Aerosol generating device with sealed internal airflow channels

Abstract

The present disclosure provides an aerosol generating device comprising an outer housing, a tubular heater, upper and lower heater casings, the tubular heater being enclosed within upper and lower heater casings, an internal airflow channel through the device extending from an air inlet in the outer housing to an air outlet in the outer housing, the internal airflow channel passing through the upper heater casing, the lower heater casing and the heater, a first sealing element between the outer housing and the lower heater casing, a second sealing element between the outer housing and the upper heater casing, and a third sealing element between the lower heater casing and the upper heater casing.

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol generating device that includes an airflow channel that passes through the device, and an arrangement for sealing the airflow channel to prevent the ingress of liquids or particles into the interior of the device that contains electrical components. [Background technology]

[0002] Aerosol-generating devices that heat an aerosol-forming substrate to generate an aerosol without burning the aerosol-forming substrate are known in the art. The aerosol-forming substrate is typically provided in an aerosol-generating article along with other components such as a filter. The aerosol-generating article may have a rod shape for insertion into the heating chamber of the aerosol-generating device. A heating element is typically disposed in or around the heating chamber to heat the aerosol-forming substrate after the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device.

[0003] The heated chamber may be disposed within the housing of the aerosol generating device and form part of an airflow channel through the aerosol generating device, and it may be desirable to prevent not only the aerosol but also other liquids and particles from entering the airflow channel and into other parts of the aerosol generating device, which could potentially damage the device's electronics.

[0004] It would be desirable to provide an arrangement for sealing airflow channels that provides a robust and reliable seal and is easy to manufacture. Summary of the Invention

[0005] According to one embodiment of the present disclosure, there is provided an aerosol generating device comprising: External housing, tubular heater, an upper heater casing and a lower heater casing, wherein the tubular heater is enclosed within the upper heater casing and the lower heater casing; an internal airflow channel through the device extending from an air inlet in the outer housing to an air outlet in the outer housing, the internal airflow channel passing through the upper heater casing, the lower heater casing, and the heater; a first sealing element between the outer housing and the lower heater casing; a second sealing element between the outer housing and the upper heater casing; and A third sealing element between the lower heater casing and the upper heater casing.

[0006] This arrangement provides a sealed airflow channel in a manner that is simple to manufacture using relatively few components. The sealing of the heater within the upper and lower heater casings, as well as the sealing of the upper and lower heater casings with the outer housing, effectively isolates the generated vapor and aerosol from the internal components of the device and prevents liquids and particles from entering the interior space of the device through the airflow channel, thereby improving the life and reliability of the device. This arrangement also effectively prevents particles from entering the airflow channel from within the device and contaminating the generated aerosol. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a schematic cross-sectional view showing the inside of an aerosol-generating device 100 and an aerosol-generating article 200 housed within the aerosol-generating device 100. As shown in FIG. [Figure 2] FIG. 2 is an exploded view of a heater module used in the system shown in FIG. [Figure 3] FIG. 3 is a partial cross-sectional view of an aerosol generating device of the type shown in FIG. 1 including the heater module shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0008] One or more of the sealing elements may include an elastomeric polymer, such as silicone.

[0009] The device may include a heater holder positioned between the heater and the lower heater casing, an airflow channel through the heater holder, and a fourth sealing element positioned between the heater holder and the lower heater casing or the upper heater casing. The heater holder may be advantageous for securing the heater during device assembly and use. The heater holder may also isolate and shield one or more of the sealing elements from the high temperature of the heater.

[0010] Advantageously, the heater is spaced at least 4 mm, preferably at least 5 mm, from the sealing element. Advantageously, the sealing elements are each shielded from the heater by at least one intermediate component, such as a heater holder. By spacing the sealing elements from the heater, heat loss through the sealing element may be reduced, thereby improving heating efficiency.

[0011] By minimizing the number of components used, the number of seals required is minimized. However, forming the airflow channel and outer housing from a single component is not complicated. Advantageously, the airflow channel is defined by only the outer housing, lower heater casing, heater holder, heater, upper heater casing, and sealing elements. This provides a balance between minimizing components and enabling a simple assembly process. Creating a device from a small number of components has the added advantage that these parts can be replaced, for example, to customize the device or for maintenance or repair.

[0012] A fourth sealing element may be provided between the heater holder and the lower heater casing. The heater may be press-fit directly into the upper heater casing. The heater holder may be press-fit directly into the heater. Pressing the heater into the surrounding components without the use of an elastomeric sealing element in contact with or close to the heater means that problems with seal degradation and production of undesirable compounds in the aerosol if the sealing element becomes too hot can be avoided.

[0013] One or more of the sealing elements may include an O-ring. Each of the sealing elements may include an O-ring.

[0014] The external housing may include an upper device casing and a lower device casing. The upper device casing may be secured to the lower device casing. The upper device casing may be secured to the lower device casing using a mechanical interface, such as a snap fit or a press fit. The upper device casing may be secured to the lower device casing using an adhesive or welding.

[0015] Advantageously, the lower heater casing is fixed to the upper heater casing. The lower heater casing may be fixed to the upper heater casing by one or more screw fastenings. The third sealing element may be compressed between the lower heater casing and the upper heater casing.

[0016] The heater may include one or more heating elements and insulation positioned around the one or more heating elements.

[0017] The electric heating element(s) may be disposed around or surround an outer surface of the heating chamber that forms part of the airflow channel. The electric heating element(s) may be disposed around or surround an inner surface of the heating chamber. The electric heating element(s) may be part of or integral with the heating chamber.

[0018] The electric heating element or elements may comprise an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-containing alloys, zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, gold-containing alloys, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal™, Kanthal™, and other iron-chromium-aluminum alloys, and iron-manganese-aluminum-based alloys. In composite materials, the electrically resistive material may optionally be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the required energy transfer kinetics and external physicochemical properties.

[0019] One or more heating elements may be formed using a metal or metal alloy that has a well-defined relationship between temperature and resistivity. Heating elements formed in this manner may be used to both heat the heating element and monitor the temperature of the heating element during operation.

[0020] The heating element may be disposed in or on a rigid carrier material or substrate. The heating element may be disposed in or on a flexible carrier material or substrate. The heating element may be formed as a track on a suitable insulating material such as ceramic or glass or polyimide film. The heating element may be sandwiched between two insulating materials.

[0021] The heater assembly may include a flexible heating element disposed around or surrounding the outer surface of the heating chamber. The flexible heating element may have a length substantially equal to the length of the aerosol-forming substrate provided in the aerosol-generating article. The heating chamber may be longer than the heating element.

[0022] The insulation may include aerogel. The insulation may comprise heat resistant tape. The heater may comprise a heater housing that holds the insulation.

[0023] The aerosol generating device may include an electrical connection pin connected to the heater, the electrical connection pin passing through an opening in the lower casing, which may be sealed with an adhesive to prevent liquid or particles from entering through the airflow channel.

[0024] The aerosol generating device may include a control circuit and a power supply within the outer housing, the control circuit being electrically connected to the power supply and the heater.

[0025] The power source can be any suitable power source, such as, for example, a DC voltage source. In one embodiment, the power source is a lithium-ion battery. Alternatively, the power source can be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, such as a lithium-cobalt, lithium-iron-phosphate, or lithium-polymer battery.

[0026] The control circuit may be configured to control the supply of power to the heater assembly. The control circuit may include a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, or an application specific integrated chip (ASIC) or other electronic circuit capable of providing control. The control circuit may include additional electronic components. For example, in some embodiments, the control circuit may include a sensor element, a switch element, or a display element. Power may be supplied to the heater assembly continuously after activation of the device, or may be supplied intermittently (such as with each puff). Power may be supplied to the heater assembly in the form of current pulses, for example, by pulse width modulation (PWM).

[0027] Preferably, the aerosol generating device is a handheld aerosol generating device that is comfortable for a user to hold between the fingers of one hand.

[0028] The outer housing can comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is lightweight and not brittle.

[0029] The aerosol-generating device may be used together with a disposable aerosol-generating article comprising an aerosol-forming substrate. An aerosol-generating system may comprise the aerosol-generating device disclosed herein and an aerosol-generating article configured for use with the aerosol-generating device. The aerosol-generating device is configured to receive the aerosol-generating article containing the aerosol-forming substrate through the air outlet and into the heater.

[0030] The terms "distal," "upstream," "proximal," and "downstream" are used to describe the relative positions of components or portions of components of an aerosol-generating apparatus or aerosol-generating article. Aerosol-generating articles and devices according to the present disclosure can have a proximal end through which aerosol exits the article or device and is delivered to a user during use, and an opposing distal end. The proximal end of an aerosol-generating article or device may also be referred to as the oral end. During use, a user breathes on the proximal end of the aerosol-generating article to inhale the aerosol generated by the aerosol-generating article or device. The terms upstream and downstream refer to the direction of travel of the aerosol through the aerosol-generating article or aerosol-generating apparatus when a user breathes on the proximal end of the aerosol-generating article. The proximal end of an aerosol-generating article is downstream of the distal end of the aerosol-generating article. The proximal end of an aerosol-generating article may also be referred to as the downstream end of the aerosol-generating article, and the distal end of an aerosol-generating article may also be referred to as the upstream end of the aerosol-generating article.

[0031] According to an embodiment of the present disclosure, there is provided an aerosol-generating system comprising the aerosol-generating device according to the above-described embodiment. The aerosol-generating system may also comprise an aerosol-generating article including an aerosol-forming substrate.

[0032] According to an embodiment of the present disclosure, there is provided an aerosol-generating system comprising an aerosol-generating device according to the above-described embodiment and an aerosol-generating article including an aerosol-forming substrate.

[0033] As used herein, the term "aerosol-generating article" refers to an article that includes an aerosol-forming substrate that, when heated in an aerosol-generating device, emits a volatile compound capable of forming an aerosol. The aerosol-generating article is separate from the aerosol-generating device and is configured to be combined with the aerosol-generating device to heat the aerosol-generating article.

[0034] The aerosol-generating article may be substantially cylindrical in shape. The aerosol-generating article may be substantially elongated. The aerosol-forming substrate may be substantially cylindrical in shape. The aerosol-forming substrate may be substantially elongated.

[0035] The aerosol-generating article may have an overall length of approximately 30 mm to approximately 100 mm. The aerosol-generating article may have an outer diameter of approximately 5 mm to approximately 12 mm. The aerosol-forming substrate may have a length of approximately 10 mm to approximately 18 mm. Further, the diameter of the aerosol-forming substrate may be approximately 5 mm to approximately 12 mm. The aerosol-generating article may comprise a filter plug. The filter plug may be located at the downstream end of the aerosol-generating article. The filter plug may be a cellulose acetate filter plug. In one embodiment, the filter plug is approximately 7 mm long, but may also have a length of approximately 5 mm to approximately 12 mm.

[0036] In one embodiment, the aerosol-generating article may have an overall length of approximately 45 mm. The aerosol-generating article may have an outer diameter of approximately 7.3 mm, but may also have an outer diameter of approximately 7.0 mm to approximately 7.4 mm. Furthermore, the aerosol-forming substrate may have a length of approximately 12 mm. Alternatively, the aerosol-forming substrate may have a length of approximately 16 mm. The aerosol-generating article may comprise an outer paper wrapper. Furthermore, the aerosol-generating article may comprise a separator between the aerosol-forming substrate and the filter plug. The separator may be approximately 21 mm or approximately 26 mm, but may also be in the range of approximately 5 mm to approximately 28 mm. The separator may be provided by a hollow tube. The hollow tube may be made of cardboard or cellulose acetate.

[0037] The aerosol-forming substrate may be a solid aerosol-forming substrate. Alternatively, the aerosol-forming substrate may comprise both solid and liquid components. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds that are released from the substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may further comprise an aerosol former. Examples of suitable aerosol formers are glycerin and propylene glycol.

[0038] When the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate may comprise, for example, one or more of powder, granules, pellets, pieces, spaghetti, strips, or sheets containing one or more of herb leaves, tobacco leaves, tobacco vein fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco. The solid aerosol-forming substrate may be in loose form or may be provided in a suitable container or cartridge. Optionally, the solid aerosol-forming substrate may contain additional tobacco or non-tobacco volatile flavor compounds that are released upon heating of the substrate. The solid aerosol-forming substrate may also contain capsules, for example containing additional tobacco or non-tobacco volatile flavor compounds, which may melt during heating of the solid aerosol-forming substrate.

[0039] As used herein, "homogenized tobacco" refers to a material formed by agglomerating particulate tobacco. The homogenized tobacco may be in the form of a sheet. The homogenized tobacco material may have an aerosol former content of greater than 5% on a dry weight basis. Alternatively, the homogenized tobacco material may have an aerosol former content of between 5% and 30% by weight on a dry weight basis. A homogenized tobacco material sheet may be formed by agglomerating particulate tobacco obtained by grinding or otherwise comminuted one or both of tobacco lamina and tobacco stem. Alternatively, or additionally, the homogenized tobacco material sheet may include one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed, for example, during tobacco processing, handling, and shipping. The homogenized tobacco material sheet may include one or more inherent binders (i.e., tobacco intrinsic binders), one or more exogenous binders (i.e., tobacco extrinsic binders), or combinations thereof to aid in the cohesion of the particulate tobacco, although alternatively or additionally, the homogenized tobacco material sheet may include other additives, including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof.

[0040] In a particularly preferred embodiment, the aerosol-forming substrate comprises an assembly of crimped sheets of homogenized tobacco material. As used herein, the term "crimped sheet" refers to a sheet having a plurality of substantially parallel ridges or corrugations. When the aerosol-generating article is assembled, the substantially parallel ridges or corrugations preferably extend along or parallel to the longitudinal axis of the aerosol-generating article. This advantageously facilitates assembling the crimped sheets of homogenized tobacco material to form the aerosol-forming substrate. However, it will be appreciated that a crimped sheet of homogenized tobacco material for inclusion in an aerosol-generating article may alternatively or additionally have a plurality of substantially parallel ridges or corrugations that are disposed at an acute or obtuse angle relative to the longitudinal axis of the aerosol-generating article when the aerosol-generating article is assembled. In certain embodiments, the aerosol-forming substrate may comprise an assembly of sheets of homogenized tobacco material that are substantially evenly textured across substantially its entire surface. For example, the aerosol-forming substrate may comprise an assemblage of a crimped sheet of homogenized tobacco material that includes a plurality of substantially parallel ridges or corrugations that are substantially evenly spaced across the width of the sheet.

[0041] Optionally, the solid aerosol-forming substrate may be provided on or embedded in a thermally stable carrier. The carrier may take the form of a powder, granules, pellets, pieces, spaghetti, strips, or sheets. Alternatively, the carrier may be a tubular carrier having a thin layer of the solid substrate deposited on its inner surface, on its outer surface, or on both its inner and outer surfaces. Such a tubular carrier may be formed, for example, of paper or paper-like material, nonwoven carbon fiber mat, low-mass open-mesh metal screen, or perforated metal foil, or any other thermally stable polymeric matrix.

[0042] The solid aerosol-forming substrate may be deposited on the surface of the carrier in the form of, for example, a sheet, foam, gel, or slurry. The solid aerosol-forming substrate may be deposited over the entire surface of the carrier, or alternatively, may be deposited in a pattern to provide a non-uniform flavor delivery during use.

[0043] Although reference has been made above to solid aerosol-forming substrates, it will be apparent to those skilled in the art that other forms of aerosol-forming substrates may be used in other embodiments. For example, the aerosol-forming substrate may be a liquid aerosol-forming substrate. When a liquid aerosol-forming substrate is provided, the aerosol-generating device preferably comprises a means for retaining the liquid. For example, the liquid aerosol-forming substrate may be retained in a container or liquid storage portion. Alternatively, or additionally, the liquid aerosol-forming substrate may be absorbed into a porous carrier material. The porous carrier material may be made of any suitable absorbent plug or body, such as a foamed metal or plastic material, polypropylene, terylene, nylon fiber, or ceramic. The liquid aerosol-forming substrate may be retained in the porous carrier material before use of the aerosol-generating device, or alternatively, the liquid aerosol-forming substrate material may be released into the porous carrier material during or immediately before use. For example, the liquid aerosol-forming substrate may be provided in a capsule. The capsule shell preferably melts upon heating, releasing the liquid aerosol-forming substrate into the porous carrier material. The capsule may optionally contain a solid in combination with a liquid.

[0044] Alternatively, the carrier may be a nonwoven fiber or fiber bundle having tobacco components incorporated therein. The nonwoven fiber or fiber bundle may comprise, for example, carbon fiber, natural cellulose fiber, or cellulose derivative fiber.

[0045] Examples according to aspects of the present disclosure will now be described with reference to the accompanying drawings.

[0046] Figure 1 is a schematic cross-sectional view showing the interior of an aerosol generating device 100 and an aerosol-generating article 200 housed within the aerosol generating device 100. The aerosol generating device 100 and the aerosol-generating article 200 together form an aerosol generation system. In Figure 1, the aerosol generating device 100 is shown in a simplified manner. Specifically, the elements of the aerosol generating device 100 are not drawn to scale. Furthermore, elements that are not relevant for understanding the aerosol generating device 100 have been omitted.

[0047] The aerosol generating device 100 comprises a housing 102 that houses the tubular heater 6, a power supply 103, and a control circuit 105. Shown in FIG. 1 are the lower heater casing section 2, the heater mount 8, and the upper heater casing section 4. The power supply 103 is a battery, which in this embodiment is a rechargeable lithium-ion battery. The control circuit 105 is connected to both the power supply 103 and the heating element and controls the supply of electrical energy from the power supply 103 to the heater to regulate the temperature of the heater.

[0048] The housing 102 includes an opening 104 at the proximal or mouth end of the aerosol-generating device 100, through which the aerosol-generating article 200 is received. The opening 104 is connected to the opening 12 of the heater module 1, through which the aerosol is discharged from the heater module 1. However, it will be appreciated that the aerosol is discharged from the aerosol-generating device 100 predominantly via the heater module 1 and the aerosol-generating article 200. The housing 102 further includes an air inlet 106 at the distal end of the aerosol-generating device 100. The air inlet 106 is connected to an air inlet disposed at the distal end of the first tubular section 2b of the lower casing 2. The first tubular section 2b delivers air from the air inlet 106 to the aerosol-generating article.

[0049] The aerosol-generating article 200 comprises an end plug 202, an aerosol-forming substrate 204, a hollow tube 206, and a mouthpiece filter 208. Each of the above-mentioned components of the aerosol-generating article 100 is a substantially cylindrical element, each having substantially the same diameter. The components are arranged consecutively in coaxial alignment and abutting contact and surrounded by an outer paper wrapper 210 to form a cylindrical rod. The aerosol-forming substrate 204 is a tobacco rod or plug comprising an assembly of crimped sheets of homogenized tobacco material surrounded by a wrapper (not shown). The crimped sheets of homogenized tobacco material contain glycerin as an aerosol former. The end plug 202 and mouthpiece filter 208 are formed from cellulose acetate fibers.

[0050] The distal end of the aerosol-generating article 200 is inserted into the aerosol-generating device 100 through the opening 104 in the housing 102 and pushed into the aerosol-generating device 100 until it engages a stop (not shown in FIG. 1 ) disposed on the heater mount 8, up to which point the aerosol-generating article 200 is fully inserted. The stop serves to precisely position the aerosol-forming substrate 204 within the heater so that the heater can heat the aerosol-forming substrate 204 to form an aerosol.

[0051] The aerosol generating device 100 may further include a sensor (not shown) for detecting the presence of the aerosol generating article 200, a user interface (not shown) such as a button for activating the heater, and a display or indicator (not shown) for presenting information to the user, such as remaining battery power, heating status, and error messages.

[0052] During use, a user inserts the aerosol-generating article 200 into the aerosol-generating device 100, as shown in FIG. 1. The user then initiates a heating cycle by activating the aerosol-generating device 100, for example, by pressing a switch to turn the device on. In response, the control circuit 105 controls the power supply 103 to the heater, causing it to heat. During the heating cycle, the heater is heated to a predetermined temperature or to a predetermined temperature range according to a temperature profile. The heating cycle may last approximately six minutes. Heat from the heater 6 is transferred to the aerosol-forming substrate 204, which releases volatile compounds from the aerosol-forming substrate 204. The volatile compounds form an aerosol within the aerosolization chamber formed by the hollow tube 206. During the heating cycle, the user places the mouthpiece filter 208 of the aerosol-generating article 200 between their lips and puffs or inhales the mouthpiece filter 208. The generated aerosol is drawn through the mouthpiece filter 208 and into the user's mouth.

[0053] Figure 2 is an exploded view of a heater module used in the system shown in Figure 1. The heater module includes an outer casing including an upper heater casing section 4 and a lower heater casing section 2. Within the outer casing is a heater 6 comprising a heater track on a flexible heater substrate. Aerogel insulation 10 and high-temperature resistant tape 12 surround the heater. The heater is mounted on a heater holder 8. The heater module also includes sealing elements 14, 16, 22, and 24. The upper heater casing section is secured to the lower heater casing section using screws 18. Electrical pins extend from the heater 6 through openings in the lower casing section 2. These openings are sealed with glue 20.

[0054] An advantage of the heater module is that the upper heater casing part contains and protects the heater 6 inside, while the lower heater casing part, after final assembly, is provided with an elongated channel along which an airflow path is created whenever a consumer puffs on a consumable in the device (see Figure 1). Another advantage of the proposed solution is that the heater module can be used as a stand-alone module that can be plugged into any kind of different device designs, the only constraint being the minimum length of the device, which basically corresponds to the length of the heater module itself.

[0055] Figure 3 is a partial cross-sectional view of an aerosol generating device of the type shown in Figure 1, including the heater module shown in Figure 2. The heater module is disposed inside an outer housing 102. The outer housing 102 has snap-fit ​​upper and lower housing sections 102a, 102b. An airflow channel is formed through the device. The airflow channel begins at an air inlet 106 formed in the lower housing section 102b. It then passes through the lower heater casing section 2, through the heater holder 8, through the tubular heater (surrounding tape 12 is shown), through the upper heater casing section 4, and through an air outlet 104 formed in the upper housing section 102a.

[0056] The airflow channel is sealed at the joint between the components that define the airflow channel. A first sealing element 24 is located between the lower outer housing portion and the lower heater casing. The first sealing element 24 is formed from silicone and is sleeved around the bottom of the lower heater casing portion 2. The first sealing element 24 is compressed between the lower heater casing 2 and the lower housing portion 102b.

[0057] The second sealing element 22 is between the upper outer housing part and the upper heater casing part 4. The second sealing element is a silicone O-ring. The second sealing element 22 is between the upper heater casing part 4 and the upper housing part 102a.

[0058] A third sealing element 16 is provided between the upper heater casing part 4 and the lower heater casing part 2. The third sealing element is a silicone O-ring. The third sealing element is compressed between the upper heater casing part 4 and the lower heater casing part 2, which are held together using screws as described.

[0059] A fourth sealing element 14 is provided between the lower heater casing part 2 and the heater holder 8. The fourth sealing element is a silicone O-ring. The fourth sealing element is compressed between the heater holder 8 and the lower heater casing part 2.

[0060] Each sealing element is configured to provide a liquid and particle proof seal of IP67 rating in accordance with the IP or Ingress Protection Code defined in IEC standard 60529.

[0061] The heater is fixed between the heater holder 8 and the upper heater casing part 4. The heater is press-fitted into both the heater holder 8 and the upper heater casing part 4. No polymer seals come into contact with the heater. The nearest sealing elements, the third sealing element 16 and the fourth sealing element 14, are each at least 4 mm from the nearest part of the heater. In this way, the polymer seals are not exposed to high temperatures that could degrade them during use of the device.

Claims

1. An aerosol generating device, comprising: External housing, tubular heater, an upper heater casing and a lower heater casing, wherein the tubular heater is enclosed within the upper heater casing and the lower heater casing; an internal airflow channel through the device extending from an air inlet in the outer housing to an air outlet in the outer housing, the internal airflow channel passing through the upper heater casing, the lower heater casing, and the heater; a first sealing element between the outer housing and the lower heater casing; a second sealing element between the outer housing and the upper heater casing; a third sealing element between the lower heater casing and the upper heater casing; a heater holder positioned between the heater and the lower heater casing, the airflow channel passing through the heater holder; and a fourth sealing element positioned between the heater holder and the lower heater casing, wherein the heater is directly press-fit into the upper heater casing.

2. 2. The aerosol generating device of claim 1, wherein the airflow channel is defined only by the outer housing, the lower heater casing, the heater holder, the heater, the upper heater casing, and the sealing element.

3. 3. The aerosol generating device according to claim 1, wherein the heater holder is directly press-fitted into the heater.

4. 4. The aerosol generating device according to claim 1, wherein one or more of the sealing elements comprises an O-ring.

5. 5. The aerosol generating device according to claim 1, wherein one or more of the sealing elements comprises an elastomeric polymer, such as silicone.

6. 6. An aerosol generating device according to claim 1, wherein the heater is spaced at least 4 mm from the sealing element.

7. 7. An aerosol generating device according to claim 1, wherein each of the sealing elements is shielded from the heater by at least one intermediate component.

8. 8. The aerosol generating device according to claim 1, wherein the outer housing comprises an upper device casing and a lower device casing, and the upper device casing is fixed to the lower device casing.

9. 9. The aerosol generating device according to claim 1, wherein the lower heater casing is fixed to the upper heater casing.

10. 10. The aerosol generating device of claim 9, wherein the lower heater casing is secured to the upper heater casing by one or more screw fasteners.

11. 11. The aerosol generating device according to claim 1, wherein the heater comprises a heating element and a thermal insulator positioned around the heating element.

12. An aerosol generating device as described in any one of claims 1 to 11, comprising an electrical connection pin connected to the heater, the electrical connection pin passing through an opening in the lower heater casing, and the opening in the lower heater casing being sealed with an adhesive.

13. 13. The aerosol generating device according to claim 1, further comprising a control circuit and a power supply within the outer housing, the control circuit being electrically connected to the power supply and the heater.

14. 14. An aerosol generating device according to any one of claims 1 to 13, configured to receive an aerosol-generating article containing an aerosol-forming substrate through the air outlet and into the heater.

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