Heater for aerosol supply device

Abstract

A heater for an aerosol supply device configured to heat at least a portion of an article 5 containing an aerosol generating material, comprising an elongated housing, a heating element disposed within the elongated housing, and a filler disposed within the elongated housing, wherein the heating element is held within the elongated housing by the filler, and the filler comprises a filler material and a particulate material, wherein the particulate material is electrically insulating and has a heat capacity less than 10 times that of the filler material.

Description

[Technical Field]

[0001] The present invention relates to a heater for an aerosol supply device, an aerosol supply device, an aerosol supply system, a method for manufacturing a heater for an aerosol supply device, and a method for generating an aerosol. [Background technology]

[0002] Smoking products such as cigarettes and cigars produce tobacco smoke by burning tobacco during use. Attempts have been made to provide alternatives to these products by creating products that release compounds without combustion. Examples of such products include so-called "non-combustion heating" products, or tobacco heating devices or products, that release compounds by heating materials without burning them. The materials may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] Aerosol supply systems including the devices or products described above are known. Typical systems use a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. Often, supplying different aerosols for inhalation requires changing or replacing the medium used. Resistance heating systems are known to be used as heaters for generating aerosols from a suitable medium. Separately, induction heating systems are also known to be used as heaters. [Overview of the project]

[0004] According to one embodiment, a heater for an aerosol supply device is provided, configured to heat at least a portion of an article containing an aerosol-generating material, comprising an elongated housing, a heating element disposed within the elongated housing, and a filler disposed within the elongated housing, wherein the heating element is held within the elongated housing by the filler, and the filler comprises a filler material and a particulate material, the particulate material being electrically insulating and having a heat capacity smaller than that of the filler material.

[0005] The elongated housing member may have a bore, and the heating element and filler may be placed within the bore. The bore may define the internal cavity of the heater. The filler may be provided between at least a portion of the inner surface of the elongated housing and a portion of the heating element. The heating element does not need to be in contact with the inner surface of the elongated housing.

[0006] At least one individual portion of the filler may extend along most of the length of the heating element. At least one individual portion of the filler may extend along 75% of the length of the heating element. At least one individual portion of the filler may extend along 90% of the length of the heating element. At least one individual portion of the filler may extend along substantially the entire length of the heating element.

[0007] A single separate portion of the filler may be provided. The single separate portion of the filler may be configured to occupy at least a portion of the space within the heater coil. A single separate portion of the filler may be provided, and the filler and heater elements may substantially fill the internal cavity within the elongated housing.

[0008] The filler may be provided with at least two separate parts.

[0009] The elongated housing can define a longitudinal axis, and at least two individual parts of the filler may be spaced apart from each other along the longitudinal axis. Gaps may exist between each of the individual parts of the filler.

[0010] At least one individual portion of the filler may be provided at the first end of the heating element. The individual filler portion may substantially surround the first end of the heating element. One individual portion of the filler material may surround the distal end of the heating element. One individual portion of the filler material may surround the proximal end of the heating element.

[0011] At least one individual portion of the filler may be provided at the second end of the heating element. The individual filler portion may substantially surround the second end of the heating element.

[0012] The filler may be provided with at least two separate portions. The at least two separate portions of the filler may extend axially along the inner surface of an elongated housing such that a substantially axially oriented passage is provided between adjacent portions of the filler.

[0013] The filler may have at least two separate parts, and these at least two separate parts may be spaced apart from each other in the axial direction. There may be a gap between each of the at least two masses.

[0014] The particulate material is approximately 700 J·kg -1 ·K -1 ~Approx. 1100J kg -1 ·K -1 It may have a specific heat capacity within the range of [specify value]. The particle material has a specific heat capacity of approximately 750 J·kg. -1 ·K -1 ~Approx. 900J kg -1 ·K -1 It may have a specific heat capacity within the range.

[0015] The particulate material may contain microspheres. Microspheres will be understood as manipulated spherical particles having dimensions on a microscale, typically in the range of 1 to 1000 μm.

[0016] The particulate material may contain hollow microspheres.

[0017] The particulate material may have a median particle size (also referred to as median particle diameter or D50 value) of less than about 500 μm. The particulate material may have a median particle size of less than about 350 μm. The particulate material may have a median particle size of less than about 250 μm.

[0018] The particulate material may have a median particle size (also referred to as median particle diameter or D50 value) of from about 15 to about 500 μm.

[0019] The particulate material may have a median particle size of from about 15 to about 65 μm. The particulate material may have a median particle size of from about 25 to about 5 μm, or from about 35 to about 50 μm.

[0020] The particulate material may have a D90 value of from about 20 to about 110 μm, from about 40 to about 85 μm, or from about 50 to about 70 μm.

[0021] The distance D between the inner surface of the elongated housing and the outer surface of the heating element may be smaller than the median particle size of the particular material.

[0022] The median particle size of the particulate material may be larger than the distance D between the inner surface of the elongated housing and the outer surface of the heating element. The distance D may be within the range of from about 1 μm to about 65 μm, or within the range of from about 1 μm to about 50 μm, or within the range of from about 5 μm to about 25 μm. The particulate material may have a median particle size larger than D.

[0023] The particulate material may have a density of less than about 0.65 g / cm 3 For example, less than about 0.1 g / cm 3 to about 0.5 g / cm 3

[0024] The filler may contain any amount of particulate material, such as from about 1 wt% to about 99 wt%, from about 10 wt% to about 90 wt%, from about 20 to about 80 wt%, from about 25 wt% to about 75 wt%, or from about 30 wt% to about 70 wt%. ​

[0025] The weight ratio of the filler material to the particulate material may be in the range of about 1:10 to about 10:1, such as about 1:5 to about 5:1, or about 1:2 to about 2:1.

[0026] The filler may contain any amount of particulate material, such as about 10 wt% to about 90 wt%, about 20 to about 80 wt%, about 25 wt% to about 75 wt%, or about 30 wt% to about 70 wt%.

[0027] The filler may contain any amount of particulate material, such as about 10 vol% to about 90 vol%, about 20 vol% to about 80 vol%, or about 30 vol% to about 70 vol%.

[0028] The particulate material may include glass particles. The particulate material may be glass microspheres. The glass microspheres may be hollow glass microspheres. The glass microspheres may have a median particle size (also called median particle diameter, D50) of about 15 to about 65 μm.

[0029] Particulate materials suitable for use in the present invention are commercially available (e.g., from 3M (trademark), Trelleborg Applied Technologies, Hollowlite Materials Co., Ltd and Poraver). Suitable commercially available glass particulate materials having the required heat capacity include 3M's Glass Bubbles iM16K and iM30K, Trelleborg's SI-100, Hollowlite's Hollow Glass Sphere HL series / HL series, and Poraver's Poraspheres (trademark). However, other suitable materials are available and those skilled in the art can select a suitable material having the required heat capacity without difficulty.

[0030] The particulate material may include fibers and / or strands. The particulate material may include glass fibers or glass strands.

[0031] The particulate material may include amorphous or crystalline materials.

[0032] The particulate material may include a combination of microspheres, fibers, and / or strands.

[0033] The particulate material may include ceramic material. The particulate material may include ceramic microspheres, fibers, or strands. The particulate material may include hollow ceramic microspheres.

[0034] A suitable commercially available ceramic particle material with the required heat capacity is SphereOne's Extendospheres™.

[0035] The particulate material may include a silicone material. The particulate material may include microspheres, fibers, or strands formed from the silicone material.

[0036] The filler material may include an electrical insulating material. The filler may also be a dielectric material. The filler material may also include an inorganic material. The filler material may include polymers such as elastomers, amorphous thermoplastic polymers, or semicrystalline thermoplastic polymers. The insulating material may include an epoxy resin. For example, a two-component epoxy consisting of a polymer resin and a curing agent may be used, which, when mixed together, trigger a chemical reaction that crosslinks the chemical bonds in the polymer chains to produce a tough and rigid compound.

[0037] The filler may be a pre-formed element.

[0038] The heater element may include at least one heater coil.

[0039] The heating element may comprise a single coil. The coil pitch may be constant. The coil may have a variable pitch, in which case the central portion of the coil has fewer windings per unit length than the two end portions. The heating element may comprise two or more coils. The coils may be helical coils.

[0040] The heating element may be a resistance heating element. The heating element may be an induction heating element.

[0041] The heater may be a resistance heater. The heating element may be a resistance heating element. The heating element may be a resistance heating coil.

[0042] The heater may be an induction heater. The heating element may be an induction heating element. The coil may be an induction coil.

[0043] The elongated housing may have one or more holes, slots, grooves, openings or recesses, which are located at the base end of the heater and are at least partially filled with insulating material.

[0044] One or more holes, slots, grooves, openings, or recesses may be configured to act as thermal insulation.

[0045] One or more holes, slots, grooves, openings, or recesses may be positioned along the length of the elongated housing at a longitudinal position intermediate between a first longitudinal position corresponding to the longitudinal position of the base end of the heating element and a second longitudinal position of the open end of the heater.

[0046] One or more holes, slots, openings, or recesses may be located at two or more longitudinal positions along the length of the elongated housing, intermediate between a first longitudinal position corresponding to the longitudinal position of the base end of the heating element and a second longitudinal position of the open end of the heater.

[0047] One or more holes, slots, grooves, openings, or recesses may be provided on the inner surface of the elongated housing. One or more holes, slots, grooves, openings, or recesses may be provided on the inner surface of the internal cavity of the elongated housing.

[0048] One or more holes, slots, grooves, openings, or recesses may be provided on the outer surface of the elongated housing.

[0049] The elongated housing may be provided with a mount at its proximal end, the mount may be provided with one or more holes, slots, one or more openings or recesses, in which case one or more holes, slots, openings or recesses are at least partially filled with thermal insulation material.

[0050] The insulating material may contain fillers.

[0051] The insulating material may include potting materials, adhesives, thermosetting plastics, epoxy resins, or ceramic materials. The insulating material may include epoxy resins. For example, a two-component epoxy consisting of a polymer resin and a curing agent may be used, which, when mixed together, trigger a chemical reaction that crosslinks the chemical bonds in the polymer chain to produce a tough and rigid compound. The insulating material may include polyurethane ("PU"), such as a thermosetting plastic. This may include a two-component compound consisting of a base resin having an isocyanate curing agent. The insulating material may also include silicone. For example, silicone rubber may be used that contains a synthetic polysiloxane polymer that transitions from a liquid to a solid state using an additive catalyst (such as platinum).

[0052] According to one embodiment, an aerosol supply device is provided that is configured to heat an article containing an aerosol-generating material, and the aerosol supply device comprises the heater described above. The aerosol supply device may also comprise a heating chamber provided with the heater.

[0053] The aerosol supply device may comprise a power supply, a controller, and a heating chamber that removably receives the aerosol product. The power supply may be aligned along the longitudinal axis of the heating chamber. The power supply may also be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0054] The aerosol supply device may be configured for wireless charging. The aerosol supply device may have a charging port, such as a USB port, which is used to connect the power supply to an external power source for charging.

[0055] According to one embodiment, an aerosol supply system is provided comprising the above-described aerosol supply device and an article containing an aerosol generating material.

[0056] The aerosol supply system may include a charging unit having a cavity for removably receiving an aerosol supply device. The charging unit may include a movable lid that covers the aerosol supply device in a closed configuration. The charging unit may include a user display. The user display may be visible to the user when the movable lid is in the closed position, and may be partially or completely hidden from view or invisible by the lid when the lid is in the open position.

[0057] In another embodiment, a method is provided for manufacturing a heater for an aerosol supply device, comprising the steps of: preparing an elongated housing having a longitudinal axis; arranging a heating element within the housing such that the heater extends in the direction of the longitudinal axis; and providing a filler within the elongated housing to hold the heating element within the elongated housing, wherein the filler comprises a filler material and a particulate material, the particulate material being electrically insulating and having a heat capacity smaller than that of the filler material.

[0058] This method may include a further step of pre-forming the filler into a desired shape. The filler may be provided as a pre-formed element.

[0059] This method may further include the steps of providing one or more holes, slots, grooves, openings or recesses at the base end of a heater, and at least partially filling one or more holes, slots, grooves, openings or recesses with thermal insulation material.

[0060] One or more holes, slots, grooves, openings, or recesses may be provided on the inner surface of the elongated housing. The method may include a step of at least partially filling one or more holes, slots, grooves, openings, or recesses with an insulating material containing a filler.

[0061] In another embodiment, a method for generating an aerosol is provided, comprising the steps of preparing an aerosol supply device including the heater described above, and inserting at least partially the aerosol product into a receiving portion of a heating chamber.

[0062] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0063] [Figure 1] This is a perspective view showing an aerosol supply system, including an aerosol supply device located within a charging unit. [Figure 2] Figure 1 is a schematic cross-sectional view showing a portion of the aerosol supply device. [Figure 3] Figure 1 is a schematic cross-sectional view showing a portion of the aerosol supply device and the aerosol products of the aerosol supply system. [Figure 4] This is a perspective view showing another aerosol supply device. [Figure 5] Figure 4 is a schematic cross-sectional view showing the device. [Figure 6] This is a schematic cross-sectional view showing one embodiment of a heater that can be used in the device shown in Figure 1 or Figure 4. [Figure 7a] This is a schematic cross-sectional view of a further embodiment of the heater. [Figure 7b] This is a schematic cross-sectional view of a further embodiment of the heater. [Figure 7c] This is a schematic cross-sectional view of a further embodiment of the heater. [Figure 8a] This figure shows an embodiment of a heater manufacturing method. [Figure 8b] This figure shows an embodiment of a heater manufacturing method. [Figure 9a] This is a schematic cross-sectional view showing the base end of a heater that can be used in the device shown in Figure 1 or Figure 4. [Figure 9b] This is a schematic cross-sectional view showing the base end of a heater that can be used in the device shown in Figure 1 or Figure 4. [Figure 9c] This is a schematic cross-sectional view showing the base end of a heater that can be used in the device shown in Figure 1 or Figure 4. [Modes for carrying out the invention]

[0064] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the constituent aerosol-generating materials (or components of those materials) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0065] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as an electrically operated non-combustible aerosol supply system.

[0066] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0067] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0068] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of one or more aerosol-generating materials, each of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0069] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0070] In some embodiments, the non-combustion aerosol supply device may include a region for receiving consumables, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter and / or an aerosol modifier.

[0071] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, packaging material, a filter, a suction nozzle and / or an aerosol modifier.

[0072] As used herein, the term “aerosol-generating material” refers to a material that can generate an aerosol when energy is supplied, for example, by heating, irradiation, or any other means. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0073] The aerosol-generating material may comprise one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0074] The aerosol-generating material may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0075] The aerosol-generating material may include an aerosol-generating film, or may be in the form of an aerosol-generating film. The aerosol-generating film may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or filler may also be present. The aerosol-generating film may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0076] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.5 mm or 0.3 mm.

[0077] The aerosol-generating film may be continuous. For example, the film may include a continuous sheet of material, or may be a continuous sheet of material. The sheet may be in the form of packaging material, may be gathered to form a gathered sheet, or may be shredded to form a shredded sheet. The shredded sheet may include one or more strands or strips of the aerosol-generating material.

[0078] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of an aerosol-generating material, such as dots, stripes, or lines, which can be supported by a support. In such embodiments, the support may be planar or non-planar.

[0079] The aerosol-generating film may be formed by combining a binder such as a gelling agent with a solvent such as water, an aerosol-forming agent, and one or more other components such as one or more substances to be delivered to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film.

[0080] An aerosol supply device can receive an article containing an aerosol-generating material for heating. In this context, “article” is a component that contains or is contained in the aerosol-generating material at the time of use, and optionally other components at the time of use, which is heated to volatilize the aerosol-generating material. The user may insert the article into the aerosol supply device before it is heated to generate an aerosol, and the user then inhales the aerosol. The article may be of a predetermined or specific size, for example, configured to be placed in or on a heater of a device sized to receive the article.

[0081] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material in order to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0082] Consumables are articles containing or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Consumables may also comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise, for example, a flammable material, a material that can be heated by electrical conductivity, or a susceptor.

[0083] A susceptor is a heating material that can be heated by penetration due to a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and as a result, penetration of the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and as a result, penetration of the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and as a result, the susceptor can be heated by both heating mechanisms. An aerosol supply device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0084] A non-combustible aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and interchangeable aerosol products. In some implementations, the non-combustible aerosol supply device may comprise a power supply and a controller (i.e., a control circuit). The power supply may comprise a power source such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol supply device may also comprise an aerosol generating component. However, in other implementations, the aerosol product may comprise the aerosol generating component partially or entirely.

[0085] Figure 1 shows an aerosol supply system 10 comprising an aerosol supply device 100 and a charging unit 101. The device is shown positioned within the cavity of the charging unit 101. The aerosol supply device 100 is configured to generate aerosols from an aerosol product (see Figure 3) that can be inserted into the aerosol supply device 100 when in use. In this embodiment, the article forms part of the aerosol supply system 10.

[0086] The aerosol supply device 100 is an elongated structure extending along its longitudinal axis. Furthermore, the aerosol supply device has a proximal end closest to the user (e.g., the user's mouth) and a distal end furthest from the user during use, for inhaling the aerosol produced by the aerosol supply device 100. The proximal end may also be called the “mouthpiece end.” Thus, the aerosol supply device 100 also defines a proximal direction that is directed toward the user during use. Furthermore, the aerosol supply device 100 also defines a distal direction that is directed away from the user during use. The terms proximal and distal applied to the features of the device 100 are explained by referring to the relative arrangement of such features toward each other in the proximal-distal direction along the longitudinal axis. The aerosol supply device 100 has an opening at its distal end that leads into a heating chamber.

[0087] The aerosol supply device 100 may be removably inserted into the charging unit 101 for charging. The charging unit 101 includes a cavity (see Figure 2) for receiving the aerosol supply device 100. The aerosol supply device 100 may be inserted into the cavity through an opening. The cavity may also include a longitudinal opening. A portion of the aerosol supply device 100 may have a first side surface. One or more user-operable control elements, such as a button 106, which can be used to operate the aerosol supply device 100, may be provided on the first side surface of the aerosol supply device 100. The first side surface of the aerosol supply device 100 may be received by a longitudinal opening provided in the charging unit 101.

[0088] In one embodiment, the cavity of the charging unit 101 may have a cross-sectional profile that allows the aerosol supply device 100 to be inserted into the charging unit 101 in only one orientation. According to one embodiment, the outer profile of the aerosol supply device 100 may include a curved portion and a straight portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also include a similar curved portion and a straight portion. The straight portion of the cross-sectional profile of the cavity may coincide with a longitudinal opening.

[0089] The charging unit 101 includes a sliding lid 103. When the aerosol supply device 100 is inserted into the charging unit 101 for recharging, the sliding lid 103 may be closed to cover the opening into the aerosol supply device 100. In other embodiments, the charging unit 101 may have an alternative lid configuration, such as a hinged or pivoted lid, or may not have a lid at all.

[0090] The charging unit 101 may include a user interface such as a display 108, which can be provided in any suitable position, such as the position shown in Figure 1.

[0091] Figure 2 is a cross-sectional view showing a portion of the aerosol supply device 100. The aerosol supply device 100 comprises a main housing 200. The main housing 200 defines the device body of the device 100. The device 100 defines a heating chamber 201. A receptacle 205 defines the heating chamber 201. An opening 203 is provided to allow access to the heating chamber 201. The receptacle 205 comprises a wall structure including a receptacle side wall 205a and a receptacle base 205b. The base 205b is at the distal end of the receptacle 205. A heating zone 201a is configured for heating at least a portion of an article.

[0092] A heater 301 is provided in a portion of the main housing 200, and the heater 301 extends into or protrudes into the heating chamber 201. The heater 301 may have a base portion 301a that can be positioned in a recess provided in a portion of the body of the device 100. The heater 301 is erected within the heating chamber 201. The heater 301 is upright from its distal end.

[0093] The heater 301 comprises an elongated heating element in the form of a pin. In other embodiments, the heater 301 comprises other elongated components such as blades. The heater 301 may be inserted into the distal end of the aerosol product 50 (see Figure 3) received in the heating chamber 201 to heat the aerosol product internally during use.

[0094] The housing comprises a housing wall 200a. The housing wall 200a extends along the longitudinal axis of the aerosol supply device 100 and surrounds the heating chamber 201. The housing wall 200a may at least partially define the receiving chamber of the aerosol supply device 100 as a volume enclosed within this wall 200a. The housing base 200b is at the distal end of the housing wall 200a. In the illustrated embodiment, the heater 301 is upright from the housing base 200b. The heater 301 protrudes through the receptacle base 205b. The receptacle base 205b has an opening 206 through which the heater 301 protrudes. In the embodiment, the heater 301 is attached to the receptacle base 205b. The heater 301 is upright from the receptacle base 205b.

[0095] The aerosol supply device 100 further comprises a removal mechanism 204 which can be detachably held in the main housing 200 of the aerosol supply device 100. The removal mechanism 204 is omitted in the embodiment. In the embodiment, the housing wall 200a defines at least partially the receptacle 205. The removal mechanism 204 may be held in the main housing 200 such that at least a portion of the removal mechanism 204 extends into the heating chamber 201. In this embodiment, the removal mechanism 204 may comprise a longitudinal portion such as a tubular peripheral wall portion 207a and a base wall portion 207b. The wall 207a may have a shape other than tubular and may be any shape that encloses (e.g., surrounds) and defines the heating chamber 201 internally.

[0096] In embodiments having a removal mechanism 204, the removal mechanism 204 defines the heating chamber 201. The removal mechanism 204 forms the receptacle 205. In embodiments where the removal mechanism 204 is omitted, other features of the device 100 define the heating chamber 201, for example, the housing side wall 200a and the housing base 200b.

[0097] The base portion 207b has an opening 206 through which the heater 301 can pass and protrude. In order to hold the removal mechanism 204 in the main housing 200, the removal mechanism 204 is pushed distally, i.e., toward the distal end of the main housing 200, to engage with the main housing 200 until the removal mechanism 204 can no longer move distally. In the following description, when the removal mechanism 204 is "held in" the main housing 200, it means that the removal mechanism 204 is engaged with the main housing 200 and cannot move distally any further.

[0098] The circumferential portion 207a and the base portion 207b may together define and enclose an article chamber for receiving the aerosol product 50, as shown in Figure 3. The article chamber has an inner surface configured to contact the aerosol product, the inner surface comprising a longitudinally extending portion provided by the tubular portion 207a and an end portion provided by the base portion 207b. In embodiments, the article chamber and the heating chamber are the same. When the aerosol product 50 is received in the heating chamber, the aerosol product may contact both the longitudinally extending portion and the end portion of the inner surface. In particular, the article chamber (i.e., the circumferential portion 207a and the base portion 207b) may be configured to receive at least a portion of the aerosol product 50, which is in the form of a longitudinally extending cylindrical rod, such that the longitudinal axis of the article is parallel to (and optionally aligned in a line with) the longitudinal axis of the aerosol supply device 100 when received in the article chamber.

[0099] The article chamber may also be called the receiving portion. When the removal mechanism 204 is held in the main housing 200, the article chamber of the removal mechanism 204 is positioned at least partially within the heating chamber 201 during use. The heater 301 may be positioned to protrude into the article chamber through an opening 206 provided in the base portion 207b of the removal mechanism 204. Thus, the removal mechanism 204 is configured to receive at least a portion of the aerosol product during use.

[0100] In this embodiment, the removal mechanism 204 may include a first magnet or magnetizable material 208. The main housing 200 may include a second magnet or magnetizable material 209. During use, the removal mechanism 204 may be magnetically held to the main housing 200 by the interaction between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209.

[0101] In the embodiment, the removal mechanism 204 is completely removable from the main housing 200. The removal mechanism 204 may be held in place by the magnetic attraction between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209. The removal mechanism 204 may be separated from the main housing 200 by overcoming the magnetic force between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209. In the embodiment, the removal mechanism 204 is removably held in place by the main housing 200 by other means. For example, the removal mechanism 204 may be configured to be removably held in place by an interlocking fit with the main housing.

[0102] The removal mechanism 204 may comprise an internal element ( comprising a tubular portion 207a and a base portion 207b) and an outer cap portion 210, and when held in the main housing 200, the outer cap portion 210 encloses (e.g., covers) at least a portion of the main housing, such as the wall 200a of the main housing 200. The tubular portion 207a, the base portion 207b and the outer cap portion 210 may comprise a single (e.g., a single) component (e.g., formed by molding). Alternatively, the tubular portion 207a and the base portion 207b may comprise a first component, and the outer cap portion 210 may comprise a second separate component. In this case, the first and second components may be fixed to each other.

[0103] Figure 4 shows another aerosol supply system 40. System 40 comprises an integrated aerosol supply device 400 for generating an aerosol from an aerosol-generating material, and the aerosol product 50 contains the aerosol-generating material. Device 400 can be used to heat the aerosol product 50 containing the aerosol-generating material to produce an aerosol or other inhalable medium that can be inhaled by the user of device 400.

[0104] The device 400 comprises a housing 500 that surrounds and houses various components of the device 400. The housing 500 is elongated. The device 400 has an opening 504 at one end into which an article 50 can be inserted for heating by the device 400. The article 50 may be fully or partially inserted into the device 400 for heating by the device 400.

[0105] The device 400 may include a user-operable control element 506, such as a button or switch, which operates the device 400 when operated, for example, when pressed. For example, the user may activate the device 400 by pressing the switch 406.

[0106] The device 400 defines a longitudinal axis 509, and the article 50 may extend along this axis when inserted into the device 400. The opening 504 is aligned with the longitudinal axis 509.

[0107] Figure 5 is a schematic cross-sectional view of the aerosol supply system 40. Features described with reference to Figure 5 in the embodiment are applicable to the embodiment described above. The aerosol supply device comprises a power supply 410, a controller 420, and a heating chamber 401, in which the aerosol product 50 is removably received.

[0108] The integrated device in Figure 5 shows a power supply 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of the integrated aerosol supply device, the power supply is aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0109] The heater 301 comprises an elongated heater 301 in the form of a pin. In other embodiments, the heater 301 comprises other elongated components such as blades and can have various cross-sectional shapes.

[0110] The heater 301 is provided within the heating chamber 401. The heater 301 described above with reference to Figure 5 and Figures 1 to 3 may each be subject to the details described herein. The heater 301 extends into or protrudes into the heating chamber 401.

[0111] The heater 301 may be inserted into the distal end of the aerosol product 50 received in the heating chamber 401 in order to heat the aerosol product 50 internally during use.

[0112] The aerosol supply devices 100 and 400 each include a heating component 300. The heating component 300 includes a heater 301 (also called a heating element). The heater 301 includes a heating element 350 (see Figure 6), such as a resistance heating coil, configured to operate to heat the heating element.

[0113] The heating component 300 is a resistance heating component. The heater is a resistance heating heater. Heating elements such as heating coils, described later, are resistance heating elements. In such a configuration, the heating assembly includes a resistance heating generator which includes components for heating the heating elements through a resistance heating process. In this case, current is applied directly to the resistance heating elements, and the resulting flow of current in the heating elements (acting as heating components) heats the heating elements by Joule heating. The resistance heating elements include a resistance material configured to generate heat when an appropriate current flows through the resistance heating elements, and the heating component includes electrical contacts for supplying current to the resistance material. In the embodiment, the heating elements form at least a portion of the resistance heating member itself. In the embodiment, the resistance heating elements transfer heat to the heating member, for example, by conduction. Providing resistance heating components enables a compact configuration. Resistance heating provides an efficient configuration.

[0114] Figure 6 shows a heater 301 for use in the aerosol supply device described above. The heater 301 acts as a heater or forms at least part of a heater. The heating component 300 comprises the heater 301. The heater 301 comprises an elongated housing 302 and a heating element 350. The elongated housing 302 is an elongated member defining a longitudinal axis.

[0115] The housing 302 is formed from a thermally conductive material such as aluminum. Other suitable materials such as stainless steel may be used. The elongated housing 302 may have a coating on its outer surface. The elongated housing 302 is configured to transfer heat from the heating element 350 to the heating zone 201a within the aerosol supply device.

[0116] The elongated housing 302 has a base end 303 and a free end 304. The base end 304 is attached to the device body. A mount 305 on the base end 303 attaches the heater 301. It will be understood that various mounting configurations, such as fastening, molding, and adhesives, may be used. The mount 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0117] The elongated housing 302 comprises a housing body 306. The housing body 306 is cylindrical. In other embodiments, the housing body 306 may have various cross-sectional shapes, such as circular, elliptical, rectangular, pentagonal, hexagonal, or octagonal, although these are not limited to these.

[0118] The housing body 306 includes a bore 307. The bore 307 defines an internal cavity 308 of the heater 301. The internal cavity 308 extends in the longitudinal direction. The inner surface 309 is defined inside the elongated housing 302. The base end 303 is provided with an open end 310 that faces the internal cavity 308.

[0119] The free end 304 of the elongated housing 302 extends toward the proximal end of the heating chamber. The free end 304 of the heater 301 is closed, or in other words, the internal cavity 308 does not extend through the free end 304. The tip 311 is provided at the free end 304. The tip 311 extends to the apex 312. Other shapes and configurations of the tip 311 may be provided; for example, the tip 311 may define a plane.

[0120] The heating element 350 is located within the elongated housing 302 of the heater 301. The heating element 350 extends longitudinally within the elongated housing 302 and has a base end 350a and a free end 350b. The heating element 350 is received within the internal cavity 308. In Figure 6, the heating element 350 extends between the base end 303 and the free end 304. In some embodiments, the heating element extends partially along the length of the internal cavity 308. In some embodiments, the heating element 350 extends to or beyond the open end 310.

[0121] In this embodiment, the heating element 350 includes a heating coil 351. The heating coil 351 includes a resistive member that defines the heating coil 351.

[0122] The heating coil 351 is a resistance heating coil. The heating coil 351 is a helical coil. The heating coil 351 has a rectangular cross-sectional shape. It will be understood that other coil configurations are also possible. In the embodiment, the heating coil 351 has a circular cross-sectional contour. In the embodiment, the heating component 300 includes two or more heating coils.

[0123] The heating element 300 includes electrical connection paths 352 and 353. The electrical connection paths extend from each end of the heating element 350. The base electrical connection path 352 extends from the distal end of the heating element 350. The return electrical connection path 353 extends from the proximal end of the heating element 350. The return electrical connection path overlaps the length of the heating element 350. The electrical connection paths are formed integrally with the heating element, for example, as a single wire. In embodiments, a connector connects the electrical connection paths to the heating element 350. The heating coil 351 is formed of a resistive material such as a nickel / chromium alloy such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0124] The heating component 300 further comprises a filler 370 positioned within the internal cavity 308. The filler 370 is in contact with at least a portion of the inner surface 309 of the internal cavity 308 and with a portion of the heating element 530. This means that the filler 370 holds the heating element 350 within the housing body 306. The heating element 350 is substantially aligned with the axis 509 to provide constant heating optimized for the elongated housing 302. This means that when the aerosol product is inserted into the aerosol supply device during use, there is constant heating along the length of the heater 301 to heat the aerosol product 50 inside.

[0125] The filler 370 is placed between the inner surface 309 of the internal cavity 308 and the outer surface of the heating element 350.

[0126] The filler 370 is a thermally conductive material that provides effective heat transfer from the heating element 350 to the housing body 306 of the elongated housing 302.

[0127] The filler 370 comprises a filler material 372 and a particle material 374 distributed within the filler material 372, wherein the particle material 374 has a smaller heat capacity than the filler material 372.

[0128] Providing a particulate material with a smaller heat capacity than the filler material means that less energy is adsorbed by the filler, and more of the energy generated by the heating element is transferred to the elongated housing of the heater. In other words, less energy is required to heat the heater assembly, and as a result, heat is transferred to the elongated housing more quickly.

[0129] The particulate material 374 is dispersed through the filler material. The term "particulate material" will be understood to include one or more of microspheres, strands, or fibers.

[0130] In some embodiments, the filler 370 is an electrically insulating material for electrically insulating the housing 302 from the heating element 350, in other words, the filler 370 prevents the heating element 350 from electrically contacting the inner surface 309 of the elongated housing 302.

[0131] In other embodiments, the heating element 350 may be provided with an electrical insulating coating (dielectric coating). When such a coating is provided on the heating element, the filler 370 does not need to provide electrical insulation.

[0132] In the embodiment shown in Figure 6, a single portion of the filler material 370 is provided, and the heating element has a length corresponding to the length of the internal cavity 308. The filler material 370 substantially fills the internal cavity 308 and holds the heating element 350 centrally, and is aligned with the axis 509.

[0133] As shown in Figure 6, a distance D is defined between the inner surface 309 of the internal cavity 308 and the outer surface of the heating element 530. In the embodiment, the filler 370 may also include particulate material 374 having a median particle size of less than D, meaning that the portion of the filler 370 placed between the heating elements 530s contains a limited amount of particulate material. This ensures that the heating elements 530s are close to the inner surface 309 and that heat can be efficiently transferred from the heating elements 350s to the elongated housing 302.

[0134] It will be understood that particulate materials can be selected to provide the optimal solution for any given heater and heating element specifications and geometric shape. To obtain maximum heat transfer between the heating element and the elongated housing, the distance D should be minimized, while electrical insulation should also be ensured. Good heat transfer is thought to be achieved when D is in the range of approximately 1 μm to approximately 65 μm, and the particulate material has a median particle size greater than D.

[0135] It will be understood that the manufacturability of the heater and the availability of particle materials may also need to be considered in any optimization of distance D.

[0136] If the heating element is provided with a dielectric coating, it will be understood that the filler does not provide electrical insulation, and therefore D can be reduced so that the heating element contacts the housing at one or more locations along its length.

[0137] The distance D is shown in Figure 6, and it will be understood that this applies to all embodiments described below.

[0138] Figure 7a shows an alternative embodiment in which two separate parts of filler 370a and 370b are provided at the base end 350a and free end 350b of the heating element 350, and a gap exists between the two separate parts of filler 370a and 370b.

[0139] Figure 7b shows a further embodiment in which one portion of the filler 370 is provided in the central part of the heating element 350, and the heating element 350 is fixed to the central part of the housing body 306.

[0140] In another embodiment, a portion of the filler is provided in the central part of the heating element, extending along most of the length of the heating element.

[0141] Figure 7c shows another embodiment in which portions of filler 370c are provided between the outer surface of the heating element 350 and the inner surface 309 of the internal cavity 308, such that the filler portions 370c define substantially axially oriented passages between adjacent portions 370c, each passage being configured to allow air to flow along it. In the basic arrangement, the two portions of filler 370c are provided opposite each other. In other embodiments, three, four, five, or six portions are provided spaced apart from each other around the inner surface 308, resulting in a corresponding number of axially oriented passages.

[0142] In other embodiments, a single, separate portion of the filler may be provided at either the base or free end of the heating element.

[0143] In other embodiments, two or more individual portions of the filler may be provided in the central portion of the heating element, or multiple individual portions of the filler may be provided along the length of the coil. The individual portions of the filler may be arranged at equal intervals or at any suitable interval.

[0144] The heater 300 described above may be manufactured by the method schematically shown in Figure 8a, which includes the steps of preparing an elongated housing 302 (step 610), inserting a heating element 350 into the elongated housing 302 (step 620), and then adding one or more individual parts of a filler 370 to the elongated housing to hold the heating element 350 in place (step 630).

[0145] In an alternative manufacturing method 600' (schematically shown in Figure 8b), one or more individual portions of the filler 370 may be provided as pre-molding elements applied on or around the heating element 350 before being inserted into the elongated housing 302 (step 630) (step 520).

[0146] Figures 9a to 9c show further embodiments of the proximal end 302 of a heater 301 having separate portions of filler 370 at the distal end 305. However, it will be understood that these may be heaters having any filler configuration as described above.

[0147] In Figure 9a, the base end of the elongated housing 302 is provided with two through-holes 380 that are at least partially filled with an insulating material 385, such as a potting compound, adhesive, thermosetting plastic, or epoxy resin, but are not limited to these. The mount 305 of the heater 301 is also provided with two through-holes 380 that are at least partially filled with an insulating material 385.

[0148] The thermal insulation material 385 is provided below the heater 301 region below the heating element 350, in other words, below the region of the elongated housing 302 inserted into the article containing the aerosol generating material. The thermal insulation material 385 provides insulation that reduces heat transfer to the base end 303 of the heater, which does not need to be heated during use. Furthermore, when the heater 301 is attached to an aerosol supply device (for example, shown in Figures 1 to 5), heat transfer to the main housing of the device is reduced.

[0149] In other embodiments, one or more through-holes, at least partially filled with thermal insulation material, are provided only at one of the base ends of the housing and the mount.

[0150] The insulating material 385 may be the filler 370 described above, or another suitable material.

[0151] It will be understood that Figure 9a shows two through-holes provided on both sides of the heater. However, it will be understood that in other embodiments, any appropriate number of through-holes can be provided at the base end of the housing and / or mount.

[0152] While a through-hole at least partially filled with insulating material has been described above, it will be understood that other embodiments include alternative configurations for this type of insulating section.

[0153] Figure 9b shows an alternative example in which a circumferential groove or ridge 380 is provided on the outer surface of the base end 303 of an elongated housing 302 that is at least partially filled with thermal insulation material 385. The thermal insulation material 385 may be the filler 370 described above or another material.

[0154] In other embodiments, one or more slots, grooves, openings or recesses are provided at the base end of the elongated housing and / or mount, and one or more holes, slots, openings or recesses are at least partially filled with thermal insulation material.

[0155] Figure 9c shows an alternative configuration in which a circumferential groove 308 is provided on the inner surface 309 of the internal cavity 308, and a filler 370 is provided in the groove 308.

[0156] Although a groove is shown in Figure 9c, it will be understood that other similar configurations of the insulation can be provided. In other embodiments, one or more slots, grooves, openings or recesses are provided on the inner surface of the elongated housing and are at least partially filled with filler 370 provided in the internal cavity 308.

[0157] The thermal insulation material 385 is applied to the heater 301 in step 640 of method 600 and 600', as shown in Figures 8a and 8b.

[0158] In the embodiments described above, the heating element is a resistance heating element. Other types of heating elements, such as induction heating elements, are used in the embodiments. The device configuration is substantially as described above, so a detailed explanation is omitted.

[0159] An induction heating configuration includes various components for heating an aerosol-generating material of an article by an induction heating process. Induction heating is a process of heating a conductive heating element (such as a susceptor) by electromagnetic induction. An induction heating configuration may include an induction element, for example, one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The fluctuating current within the induction element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor (heating element) appropriately positioned relative to the induction element. Compared to heating by conduction, for example, induction heating generates heat inside the susceptor, enabling rapid heating. Furthermore, it does not require any physical contact between the induction element and the susceptor, increasing the freedom of structure and application.

[0160] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0161] In the embodiment, the heating element of the aerosol supply system is not part of the aerosol supply device but part of the aerosol product. The heating element may be a resistive heating element, for example, in the form of a resistive coil as described above, provided as part of the aerosol product. Electrical connections may allow current to flow through the resistive heating element.

[0162] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features(parts), structures and / or other aspects described herein should not be considered as limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A heater for an aerosol supply device configured to heat at least a portion of an article containing an aerosol generating material, The long, slender housing, A heating element is disposed within the elongated housing, A filler is placed inside the aforementioned elongated housing, Equipped with, The heating element is held within the elongated housing by the filler, The filler comprises a filler material and a particle material. A heater wherein the particle material is electrically insulating and has a heat capacity smaller than that of the filler material.

2. The heater according to claim 1, wherein at least two separate portions of the filler are provided.

3. The heater according to claim 2, wherein the elongated housing defines a longitudinal axis, and at least two individual portions of the filler are spaced apart from each other along the longitudinal axis.

4. The heater according to any one of claims 1 to 3, wherein at least one individual portion of the filler is provided at the first end of the heating element.

5. The heater according to any one of claims 1 to 4, wherein at least one individual portion of the filler is provided at the second end of the heating element.

6. The heater according to any one of claims 1 to 5, wherein at least two individual portions of the filler are provided to extend axially along the inner surface of the elongated housing.

7. The heater according to claim 1, wherein a single individual portion of the filler is provided.

8. The heater according to any one of claims 1 to 7, wherein the filler and heater elements substantially fill the internal cavity within the elongated housing.

9. The heater according to any one of claims 1 to 8, wherein the particle material includes microspheres.

10. The heater according to any one of claims 1 to 9, wherein the particle material includes fibers and / or strands.

11. The aforementioned particulate material is approximately 0.65 g / cm³ ３ Less than, for example, about 0.1 g / cm³ ３ ~Approx. 0.5g / cm ３ A heater according to any one of claims 1 to 10, having a density of the specified value.

12. The heater according to any one of claims 1 to 11, wherein the particle material includes glass.

13. The heater according to any one of claims 1 to 12, wherein the particle material has a median particle size of about 15 to about 500 μm.

14. The aforementioned particulate material is approximately 700 J·kg －１ ・K －１ ~Approx. 1100J・kg －１ ・K －１ A heater according to any one of claims 1 to 13, having a heat capacity within the range.

15. The heater according to any one of claims 1 to 14, wherein the filler material includes an inorganic material.

16. The heater according to any one of claims 1 to 15, wherein the heater element comprises at least one heater coil.

17. The heater according to any one of claims 1 to 16, wherein the heating element is a resistance heating element.

18. The heater according to any one of claims 1 to 17, wherein the elongated housing comprises one or more holes, slots, grooves, openings or recesses, the one or more holes, slots, grooves, openings or recesses provided at the base end of the heater and at least partially filled with thermal insulation material.

19. An aerosol supply device configured to heat an article containing an aerosol-generating material, comprising a heater according to any one of claims 1 to 18.

20. A system comprising a device having a heater according to any one of claims 1 to 18, and an article containing an aerosol generating material.

21. A method for manufacturing a heater for an aerosol supply device, The steps include preparing an elongated housing having a longitudinal axis, The steps include: arranging the heating element within the housing such that the heater extends in the direction of the longitudinal axis; The step includes providing a filler within the elongated housing to hold the heating element within the elongated housing. A method wherein the filler comprises a filler material and a particle material, wherein the particle material is electrically insulating and has a heat capacity smaller than that of the filler material.

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