an aerosol generating device 1. Device 1 has a casing 10 comprising a base portion 12 and a side portion 14. More specifically, side portion 14 extends from base portion 12 to define a chamber 15. In this embodiment, side portion 14 comprises an outer wall 14a and an inner wall 14b, although it will be understood that side portion 14 may comprise only a single wall.

[0024] The device 1 comprises a heating device 100 held within a casing 10, such as within a chamber 15. The casing 10 thus encloses the heating device 100. Further details of the heating device 100 are shown in cross section in FIG. 1B. The heating device 100 comprises an insulator 102. The insulator 102 comprises an inner wall 104 and an outer wall 106, which are spaced apart such that an insulating region 108 is enclosed in the space between them. Preferably, the insulating region 108 comprises a vacuum, thereby providing vacuum insulation 102. Alternatively or additionally, the insulating region 108 may comprise an air gap, an aerogel, a foam material, a fibrous material, and / or any combination of the above.

[0025] The heating device 100 includes a cavity 110 adjacent to the inner wall 104 and configured to receive an aerosol-forming substrate. For example, a consumable 5 may be inserted into the cavity 110, where the consumable 5 includes an aerosol-forming substrate such as tobacco 6. The consumable 5 is typically an elongated rod or stick that a user can insert into the cavity 110 through an opening 111 into the cavity 110. The insulator 102 has a generally cylindrical shape, allowing the insulator 102 to completely surround the consumable 5 and maximize its insulating effect. In this example, the insulator 102 has an opening 111 at one longitudinal end for receiving the consumable 5, and the opposite end is closed. Thus, the insulator 102 has a cup-shaped cross section when viewed perpendicular to its longitudinal axis. In other words, the cavity 110 has a single opening 111 where the inner wall 104 is joined to the outer wall 106.

[0026] A heater 112 is provided within the insulating region 108 and on the interior wall 104. The heater 112 is configured to heat the interior wall 104 by conduction, which in turn heats the consumable 5 and the air within the cavity 110 by conduction and radiation. The heater 112 is powered by a power source, such as a battery (not shown), located in the base portion 12 of the casing 10 of the device 1.

[0027] By providing the heating apparatus 100 with insulation 102, the amount of wasted heat is reduced because the insulating region 108 inhibits direct heat conduction or convection from the heater 112 to the outer wall 106. Nevertheless, during use of the device 1, the outer wall 106 may heat up, such as due to air convection from the opening 111 of the cavity 110 or conduction between the inner wall 104 and the outer wall 106 at the opening 111. By providing the heating apparatus 100 within the chamber 15 of the device 1, an air gap is provided between the outer wall 106 of the heating apparatus 100 and the casing 10 of the device 1. Advantageously, this reduces heating of the casing 10, thereby increasing the efficiency of the device 1 and may prevent discomfort to a user holding the casing 10 of the device 1.

[0028] The heating apparatus 100 includes one or more electrical contacts 116 connected to the heater 112, such as by a first wire connector 114a and a second wire connector 114b. The electrical contacts 116 are mechanically connectable to the casing 10 of the device 1. In this embodiment, the electrical contacts 116 are mechanically connectable to the base portion 12 of the casing 10. By using the same means to provide both the mechanical and electrical connection between the insulation 102 and the casing 10, the number of heat conduction paths is reduced. Advantageously, this may further reduce heating of the casing 10, thereby increasing the efficiency of the device 1 and preventing discomfort to a user holding the casing 10 of the device 1.

[0029] Preferably, the electrical contacts 116 provide the only connection between the insulation 102 and the casing 10. In this way, the number of thermal conduction paths is minimized, further reducing heat transfer between the insulation 102 and the casing 10. To accomplish this, the material and shape of the electrical contacts 116 are selected to provide sufficient strength to keep the heating device 100 in place within the chamber 15 during use of the device 1, without requiring additional contacts between the heating device 100 and the casing 10. In other words, the electrical contacts 116 provide a rigid connection, thereby inhibiting movement of the insulation 102 relative to the casing 10.

[0030] Preferably, the electrical contacts 116 are also mechanically disconnectable from the casing 10 such that the heating device 100 is removable from the casing 10. Advantageously, by providing a heating device 100 that is removable from the casing 10, parts of the heating device 100 can be easily repaired and / or replaced without having to replace the entire device 10.

[0031] In this example, the electrical contacts 116 comprise a pair of pins that may be connectable to the casing 10 by a lockable coupling. The pins can be inserted into the base portion 12 and locked into place via a small rotation or translation.

[0032] In one implementation, the connection between the pin and the base portion 12 may correspond to the connection used between a fluorescent starter and its corresponding socket. More specifically, the pin may include a flange portion that retains the pin within a protruding groove in the base portion 12, and movement of the pin through the groove (e.g., by rotating the heating device 100) allows the pin to be removed from the base portion 12 at an opening. The electrical and mechanical connection between the heating device 100 and the casing 10 may be provided in other ways. For example, the heating device 100 may be connected to the casing 10 using a bayonet connector, where a radial pin connected to the heating device 100 engages within a pair of L-shaped slots on the casing 10. Alternatively, a threaded connector may be provided, where the heating device 100 includes a threaded exterior that can engage with corresponding threads in the base portion 12 of the casing 10. As a further alternative, the electrical contact 116 may include a (single) pin and a threaded exterior that can engage with the casing 10 to hold the insulator 102 in place. Such a configuration allows for a strong mechanical connection between the heating device 100 and the casing 10 while also providing a stable supply of power to the heating device 100 via the electrical contacts 116 .

[0033] The electrical contacts 116 are preferably located on the insulation 102 at a position that minimizes heat flow between the opening 111 and the electrical contacts 116. In this way, the electrical contacts 116 are made in the portion of the outer wall 106 that remains coolest during use of the aerosol generating device 1. This reduces heat transfer between the insulation 102 and the casing 10. The electrical contacts 116 may be located on the insulation 102 at a position that maximizes their distance from the opening 111 of the cavity 110. The maximum distance may correspond to a direct path between the opening 111 and the electrical contacts 116. Preferably, the maximum distance is determined to be the greatest distance along the thermal path between the opening 111 and the electrical contacts 116. Because heat flow is inhibited through the insulating region 108 of the insulation 102, this distance may be measured along the thermal path through the air surrounding the insulation 102 and / or along the outer wall 106 of the insulation 102.

[0034] 1A and 1B, the electrical contact 116 may be located at the base of the insulator 102 opposite the opening 111 of the cavity 110. In other words, the insulator 102 is attached to the casing 10 in a cantilevered configuration, with only one end of the insulator 102 connected to the casing 10. In this manner, the distance along the thermal path between the opening 111 and the electrical contact 116 is maximized, thereby reducing heat transfer therebetween. In other words, the electrical contact 116 is made at the coldest portion of the outer wall 106 during use, thereby reducing the amount of heat transferred from the insulator 102 to the casing 10 of the device 1.

[0035] Figure 2A depicts a schematic cross-section of a second embodiment of an aerosol generating device 1. The device 1 is similar to the device 1 described above in that it comprises a casing 10 having a base portion 12 and a side portion 14 surrounding a chamber 15. However, the device 1 comprises an alternative heating device 200, which is shown in more detail in Figure 2B. In Figure 2B, the heating device 200 is depicted with a consumable item 5 inserted, which includes a tobacco 6 and a filter 7.

[0036] 1A and 1B, the insulator 202 in this embodiment is open at both longitudinal ends such that it has a tubular cross-section when viewed perpendicular to its longitudinal axis. More specifically, the cavity 210 has a first opening 211a at a first longitudinal end and a second opening 211b at a second longitudinal end. The first opening 211a is configured to receive the consumable 5. A plug 236 may be provided in the second opening 211b to prevent the consumable 5 from being over-inserted into the cavity 210. The plug 236 may comprise PEEK, rubber, or other suitable heat-resistant material.

[0037] The thermal insulator 202 also includes one or more electrical contacts 216 connected to the heater 212. The electrical contacts 216 are mechanically connectable to the casing 10 of the device 1. In this embodiment, the electrical contacts 216 are mechanically connectable to the side portion 14 of the casing 10. More specifically, the electrical contacts 216 are mechanically connectable to the inner wall 14b of the side portion 14 of the casing 10. It will be understood that if the side portion 14 has only a single wall, the electrical contacts 216 may be mechanically connectable to a single wall (e.g., an outer wall). By providing both mechanical and electrical connections between the thermal insulator 202 and the casing 10 using the same means, the number of thermal conduction paths is reduced. Preferably, the electrical contacts 216 provide the only connection between the thermal insulator 202 and the casing 10. In this manner, the number of thermal conduction paths is minimized, further reducing heat transfer between the thermal insulator 202 and the casing 10. To achieve this, the material and shape of the electrical contacts 216 are selected to provide sufficient strength to keep the heating device 200 in place within the chamber 15 during use of the device 1 without the need for additional contacts between the heating device 200 and the casing 10. In other words, the electrical contacts 216 provide a rigid connection, which inhibits movement of the insulation 202 relative to the casing 10.

[0038] Preferably, the electrical contacts 216 are also mechanically disconnectable from the casing 10 so that the heating device 200 is removable from the casing 10. Advantageously, by providing a heating device 200 that is removable from the casing 10, parts of the heating device 200 can be easily repaired and replaced without having to replace the entire device 1.

[0039] In this example, the electrical contacts 216 comprise a pair of pins. The pins may be connectable to the casing 10 by a lockable coupling. The pins may be inserted into the side portion 14 of the casing 10 and locked into place via a small rotation or translation. As discussed above with respect to the heating device 100, various connection configurations may be used to provide both a strong mechanical and electrical connection between the heating device 200 and the casing 10 via the electrical contacts 216.

[0040] The electrical contacts 216 are preferably located on the insulation 202 at a position that minimizes heat flow between the openings 211 a, 211 b and the electrical contacts 216. In this way, the electrical contacts 216 are made in the part of the outer wall 206 that remains coolest during use of the aerosol generating device 1. This reduces heat transfer between the insulation 202 and the casing 10.

[0041] 2A and 2B, the electrical contacts 216 may be located on a side of the insulator 202 that is spaced apart from the first opening 211 a and the second opening 211 b of the cavity 210. For example, the electrical contacts 216 may be located on a side of the insulator 202 that is substantially equidistant from both the first opening 211 a and the second opening 211 b of the cavity 210. In this location, the shortest distance between the electrical contacts 216 and either of the openings 211 a, 211 b is maximized, thereby reducing the transfer of heat from either of the openings 211 a, 211 b to the electrical contacts 216. Alternatively, if it is determined that one of the openings 211 a, 211 b generates more heat than the other (e.g., due to the insulating properties of the plug 236), the locations of the electrical contacts 216 may be adjusted accordingly (e.g., by moving them closer to the opening 211 b with the plug 236). In other words, the electrical contacts 216 are made at the coolest portion of the outer wall 206 during use, thereby reducing the amount of heat transferred from the insulation 202 to the casing 10 of the device 1. In any of the embodiments described herein, the coolest portion of the outer wall 206 may be calculated, such as by computer simulation, to determine the optimal placement of the electrical contacts 216.

[0042] It will be understood that the electrical contacts 116, 216 described above can be located at other locations on the insulation 102, 202 to provide a mechanical connection to the casing 10 of the device 1. Figures 3 and 4 show alternative embodiments of heating devices 300, 400 that can be used with the device 1. The heating device 300 is similar to the cup-shaped heating device 100 described above, except that the electrical contacts 316 are located at the end of the insulation 302 adjacent the opening 311 of the cavity 310. The heating device 400 is similar to the cup-shaped heating device 100, 300 described above, except that the electrical contacts 416 are located on the side of the insulation 402 near the opening 411 of the cavity 410. This can allow for easier inspection and / or repair of the heating devices 300, 400 and may be preferred for certain types of devices 1. As previously mentioned, the electrical contacts 316 , 416 are mechanically connectable to the casing 10 of the device 1 and preferably provide the only connection between the insulation 302 , 402 and the casing 10 .

[0043] While the foregoing is directed to exemplary embodiments of the invention, it will be understood that the invention is described herein by way of example only and that modifications of detail can be made within the scope of the invention. Furthermore, those skilled in the art will appreciate that the invention is not limited to the embodiments disclosed herein, nor to any details shown in the accompanying drawings, which are not described in detail herein or defined in the claims.

[0044] Moreover, other and further embodiments of the invention will become apparent to those skilled in the art upon consideration of this specification and may be devised without departing from the basic scope of the invention as determined by the following claims.

Claims

1. 1. An aerosol generating device comprising: an insulator comprising an inner wall and an outer wall separated from each other, a cavity defined within the inner wall capable of receiving an aerosol-forming substrate, and a heater positioned to heat the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity; a casing surrounding the thermal insulator; electrical contacts connected to the heater, at least one of the electrical contacts being mechanically connectable to the casing to hold the insulation in place; An aerosol generating device comprising:

2. 2. The aerosol generating device of claim 1, wherein the electrical contact provides the only connection between the insulation and the casing.

3. 3. The aerosol generating device of claim 1, wherein the inner and outer walls of the insulation are separated from each other by a vacuum, thereby providing a vacuum insulator.

4. The aerosol generating device according to any one of claims 1 to 3, wherein the insulator is removable from within the casing.

5. An aerosol generating device as described in any one of claims 1 to 4, wherein the cavity has at least one opening where the inner wall is joined to the outer wall, and the one or more electrical contacts are located on the insulator in a location that minimizes heat flow between the at least one opening and the electrical contacts.

6. 6. The aerosol generating device of claim 5, wherein the insulator is cup-shaped so that the cavity has a single opening where the inner wall is joined to the outer wall, and the electrical contact is located at the base of the insulator opposite the opening of the cavity.

7. 6. The aerosol generating device of claim 5, wherein the insulator is tubular so that the cavity has two openings where the inner wall is joined to the outer wall, and the electrical contacts are located on a side of the insulator spaced apart from both of the two openings.

8. An aerosol generating device according to any one of claims 1 to 7, wherein the electrical contacts are mechanically connectable to the base portion of the casing.

9. An aerosol generating device according to any one of claims 1 to 7, wherein the electrical contacts are mechanically connectable to the side portions of the casing.

10. 10. The aerosol generating device of claim 9, wherein the side portion of the casing comprises an inner wall and an outer wall, and the electrical contact is mechanically connectable to the inner wall.

11. An aerosol generating device according to any one of claims 1 to 10, wherein the electrical contacts comprise a pair of pins.

12. 12. The aerosol generating device of claim 11, wherein the pair of pins are connectable to the casing by a lockable coupling.

13. 13. The aerosol generating device of claim 12, wherein the pair of pins are connectable to the casing using a bayonet connection or a screw thread.

14. 11. An aerosol generating device according to any one of claims 1 to 10, wherein the electrical contact comprises a pin and a threaded outer surface engageable with the casing to hold the insulator in place.

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