Layered Heater Assembly

Abstract

A layered heater assembly for an aerosol generating device, the layered heater assembly including a thermally conductive layer operable to emit heat through an outer surface of the layered heater assembly, a first conductive track operable to generate heat, and an electrically insulating layer between the thermally conductive layer and the first conductive track. A method for manufacturing the layered heater assembly and an aerosol generating device incorporating the layered heater assembly.

Description

[Technical Field]

[0001] The present disclosure relates to heaters for aerosol-generating devices. In particular, the present disclosure relates to heaters configured to heat solid aerosol-generating matrix materials to generate aerosols. Such devices may heat tobacco or other suitable aerosol-generating matrix materials by conduction, convection, and / or radiation, rather than by combustion, to generate inhalable aerosols. [Background technology]

[0002] The popularity and use of reduced-risk or modified-risk devices (also known as vaporizers) has grown rapidly in recent years as aids to assist smokers who wish to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and roll-your-own cigarettes. A variety of devices and systems are available that heat or warm aerosolizable substances, as opposed to burning tobacco in traditional tobacco products.

[0003] A commonly available low-risk or risk-modified device is the heated matrix aerosol-generating device, or heated device. This type of device generates an aerosol or vapor by heating an aerosol-generating matrix, typically containing moist tobacco or other suitable aerosolizable material, to a temperature typically ranging from 150°C to 350°C. By heating, rather than combusting or burning, the aerosol-generating matrix releases an aerosol that contains the ingredients desired by the user but without the toxic and carcinogenic by-products of combustion. Furthermore, aerosols generated by heating tobacco or other aerosolizable material typically do not contain the burnt or bitter taste that results from combustion, which can be unpleasant to users, and therefore the matrix does not require sugar or other additives that are typically added to these materials to make the smoke and / or vapor more palatable to users. Summary of the Invention [Problem to be solved by the invention]

[0004] In such devices, it is desirable to improve the heating rate and efficiency. Therefore, it is desirable to provide alternative configurations for the heater that can improve one or more of the heating rate and efficiency, or that are controllable to improve the heating rate or efficiency. Furthermore, it is desirable to make the aerosol generating device easier to configure and maintain, and therefore it is desirable to provide a heating unit that can be easily installed in the aerosol generating device and is easily maintainable. [Means for solving the problem]

[0005] According to a first aspect, the present disclosure provides a layered heater assembly for an aerosol generating device, comprising: a thermally conductive layer operable to emit heat through an outer surface of the layered heater assembly; a first conductive track operable to generate heat; and an electrically insulating layer between the thermally conductive layer and the first conductive track.

[0006] Optionally, the layered heater assembly further comprises a second conductive track operable to sense temperature based on a resistance-temperature characteristic.

[0007] By providing a second track operable to sense temperature, each track can be optimized for its respective function: the first track can be optimized for generating heat and the second track can be optimized for sensing temperature.

[0008] Optionally, the first and second conductive tracks are formed on the same side of the electrically insulating layer.

[0009] By providing the first and second conductive tracks on the same side of the electrically insulating layer, the heater assembly manufacturing process can be simplified.

[0010] Optionally, the first and second conductive tracks are formed in a common plane.

[0011] By arranging the conductive tracks in a common plane, the correspondence between the temperatures of the first and second conductive tracks is improved.

[0012] Optionally, the first conductive track forms an open loop between two electrical contacts on one side of the layered heater assembly, and the second conductive track is confined between the first conductive track and that side of the layered heater assembly.

[0013] By arranging the first conductive track to substantially surround the second conductive track, an improved correspondence between the temperatures of the first and second conductive tracks is achieved.

[0014] Optionally, the first conductive track comprises a first material and the second conductive track comprises a second material, the first material being different from the second material.

[0015] Optionally, the second conductive track comprises platinum, stainless steel, or ceramic.

[0016] By configuring the first and second conductive tracks, the tracks can be more dynamically optimized to perform the different functions of heat generation and temperature sensing.

[0017] Optionally, the layered heater assembly further comprises a protective layer, the first conductive track being disposed between the electrically insulating layer and the protective layer.

[0018] The protective layer protects the first conductive track from interaction with the external environment. For example, the protective layer can be configured to prevent oxidation of material within the first conductive track when the first conductive track is generating heat.

[0019] Optionally, the protective layer is a second electrically insulating layer.

[0020] By providing additional electrical insulation, the first conductive tracks can be routed at a higher density without risking short circuits.

[0021] Optionally, the layered heater assembly includes a second conductive track and a protective layer as described above, the first and second conductive tracks being disposed between the electrically insulating layer and the protective layer.

[0022] The protective layer protects the first and second conductive tracks from interaction with the external environment. Furthermore, this arrangement facilitates manufacturing.

[0023] Optionally, the protective layer is disposed so that a portion thereof contacts the electrically insulating layer.

[0024] The protective layer is disposed so that a portion thereof is in contact with the electrical insulating layer.

[0025] Optionally, the outer surface is configured as a flat heater surface.

[0026] The flat surface allows for a simple construction of the aerosol generation chamber, with the heater forming one wall of the chamber.

[0027] Optionally, the outer surface is the exposed surface of the thermally conductive layer.

[0028] The exposed surface of the thermally conductive layer can be used to improve thermal contact between the aerosol-generating matrix and the layered heater assembly.

[0029] Optionally, the exposed surface is a polished surface.

[0030] When a heater assembly is used to heat an aerosol-generating host material, residue from the host material typically adheres or burns to the heater assembly, reducing thermal contact. By providing a polished surface, the surface can be made easier to clean, and the surface provides effective heat transfer for a longer period of time.

[0031] Optionally, the electrically insulating layer completely separates the thermally conductive layer from the first conductive track.

[0032] Optionally, the thermally conductive layer is metallic.

[0033] Optionally, the thermally conductive layer comprises stainless steel.

[0034] Preferably, the layered heater assembly is for heating an aerosol-generating matrix to generate an aerosol for inhalation by a user.

[0035] According to a second aspect, the present disclosure provides an aerosol generating device comprising: a receiving means configured to receive an aerosol-generating base material; and a layered heater assembly according to any one of the preceding claims arranged adjacent to the receiving means, the layered heater assembly being arranged such that its outer surface faces the receiving means.

[0036] According to a third aspect, the present disclosure provides a method for manufacturing a layered heater assembly for an aerosol generating device, the method comprising the steps of forming an electrically insulating layer on a thermally conductive layer and forming a first conductive track on the electrically insulating layer, wherein the thermally conductive layer is operable to emit heat through an outer surface of the layered heater assembly and the first conductive track is operable to generate heat. [Brief explanation of the drawings]

[0037] [Figure 1] FIG. 1 is a schematic perspective view of a layered heater assembly. [Figure 2A] FIG. 2 is a schematic cross-sectional view of a heater assembly. [Figure 2B] FIG. 1 is a schematic cross-sectional view of a heater assembly arranged to deliver heat to an aerosol-generating matrix during use. [Figure 3] 1 is a photograph of an example of a heater assembly. [Figure 4] 1 is a flow chart that schematically illustrates a method of manufacturing a heater assembly. [Figure 5]1 is a schematic cross-sectional view of an example of an aerosol generating device incorporating a heater assembly. [Figure 6] 1 is a schematic diagram of an example of an aerosol generating device. [Figure 7] FIG. 1 is a schematic diagram of a second embodiment of an aerosol generating device. DETAILED DESCRIPTION OF THE INVENTION

[0038] FIG. 1 is a schematic perspective view of a layered heater assembly 1.

[0039] The heater assembly includes a bottom layer 11 and a first conductive track 12 and a second conductive track 13 attached to the bottom layer 11 .

[0040] The first conductive track 12 is operable to generate heat by resistive heating when an electric current passes along the track. At each end 121 of the first conductive track 12 is an electrical connector for attaching a power source to the first conductive track 12. In this embodiment, the electrical connectors are solder pads, although any other type of electrical connector could be used.

[0041] The second conductive track 13 is operable to sense temperature based on the resistance-temperature characteristic of the second conductive track 13. In other words, temperature is sensed indirectly by the second conductive track 13 by measuring the resistance of the second track 13 and converting this resistance to a temperature value using the resistance-temperature characteristic. The resistance-temperature characteristic may be measured specifically for the second conductive track 13 or may be calculated based on the material and dimensions of the second conductive track 13. At each end 131 of the second conductive track 13 is an electrical connector for attaching a power source to the second conductive track 13. In this embodiment, the electrical connectors are solder pads, but any other type of electrical connector may be used.

[0042] The second conductive track 13 is configured to have a higher resistance than the first conductive track 12 at a certain temperature (e.g., room temperature 20°C). A higher resistance increases the sensitivity of the second track 13 to temperature changes, while a lower resistance of the first track 12 increases the current flow through the first track 12 and increases the heating rate. The difference in resistance can be achieved by using different materials. For example, the first conductive track 12 can include copper, and the second conductive layer 13 includes platinum, stainless steel, or a conductive ceramic. Platinum is particularly advantageous in that its resistance change with temperature is more linear. Additionally or alternatively, the difference in resistance can be achieved by using different dimensions for the tracks. For example, as shown in FIG. 1, the second conductive track 13 is longer and narrower than the first conductive track 12.

[0043] In some embodiments, rather than having two conductive tracks dedicated to the separate functions of heating and temperature sensing, one conductive track may serve both functions. In other words, the second conductive track 13 may be omitted, and the temperature may be sensed by measuring the resistance of the first conductive track 12 and using the resistance-temperature characteristic of the first conductive track 12. Furthermore, a separate temperature sensor may be used that does not form part of the layered structure of FIG. 1 .

[0044] Additionally, in some embodiments, two or more conductive tracks may be independently configured for heat generation, thereby allowing the overall heating rate to be varied by varying the number of tracks receiving power.

[0045] 2A is a schematic cross-sectional view of heater assembly 1 taken along dashed line X shown in FIG. 1. FIG. 2B is a schematic cross-sectional view of heater assembly 1 positioned to deliver heat to aerosol-generating matrix 2 during use. In FIG. 2B, heater assembly 1 is upside down with respect to FIG. 2A. The orientation in FIG. 2A illustrates a possible manufacturing method, as described below, while the orientation in FIG. 2B illustrates the in-use state.

[0046] As shown in FIG. 2A, the lower layer 11 includes a thermally conductive layer 111 and an electrically insulating layer 112 .

[0047] The thermally conductive layer 111 is operable to emit heat through the outer surface 15 of the heater assembly 1. The thermally conductive layer 111 may be, for example, a metal. More specifically, the thermally conductive layer 111 may include stainless steel such as steel grade 1.4404 (316L) or 1.4301 (304).

[0048] Preferably, outer surface 15 is a non-stick surface that is easily cleaned to maximize the life of the heater assembly. However, it is also preferable to maximize thermal contact between the heater assembly and the aerosol-generating host material, and therefore outer surface 15 can be the exposed surface of thermally conductive layer 111. To achieve both of these preferences, the exposed surface of thermally conductive layer 111 can be polished to provide outer surface 15.

[0049] The outer surface 15 is also preferably flat, which allows the heater assembly 1 to be easily integrated into a variety of applications and allows for easy consideration of heat distribution. Alternatively, the outer surface 15, or the entire heater assembly 1, can be tailored to fit the required surface depending on the desired application.

[0050] The electrically insulating layer 112 is located between the thermally conductive layer 111 and the first conductive tracks 12. This arrangement means that electrically conductive materials can be used in the thermally conductive layer 111 without affecting the heat generation in the first conductive tracks 12. Preferably, the electrically insulating layer 112 completely separates the thermally conductive layer 111 from the first conductive tracks 12. Preferably, the electrically insulating layer 112 comprises a material that is a good electrical insulator but a poor thermal insulator. Additionally, the electrically insulating layer 112 preferably comprises a material with low or zero thermal conductivity. The electrically insulating layer 112 may comprise, for example, silica (SiO2), polyimide (PI), such as Novaclear® Polyimide (see http: / / nexolvematerials.com / low-and-zero-cte-polyimides / novastrat-400), or alumina (Al2O3).

[0051] In a preferred embodiment, the first and second conductive tracks 12, 13 are formed on the same side of the electrically insulating layer 112. This simplifies the construction and allows the second conductive track 13 to sense a temperature that is more consistent with the first conductive track 12. However, the electrically insulating layer 112 may instead be arranged to separate the first conductive track 12 from the second conductive track 13. For example, if the thermally conductive layer 111 comprises a poor conductor or an electrical insulator, the second conductive track 13 may be arranged in direct contact with the thermally conductive layer 111. This has the effect of the second conductive track 13 better reflecting the temperature of the outer surface 15, while the first conductive track 12, which carries the current (and dissipates the heat), is still insulated from the thermally conductive layer 111.

[0052] As further shown in FIG. 2A , the protective layer 14 is provided with the first and second conductive tracks 12, 13, which are disposed between the electrical insulating layer 112 and the protective layer 14. The protective layer 14 is configured to protect the first and second conductive tracks 12, 13 from oxidation when they are exposed to high temperatures during use. Additionally, the protective layer 14 can protect the first and second conductive tracks 12, 13 from damage when they are installed in the aerosol generating device, thereby improving the precision with which the heater assembly 1 can be controlled during use. Furthermore, the material for the protective layer 14 can be selected to be an electrical insulator to enable more dense packaging of the wiring routes within the first and second conductive tracks 12, 13 without risk of short circuits. The protective layer 14 can include, for example, silica, polyimide, alumina, or a photoresist material. The protective layer 14 can include the same material as the electrical insulating layer 112.

[0053] Protective layer 14 may be omitted in some embodiments. For example, if heater assembly 1 is to be fixed in place within a larger device, first and second conductive tracks 12, 13 may be otherwise protected by the structure of the larger device. Because oxidation does not pose a significant risk until heater assembly 1 is turned on and generating heat, protective layer 14 may be omitted if heater assembly 1 is to be included within such a larger device during further manufacturing steps prior to use.

[0054] Some examples of layer dimensions are: The thermally conductive layer 111 may have a relatively large thickness, for example about 0.05 mm. The electrically insulating layer 112 may have a much smaller thickness, for example 1-2 nm. The conductive tracks may have a thickness of the order of 100 nm to 1 μm, with the first conductive track 12 preferably being thicker than the second conductive track 13. In one specific example, the first conductive track 12 has a thickness of 500 nm and the second conductive track 13 has a thickness of 300 nm. The protective layer 14 has a much smaller thickness, for example 1-2 nm.

[0055] In the above example, the electrical insulating layer 112 and the protective layer 14 each have a thickness of only 1-2 nm. While this configuration provides efficient heating, the inventors have recognized that damage to the electrical insulating layer 112 or the protective layer 14 can shorten the life of the heater assembly. To mitigate this risk, in other embodiments, the electrical insulating layer 112 and the protective layer 14 each have a greater thickness of 300-3,000 nm (0.3-3 μm). This alternative configuration extends the expected life of the heater assembly. Thus, depending on the relative importance of efficiency and life in different cases, the thickness of the electrical insulating layer 112 and the protective layer 14 can each be 1-3,000 nm.

[0056] To improve the correspondence between the temperature sensed by the second conductive track 13 and the temperature caused by heat generation in the first conductive track 12, the first and second conductive tracks are preferably positioned close to each other.

[0057] One way to achieve this is to form the first and second conductive tracks 12, 13 in a common plane within the layered heater assembly 1 (as shown in FIG. 2A ). This is effective because the tracks are then positioned at a common distance from the thermally conductive layer 111. As mentioned above, in many embodiments, the thermally conductive layer 111 is much thicker (and has a much larger volume) than the conductive tracks, so that the thermally conductive layer 111 can act as a buffer for the overall temperature of the heater assembly 1.

[0058] Another way to improve the correspondence between the temperature sensed by the second conductive track 13 and the temperature resulting from heat generation in the first conductive track 13 is to position the first conductive track 12 to surround the second conductive track. Referring to Figure 1, the first conductive track 12 forms an open loop between two electrical contacts at its end 121, which are located on one side of the heater assembly 1. The second conductive track 13 is confined between the first conductive track 12 and the side of the layered heater assembly with the contacts 121, meaning that the second conductive track 13 is substantially surrounded by the first conductive layer 12.

[0059] Advantageously, the second conductive track 13 may similarly form an open loop between its two ends 131, and the electrical contacts for both tracks may be located along one face of the heater assembly.

[0060] 2B, heater assembly 1 is oriented for use with aerosol-generating matrix 2 resting on heater assembly outer surface 15. Heat is generated by first conductive track 12 and conducted to aerosol-generating matrix 2 through electrically insulating layer 112 and thermally conductive layer 111.

[0061] The aerosol-generating matrix 2 may include, for example, nicotine or tobacco and an aerosol precursor. The tobacco may take the form of various materials, such as shredded tobacco, granulated tobacco, leaf tobacco, and / or reconstituted tobacco. Suitable aerosol precursors include polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol; monohydric alcohols; acids such as lactic acid; glycerol derivatives; esters such as triacetin; and non-polyols such as triethylene glycol diacetate, triethylene citrate, glycerin, or vegetable glycerin. In some embodiments, the aerosol-generating agent may be glycerol, polypropylene glycol, or a mixture of glycerol and propylene glycol. The matrix may also include at least one of a gelling agent, a binder, a stabilizer, and a humectant.

[0062] FIG. 3 is a photograph of an example of the heater assembly 1.

[0063] As shown in Figure 3, the electrical connections at ends 121, 131 of the first and second heater tracks 12, 13 may take the form of respective wires 16. Wires 15 may be attached to ends 121, 131 by solder 17 as shown in Figure 3, or alternatively, wires may be welded to ends 121, 131 using, for example, laser welding. Alternatively, removable contacts, for example resilient contacts, may be used to provide wire connections to the first and second heater tracks 12, 13.

[0064] The wires 16 may be connected to a control circuit for controlling the heater assembly 1. For example, the control circuit may provide a current to drive the first conductive track 12 based on a temperature sensed by the second conductive track 13. The control circuit may obtain a temperature measurement by measuring the resistance of the second conductive track 13, for example, using a voltage divider, and the control circuit may store a temperature-resistance characteristic of the second conductive track 13. The temperature-resistance characteristic may take the form of a table of one or more known data points and / or calculations using a known characteristic function. The characteristic function may be used, for example, to interpolate between the known data points. The control circuit may additionally provide a current to drive the first conductive track 12 based on a timing scheme and / or one or more user inputs.

[0065] Figure 4 is a flow chart that generally illustrates a method for manufacturing the aforementioned heater assembly 1. See also Figure 2A, which shows the order in which the layers may be added one on top of the other.

[0066] In step S101, a thermally conductive layer 111 is obtained. The thermally conductive layer 111 initially takes the form of a foil sheet. The foil sheet may also be polished on what will become the outer surface 165 to obtain the required thickness. The foil may also be polished on the opposing inner surface to improve bonding of the inner surface to the adjacent layer.

[0067] In step S102, an electrically insulating layer 112 is formed on the inner surface of the thermally conductive layer 111. The electrically insulating layer 112 may be formed, for example, by evaporation to the required depth. Bonding of the electrically insulating layer 112 to the thermally conductive layer 111 is improved if the inner surface of the thermally conductive layer 111 has already been polished as described above.

[0068] In steps S103 and S104, a first conductive track 12 and a second conductive track 13 are formed on the electrically insulating layer 112. Each track may be formed, for example, using photolithography with a photoresist material. Either step S103 or S104 may be performed first, and step S104 may be omitted in embodiments where the second track 13 is not present.

[0069] In step S105, a protective layer 14 is formed on the first conductive track 12 and the second conductive track 13. The protective layer 14 is preferably formed so that a portion thereof contacts the electrically insulating layer 112. This increases the insulation between the individual portions of the tracks 12, 13, which may flex back and forth as shown in FIG. 1, and therefore reduces the chance of shorting. In addition to, or instead of, step S105, some of the photoresist material from steps S103 and S104 may be left in place to form part of the protective layer 14. In embodiments without the protective layer 14, step S105 may be omitted.

[0070] The above-described techniques may be used to form a single heater assembly 1. Preferably, however, the layered construction step is used to generate a sheet containing multiple instances of heater assemblies 1. In this preferred situation, in step S106, the sheet may be divided into individual units of heater assemblies 1. This division may be achieved using laser cutting, stamping, or other means to separate the units. If a single heater assembly 1 is formed in steps S101-S105, the heater assembly may still be trimmed to the required size using laser cutting, stamping, or other means.

[0071] In step S107, electrical connections are attached to ends 121, 131 of conductive tracks 12, 13. Step S107 may be performed as part of the manufacture of heater assembly 1 or as part of the assembly of an aerosol generating device in which heater assembly 1 is used. Step S107 may be achieved by soldering or laser welding wires 16, as shown in FIG. 3 . Alternatively, removable connectors, such as sockets or plugs for sockets, may be attached to ends 121, 131. As another alternative, ends 121, 131 may be configured as contacts for a card-type connection, in which case heater assembly 1 is designed to plug into a row of spring contacts, for example. In such a case, step S107 may be omitted.

[0072] 5A, 5B, and 5C are schematic cross-sectional views of an example of an aerosol generating device 3 incorporating a heater assembly 1 as described above, with lines x, y, and z indicating relative planes of the cross-section.

[0073] The aerosol generating device 3 includes a first housing element 31 and a second housing element 32. When the aerosol generating device 3 is in the closed position as shown in Figures 5B and 5C, the first housing element 31 and the second housing element 32 cooperate to define an aerosol generating chamber 33 within which the aerosol-generating matrix aerosol portion 2 is enclosed and from which the aerosol is generated.

[0074] The first housing element 31 includes a recess 331 (receiving means) for receiving the portion 2 of the aerosol-generating matrix, and the second housing element 32 includes a surface 332 arranged opposite the flat bottom surface of the recess 331. The recess 331 may be substantially cubic, having a length L and a width W in the plane of FIG. 5A , and a depth d. The portion 2 of the aerosol-generating matrix may have a corresponding length L and width W, but may also have a depth D.

[0075] Additionally, when the aerosol generating device 3 is in the closed position, the lid surface 332 is arranged to face the bottom surface of the recess 331, and if the depth D of the portion 2 is greater than the depth d of the recess 331, the portion 2 is compressed by the lid surface 332 towards the bottom surface of the recess 331. The surface 331 may optionally be configured such that the portion 2 is compressed therebetween. In this embodiment, the lid surface 332 is simply an extension of the flat surface around the second housing element 32, and is the part of the flat surface that is arranged to face the recess 331 in the closed position.

[0076] Heater assembly 1 is positioned to supply heat to aerosol-generation chamber 33 through exterior surface 15 to heat the aerosol-generating matrix and generate an aerosol. Applying pressure between surfaces 331 and 332 can be used to increase the yield of aerosol from the aerosol-generating matrix compared to heating alone. In the embodiment of Figures 5A-5C, heater assembly 1 is positioned to supply heat through the bottom surface of recess 331.

[0077] Portion 2 of the aerosol-generating matrix may also optionally include a pressure-activated heat-generating element, such as a capsule of ingredients for an exothermic reaction.

[0078] The device 3 also includes an air flow path 35 through the aerosol generation chamber 33, which is provided for extracting the generated aerosol from the aerosol generation chamber 33. In the embodiment of Figures 5A-5C, the air flow path 35 includes an inlet 351 connected between the exterior of the device 3 and one end of the aerosol generation chamber 33, and an outlet 352 connected between the exterior of the device 3 and the other end of the aerosol generation chamber 33. The exterior of the device 3 around the outlet 352 is configured as a mouthpiece, allowing a user to inhale air and aerosol through the device 3. Alternatively, air can be artificially pumped through the air flow path 35, for example, using a fan.

[0079] In the embodiment shown in FIGS. 5A-5C, the first and second housing members 31 and 32 are connected by one or more fasteners 36, in this case a hinge, along a pivot line generally aligned with the length between the inlet 351 and the outlet 352. By rotating the hinge 36, the first and second housing elements 31, 32 move between an open position (shown in FIG. 5A) and a closed position (shown in FIGS. 5B and 5C). In the open position, the recess 331 is exposed, allowing the addition or removal of a portion 2 of the aerosol-generating matrix and cleaning of the device 3 (and particularly the heater assembly 1). In the closed position, the aerosol-generating chamber is complete, allowing aerosol generation. In other embodiments, the first and second housing members 31 and 32 can be completely separated in the open position and connected to each other in the closed position by one or more releasable fasteners, such as magnets or snap-fit ​​connectors.

[0080] FIG. 6 is a perspective view of a first embodiment of the aerosol generating device 3 in an open position.

[0081] In this example, each of the first and second housing elements 31, 32 includes an inner portion 311, 321 and an outer portion 314, 322. The outer portions 314, 322 provide an outer casing configured for gripping. For example, the outer portions 314, 322 may include a rigid metal casing that supports the weaker inner portions 311, 321. Additionally or alternatively, the outer portions 314, 322 may have a lower thermal conductivity than the inner portions, thereby protecting the user's hands, for example, by providing an elastomeric grip on the outer surface of the device.

[0082] Additionally, in the first embodiment, the air flow passage 35 includes a plurality of different inlets 3511 (two in this case) at one end of the outer portion 322 of the second housing element 32, providing the inlet 351. Air then flows in two parallel paths formed as grooves in the surface of the inner portion 321 of the second housing element 32, connected between the inlet and outlet. The grooves are surrounded by and separated by part of the compression surface 332, which has the effect of providing an improved aerosol-generation region adjacent to the region of improved airflow within the aerosol-generating matrix portion 2.

[0083] The grooves provide a path of varying width between the inlet and outlet, with a small inlet and a relatively large outlet. When air is drawn into the device 3 in the closed position, this configuration creates a pressure gradient within the air flow passage 35, reducing the air pressure adjacent the aerosol-generating matrix portion 2, thereby further increasing aerosol generation.

[0084] Additionally, in the first embodiment, the heater assembly (not shown in FIG. 6 and configured on the flat bottom surface of the recess 331, similar to FIGS. 5B and 5C ) is powered by an external power source connected by an electrical wire 16. The device 1 can be manufactured for use with an external power source by cutting or molding a space for the electrical wire 16 in the inner portion 311 of the first housing element 31, and then providing a glue-filled portion 381 to separate the air flow passage 35 from the electrical wire 16. Alternatively, the portion 381 can be an additional solid component that snaps into place, such as a snap-fit ​​or press-fit component. In some embodiments, the electrical wire 16 connected to the external power source can be replaced with an internal power source. Using an internal power source, the aerosol generating device can be provided as a portable handheld device.

[0085] Furthermore, in the first embodiment, the device 3 includes several opening and closing means 391, 392, 393 for better closing the device 3 in the closed position, thereby making the device 3 more likely to operate under good aerosol generation conditions.

[0086] First, the first and second housing elements 31, 32 are held in place in the closed position using one or more releasable fasteners (e.g., a pair of opposing magnets 391) that oppose the hinge 36. Providing a releasable fastener means that the device 3 does not need to be manually held in the closed position throughout aerosol generation, thereby making the device easier to use.

[0087] Second, a tab surface 392 is provided that can be manually manipulated by a user using their hand to open and close the device 3 between the open and closed positions. Providing the tab surface 392 means that the strength of the releasable fastener can be increased while still making it easier for the user to move the device 3 from the closed position to the open position.

[0088] Third, a gasket 393 is provided which improves the sealing of the air flow passage 35 between the inlet and outlet in the closed position. The gasket may be made of an elastomer, for example rubber.

[0089] FIG. 7 shows a second embodiment of the aerosol generating device in an open position.

[0090] In a second embodiment, the first and second housing elements 31, 32 are connected by a pivot line perpendicular to the length between the inlet 351 and the outlet 352. In this case, the inlet may be the gap between the first and second housing elements 31, 32 along the pivot line.

[0091] Additionally, to improve the seal provided by the gasket 393 , the gasket is positioned to engage the outer recess wall 316 of the first housing element 31 which extends around the recess 33 and the heater assembly 1 .

[0092] Additionally, as shown in Figure 7, in some embodiments, the electrical wires 16 connected to the external power source can be replaced with an internal power source 382. The internal power source allows the aerosol generating device 3 to be provided as a portable handheld device. In the example of Figure 7, the internal power source 382 is provided within the extended inlet portion 313 of the device 3, although other arrangements for the internal power source will be apparent to those skilled in the art.

Claims

1. 1. A layered heater assembly for an aerosol generating device, comprising: a thermally conductive layer operable to emit heat through an outer surface of the layered heater assembly; a first conductive track operable to generate heat; an electrically insulating layer between the thermally conductive layer and the first conductive track; a second conductive track operable to sense temperature based on a resistance-temperature characteristic; Including, the second conductive track is longer and narrower than the first conductive track; A layered heater assembly wherein the first and second conductive tracks are formed on the same side of the electrically insulating layer.

2. The layered heater assembly of claim 1 , wherein the first and second conductive tracks are formed in a common plane.

3. 3. The layered heater assembly of claim 1 or claim 2, wherein the first conductive track forms an open loop between two electrical contacts on one side of the layered heater assembly, and the second conductive track is confined between the first conductive track and the side of the layered heater assembly.

4. 4. The layered heater assembly of claim 1, wherein the first conductive track comprises a first material and the second conductive track comprises a second material, the first material being different from the second material.

5. The layered heater assembly of any one of claims 1 to 4, wherein the second conductive tracks comprise a second material, the second material comprising platinum, stainless steel, or ceramic.

6. The layered heater assembly of any one of claims 1 to 5, further comprising a protective layer, said first conductive track being disposed between said electrically insulating layer and said protective layer.

7. The layered heater assembly of claim 6 wherein said protective layer is a second electrically insulating layer.

8. 8. The layered heater assembly of claim 6 or claim 7, wherein the protective layer is disposed so that a portion of the protective layer is in contact with the electrically insulating layer.

9. The layered heater assembly of any preceding claim, wherein the outer surface is configured as a flat heater surface.

10. The layered heater assembly of any one of claims 1 to 9, wherein the outer surface is the exposed surface of the thermally conductive layer.

11. The layered heater assembly of claim 10 , wherein the exposed surface is a polished surface.

12. The layered heater assembly of any one of claims 1 to 11, wherein the electrically insulating layer completely separates the thermally conductive layer from the first conductive track.

13. The layered heater assembly of any preceding claim, wherein the thermally conductive layer is metal.

14. The layered heater assembly of claim 13 , wherein the thermally conductive layer comprises stainless steel.

15. 15. A layered heater assembly according to any preceding claim for heating an aerosol-generating matrix to generate an aerosol for inhalation by a user.

16. An aerosol generating device, comprising: receiving means configured to receive an aerosol-generating matrix; a layered heater assembly according to any one of claims 1 to 15 positioned adjacent to said receiving means; wherein the outer surface is positioned to face the receiving means.

17. 17. The aerosol generating device of claim 16, wherein the layered heater assembly is configured to heat the aerosol-generating matrix to generate an aerosol for inhalation by a user.

18. 1. A method of manufacturing a layered heater assembly for an aerosol generating device, comprising: forming an electrically insulating layer over the thermally conductive layer; forming a first conductive track on said electrically insulating layer; forming a second conductive track on the electrically insulating layer; the thermally conductive layer is operable to emit heat through an outer surface of the layered heater assembly, and the first conductive track is operable to generate heat; A method for manufacturing a layered heater assembly for an aerosol generating device, wherein the second conductive track is operable to sense temperature based on resistance-temperature characteristics, and the second conductive track is longer and narrower than the first conductive track.

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