Aerosol generating device having a heat dissipating housing

Abstract

The present invention relates to an aerosol-generating device, and more particularly to an aerosol-generating device including a cover element having a heat-dissipating material, the aerosol-generating device including a heating unit for heating an aerosol-generating substrate to generate an aerosol, and an apparatus housing forming at least a portion of the exterior surface of the aerosol-generating device, the apparatus housing including an aerogel material configured to insulate the heating unit and / or dissipate heat generated by the heating unit.

Description

[Technical Field]

[0001] The present invention relates to an aerosol generating device, and more particularly to an aerosol generating device including a cover element having a heat dissipating material. [Background technology]

[0002] Aerosol generating devices commonly found in markets include an aerosol generating unit for generating an aerosol for consumption by a user of the aerosol generating device. The aerosol generating unit typically includes a heating unit that generates the aerosol by applying heat to an aerosol-generating substrate. While a portion of the heat generated by the heating unit in the aerosol-generating process is dissipated through the aerosol and the airflow that transports the aerosol to the user for inhalation, a substantial portion of the generated heat is transferred to the surroundings of the heating unit within the aerosol generating device and then dissipated externally through the device housing of the aerosol generating device. Furthermore, the exterior surfaces of the aerosol generating device, particularly those adjacent to the heating unit, can also become hot. As a result, the device housing may become too hot to comfortably hold or touch, potentially causing injury to the user.

[0003] To address the above problems, some aerosol generating devices provide an insulating element, such as an insulating sleeve or wrapper. The insulating element typically surrounds or encases at least the heating unit to reduce heat transfer from the heating unit to the exterior surface of the device housing. However, the insulating element increases the overall size of the aerosol generating device and must accommodate spatial requirements imposed by the interior space of the aerosol generating device occupied by multiple components of the aerosol generating device. This increases manufacturing complexity and drives up manufacturing costs.

[0004] Therefore, there is a need for an aerosol generating device that is durable, compact, cost-effective to manufacture, and has an insulated unit that is capable of dissipating heat from the heating unit. Summary of the Invention [Means for solving the problem]

[0005] Some or all of the above objects are achieved by the invention as defined by the features of the independent claims. Preferred embodiments of the invention are defined by the features of the dependent claims.

[0006] A first aspect of the present invention is a heating unit for heating an aerosol-generating substrate for generating the aerosol; - a device housing forming at least a portion of the exterior surface of the aerosol generating device; Including, the device housing includes an aerogel material configured to insulate the heating unit and / or dissipate heat generated by the heating unit; It is an aerosol generating device.

[0007] By having aerogel material within the device housing, the device housing can be made thinner than with other insulating materials, with at least the same insulating performance, thereby reducing the size and / or expanding the interior space of the device. Also, by having aerogel material within the device housing instead of placing aerogel inside the device, there is more space for heat dissipation within the device.

[0008] According to a second embodiment, in the previous embodiment, the device housing includes an aerogel layer comprising, preferably made of, an aerogel material.

[0009] According to a third aspect, in the previous aspect, the aerogel material is 0.10 to 0.15 g / cm 3 , preferably 0.11 to 0.12 g / cm 3 It has a density of

[0010] By having the configuration of the third embodiment, the aerogel material can be in a stable solid state.

[0011] According to a fourth embodiment, in any one of the second and third embodiments, the aerogel layer (311) is in a solid state.

[0012] By having the configuration of the fourth aspect, the solid aerogel can make the device lighter and easier to manufacture.

[0013] According to the fifth aspect, in any one of the second to fourth aspects, the aerogel layer (311) has the shape of a sheet or a film.

[0014] According to a sixth aspect, in any one of the second to fifth aspects, the device housing (200, 300) further comprises a plastic layer (310, 312), and at least one of the aerogel layer (311) or the plastic layer (310, 312) is arranged as the outermost layer of the device housing (200, 300), and one side of the aerogel layer (311) is arranged so as to be directly, preferably completely, attached to the plastic layer (310, 312).

[0015] The presence of the plastic layer makes the aerogel layer more rigid and therefore less susceptible to damage or scratches, thereby increasing the lifespan of the aerogel.

[0016] According to a seventh aspect, in any one of the second to sixth aspects, the device housing (200, 300) comprises another plastic layer (310, 312) arranged so as to be directly, preferably completely, attached to another side of the aerogel layer (311) in such a way that the aerogel layer (311) is sandwiched between the two plastic layers.

[0017] According to the eighth aspect, in any one of the second to seventh aspects, the plastic layer (312) is a transparent plastic, and the other plastic layer (310) is an opaque plastic.

[0018] According to the ninth aspect, in any one of the second to eighth aspects, one surface of the aerogel layer (311) is completely attached to the surface of the plastic layer (310, 312).

[0019] According to a tenth aspect, in any one of the second to ninth aspects, the aerogel layer has the shape of a sheet or film.

[0020] According to an eleventh aspect, in any one of the second and tenth aspects, the aerogel layer does not contain aerogel powder or is not made of aerogel powder.

[0021] The tenth and eleventh aspects are advantageous because, unlike aerogel powder, aerogel, especially in sheet or film form, allows the material to be transparent, more compact, and easier to form into predetermined shapes.

[0022] According to a twelfth aspect, in any one of the second and eleventh aspects, the aerogel layer is in the form of granules.

[0023] According to a thirteenth aspect, in any one of the second to twelfth aspects, the device housing preferably includes a first layer of opaque plastic.

[0024] According to a fourteenth aspect, in the above aspects, the opaque plastic layer is a decorative layer having a printed pattern configured to indicate the location and / or function of the user control and / or other information related to the aerosol generating device, and / or the decorative layer is IDF (in-decoration film) colored plastic, OMR (outside transfer) colored plastic, or NCVM (non-conductive vacuum metallization) colored plastic.

[0025] The thirteenth and fourteenth aspects are advantageous because the transparency of the aerogel films and sheets allows for the application of the aerogel material over plastics with decorative elements such as patterns or prints.

[0026] According to the fifteenth aspect, in the fourteenth and fifteenth aspects, the aerogel layer is configured on a first layer of plastic.

[0027] According to a sixteenth aspect, in the sixth aspect, the aerogel layer is configured below the first layer of plastic.

[0028] The fifteenth and sixteenth aspects are advantageous because the plastic material can harden and support the aerogel layer.

[0029] According to a seventeenth aspect, in any one of the thirteenth to sixteenth aspects, the device housing includes a second layer, preferably transparent plastic, which is the outermost layer of the device housing, and the aerogel layer is configured between the first layer of plastic and the second layer of plastic.

[0030] The seventeenth embodiment is advantageous because placing another transparent plastic over the aerogel and opaque plastic prevents damage to the aerogel and opaque plastic, such as scratches and discoloration due to ultraviolet light.

[0031] According to an eighteenth aspect, in any one of the second to seventeenth aspects, the aerogel layer is thicker in at least a portion of the housing adjacent to the heating unit than in other portions of the housing not adjacent to the heating unit.

[0032] The eighteenth aspect is advantageous because this arrangement allows the device housing to have a consistent tactile temperature throughout the device housing and allows for less aerogel material to be used.

[0033] According to a nineteenth aspect, in any one of the second to eighteenth aspects, the aerogel layer has an average thickness of at least 0.2 mm, preferably at least 0.4 mm, more preferably at least 0.5 mm, and most preferably at least 0.6 mm, and at most 1.2 mm, more preferably at most 1.0 mm, even more preferably at most 0.8 mm, and most preferably at most 0.7 mm.

[0034] According to the twentieth aspect, in any one of the second to nineteenth aspects, the aerogel layer has a flexural strength of at least 0.025 MPa, preferably at least 0.05 MPa, more preferably at least 0.1 MPa, and most preferably at least 0.15 MPa, and at most 0.45 MPa, more preferably at most 0.4 MPa, even more preferably at most 0.3 MPa, and most preferably at most 0.25 MPa.

[0035] With the thickness and bending strength of the nineteenth and twentieth embodiments, the aerogel layer is thin and can be easily molded into different shapes.

[0036] According to a 21st aspect, in any one of the preceding aspects, the aerogel material has a thermal conductivity of at least 0.010 W / m·K, preferably at least 0.011 W / m·K, more preferably at least 0.012 W / m·K, and most preferably at least 0.013 W / m·K, and at most 0.017 W / m·K, more preferably at most 0.016 W / m·K, even more preferably at most 0.015 W / m·K, and most preferably at most 0.014 W / m·K.

[0037] The aerogel layer according to the twenty-first embodiment has excellent thermal insulation properties to provide excellent thermal insulation and heat dissipation performance.

[0038] According to a twenty-second aspect, in any one of the preceding aspects, the aerogel material has a visible light transmittance of at least 92% at 800 nm, preferably at least 93% at 800 nm, more preferably at least 94% at 800 nm, and most preferably at least 95% at 800 nm, and at most 99% at 800 nm, more preferably at most 98% at 800 nm, even more preferably at most 97% at 800 nm, and most preferably at most 96% at 800 nm.

[0039] The transparency of the aerogel material according to the twenty-second embodiment allows it to be placed on a surface with color, pattern, and light. Aerogel materials with the above light transmittance can be high throughout the visible light range and can be morphologically stable.

[0040] According to a 23rd aspect, in any one of the preceding aspects, the aerogel material has a superhydrophobic water contact angle of at least 125°, preferably at least 130°, more preferably at least 135°, and most preferably at least 140°, and at most 160°, more preferably at most 155°, even more preferably at most 150°, and most preferably at most 145°.

[0041] Due to the hydrophobic or water-repellent properties of the aerogel material according to the sixteenth aspect, its performance or insulating properties remain even when vapors due to heating are present in the device.

[0042] According to a 24th aspect, in any one of the preceding aspects, the device housing includes a main body and a cover element removably attached or connected to the main body, the cover element comprising an aerogel material.

[0043] According to a 25th aspect, in any one of the preceding aspects, the aerogel material is disposed throughout substantially the entire device housing.

[0044] According to a twenty-sixth aspect, in any one of the preceding aspects, the cover element has a curvature such that heat from the heating unit can be dissipated in multiple directions when the device is in use.

[0045] With the structure of the 26th embodiment, the aerogel layer dissipates heat from the heating unit more effectively, and the surface temperature of the entire device is maintained consistently.

[0046] According to a 27th aspect, in any one of the preceding aspects, the aerogel material has a density of 0.10 to 0.15 g / cm 3 , preferably 0.11 to 0.12 g / cm 3 It has a density of

[0047] The density of the 27th embodiment allows the aerogel material to have relatively high heat dissipation performance and low thermal conductivity of 0.01 W / m·K or less, while remaining solid and resistant to cracking, allowing it to be stably fixed to a plastic layer. Additionally, aerogel composites of this density can be used for water repellency, sound absorption, static vibration, catalyst support, and other applications.

[0048] According to a 28th aspect, in any one of the preceding aspects, the aerogel material has a compressive strength of 8 to 10 MPa, preferably 8.5 to 9.5 MPa, more preferably 9.1 to 9.5 MPa, and most preferably 9.2 to 9.25 MPa, and / or a compressive modulus of 0.5 to 1 MPa, preferably 0.6 to 0.9 MPa, and more preferably 0.7 to 0.75 MPa.

[0049] According to a 29th aspect, in any one of the preceding aspects, the aerogel material has an average pore size of 20 to 100 nm, preferably 30 to 90 nm, more preferably 40 to 80 nm, and most preferably 50 to 70 nm.

[0050] According to a thirtieth aspect, in any one of the preceding aspects, the aerogel material has a refractive index of 1.02 to 1.08, preferably 1.03 to 1.07, more preferably 1.04 to 1.06.

[0051] According to a thirty-first aspect, in any one of the preceding aspects, the aerogel material has a dielectric constant of 1.05 to 1.15, preferably 1.08 to 1.12, more preferably 1.09 to 1.11.

[0052] According to a thirty-second aspect, in any one of the preceding aspects, the aerogel material has a heat resistance temperature of up to 550°C, preferably up to 600°C, more preferably up to 615°C, and most preferably up to 630°C in a nitrogen atmosphere, and up to 350°C, preferably up to 400°C, more preferably up to 450°C, and most preferably up to 467°C in an air atmosphere.

[0053] According to a thirty-third aspect, in any one of the preceding aspects, the aerogel material is 62×10 -6 ~66×10 -6 / K, preferably 63 × 10 -6 ~65×10 -6 / K, more preferably 63.5 × 10 -6 ~64.5×10 -6 / K.

[0054] A 34th aspect of the present invention relates to a method for manufacturing a device housing for an aerosol-generating device according to any one of the second to 33rd aspects, the device housing including a heating unit for heating an aerosol-generating substrate for generating an aerosol, the method comprising: - attaching an aerogel layer to a plastic layer by gluing, in-mold decoration or out-mold decoration, or - Fixing the aerogel layer between two plastic layers Includes:

[0055] In the manufacturing method according to the thirty-fourth embodiment, the aerogel layer is easy to form into a shape and is easy to fix to the plastic layer.

[0056] According to a thirty-fifth embodiment, in any of the preceding embodiments, the aerogel layer is in a solid state.

[0057] According to a thirty-sixth aspect, in the thirty-fourth or thirty-fifth aspect, one surface of the aerogel layer (311) is completely attached to the surface of the plastic layer (310, 312).

[0058] According to a 37th aspect, in the 34th, 35th or 36th aspect, the method comprises: - 0.10~0.15g / cm 3 , preferably 0.11 to 0.12 g / cm 3 obtaining an aerogel layer (311) comprising, and preferably made of, an aerogel material having a density of Further includes:

[0059] Preferred embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0060] [Figure 1A-B] 1A and 1B show schematic side and top views, respectively, of an aerosol generating device according to an embodiment of the present invention. [Figure 2A-B] 1A and 1B each show a schematic cross-sectional view of a portion of a cover element of an aerosol generating device according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0061] In describing the present invention, terms indicating orientation or positional relationships, such as "one end," "the other end," "outside," "top," "upper," "inner," "lower," "below," "horizontal," "coaxial," "center," "end," "portion," "length," "outer end," and the like, should be understood to be based on the orientation or positional relationships shown in the drawings. Terms such as "top," "upper," "lower," and "below" used herein to indicate relative position in space are used for ease of discussion to describe a unit or feature shown in the drawings relative to the relationship of another unit or feature. Terms of relative position in space may be intended to encompass various orientations of the device during use or operation other than those depicted in the figures. For example, if a device in the figures were inverted, a unit described as being "below" or "below" another unit or feature would then be "above" that other unit or feature. Thus, the exemplary term "lower" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations), and the spatially related descriptors used herein will be interpreted accordingly. More specifically, the term "above" means that one unit, layer, or element is positioned or configured relatively toward the exterior of the device toward other units, layers, or elements, and the term "below" means that one unit, layer, or element is positioned or configured relatively toward the interior of the device toward other units, layers, or elements.

[0062] As shown in FIGS. 1A and 1B , the aerosol generating device 100 includes a device housing including a main housing 200 and an optional cover element 300. The main housing 200 is configured to house an aerosol generating unit for generating an aerosol for consumption by a user. The aerosol generating unit includes a heating unit 110 configured to heat a consumable 120 including an aerosol-generating substrate. The aerosol generating device 100 also includes a power source, which may be a replaceable and / or rechargeable power source, and may additionally include a USB port that functions as a charging port or data transmission line for charging the rechargeable power source, and an operator / CPU. The power source may be a battery, which may include a battery vent and a battery vent cover. The cover element 300 may be removably attached to the main housing 200. The removable cover element means that the cover element 300 can be removed from the main housing by a user of the aerosol generating device 100 without the need for additional tools or aids, and thus the user can remove the cover element 300 using one or both hands. Alternatively, the cover element may not be removable but may be integrally formed with the main housing.

[0063] The aerosol generating device 100 may have an elongated shape to improve the comfort of a user when holding the aerosol generating device 100. The longitudinal direction of the aerosol generating device 100 is the direction in which the aerosol generating device 100 is elongated.

[0064] When the cover element 300 is provided as shown in FIG. 1A , an operation interface unit (not shown) can be provided on a portion of the main housing 200 covered by the cover element 300. The operation interface unit is protected from external influences by the cover element 300 and, like the user operation unit 320, can be operated by a user to provide operation input to the aerosol generation device 100. The operation interface unit includes one or more operation input elements 230, such as a mechanical or capacitive touch button or switch, an optical sensor, or a magnetic sensor. In a preferred configuration shown in FIG. 1B , the user operation unit 320 and the operation interface unit can be configured such that activating the user operation unit 320 activates the operation interface unit to provide operation input to the aerosol generation device 100. In this case, activating the user operation unit 320 alone cannot provide operation input to the aerosol generation device 100. Conversely, the resulting activation of the operation interface unit due to activation of the user operation unit 320 results in operation input. For example, the user operation unit 320 can include a mechanical button or switch that a user can press or move. The mechanical button or switch 320 has a protrusion or similar arrangement that protrudes toward the operation input element 230 of the operation interface unit, such as the button or switch 230, thereby activating the operation input element 230 of the operation interface unit. When the button or switch of the user operation area 320 is pressed, the protrusion presses the button or switch of the operation interface unit. Additionally or alternatively, the user operation unit 320 may include a magnetically detecting object, such as a magnet or ferromagnetic material, or an optically detecting object, such as a reflective surface, that can activate a magnetic sensor or optical sensor, respectively, provided as the operation input element 230 of the operation interface unit, when the button or switch 330 is activated. Alternatively, instead of a mechanical button or switch, the user operation unit 320 may include a flexible area that can flexibly deform toward the operation interface unit when pressed by a user to activate the operation input element 230 of the operation interface unit.This configuration allows a user to operate the operation interface portion for providing operation input to the aerosol generating device 100 from outside the aerosol generating device by activating the user operation area 320 without directly accessing or exposing the operation interface portion covered by the cover element 300.

[0065] The aerosol-generating device 100 may be an electronic cigarette and may be configured to generate an aerosol from an e-vapor or t-vapor aerosol-generating substrate. For example, the heating unit 110 may include a container configured to receive a tobacco stick or similar consumable product 120, and a heating element may be configured to heat the container and the tobacco stick received in the container. Alternatively, the container may be configured to receive a cartridge containing an aerosol-generating substrate, such as a liquid, and the heating unit 110 may include a wicking element and a heating element configured to heat the wicking element. Depending on the aerosol-generating substrate, the heating unit may heat the aerosol-generating substrate to a temperature of up to 350°C to generate an aerosol. The aerosol-generating device includes an airflow path extending from an inlet through the aerosol-generating unit to an air outlet. When a user consumes the consumable product by inhaling the generated aerosol, air enters the inlet and flows into the aerosol-generating unit, where the aerosol is generated by the heating unit by heating the aerosol-generating substrate, and transports the generated aerosol to an air outlet, such as a mouthpiece. Although the airflow path communicates with the aerosol-generating unit, the airflow path typically does not communicate with the rest of the aerosol-generating device's interior space. A portion of the heat generated by the heating unit 110 is transferred to the aerosol-generating substrate for generating the aerosol and to the airflow that transports the generated aerosol to the user for inhalation. However, a significant portion of the remaining generated heat is transferred to the interior space of the aerosol-generating device that is not in communication with the airflow path and the aerosol-generating unit. This significant portion of the generated heat is then dissipated over time through thermal conduction and thermal radiation to the outer surface of the aerosol-generating device and then to the ambient air. Because this heat does not contribute to heating the aerosol-generating substrate, it corresponds to lost heat lost to the interior space of the aerosol-generating device around the heating unit 110 that is not in communication with the heating unit 110. Therefore, the heat may increase the temperature of the outer main housing 200 during continuous vaping, potentially rendering the device 100 unusable until the temperature returns to normal.It is necessary to prevent the consumer and the device body from becoming hot due to the heat coming from the heater.

[0066] To address this issue, the device housing contains an aerogel material. By providing the aerogel material within the device housing instead of placing an additional thermal insulation unit inside the aerosol generating device 100, the aerosol generating device 100 becomes more compact and has better thermal insulation performance.

[0067] In some embodiments, the aerogel material is an aerogel powder loaded into the cover element 300 along with other insulating materials such as diatomaceous earth powder, zirconia powder, etc.

[0068] In some preferred embodiments of the present invention, aerogel sheets and / or aerogel films are used. Preferably, monolithic aerogels (sheet-shaped aerogels and film-shaped aerogels) having a block shape, such as Super Functional Air (SUFA) developed by T.M. Factory Co., Ltd., are used. In other preferred embodiments of the present invention, aerogel granules (granular aerogels), such as Super Functional Air (SUFA) developed by T.M. Factory Co., Ltd., are used. The manufacturing method, properties, and statistical information of SUFA from T.M. Factory Co., Ltd. are disclosed in International Publication No. WO 2020166302 A1 (T.M. Factory Co., Ltd. [JP]; Mamoru Aizawa, Ai Kamikaki).

[0069] In some embodiments, the aerogel material can be obtained by a sol generation step of adding a silicon compound to an aqueous solution containing an acid catalyst and performing hydrolysis, that is, hydrolyzing it to generate a sol. The silicon compound includes a tetrafunctional silane compound and a trifunctional silane compound, preferably further includes a bifunctional silane compound. More preferably, when Qx, Tx, and Dx represent the mass percentages of the tetrafunctional silane compound, trifunctional silane compound, and bifunctional silane compound respectively, the silicon compound is a mixture of a tetrafunctional silane compound, a trifunctional silane compound, and a bifunctional silane compound having a portion satisfying 0 < Qx < 50, 50 ≤ Tx < 100, 0 ≤ Dx < 30, and Qx + Tx + Dx = 100.

[0070] With this composition, the heat insulation properties of the aerogel material can be improved. In addition, using the aerogel material, a plate shape or film shape having a large area of 400 cm2 or more can be produced, thereby enabling mass production.

[0071] In some embodiments, when the structure of the aerogel of the present invention is microscopically observed, it mainly includes a bulk portion (skeleton portion) filled with a solid substance and a pore portion penetrating in a three-dimensional network shape within the bulk portion.

[0072] The bulk portion is composed of a continuum in which the solid forms a three-dimensional network by siloxane bonds. In the three-dimensional network, when the lattice, which is the minimum unit of the network, is approximated by a cube, the average length of one side thereof is 2 nm or more and 25 nm or less. The average length of one side is preferably 2 nm or more, 5 nm or more, 7 nm or more, 10 nm or more, and 25 nm or less, 20 nm or less, and 15 nm or less.

[0073] Furthermore, the pores have a tubular shape that penetrates the interior of the bulk portion, and the pores are approximated by tubes, and the average inner diameter of the tubes when approximated by a circle is 5 nm or more and 100 nm or less. The average inner diameter of the pores is preferably 5 nm or more, 7 nm or more, 10 nm or more, 20 nm or more, 30 nm or more, 50 nm or more, and 100 nm or less, 90 nm or less, 80 nm or less, or 70 nm or less. Here, the inner diameter of the tubes is smaller than the mean free path (MFP) of the element molecules that make up air at atmospheric pressure.

[0074] Furthermore, the porosity of the aerogel, i.e., the ratio of the volume of pores to the total volume of the aerogel, is 70% or more. As an example of the porosity, it may be 75% or more, 80% or more, 85% or more, or 90% or more.

[0075] In other embodiments, the aerogel of the present invention may include structures other than the bulk and pores, as long as it satisfies other physical properties of the aerogel. For example, it may include voids other than the pores. In addition, as yet another example, it may include organic solvents, surfactants, catalysts, and their decomposition products in addition to water.

[0076] 1A and 1B, the cover element 300 includes an aerogel layer, preferably in a solid state, more preferably an aerogel sheet and / or an aerogel film, solidified from an aerogel material during the manufacturing process. The aerogel layer enables the cover element 300 to reduce the temperature rise of the exterior surface of the aerosol generating device 100 due to heat loss from the heating unit 110, thereby preventing a user from being injured by heat while touching the cover element 300 to use the user control 320.

[0077] The cover element 300 can have a substantially planar central portion and one or more peripheral or outer periphery portions that are curved or bent to define or enclose a space between the main housing 200 and the cover element 300, locating the cover element 300 adjacent to the main housing 200, within which one or more operational input elements 230 can be positioned. Alternatively, the cover element 300 can have a continuously curved shape, with the central portion having a curvature that is smaller than the curvature of the one or more peripheral or outer periphery portions. The aerogel layers of the present invention are flexible and easily formed into the above-described shapes due to a certain level of bending strength possessed by aerogel films and sheets. The bending strength of the aerogel films and sheets of the present invention is at least 0.025 MPa, preferably at least 0.05 MPa, more preferably at least 0.1 MPa, and most preferably at least 0.15 MPa, and at most 0.45 MPa, more preferably at most 0.4 MPa, even more preferably at most 0.3 MPa, and most preferably at most 0.25 MPa. The density of the aerogel layer is 0.10 to 0.15 g / cm. 3 , preferably 0.11 to 0.12 g / cm 3This configuration, particularly the density, allows the aerogel material to be in a stable solid state, as shown, and thus can be mass-produced. As the density of the aerogel decreases, its thermal conductivity decreases, and its insulating properties correspondingly improve. At densities of 0.15 g / cm3 or less, its thermal conductivity can be as low as 0.01 W / m·K or less. Aerogel materials of this density are obtained during the manufacturing process by mercury porosimetry, also known as mercury intrusion. The aerogel layer has a compressive strength of 8 to 10 MPa, preferably 8.5 to 9.5 MPa, more preferably 9.1 to 9.5 MPa, and most preferably 9.2 to 9.25 MPa, and a compressive modulus of 0.5 to 1 MPa, preferably 0.6 to 0.9 MPa, and more preferably 0.7 to 0.75 MPa. The combination of the aerogel layer and the curved shape of the cover element 300 allows heat to dissipate in multiple directions, significantly improving its insulating and heat-dissipating properties. This configuration allows the aerogel layer 311 to more effectively dissipate heat from the heating unit, maintaining a consistent surface temperature of at least the cover element. In one embodiment of the present invention, the aerogel layer is thicker in at least a portion of the housing adjacent the heating unit than in other portions of the housing not adjacent the heating unit. More specifically, the center portion has a thicker aerogel layer than the peripheral or outer periphery. This arrangement allows the device housing to have a consistent tactile or surface temperature through its cover element, and may require less aerogel material.

[0078] The aerogel layer also reduces the thickness of the insulation applied to the heating unit 110, reducing the overall size of the aerosol generating device 100 and increasing its internal space. The aerogel sheet or film 311 is half or even only one-third the thickness of most conventional insulation materials, such as PEEK and copper, yet can provide nearly the same performance. More specifically, the aerogel layer used in the present invention has an average thickness of at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.3 mm, and most preferably at least 0.5 mm, and at most 1.2 mm, more preferably at most 1.0 mm, even more preferably at most 0.8 mm, and most preferably at most 0.6 mm. Its thermal conductivity is at least 0.010 W / m·K, preferably at least 0.011 W / m·K, more preferably at least 0.012 W / m·K, and most preferably at least 0.013 W / m·K, and at most 0.017 W / m·K, more preferably at most 0.016 W / m·K, even more preferably at most 0.015 W / m·K, and most preferably at most 0.014 W / m·K. The average pore size of the aerogel layer is 20 to 100 nm, preferably 30 to 90 nm, more preferably 40 to 80 nm, and most preferably 50 to 70 nm. Its dielectric constant is 1.05 to 1.15, preferably 1.08 to 1.12, and more preferably 1.09 to 1.11. The heat resistance temperature is up to 550°C, preferably 600°C, more preferably up to 615°C, and most preferably up to 630°C in a nitrogen atmosphere, and up to 350°C, preferably 400°C, more preferably up to 450°C, and most preferably up to 467°C in an air atmosphere. The thermal expansion coefficient is 62×10 -6 ~66×10 -6 / K, preferably 63 × 10 -6 ~65×10 -6 / K, more preferably 63.5 × 10 -6 ~64.5×10 -6 / K.

[0079] Another benefit of the aerogel layer is that it can be ultra-water-repellent. During consumption of an aerosol-generating substrate, such as a liquid, vaporized liquid may flow into the aerosol-generating device 100. Other insulating materials lose their insulating performance when they absorb moisture. However, the aerogel layer of the present invention maintains its insulating performance thanks to its ultra-water-repellent properties. More specifically, the aerogel layer of the present invention has a super-water-repellent water contact angle of at least 125°, preferably at least 130°, more preferably at least 135°, and most preferably at least 140°, and at most 160°, more preferably at most 155°, even more preferably at most 150°, and most preferably at most 145°.

[0080] As shown in FIG. 2A , a decorative layer (color layer or ink layer) 310 having a printed pattern indicating, for example, the location and / or function of the user control 320 and / or other information related to the aerosol generating device 100 is disposed beneath the aerogel layer 311. In other words, the decorative layer 310 is disposed at a position more internal to the device 100 than the aerogel layer 311. The decorative layer is an opaque plastic layer. Due to the transparency of the aerogel sheet or film 311, unlike aerogel powder, the aerogel sheet or film does not block the visibility of the pattern and color from the decorative layer and LED display that may be disposed beneath the cover element 300. Therefore, the aerogel layer 311 is the outermost layer. The visible light transmittance of the aerogel layer 311 of the present invention is at least 92% at 800 nm, preferably at least 93% at 800 nm, more preferably at least 94% at 800 nm, and most preferably at least 95% at 800 nm, and at most 99% at 800 nm, more preferably at most 98% at 800 nm, even more preferably at most 97% at 800 nm, and most preferably at most 96% at 800 nm. Its refractive index is 1.02 to 1.08, preferably 1.03 to 1.07, and more preferably 1.04 to 1.06.

[0081] 2B, to prevent scratches on the aerogel layer 311 and the decorative layer 310 and damage such as discoloration of the decorative layer 310 due to ultraviolet light, a transparent plastic layer 312, preferably a plastic plate, is formed thereon. The transparent plastic layer 312 is configured as the outermost layer of the device housing, and the aerogel layer 311 is configured between the transparent plastic layer 312 and the decorative layer 310. Although not shown in the figure, several other layers may be disposed below the transparent plastic layer 312, which will be introduced below.

[0082] As shown in both Figures 2A and 2B, the aerogel layer 311 is positioned in a manner that it adheres tightly to at least one, and preferably two, plastic layers, i.e., sticks or adheres to them. This arrangement prevents condensation from forming inside the device. In other words, one surface of the aerogel layer 311 is fully adhered to at least one surface of the plastic layers 310, 312, and preferably to one surface of each of the plastic layers 310, 312.

[0083] To manufacture the cover element 300, the aerogel material of the present invention is applied to the cover element 200 in such a way that the aerogel sheet or film 311 of the present invention adheres to at least one of the plastic layers. Preferably, the aerogel film or sheet 311 is applied to the cover element 200. Because aerogel films and sheets, unlike aerogel powders, are already shaped due to their flexibility, manufacturing the cover element 200 is easier and does not require stringent or complicated manufacturing conditions and environments.

[0084] More specifically, the aerogel sheet or film 311 of the present invention can be adhered onto the decorative layer 310 by applying a layer of adhesive onto the decorative layer 310 and then attaching the aerogel sheet or film 311 onto the layer of adhesive on the decorative layer 310. In other words, the aerogel layer 310 is configured as the outer layer, and the decorative layer is set below the aerogel layer 310.

[0085] The adhesive layer serves to combine the decorative layer 310, preferably comprising molded plastic, with the aerogel layer 311. The molded plastic may be an IDF (In-Decoration Film) colored plastic, an OMR (Outer Transfer) colored plastic, or an NCVM (Non-Conductive Vacuum Metallization) colored plastic. The adhesive layer is preferably made from one selected from the group consisting of acrylic, nitrated fiber, polyamine format, chlorinated rubber, vinyl chloride-co-vinyl acetate ester copolymer, polyamide, polyester, epoxy, polycarbonate, olefin, and acrylonitrile-butylene-styrene monomer resin. The adhesive layer is generally applied via, for example, intaglio printing, screen printing, and offset printing, or spraying, dip coating, or reverse coating. The decorative layer 310 may include a plastic base layer and a printing layer. As described above, the decorative layer 310 is used to display patterns and colors and is formed by coating the plastic base layer with printing ink, which is the printing layer.

[0086] The thickness of the cover element T is at least 0.75 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 2.8 mm, preferably at most 2.4 mm, and most preferably at most 2.1 mm. The thickness of the plastic base layer is at least 0.6 mm, more preferably at least 0.7 mm, even more preferably at least 0.8 mm, most preferably at least 0.9 mm, and at most 1.2 mm, preferably at most 1.1 mm, and most preferably at most 1.0 mm. The thickness of the printing layer is at least 0.1 mm, more preferably at least 0.15 mm, even more preferably at least 0.2 mm, and most preferably at least 0.25 mm, and at most 0.4 mm, preferably at most 0.35 mm, and most preferably at most 0.3 mm.

[0087] In other embodiments, the aerogel sheet or film 311 can be adhered to the plastic layer 310 by in-mold decoration or out-mold decoration. In-mold decoration and out-mold decoration methods, i.e., OMR (out-mold release), IMR (in-mold release), OMF (out-mold film), and IMF (in-mold film), are known to those skilled in the art. Methods are known, for example, from JP316025, JP322046, JP345288, Taiwan Patent No. I230002, U.S. Patent No. 7,070,849, and EP1327510. Generally, a film (decorative film or labeling film) is attached to a plastic object during molding. If the base of the film is removed during molding, it is "released," and thus is OMR or IMR. If the base remains in the mold, it is OMF or IMF.

[0088] To produce a cover element by in-mold or out-mold decoration, first, a film is produced. The film may include multiple layers in this order: a base, a first adhesive layer (or binder), an aluminum sheet (silver) layer (as an anti-reflection layer or metal film layer), a second adhesive layer (or binder), an aerogel layer of the present invention, a second adhesive layer (or binder), a printing layer or color sheet (red), a third adhesive layer, and a top coating layer. Second, the film is placed in a mold cavity so that the base surface contacts the cavity surface. Third, resin is injected into the mold to obtain an integrated body of the film and a substrate (plastic layer) composed of resin. Those skilled in the art will remove any one of the above layers, such as the aluminum sheet layer, from the film as needed to achieve a thinner product.

[0089] In this case, the thickness of the cover element T is at least 0.75 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 2.8 mm, preferably at most 2.4 mm, and most preferably at most 2.1 mm. The thickness of the plastic base layer is at least 0.6 mm, more preferably at least 0.7 mm, even more preferably at least 0.8 mm, most preferably at least 0.9 mm, and at most 1.2 mm, preferably at most 1.1 mm, and most preferably at most 1.0 mm. The thickness of the remainder of the film excluding the printing layer or aerogel layer is at least 0.1 mm, more preferably at least 0.15 mm, even more preferably at least 0.2 mm, most preferably at least 0.25 mm, and at most 0.4 mm, preferably at most 0.35 mm, and most preferably at most 0.3 mm.

[0090] If there is a concern about external pressure, another transparent substrate (another plastic layer) made of resin can be further attached, or in-mold or out-mold decoration can be performed on the integrated body, so that the transparent substrate or plastic as the outermost layer or surface of the cover element can protect the aerogel and colored plastic.

[0091] In this case, the thickness of the cover element T is at least 1.35 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 4.0 mm, preferably at most 3.0 mm, most preferably at most 2.1 mm. The thickness of the remainder of the film excluding the printing layer or the aerogel layer is at least 0.1 mm, more preferably at least 0.15 mm, even more preferably at least 0.2 mm, most preferably at least 0.25 mm, and at most 0.4 mm, preferably at most 0.35 mm, most preferably at most 0.3 mm.

[0092] In yet another embodiment, the aerogel layer 311 can be secured internally or sandwiched or placed between the decorative plastic layer 310 and the clear plastic layer 312 by a male-female mating using fasteners such as connectors or screws in a manner that allows the aerogel layer 311 to be adhered to one plastic layer, preferably two plastic layers on different sides of the aerogel layer 311, as shown in Figures 2A and 2B.

[0093] In this case, the thickness of the cover element T is at least 0.75 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 2.8 mm, preferably at most 2.4 mm, most preferably at most 2.1 mm.

[0094] In an alternative embodiment, the aerogel layer 311 may be configured below or in between the decorative layer 310 .

[0095] In the above-described embodiment, only the cover element 200 is configured with the aerogel material or aerogel layer 310 disposed over its entire surface area, but the aerogel material or aerogel layer 310 may also be configured over the entire outer housing of the device 100 or any other exterior part of the device 100, i.e., may be disposed over the complete surface area of ​​the housing of the device 100.

Claims

1. An aerosol generating device (100), comprising: a heating unit (110) for heating an aerosol-generating substrate (120) for generating an aerosol; a device housing (200, 300) forming at least part of the outer surface of said aerosol generating device (100); Including, the device housing (200, 300) comprises a plastic layer (310, 312) arranged as the outermost layer of the device housing, and an aerogel layer (311), the aerogel layer (311) comprising and / or consisting of an aerogel material (311) configured to insulate the heating unit (110) and to dissipate heat generated by the heating unit (110); One side of the aerogel layer (311) is positioned so as to adhere directly onto the plastic layer (310, 312); An aerosol generating device (100).

2. The aerogel material has a density of 0.10 to 0.15 g / cm ３ , preferably 0.11 to 0.12 g / cm ３ 2. The aerosol generating device (100) of claim 1, having a density of

3. 3. The aerosol generating device (100) according to claim 1 or 2, wherein the aerogel layer (311) has the shape of a sheet or a film.

4. The aerosol generating device (100) according to any one of claims 1 to 3, wherein the device housing (200, 300) comprises another plastic layer (310, 312) arranged so as to be directly attached to another side of the aerogel layer (311) in such a way that the aerogel layer (311) is sandwiched between two plastic layers.

5. 5. The aerosol generating device (100) of claim 4, wherein the plastic layer is a transparent plastic (312) and the other plastic layer (310) is an opaque plastic.

6. 6. The aerosol generating device (100) according to any one of claims 1 to 5, wherein one surface of the aerogel layer (311) is completely attached to the surface of the plastic layer (310, 312).

7. 7. The aerosol generating device according to claim 1, wherein the aerogel layer has an average thickness (A) of at least 0.2 mm, preferably at least 0.4 mm, more preferably at least 0.5 mm, and most preferably at least 0.6 mm, and at most 1.2 mm, more preferably at most 1.0 mm, even more preferably at most 0.8 mm, and most preferably at most 0.7 mm.

8. 8. The aerosol generating device (100) according to any one of claims 1 to 7, wherein the aerogel layer (311) has a flexural strength of at least 0.025 MPa, preferably at least 0.05 MPa, more preferably at least 0.1 MPa, and most preferably at least 0.15 MPa, and at most 0.45 MPa, more preferably at most 0.4 MPa, even more preferably at most 0.3 MPa, and most preferably at most 0.25 MPa.

9. 9. The aerosol generating device (100) according to any one of claims 1 to 8, wherein the aerogel material (311) has a thermal conductivity of at least 0.010 W / m K, preferably at least 0.011 W / m K, more preferably at least 0.012 W / m K, and most preferably at least 0.013 W / m K, and at most 0.017 W / m K, more preferably at most 0.016 W / m K, even more preferably at most 0.015 W / m K, and most preferably at most 0.014 W / m K.

10. 10. The aerosol generating device (100) according to any one of claims 1 to 9, wherein the aerogel material (311) has a visible light transmittance of at least 92% at 800 nm, preferably at least 93% at 800 nm, more preferably at least 94% at 800 nm, and most preferably at least 95% at 800 nm, and at most 99% at 800 nm, more preferably at most 98% at 800 nm, even more preferably at most 97% at 800 nm, and most preferably at most 96% at 800 nm.

11. 11. The aerosol generating device (100) according to claim 1, wherein the aerogel material (311) has a superhydrophobic water contact angle of at least 125°, preferably at least 130°, more preferably at least 135°, and most preferably at least 140°, and at most 160°, more preferably at most 155°, even more preferably at most 150°, and most preferably at most 145°.

12. The aerosol generating device (100) of any one of claims 1 to 11, wherein the device housing (200, 300) comprises a main body (200) and a cover element (300) removably attached or connected to the main body (200), the cover element (300) comprising the aerogel material (311).

13. The aerosol generating device (100) of claim 12, wherein the cover element (300) has a curvature so that the heat from the heating unit (110) can be dissipated in multiple directions when the aerosol generating device is in use.

14. 14. A method for manufacturing a device housing (300) for an aerosol-generating device (100) according to any one of claims 1 to 13, comprising a heating unit (110) for heating an aerosol-generating substrate (120) for generating an aerosol layer, said method comprising: - attaching said aerogel layer (311) to the plastic layers (310, 312) by gluing, in-mold decoration or out-mold decoration, or - Fixing said aerogel layer (311) between two plastic layers using a male-female fit. A manufacturing method comprising:

15. The method of claim 14, wherein one surface of the aerogel layer (311) is completely attached to the surface of the plastic layer (310, 312).

Images