A method for manufacturing an aerosol generating device and a light diffuser for an aerosol generating device.

Abstract

An aerosol generating device (1) comprising: a main body (2) having a non-opaque window (3); an array (4) of light sources (10) located inside the main body (2); and a light diffuser (5) disposed between the array of light sources (10) (4) and the non-opaque window (3), the light diffuser (5) having a first surface (6) facing the array of light sources (10) (4) and including a pattern (7) of a plurality of dome-shaped recesses (8); and a second surface (9) opposite to the first surface (6) and visible directly or indirectly through the non-opaque window (3).

Description

Technical Field

[0001] An aerosol generating device will be described. The aerosol generating device is configured to receive a consumable item that is resistively or inductively heated and generate an inhalable aerosol. The consumable item can be any one of a liquid, a gel, or a solid, and can contain an aerosol precursor material with or without tobacco. A method for manufacturing a light diffuser of the aerosol generating device will also be described.

Background Art

[0002] The aerosol generating device is an alternative to conventional cigarettes. Instead of generating inhalable smoke by burning an aerosol generating material such as tobacco, the aerosol generating device heats an aerosol precursor material containing an aerosol former component without burning it to generate an aerosol that can be inhaled by the user. The aerosol generating device is a handheld inhaler system having a housing for accommodating functional components. The housing of the aerosol generating device can be elongated for the user to hold. It typically includes a mouthpiece portion, a housing for the consumable item, a vaporizer, a heating unit, and a power supply unit such as a battery. Vaporization is achieved when the heating unit heats the consumable item to form an inhalable aerosol through the mouthpiece portion.

[0003] The power supply unit can include a battery, electronic control circuits disposed at least partially on a printed circuit board (PCB) for example, and optionally a sensor, a wireless communication chip or module, and a control switch. A receptacle, such as a USB-C receptacle, is provided on the aerosol generating device. The receptacle is configured to mechanically and electrically connect to a plug such that it receives power and recharges the battery from an external power source by the plug. Additionally or alternatively, a wireless charging coil may be provided on the aerosol generating device.

[0004] Power consumption, device status, or any other useful information may be provided via illuminated status indicators.

[0005] An aerosol generating device with an improved indicator light status is needed. [Overview of the project] [Means for solving the problem]

[0006] This disclosure will improve the situation.

[0007] A body having an opaque window, An array of light sources located inside the main unit, A light diffuser placed between an array of light sources and a non-opaque window, A first surface facing the array of light sources and including a pattern of multiple dome-shaped recesses, A second surface, located opposite the first surface, can be seen directly or indirectly through a non-opaque window. A light diffuser having, An aerosol generating device including the above is proposed.

[0008] The presence of a light diffuser with such a special pattern makes it possible to create a homogeneous bar visible to the user. This means that the array of light sources appears as a continuous bar, and the light sources cannot be seen individually. The dome-shaped recess pattern has broad diffusion properties. The dome-shaped recess pattern can disrupt the light rays from the light sources in the array.

[0009] This user interface can be implemented in a wide range of aerosol generating devices. It allows for the display of multiple pieces of information through an array of light sources.

[0010] A “dome-shaped recess” is understood to include a relief in which the first surface is concave toward the array of light sources, and the relief has the shape of a dome, i.e., a curved surface, such as a sphere.

[0011] The following features can be implemented separately or in combination with other features as desired.

[0012] The light diffuser may be configured such that at least one dome-shaped recess of a plurality of dome-shaped recesses, preferably at least two dome-shaped recesses, lies on the straight optical path of one light source in the array of light sources.

[0013] This ensures that the optical path passes through at least one, preferably at least two, dome-shaped recesses, and as a result, a sufficient light diffusion effect can be obtained.

[0014] The light diffuser may be positioned directly behind the array of light sources, with its first surface facing the light sources. This means that the light sources are touching or nearly touching part of the light diffuser. This helps to scatter the light rays and combine them on the second surface (or side) opposite the light diffuser.

[0015] The dome-shaped recesses, preferably at least a portion of each dome-shaped recess, may have a spherical shape. Preferably, at least a portion of the dome-shaped recesses are identical to one another. The dome-shaped recesses may all be identical to one another. The dome-shaped recesses may have a symmetrical shape. If the dome-shaped recesses are symmetrical and spherical, there may be a point at the center of the dome-shaped recess that is also the point furthest from the light source.

[0016] At least two of the multiple dome-shaped recesses may be in contact with each other side by side. They may have a common edge.

[0017] The pattern may include multiple parallel ranges of a dome-shaped recess, which are oriented perpendicular to the longitudinal axis of the non-opaque window.

[0018] In one example, the light diffuser includes 34 parallel ranges, each range extending perpendicular to the longitudinal axis of a non-opaque window, and each range has six dome-shaped recesses. The number of ranges and dome-shaped recesses may vary without departing from the scope of the disclosure.

[0019] At least one dome-shaped recess in the pattern, preferably each dome-shaped recess, may be part of a virtual sphere having a diameter equal to about 1 mm.

[0020] In particular, the width of the dome-shaped recess within the range may be equal to 0.55 mm. In particular, the length of the dome-shaped recess within the range may be equal to 0.7 mm. In particular, the front peripheral shape of a dome-shaped recess within a range that has other dome-shaped recesses all around its periphery may be rectangular. This peripheral shape of one dome-shaped recess may be defined by the peripheral shapes of adjacent dome-shaped recesses, for example, except at the ends of the range.

[0021] Several dome-shaped recesses may be placed above each single light source. This scatters and diffuses the light rays multiple times, returning them to a second surface, which is the rear surface.

[0022] The second surface of the light diffuser is, for example, substantially flat and, in particular, without any relief. In such a case, the flat surface of the second surface combines the light rays that are disturbed by the pattern of dome-shaped recesses, thereby producing the perception of a homogeneous light bar.

[0023] In another example, the second surface of the light diffuser includes at least one recess, and more particularly, a plurality of recesses. Such plurality of recesses may preferably be made of a plurality of parallel grooves extending perpendicular to the longitudinal axis of the non-opaque window. The recesses, for example, grooves, are preferably concave toward the non-opaque window.

[0024] The light diffuser can be made of a non-transparent and non-opaque, preferably white polymer material selected from the group consisting of high-toughness PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), PA (polyamide), PMMA (acrylic or polymethyl methacrylate), PC (polycarbonate), POM (polyoxymethylene), and ASA (acrylonitrile styrene acrylate).

[0025] The light diffuser is preferably made by 3D printing with a high-resolution 3D printer. In one variant form, the light diffuser is injection molded.

[0026] At least one of the first and second surfaces of the light diffuser may be polished.

[0027] The light diffuser may be inserted into the inner tray of the aerosol generation device between the non-opaque window and the array of light sources. The light sources of the array are preferably fixed to the printed circuit board of the aerosol generation device.

[0028] The light diffuser may be part of the inner tray of the aerosol generation device. In such a case, post-processing can be reduced and the positioning issues can be resolved in advance.

[0029] The array of light sources may be a linear array. In such a case, the light sources of the array can be arranged at intervals from each other. The array of light sources may include 8 light sources, preferably 8 aligned light sources. The distance between two adjacent light sources may be included in the range of 1 mm to 6 mm.

[0030] The light sources of the array are preferably light-emitting diodes (LEDs).

[0031] The light distribution angle of at least one light source of the array of light sources may be equal to 120°.

[0032] The aerosol generating device may include a light source controller, such as an LED controller. Such a controller may be able to operate a maximum number of light sources, which may be, for example, equal to 8. The number of light sources in the array may be less than 8, without departing from the scope of this disclosure. In such cases, the power consumption of the aerosol generating device may be reduced. Such an LED controller may be provided as an integrated circuit.

[0033] The device may include glass that covers the light diffuser outward and extends into a non-opaque window. In such a case, the second surface of the light diffuser may be indirectly visible through the non-opaque window. In another example, the non-opaque window does not include any glass. In the latter case, the second surface of the light diffuser may be directly visible through the non-opaque window.

[0034] In another embodiment, in combination with the above, a method is proposed for manufacturing a light diffuser for the above aerosol generating device, comprising 3D printing the light diffuser from an opaque, preferably white, polymer material selected from the group consisting of, for example, high-toughness PLA, ABS, and acrylic glass, preferably using a high-resolution 3D printer, wherein the 3D printing includes forming a plurality of dome-shaped recesses on a first surface of the light diffuser.

[0035] This method provides a light diffuser that can be included in the above-mentioned aerosol generating device by either inserting it into the inner tray of the aerosol generating device between a non-opaque window and an array of light sources, or by being part of the inner tray of the aerosol generating device.

[0036] The light diffuser produced by this method contributes to the desired effect, namely, the generation of a homogeneous light effect that can be seen by the user through an opaque window, and the light effect from the light source array passes through the light diffuser.

[0037] This method may include creating a 3D model of the light diffuser before manufacturing it by 3D printing.

[0038] Other features, details, and advantages are shown in the detailed description and drawings below. [Brief explanation of the drawing]

[0039] [Figure 1] This is a schematic perspective view of an example aerosol generating device in the closed position. [Figure 2] Figure 1 is a schematic longitudinal cross-sectional view of a portion of the aerosol generating device. [Figure 3] This is a schematic diagram similar to Figure 2, after the light source has been switched on. [Figure 4] This figure is similar to Figure 3, but is an example without a light diffuser, which is not included in this disclosure. [Figure 5] This is a schematic front view of a light diffuser separation example. [Figure 6] Figure 5 is a schematic longitudinal cross-sectional view of the light diffuser. [Figure 7] This is a schematic side view of the light diffuser shown in Figure 5, as seen from its bottom. [Figure 8] This is a schematic side view of a 3D model of a light diffuser created before the 3D printing process, as an example. [Figure 9] This is a schematic perspective view of the separation of a light diffuser using another example. [Figure 10] Figure 9 is a schematic longitudinal cross-sectional view of the light diffuser. [Figure 11] This is a schematic perspective view of an example of an aerosol generating device in the open position, showing a printed circuit board housed within the aerosol generating device. [Figure 12] Figure 11 is a schematic perspective view of a portion of the inner tray of the aerosol generating device that has been separated. [Figure 13] This is a schematic perspective view illustrating the separation of a portion of the inner tray of an aerosol generating device, as an example. [Figure 14] Figure 13 is a schematic perspective view of an example of an aerosol generating device including the inner tray, with the aerosol generating device shown in the open position. [Modes for carrying out the invention]

[0040] The embodiments described below represent information necessary to enable a person skilled in the art to practice this disclosure. The same reference numeral corresponds to the same element in different drawings. These elements may be shown in only one or more drawings, but they apply to all drawings except those described to the contrary.

[0041] Refer to Figures 1 and 2 here. An aerosol generating device 1 is shown, comprising a body 2 having a non-opaque window 3, an array 4 of light sources 10 located inside the body 2, and a light diffuser 5 positioned between the array of light sources 10 4 and the non-opaque window 3, the light diffuser 5 having a first surface 6 facing the array of light sources 10 4 and including a pattern 7 of a plurality of dome-shaped recesses 8, and a second surface 9 opposite to the first surface 6 and visible directly or indirectly, in this example, indirectly, through the non-opaque window 3. The aerosol generating device 1 includes glass 12 covering the light diffuser 5 outward and extending into the non-opaque window 3. This illustrates that, in this example, the second surface 9 is visible indirectly through the non-opaque window 3. Such glass may be present without departing from the scope of the present disclosure. In the latter case, the second surface 9 may be directly visible from the non-opaque window.

[0042] The main body 2 also houses the printed circuit board 14 (PCB) of the aerosol generating device 1 using a method known to the public. As shown in Figure 2, the array 4 of the light sources 10 is positioned on the surface 17 of the PCB 14, while the other components of the PCB 14 are positioned on the other surface 18 of the PCB 14. In this example, the array 4 of the light sources 10 is positioned between the surface 17 of the PCB 14 and the light diffuser 5, in contact with them in this example. In other words, the array 4 of the light sources 10 is mounted on the surface 17 of the PCB 14 such that the array 4 of the light sources 10 faces the light diffuser 5.

[0043] In this example, as shown in Figure 3, which specifically shows the optical path L from the light source 10, the light diffuser 5 is configured such that at least one of the multiple dome-shaped recesses 8, in this example at least two dome-shaped recesses 8, are on the straight optical path L of one of the array 4 of the light sources 10, in this example each light source 10.

[0044] The light diffuser 5 allows the optical path L to become a continuous, homogeneous bar B visible to the user, as seen in Figures 1 and 3. The bar B forms a lit-up status indicator. In contrast, as shown in Figure 4, without the light diffuser, the optical path L' becomes a discontinuous, heterogeneous bar, and the user can see separate light points S'. Figure 4 shows a device not included in this disclosure, and is shown for comparison with the device shown in Figure 3.

[0045] In the examples shown in Figures 1 to 3, the array 4 of light sources 10 is a linear array. The light sources 10 in array 4 are spaced apart from each other. There is a distance I between two light sources 10, which can be between 1 mm and 6 mm.

[0046] Furthermore, in this example, the light source 10 of array 4 is a light-emitting diode (LED).

[0047] At least one light source 10; in this example, the beam angle α of all light sources 10 is equal to 120°.

[0048] The array 4 of light sources 10 allows the aerosol generating device 1 to provide the user with one or more pieces of information, such as power consumption, device status, or any other useful information. Naturally, the number of light sources 10 that are switched on by the illuminated status indicators depends on the information provided and may differ from the total number of light sources.

[0049] An example of the light diffuser 5 is shown individually in Figures 5 to 7. As can be seen from the figures, at least a portion 8 of the dome-shaped recesses, in this example each dome-shaped recess 8 has a spherical shape. Furthermore, at least a portion 8 of the dome-shaped recesses, in this example all of them, are identical to one another.

[0050] As can also be seen from these figures, at least two of the multiple dome-shaped recesses 8, for example, numbered 8a and 8b, are adjacent to each other and in contact, and share a common edge.

[0051] Furthermore, in this example, pattern 7 includes multiple parallel ranges 11 of the dome-shaped recess 8, which are oriented perpendicular to the longitudinal axis X of the non-opaque window 3.

[0052] In one example, the light diffuser 5 may include 34 parallel ranges 11 extending vertically and perpendicularly to the longitudinal axis X along the longitudinal axis X, with each parallel range 11 having six dome-shaped recesses 8. Ranges at the longitudinal ends of the light diffuser 5 may, in one example, have fewer than six dome-shaped recesses due to the rounded shape of these ends.

[0053] Figure 8 shows a 3D model of the light diffuser 5 created before 3D printing. In this model, which virtually shows pattern 7, at least some of the dome-shaped recesses 8 of pattern 7, preferably each dome-shaped recess 8, are part of a virtual sphere V having a diameter D equal to approximately 1 mm in this example.

[0054] In particular, the width W of the dome-shaped recess 8 within range 11 is equal to 0.55 mm in this example. The width W is measured perpendicular to the longitudinal axis X. In particular, the length G of the dome-shaped recess 8 within parallel range 11 is equal to 0.7 mm. The length G is measured parallel to the longitudinal axis X.

[0055] The front peripheral shape of the dome-shaped recess 8, particularly within the parallel range 11, which has other dome-shaped recesses 8 around its entire periphery, can be rectangular, as can be seen, for example, from Figure 5.

[0056] In the examples shown in Figures 1 to 8, the second surface 9 of the light diffuser 5 is substantially flat, and in particular, there is no relief on it.

[0057] In the examples of Figures 9 and 10, the second surface 9 of the light diffuser 5 includes at least one recess 15, in particular, a plurality of recesses 15 made up of a plurality of parallel grooves 16 that extend perpendicular to the longitudinal axis X in this example and are concave toward a non-opaque window when introduced into the aerosol generating device.

[0058] In the examples shown in Figures 1 to 10, the light diffuser 5 is made of a non-transparent and non-opaque polymer material, preferably white, selected from the group consisting of high-toughness PLA and ABS.

[0059] The light diffuser 5, having a pattern 7 of dome-shaped recesses 8, can preferably be fabricated in this example by 3D printing with a high-resolution 3D printer. Furthermore, at least one of the first surface 6 and the second surface 9 of the light diffuser 5 can be polished. This can be achieved through surface treatment performed after the 3D printing manufacturing process.

[0060] After 3D printing, the light diffuser 5 can be cut to have a suitable outline having two longitudinally parallel edges and rounded edges at the top and bottom, for example, as shown in Figures 5 and 9. This outline may be the same as the outline of a non-opaque window shown in Figure 1, for example.

[0061] In the examples of Figures 11 and 12, the light diffuser 5 is inserted into an inner tray 20 of the aerosol generating device 1 between a non-opaque window 3 and an array 4 of light sources 10, and the light sources 10 of the array 4 are preferably fixed to a surface 17 of the PCB 14 of the aerosol generating device 1. The inner tray 20 is shown separately in Figure 12. The inner tray 20 contains the light diffuser 5 and is manufactured to accommodate the PCB 14, and the inner tray 20 has a surface 21 including an opening 27 for accommodating the light diffuser 5, and a side wall 22 extending perpendicularly from the periphery of the surface 21. The side wall 22 surrounds the edge of the PCB 14. In this example, the opening 27 has the same shape and dimensions as the light diffuser 5, as shown in Figure 12.

[0062] Other shapes can be implemented without departing from the scope of this disclosure. This disclosure has been described with reference to preferred embodiments. However, many variations are possible within the scope of this disclosure.

[0063] In the examples shown in Figures 13 and 14, the light diffuser 5 is part of the inner tray 25 of the aerosol generating device 1. The inner tray 25 covers the component parts of the aerosol generating device 1 from the inside, as shown in Figures 13 and 14. In such examples, the light diffuser 5 may be fabricated together with the inner tray 25, for example, by 3D printing.

[0064] To fabricate a light diffuser 5 for the aerosol generating device 1, the light diffuser 5 can be 3D printed, preferably using a high-resolution 3D printer, from an opaque, preferably white, polymer material selected from the group consisting of, for example, high-toughness PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), PA (polyamide), PMMA (acrylic or polymethyl methacrylate), PC (polycarbonate), POM (polyoxymethelen), and ASA (acrylonitrile styrene acrylate). During 3D printing, a plurality of dome-shaped recesses 8 are created on the first surface 6 of the light diffuser 5. 3D printing may also include forming a plurality of depressions on the second surface 9, as shown in Figure 9. Prior to 3D printing, a 3D model may be created, as shown in Figure 8.

[0065] The aerosol generating device can be of any type with respect to the type of consumables (e.g., whether the precursor is liquid, solid, or gel, and whether or not it contains tobacco) and the type of heating unit (e.g., resistance heating or induction heating).

[0066] The light diffuser may be injection molded instead of 3D printed.

Claims

1. A main body (2) having a non-opaque window (3), An array (4) of light sources (10) located inside the main body (2), A light diffuser (5) is disposed between the array (4) of the light source (10) and the non-opaque window (3), The first surface (6) faces the array (4) of the light source (10) and includes a pattern (7) of a plurality of dome-shaped recesses (8), A second surface (9) is located on the opposite side of the first surface (6) and can be seen directly or indirectly through the opaque window (3), A light diffuser (5) having, an aerosol generating device (1), including the above.

2. The aerosol generating device (1) according to claim 1, wherein the light diffuser (5) is configured such that at least one of the plurality of dome-shaped recesses (8), preferably at least two dome-shaped recesses (8), lies on the straight optical path (L) of one of the light sources (10) of the array (4) of the light sources (10).

3. The aerosol generating device (1) according to claim 1 or 2, wherein at least a portion of the dome-shaped recesses (8), preferably each dome-shaped recess (8), has a spherical shape, and at least a portion of the dome-shaped recesses (8) are preferably identical to one another.

4. The aerosol generating device (1) according to claim 1, wherein at least two of the plurality of dome-shaped recesses (8) are in contact with each other side by side.

5. The aerosol generating device (1) according to claim 1, wherein the pattern (7) includes a plurality of parallel ranges (11) of a dome-shaped recess (8), and the parallel ranges (11) are oriented perpendicular to the longitudinal axis (X) of the non-opaque window (3).

6. The aerosol generating device (1) according to claim 1, wherein the second surface (9) of the light diffuser (5) is substantially flat, and in particular, there is no relief on the second surface (9).

7. The aerosol generating device (1) according to claim 1, wherein the second surface (9) of the light diffuser (5) includes at least one recess (15), more preferably a plurality of recesses (15) made of a plurality of parallel grooves (16) extending perpendicular to the longitudinal axis (X) of the non-opaque window (3).

8. The aerosol generating device (1) according to claim 1, wherein the light diffuser (5) is preferably manufactured by 3D printing using a high-resolution 3D printer.

9. The aerosol generating device (1) according to claim 1, wherein the light diffuser (5) is inserted in the inner tray (20) of the aerosol generating device (1) between the opaque window (3) and the array (4) of the light sources (10), and the light sources (10) of the array (4) are preferably fixed to the printed circuit board (14) of the aerosol generating device.

10. The aerosol generating device (1) according to claim 1, wherein the light diffuser (5) is part of the inner tray (25) of the aerosol generating device.

11. The aerosol generating device (1) according to claim 1, wherein the array (4) of the light source (10) is a linear array, and the light sources (10) of the array (4) are arranged at intervals from one another.

12. The aerosol generating device (1) according to claim 1, wherein the light source (10) of the array (4) is a light-emitting diode (LED).

13. The aerosol generating device (1) according to claim 1, wherein the beam angle (α) of at least one light source (10) of the array (4) of the light source (10) is equal to 120°.

14. The aerosol generating device (1) according to claim 1, comprising a glass (12) that covers the light diffuser (5) outward and extends into the non-opaque window (3).

15. A method for manufacturing a light diffuser for an aerosol generating device (1) according to claim 1, comprising 3D printing the light diffuser (5) from an opaque, preferably white, polymer material selected from the group consisting of high-toughness PLA, ABS, and acrylic glass, preferably using a high-resolution 3D printer, wherein the 3D printing includes forming a plurality of dome-shaped recesses (8) on the first surface (6) of the light diffuser (5), method.

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