Heating assembly for aerosol generating device

Abstract

A heating assembly for an aerosol generating device is disclosed, the heating assembly (100) comprising an outer tube (102) having a first end and a second end, and a heater cup (104) positioned radially inward of the outer tube, the heater cup comprising a heating element (106) provided on the outward-facing surface of the heater cup, the heater cup having an opening at the first end of the outer tube for receiving an aerosol-forming substrate, an electrical connector (112) configured to supply power to the heating element, and a base portion (114) positioned at the closed end of the heater cup, the base portion comprising a base portion including one or more slots in which the electrical connector can be received, and an end wall (110) positioned at the second end of the outer tube, the electrical connector extending from the end wall, the base portion comprising a base portion including an end wall, the base portion being configured to bias at least a portion of each electrical connector radially inward toward the heating element when the electrical connector is received in the slots, in order to press the electrical connector toward the heating element.

Description

Technical Field

[0001] The present invention relates to a heating device for an aerosol generating device and an aerosol generating device including the heating device. The present disclosure is particularly applicable to a portable aerosol generating device that can be self - contained and operate at low temperatures. In particular, the present invention relates to an aerosol generating device having a heater disposed within a vacuum chamber or an insulator chamber.

Background Art

[0002] Aerosol generating devices, such as heat - non - combustible devices, typically generate an aerosol or vapor by heating an aerosol - forming substrate or consumable, which typically contains moist tobacco or other suitable material, to a temperature in the range of 150°C to 300°C. By heating the aerosol - forming substrate without burning or combustion, an aerosol that does not contain undesirable combustion by - products is released as desired by the user. For example, an aerosol produced by heating tobacco typically does not contain the burnt or bitter taste that can result from combustion.

[0003] In such an aerosol generating device, it is desirable to improve the efficiency of the heating operation so as to extend the battery life of the device. For this purpose, an insulator is mounted within the aerosol generating device to insulate the cavity in which the aerosol substrate is heated and suppress heat loss to the external environment.

[0004] However, a heating assembly including a vacuum insulator is difficult to manufacture. A particular problem to be overcome when manufacturing this type of heating device is how to provide an effective electrical connection between a power source outside the insulation chamber and a heating element inside the insulation chamber while maintaining an effective vacuum or insulating space within the heater assembly. The object of the present invention is to address this problem.

Summary of the Invention

Means for Solving the Problems

[0005] According to one aspect of the present invention, a heating assembly for an aerosol generating device is provided, comprising: an outer tube having a first end and a second end; a heater cup disposed radially inward of the outer tube, the heater cup including a heating element provided on the outward-facing surface of the heater cup, the heater cup having an opening at the first end of the outer tube for receiving an aerosol-forming substrate; an electrical connector configured to supply power to the heating element; a base portion disposed at the closed end of the heater cup, the base portion including one or more slots from which the electrical connector can be received; and an end wall disposed at the second end of the outer tube, the electrical connector extending from the end wall, the base portion being configured to bias at least a portion of each electrical connector radially inward toward the heating element when the electrical connector is received in the slots, in order to press the electrical connector toward the heating element.

[0006] Thus, a direct electrical connection is effectively formed between the electrical connector and the heating element without the need for soldering (as in known heating assemblies). Typically, such soldering connections between electrical connectors and heating elements are performed in a vacuum, which presents various challenges during the design and manufacturing phases. For example, not only is cleaning required after soldering, but the surface must also be kept clean before soldering. By preventing the use of solder and flux, the risk of gas release and any undesirable pressure rise in the insulating space between the heater cup and the outer tube, which would reduce the insulating capacity of the vacuum insulator, is reduced.

[0007] The base portion of the present invention is configured such that the electrical connector is pressed toward the center of the outer tube so that a direct electrical connection is formed when the heater cup (and heating assembly) is pushed or inserted into the space between the electrical connectors. The radially inward biasing of the electrical connector by the base portion ensures that a good electrical connection is reliably maintained throughout the operating life of the heating assembly. As should be recognized, the electrical connection between the heating element and the electrical connector may undergo more than 10,000 heating and cooling cycles during its operating life, which can lead to undesirable loss of flexibility / elasticity of the material or material loss of the electrical connector and / or heating element, resulting in an unreliable electrical connection. Advantageously, this base portion provides a physical limit on the biasing of the electrical connector in order to maintain a reliable electrical connection with the heating element.

[0008] Preferably, one or more slots open to the radially inward portion of the base. In this way, the base portion directly biases at least a portion of each electrical connector radially inward to the heating element of the heater cup, ensuring that good electrical connection is maintained throughout the life of the heating assembly.

[0009] Preferably, one or more slots include one or more respective surfaces positioned radially outward of at least a portion of the accepted electrical connector. Each electrical connector may include a base portion and a predetermined length extending from the second end of the outer tube, and the base portion may bias the electrical connector entirely or only a portion of a predetermined length. Optionally, some portions of the biased electrical connector may bend radially outward away from the heater cup. Therefore, the base portion may be configured to ensure that radial outward bias of the electrical connector is suppressed in order to ensure that a good electrical connection is maintained between the electrical connector and the heating element. The base portion may be in the shape of a ring, providing a single surface surrounding the electrical connector. Alternatively, the slots may include separate surfaces for each electrical connector.

[0010] Preferably, the base portion is configured to be removably attachable to the heater cup and / or end wall. In this way, the base portion can be easily attached to or removed for mounting to the heater cup and / or end wall during the assembly of the heating assembly. It should be recognized that when an electrical connector is received in one or more slots of the base portion, the base portion provides a radially inward biasing force to the electrical connector.

[0011] To ensure good alignment of the electrical connector with the heating assembly, the heating assembly may further include a shape-mating connection configured to substantially align the electrical connector with the electrical contacts of the heating element. The mating connection may be located between the base portion subassembly and the heater cup or between the base portion and the end wall. Alternatively, the heater cup and the end wall (with the base portion attached) may each have a shape-mating connection with the outer tube. For example, the outer tube may include notches or grooves at each end, and the heater cup and end wall may each include corresponding tongues that fit into the corresponding notches / grooves. Thus, the shape-mating connection can effectively ensure that the electrical connector aligns with the corresponding electrical contacts in the heating element. It will be apparent to those skilled in the art that shape-mating connections can be designed, or that appropriate materials can be selected to minimize any undesirable heat loss.

[0012] One or more slots in the base portion may be shorter than the length of the electrical connector so that the electrical connector is compressed axially within the slot, thereby biasing the electrical connector radially inward. The base portion may include shelf-like sections or inclined surfaces configured to compress the electrical connector axially and bias it radially inward. Each electrical connector may include an end, which is pressed against the shelf-like section or biased by the inclined surface to bend, curve, or wrinkle the electrical connector radially inward. In this way, axial compression reliably causes radial extension or expansion of the electrical connector.

[0013] The electrical connectors may have a curved or corrugated shape to facilitate radial inward biasing of at least a portion of each accepted electrical connector. In this way, each electrical connector can be compressed axially to form contact with the heating element. The electrical connectors may be molded or designed to be wrinkled or folded in a zigzag or corrugated arrangement. Such arrangements may result in multiple radial inward extensions of the electrical connector, thereby providing multiple contacts between the electrical connector and the heating element.

[0014] Preferably, the base portion includes a non-gas-releasing material such as ceramic or polyetheretherketone (PEEK). In this way, the base portion does not cause a pressure increase in the insulating space between the heater cup and the outer tube when heat is generated by the heating element. In addition, materials such as ceramic or PEEK can exhibit effective insulating properties.

[0015] Preferably, a vacuum is sealed between the outer tube, the heater cup, and the end wall. In this way, a vacuum is created when the base portion is connected to the outer tube to provide a vacuum insulator. Alternatively, an insulating material may be sealed between the outer tube, the heater cup, and the end wall. Examples of insulating materials that can be provided include, but are not limited to, air, aerogel material, powder, or fibrous insulating material.

[0016] Preferably, the end wall completely covers the second end of the outer tube. In this way, the attachment of the end wall to the outer tube simplifies the manufacture of the heating assembly, as the electrical connector is connected to the heating element while the outer tube is closed.

[0017] Preferably, the end walls are welded or brazed to the outer tube. This enhances the integrity of the insulating space, such as a vacuum, between the outer tube and the heater cup.

[0018] Preferably, the inner surface of the heater cup is electrically insulated. This improves the electrical safety of the heating assembly. The electrical insulating material may be provided as a separate layer, or the heater cup material may be selected as the electrical insulating material.

[0019] Preferably, the end wall further includes a connection point. The connection point may include an access hole in the space between the outer tube and the heater cup, through which a vacuum can be formed in the space. The access hole may be sealed after the vacuum has been formed. For example, a conduit may be connected to the access hole to generate a vacuum in the space, and the conduit may be clamped or otherwise sealed to close the access hole and maintain the vacuum in the space. In another example, a vacuum in a heating assembly may be formed after a vacuum has been formed in the space by manufacturing the heating assembly in a vacuum chamber to seal the access hole.

[0020] The connection point may be configured such that a structural element allows the heating assembly to be connected to the aerosol generating device. Since the connection point is part of the end wall, the structural element extending from the base portion to the device suppresses conduction heat loss or heat transfer from the heater cup to the device. Preferably, the heating assembly further includes a structural member positioned to secure the heating assembly to the aerosol generating device.

[0021] Preferably, the heating element is a resistance heater. In this way, a heater that is small, simple, and easy to power is provided.

[0022] According to another aspect of the present invention, an aerosol generating device is provided which is configured to generate an aerosol for a user to inhale, the aerosol generating device comprising a heating assembly according to the first aspect and a power supply for supplying power to the heating element through an electrical connector.

[0023] According to yet another aspect of the present invention, there is provided a method of manufacturing a heating assembly for an aerosol generating device, the method comprising the step of providing an outer tube, the outer tube having a first end and a second end; the step of disposing a heater cup radially inwardly of the outer tube, the heater cup including a heating element provided on an outward facing surface of the heater cup and having an opening at the first end of the outer tube for receiving an aerosol forming substrate; the step of providing an end wall to be disposed at the second end of the outer tube; the step of extending an electrical connector from the end wall, the electrical connector being configured to supply power to the heating element; the step of providing a base portion to be disposed at a closed end of the heater cup, the base portion including one or more slots capable of receiving the electrical connector; the step of inserting the electrical connector into the one or more slots of the base portion, the base portion being configured to urge at least a respective portion of the electrical connector radially inwardly towards the heating element when the electrical connector is received in the slot to press the electrical connector towards the heating element; and the step of attaching the end wall to the second end of the outer tube.

[0024] Here, embodiments of the present invention will be described by way of example with reference to the drawings.

Brief Description of the Drawings

[0025] [Figure 1] A perspective view of an aerosol generating device including a heating device according to an embodiment of the present invention. [Figure 2] A cross-sectional view of an aerosol forming consumable. [Figure 3A-3C] A schematic view of a heating assembly according to an embodiment of the present invention. [Figure 4] A schematic cross-sectional view of a base portion and an end wall of a heating device according to another embodiment of the present invention.

Embodiments of the Invention

[0026] As described herein, vapor is generally understood to refer to a substance that is in the gaseous phase at temperatures below its critical temperature; that is, vapor can condense into a liquid by increasing its pressure without lowering its temperature, while aerosol is fine solid particles or droplets suspended in the air or another gas. However, it should be noted herein that the terms “aerosol” and “vapor” may be used interchangeably, particularly in reference to the form of an inhalable medium generated for inhalation by the user.

[0027] Figure 1 shows an aerosol generating device 2 according to one embodiment of the present invention. The aerosol generating device 2 is shown in an assembled configuration with exemplary internal components visible. The aerosol generating device 2 is a heated, non-combustible device, sometimes called a tobacco vapor device, and includes a heating device 4 configured to receive an aerosol substrate, such as a rod of aerosol generating material (e.g., tobacco). The aerosol generating device 2 may include a power source, such as a battery, and a control circuit for controlling the supply of power from the power source to the heating assembly 4. The heating assembly 4 is operable to heat the rod of aerosol generating material rather than combust it, thereby generating vapor or aerosol for inhalation by the user. As will be understood by those skilled in the art, the aerosol generating device 2 shown in Figure 1 is merely an exemplary aerosol generating device according to the present invention. Other types and configurations of tobacco vapor products, vaporizers, or e-cigarettes may also be used as aerosol generating devices according to the present invention.

[0028] Figure 2 shows a schematic diagram of an aerosol-forming consumable 6 for insertion into the heating device 4 of the aerosol-generating device 2. The aerosol-forming consumable 6 has a cylindrical body 8, the body of which a filter 10 is provided on the first end side and an aerosol-forming material 12 on the second end of the body 8. The aerosol-forming material 12 may be a solid or semi-solid aerosol-forming substrate, including tobacco. The aerosol-forming consumable 6 further includes an empty space 14 positioned within the body 8 between the filter 10 and the aerosol-forming material 12. This space 14 collects the aerosols formed or generated from the aerosol-forming material 12 when the aerosol-forming material 12 is heated, before the generated aerosols are inhaled by the user through the filter 10.

[0029] The aerosol-forming consumable 6 also includes packaging material 16, which holds the filter 10 and the aerosol-forming substance 12 in place and provides a space 14 between the filter 10 and the aerosol-forming substance 12. The packaging material 16 has properties suitable for ensuring the integrity of the aerosol-forming consumable 6, for example, so that it does not wrinkle and collapse into the space 14 when the aerosol-forming consumable 6 is inserted into the heating device, or break when the aerosol-forming consumable 6 is removed from the heating device. The space 14 may be formed from a tubular member made of a rigid paper material that provides some rigidity while allowing the generated aerosol to easily flow through the space 14 to the filter 10. The length of the aerosol-forming substance 12 in the main body 8 may be approximately the same as the longitudinal length of the heating area in the heating assembly.

[0030] Figures 3A, 3B, and 3C show a heating assembly 100 at different stages of a manufacturing assembly according to one embodiment of the present invention. The heating assembly 100 includes an outer tube 102 and a heater cup 104 radially provided within the outer tube 102. The heater cup 104 is joined to the outer tube 102 at a first end of the heating assembly 100 by welding or by any other means apparent to those skilled in the art.

[0031] The heater cup 104 defines a cavity into which an aerosol-generating consumable, such as a tobacco rod or an aerosol-forming consumable 6, can be received. The heater cup 104 further includes a heating element 106 located on the outer surface of the heater cup 104. The heating element 106 is configured to generate heat when an electric current passes through it, and the generated heat is conducted through the heater cup wall to heat the air and consumable received in the cavity. The heating element 106 can be powered by a battery or other form of power source within the aerosol-generating device.

[0032] The outer tube 102 and heater cup 104 have a substantially elliptical or substantially circular cross-section to provide a substantially cylindrical heating assembly 100 when viewed along one of their ends parallel to their longitudinal axis. However, in alternative embodiments, the heating assembly 100 may be formed in a shape with other cross-sectional shapes, such as substantially square or polygonal.

[0033] The heater cup 104 and the outer tube 102 are arranged radially apart from each other to define a sealed, insulating space 108 in which a vacuum can be formed. Those skilled in the art will understand that the term "vacuum" refers to a space in which the pressure is significantly lower than atmospheric pressure due to the removal of free matter (especially air). The quality of the vacuum formed between the heater cup 104 and the outer tube 102 may be low vacuum, medium vacuum, or high vacuum.

[0034] In an alternative embodiment, instead of a vacuum, an insulating material such as powder, a fibrous material such as aerogel, and / or air may be placed between the heater cup 104 and the outer tube 102.

[0035] The heating element 106 is a resistance heating element that generates heat by resistance heating. In this disclosure, the heating element 106 is a track that surrounds the heater cup 104, preferably around the entire circumference of the heater cup 104. Different patterns or arrangements of the heating element 106 will be apparent to those skilled in the art. For example, the heating element 106 may include a heating sheet that partially or completely surrounds the heater cup 104. In another example, the heating element 106 may be printed, coated or otherwise attached to the outer surface of the heater cup 104. The heating element 106 further includes a first electrical contact and a second electrical contact (not shown) located on the bottom end side of the heater cup 104 for electrical connection to a power source.

[0036] The heating assembly 100 further includes an end wall 110 formed to cover the bottom end of the outer tube 102 and to seal a vacuum or insulating space 108 between the heater cup 104 and the outer tube 102. The outer tube 102 and the end wall 110 may each include a metal such as stainless steel so that the two components can be welded or brazed together to seal the connection.

[0037] The heating assembly 100 further includes an electrical connector 112 configured to connect the heating element 106 to a power source or battery in the aerosol generating device. The electrical connector 112 may be a wire or ribbon of a conductive material such as metal (e.g., spring steel, stainless steel, or copper). The material of the electrical connector 112 is configured to bend, wrinkle, or otherwise bend to a desired degree without breaking. The electrical connector 112 extends from the end wall 110 into the space 108 between the heater cup 104 and the outer tube 102 to contact the electrical connection of the heating element 106. As will be recognized by those skilled in the art, the electrical connector 112 may be electrically insulated from the end wall 110 and the outer tube 102 by using a non-conductive seal (not shown).

[0038] The heating assembly 100 further includes a ring-shaped base portion 114 having one or more slots configured to fit around an electrical connector 112 so that the electrical connector 112 extending from the end wall 110 is received in the slots of the base portion 114. The base portion 114 is made of a non-conductive material such as ceramic or a gas-free plastic such as polyetheretherketone (PEEK).

[0039] As can be seen in Figures 3A and 3B, the base portion 114 fits around the electrical connector 112 such that the surface of one or more slots biases the electrical connector 112 radially inward toward the center of the insulating space 108 before the end wall 110 and the base portion 114 are inserted into the outer tube 102. When the heater cup 104 descends into the base portion 114 (or when the end wall 110 and the base portion are inserted into the outer tube 102 and onto the heater cup 104), it can be understood that an electrical connection 116 is formed between the electrical connector 112 and the electrical contacts of the heating assembly 106, as shown in Figure 3C. Since the electrical connector 112 is biased radially inward toward the space of the heater cup 104, the electrical connector 112 is pressed directly against the heating element 106 when the heater cup 104 is accepted into the base portion 114.

[0040] In this specific example, the base portion 114 includes a shelf-like portion 118 or an inclined surface, and the electrical connector 112 is pressed against the shelf-like portion 118 or the inclined surface to compress the electrical connector 112 in the axial direction. The axial compression causes the electrical connector 112 to wrinkle and take on a zigzag shape, and the electrical connector 112 extends radially toward the center of the outer tube 102 / heating assembly 100.

[0041] The end wall 110 further includes an opening 120 that serves as a connection point to a vacuum generator tube 122, and during assembly, the vacuum generator tube 122 may be used to form a vacuum in the insulating space 108 before the opening 120 or the vacuum generator tube 122 is sealed. The opening 120 may also be used to allow one or more sensors, such as temperature or pressure sensors for the heating assembly 100, to be mounted on the end wall 110. In yet another example, the opening 120 may be used to connect the heating assembly 100 to an aerosol generating device by providing a rigid structural element to fix the heating assembly 100 in place.

[0042] Figure 4 shows schematic contours of the end wall 210 and base portion 212 according to another example of the present disclosure. The end wall 210 largely corresponds to the example shown in Figure 3. However, in this specific example, the electrical connector 214 is shown to bend radially inward as a single curved arch when compressed axially by the shelf portion 216 of the base portion 212.

[0043] As can be seen from the examples in Figures 3 and 4, the electrical connector can be made to wrinkle and form a zigzag shape, or to bend or flex radially inward when compressed against the shelf-like portion of the base. This may depend on the initial shape and dimensions of the electrical connector and the design of the base portion. Other designs of the base portion that cause the electrical connector to be biased radially inward to form a direct electrical connection with the heater cup during assembly will also be apparent to those skilled in the art.

Claims

1. A heating assembly for an aerosol generating device, An outer tube having a first end and a second end, A heater cup disposed radially inward of the outer tube, the heater cup includes a heating element provided on the outward-facing surface of the heater cup, and the heater cup has an opening at the first end of the outer tube for receiving an aerosol-forming substrate, An electrical connector configured to supply power to the heating element, A base portion located at the closed end of the heater cup, the base portion including one or more slots capable of receiving the electrical connector, An end wall located at the second end of the outer pipe, wherein the electrical connector extends from the end wall and Includes, A heating assembly for an aerosol generating device, wherein the base portion is configured to bias at least a portion of each of the electrical connectors radially inward toward the heating element when the electrical connector is received in the slot, in order to press the electrical connector toward the heating element.

2. The heating assembly according to claim 1, wherein one or more of the slots open to the radially inward portion of the base portion.

3. The heating assembly according to claim 1 or 2, wherein the one or more slots include one or more surfaces located radially outward from each of the at least portion of the accepted electrical connector.

4. The heating assembly according to any one of claims 1 to 3, wherein the base portion is configured to be removably attached to the heater cup and / or the end wall.

5. The heating assembly according to any one of claims 1 to 4, wherein the one or more slots in the base portion have a length shorter than the length of the electrical connector such that the electrical connector is compressed axially within the slot, thereby biasing the electrical connector radially inward.

6. The heating assembly according to any one of claims 1 to 5, wherein the electrical connector has a curved or wavy shape to facilitate the radially inward biasing of at least a portion of the received electrical connector.

7. The heating assembly according to any one of claims 1 to 6, wherein the base portion comprises a non-gas-releasing material such as ceramic or polyetheretherketone (PEEK).

8. The heating assembly according to any one of claims 1 to 7, wherein a vacuum is sealed between the outer tube, the heater cup, and the end wall.

9. The heating assembly according to any one of claims 1 to 8, wherein the end wall is welded or brazed to the outer tube.

10. The heating assembly according to any one of claims 1 to 9, wherein the inner surface of the heater cup is electrically insulated.

11. The heating assembly according to any one of claims 1 to 10, wherein the end wall includes a connection point.

12. The heating assembly according to claim 11, further comprising a structural member arranged to fix the heating assembly to an aerosol generating device.

13. The heating assembly according to any one of claims 1 to 12, wherein the heating element is a resistance heater.

14. An aerosol generating device configured to generate an aerosol for inhalation by a user, wherein the aerosol generating device is A heating assembly according to any one of claims 1 to 13, A power supply for supplying power to the heating element via an electrical connector Aerosol generating device, including

15. A method for manufacturing a heating assembly for an aerosol generating device, wherein the method is: A step of providing an outer pipe, wherein the outer pipe has a first end and a second end, A step of positioning a heater cup radially inward of the outer tube, wherein the heater cup includes a heating element provided on the outward-facing surface of the heater cup and has an opening at the first end of the outer tube for receiving an aerosol-forming substrate; The steps include providing an end wall so as to be positioned at the second end of the outer pipe, A step of extending an electrical connector from the end wall, wherein the electrical connector is configured to supply power to the heating element, A step of providing a base portion so as to be positioned at the closed end of the heater cup, wherein the base portion includes one or more slots capable of receiving the electrical connector, Inserting the electrical connector into one or more slots of the base portion, wherein the base portion is configured to bias at least a portion of each electrical connector radially inward toward the heating element when the electrical connector is received in the slot, in order to press the electrical connector toward the heating element; The steps of attaching the end wall to the second end of the outer pipe and Methods that include...

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