Aerosol generator with thermally conductive assemblies

Abstract

To provide an aerosol-generating device comprising an aerosol generator and a control circuit that facilitates the dissipation of excess heat generated by the control circuit.SOLUTION: There is provided an aerosol-generating device (10) comprising an aerosol generator (18) for generating an aerosol from an aerosol-forming substrate, a power supply (24), and a circuit board (28) comprising a control circuit (30) for controlling a supply of power from the power supply (24) to the aerosol generator (18). The aerosol-generating device (10) also comprises a heat conductive assembly (46) comprising a first end (48) in thermal contact with the circuit board (28) and a second end (50) spaced apart from the circuit board (28).SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to an aerosol generating device including a thermally conductive assembly.

Background Art

[0002] Aerosol generation systems in which an aerosol-forming substrate, such as a tobacco-containing substrate, is heated rather than burned are well known in the art. The purpose of such aerosol generation systems is to reduce the well-known harmful smoke components produced by the combustion and pyrolytic degradation of tobacco in conventional cigarettes. Typically in such aerosol generation systems, an aerosol is generated by the transfer of energy from an aerosol generator of the aerosol generating device to an aerosol-forming substrate or material in an aerosol-generating article that is physically separated from the aerosol generating device. For example, the aerosol generator may be an electric heater, and the aerosol may be generated by the transfer of heat from the electric heater to the aerosol-forming substrate. The aerosol-generating article may be located within, around, or downstream of the electric heater. During use, volatile compounds are released from the aerosol-forming substrate by the transfer of heat from the electric heater to the aerosol-forming substrate and entrained in the air drawn through the aerosol-generating article. The released compounds condense as they cool to form an aerosol that can be inhaled by a consumer.

Summary of the Invention

Problems to be Solved by the Invention

[0003] During use of such aerosol generating devices, a control circuit for controlling the supply of power to the electric heater typically generates a significant amount of heat. In order to prevent damage to the control circuit, dissipation of the heat generated by the control electronics is necessary. However, the small size of typical aerosol generating devices, which requires the user to hold the device during use, makes such dissipation of excess heat difficult.

[0004] It is possible to describe an aerosol generating device that includes an aerosol generator and a control circuit that facilitates the dissipation of excess heat generated by the control circuit. [Means for solving the problem]

[0005] According to this disclosure, an aerosol generator is provided. The aerosol generator may include an aerosol generator. The aerosol generator may generate an aerosol from an aerosol-forming substrate. The aerosol generator may include a power supply. The aerosol generator may include a circuit board. The circuit board may include a control circuit. The control circuit may be for controlling the supply of power from the power supply to the aerosol generator. The circuit board and the power supply may be arranged for heat transfer from the circuit board to the power supply.

[0006] According to this disclosure, an aerosol generating apparatus is provided, comprising an aerosol generator for generating aerosols from an aerosol-forming substrate, a power supply, and a circuit board equipped with a control circuit for controlling the supply of power from the power supply to the aerosol generator. The circuit board and power supply are arranged for heat transfer from the circuit board to the power supply.

[0007] The circuit board and power supply are preferably arranged to facilitate conductive heat transfer from the circuit board to the power supply.

[0008] The circuit board may be in direct contact with the power supply. Advantageously, direct contact between the circuit board and the power supply may facilitate direct conductive heat transfer from the circuit board to the power supply.

[0009] The circuit board and power supply may be arranged for indirect conductive heat transfer from the circuit board to the power supply. In other words, the aerosol generator may have at least one additional element arranged for conductive heat transfer from the circuit board to the power supply by at least one additional element. Advantageously, the at least one additional element may facilitate a desired orientation and position of the circuit board relative to the power supply while providing conductive heat transfer from the circuit board to the power supply. The desired orientation and position of the circuit board relative to the power supply may be suited to at least one of a desired size and desired shape of the aerosol generator.

[0010] At least one additional element may include a thermally conductive assembly. The thermally conductive assembly may have a first end that is in thermal contact with the circuit board. The thermally conductive assembly may have a second end that is separated from the circuit board.

[0011] According to this disclosure, an aerosol generator is provided. The aerosol generator may include an aerosol generator. The aerosol generator may generate an aerosol from an aerosol-forming substrate. The aerosol generator may include a power supply. The aerosol generator may include a circuit board. The circuit board may include a control circuit. The control circuit may control the supply of power from the power supply to the aerosol generator. The aerosol generator may include a thermally conductive assembly. The thermally conductive assembly may have a first end that is in thermal contact with the circuit board. The thermally conductive assembly may have a second end that is separated from the circuit board.

[0012] The disclosure provides an aerosol generator comprising an aerosol generator for generating an aerosol from an aerosol-forming substrate, a power supply, and a circuit board having a control circuit for controlling the supply of power from the power supply to the aerosol generator. The aerosol generator also comprises a thermally conductive assembly having a first end in thermal contact with the circuit board and a second end separated from the circuit board.

[0013] Advantageously, the thermal conductive assembly conducts excess heat away from the circuit board and toward a second end of the thermal conductive assembly. Advantageously, the thermal conductive assembly provides at least some control over where excess heat from the circuit board is transferred. Advantageously, the second end of the thermal conductive assembly may be positioned where it is desirable to dissipate excess heat generated by the control circuit.

[0014] As used herein, the term "aerosol generator" refers to a device that generates aerosols by interacting with an aerosol-forming substrate.

[0015] As used herein, the term “aerosol-forming substrate” refers to a substrate having the ability to release volatile compounds that can form aerosols. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may form part of an aerosol-generating article.

[0016] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-forming substrate having the ability to release volatile compounds capable of forming aerosols. For example, an aerosol-generating article may be an article that generates an aerosol that can be directly inhaled by a user who is sucking or inhaling smoke from a mouthpiece at the proximal end of a system or the user-side end. Aerosol-generating articles may be disposable. An article comprising an aerosol-forming substrate containing tobacco may be called a tobacco stick.

[0017] As used herein, the term "aerosol generating system" refers to a combination of an aerosol generating device and an aerosol generating article. In an aerosol generating system, the aerosol generating article and the aerosol generating device work together to generate an aerosol.

[0018] The second end of the thermally conductive assembly is preferably in thermal contact with the power supply.

[0019] Advantageously, a high thermal gradient may exist between the circuit board and the power supply during use. Advantageously, the high thermal gradient and thermal contact between the second end of the thermal conductive assembly and the power supply may increase or maximize the rate of heat transfer away from the circuit board by the thermal conductive assembly.

[0020] Advantageously, heat transfer from the circuit board to the power supply can facilitate the use of aerosol generators at cold ambient temperatures. For example, at temperatures below approximately 5 degrees Celsius, the performance of some power supplies may degrade. Therefore, heat transfer from the circuit board to the power supply can advantageously raise the power supply temperature above the ambient temperature. Advantageously, raising the power supply temperature above the ambient temperature can maintain or improve the power supply's performance.

[0021] The thermally conductive assembly preferably comprises a thermally conductive frame defining a second end of the thermally conductive assembly. The power supply is preferably located at least partially within the thermally conductive frame.

[0022] Advantageously, providing a thermally conductive frame to a thermally conductive assembly can facilitate the relative positioning of the power supply and the thermally conductive assembly during the assembly of the aerosol generator.

[0023] Advantageously, positioning the power supply within a thermally conductive frame can facilitate heat transfer from the second end of the thermally conductive assembly to the power supply.

[0024] The aerosol generator according to any one of the preceding claims, wherein the thermally conductive assembly comprises at least one transverse member at a first end of the thermally conductive assembly, and a portion of at least one transverse member is positioned within a slot defined by a circuit board.

[0025] Advantageously, providing at least one transverse member positioned within a slot defined by a circuit board to a thermally conductive assembly may facilitate thermal contact between the circuit board and a first end of the thermally conductive assembly.

[0026] Advantageously, providing at least one transverse member positioned within a slot defined by a circuit board to a thermally conductive assembly may serve to hold a first end of the thermally conductive assembly in a state of thermal contact with the circuit board. Advantageously, the combination of at least one transverse member and the slot may eliminate the need to solder or adhere a first end of the thermally conductive assembly to the circuit board. Advantageously, eliminating the need to solder or adhere a first end of the thermally conductive assembly to the circuit board may simplify at least one of the manufacture and repair of the aerosol generating device.

[0027] Advantageously, providing at least one transverse member positioned within a slot defined by a circuit board to a thermally conductive assembly may facilitate positioning of the circuit board and the thermally conductive assembly relative to each other during assembly of the aerosol generating device.

[0028] Preferably, at least one transverse member is received within the slot by an interference fit. Advantageously, the interference fit may facilitate thermal contact between at least one transverse member and the circuit board. Advantageously, the interference fit may facilitate retention of at least one transverse member within the slot.

[0029] At least one transverse member may comprise a plurality of transverse members. The circuit board may define a plurality of slots, and each of the transverse members is received within a different slot defined by the circuit board.

[0030] Advantageously, providing a plurality of transverse members may increase the rate of heat transfer from the circuit board to a first end of the thermally conductive assembly.

[0031] Advantageously, providing multiple transverse members may facilitate thermal contact between the first end of the thermally conductive assembly and multiple locations on the circuit board. Advantageously, the multiple locations may be selected to provide a desired profile of heat transfer from the circuit board to the first end of the thermally conductive assembly. For example, if heat generated by a control circuit results in a non-uniform temperature distribution across at least a portion of the circuit board during use, the multiple transverse members may be positioned to accommodate the non-uniform temperature profile.

[0032] Advantageously, providing multiple transverse members may further facilitate the positioning of the circuit board and thermal conductive assemblies relative to each other during the assembly of the aerosol generator.

[0033] The slot defined by the circuit board may be a first slot, or the circuit board may define a second slot. At least one transverse member may comprise a first transverse member having a first portion located within the first slot, and a second transverse member having a second portion located within the second slot.

[0034] A slot defined by the circuit board may extend through the circuit board from a first side of the circuit board to a second side of the circuit board. At least one transverse member may extend through the slot such that at least one transverse member protrudes from the first side of the circuit board and from the second side of the circuit board. In other words, at least one transverse member may extend through the entire thickness of the circuit board.

[0035] Advantageously, transverse members that extend through the entire thickness of the circuit board may increase or maximize the thermal contact area between at least one transverse member and the circuit board.

[0036] The thermally conductive assembly may include at least one longitudinal arm extending between at least one transverse member and a thermally conductive frame.

[0037] Advantageously, at least one longitudinal arm may facilitate heat transfer from at least one transverse member at the first end of the thermally conductive assembly to the thermally conductive frame at the second end of the thermally conductive assembly.

[0038] Advantageously, at least one longitudinal arm may be flexible. Advantageously, at least one flexible longitudinal arm may facilitate the positioning of at least one transverse member within the slot during the assembly of the aerosol generator.

[0039] In embodiments in which the thermally conductive assembly comprises multiple transverse members, it is preferable that the thermally conductive assembly comprises multiple longitudinal arms. Each longitudinal arm is preferably extending between one of the transverse members and the thermally conductive frame.

[0040] In embodiments in which the thermally conductive assembly comprises a first transverse member and a second transverse member, it is preferable that at least one longitudinal arm comprises a first longitudinal arm extending between the first transverse member and the thermally conductive frame, and a second longitudinal arm extending between the second transverse member and the thermally conductive frame.

[0041] The circuit board may be a first circuit board, and the aerosol generator may further include a second circuit board. Preferably, the first end of the thermally conductive assembly is in thermal contact with the first circuit board and the second circuit board.

[0042] Advantageously, the first and second circuit boards may facilitate providing the aerosol generator with at least one of the desired size and shape. For example, the first and second circuit boards may facilitate an aerosol generator having a shorter length compared to an aerosol generator having a single circuit board.

[0043] Advantageously, the first and second circuit boards may facilitate the separation of two or more electrical components of the aerosol generator. Advantageously, providing a first set of electrical components on the first circuit board and a second set of electrical components on the second circuit board may facilitate the thermal separation of the first set of electrical components and the second set of electrical components.

[0044] Preferably, the second circuit board rests at least partially on the first circuit board. Advantageously, resting at least partially on both the first and second circuit boards may facilitate thermal contact between the first end of the thermally conductive assembly and both the first and second circuit boards.

[0045] Preferably, the first end of the thermally conductive assembly is positioned between the first circuit board and the second circuit board. Advantageously, positioning the first end of the thermally conductive assembly between the first and second circuit boards may facilitate thermal contact between the first end of the thermally conductive assembly and both the first and second circuit boards.

[0046] Preferably, a control circuit for controlling the supply of power from the power source to the aerosol generator is provided on a first circuit board. Preferably, the aerosol generator is electrically connected to the first circuit board.

[0047] As used herein, the term "electrically connected" refers to a connection via a conductive path.

[0048] The power supply is preferably electrically connected to at least one of the first circuit board and the second circuit board. The power supply may also be electrically connected to both the first circuit board and the second circuit board.

[0049] The aerosol generator preferably comprises one or more additional electrical components. The one or more additional electrical components preferably comprise at least one of a charging connector, a feedback device, a user input device, and an airflow sensor. At least one of the one or more additional electrical components is preferably located on or electrically connected to a second circuit board.

[0050] The aerosol generator preferably comprises an instrument controller configured to control the operation of the aerosol generator. The instrument controller is preferably provided on a second circuit board. The instrument controller is preferably in electrical communication with one or more additional electrical components. The instrument controller is preferably electrically connected to a power supply. The instrument controller is preferably in electrical communication with a control circuit to control the supply of power from the power supply to the aerosol generator. The first circuit board is preferably electrically connected to the second circuit board. The electrical connection between the first and second circuit boards preferably provides electrical communication between the instrument controller and the control circuit to control the supply of power from the power supply to the aerosol generator.

[0051] In embodiments in which the thermally conductive assembly comprises at least one transverse member, it is preferable that at least a portion of the at least one transverse member is positioned within a slot defined by the second circuit board. Advantageously, positioning the at least one transverse member within a slot defined by the first and second circuit boards may facilitate heat transfer by the thermally conductive assembly away from both the first and second circuit boards.

[0052] In embodiments in which at least one transverse member comprises multiple transverse members, at least one of the transverse members may be received in a slot defined by a first circuit board and a slot defined by a second circuit board. At least one of the transverse members may have a first end received in a slot defined by the first circuit board and a second end received in a slot defined by the second circuit board.

[0053] Advantageously, providing at least one transverse member received within a slot defined by the first and second circuit boards may reduce or minimize the number of transverse members required to provide the desired thermal contact between the first end of the thermally conductive assembly and each of the first and second circuit boards.

[0054] Preferably, at least one of the transverse members is in thermal contact with only the first circuit board. Advantageously, providing transverse members that are in thermal contact with only the first circuit board may facilitate a higher rate of heat transfer away from the first circuit board by the thermal conductive assembly compared to the rate of heat transfer away from the second circuit board by the thermal conductive assembly. Advantageously, the higher rate of heat transfer away from the first circuit board by the thermal conductive assembly may accommodate the significant amount of heat generated by the control circuit for controlling the supply of power from the power source to the aerosol generator.

[0055] As described herein, the thermally conductive assembly may comprise a first transverse member positioned within a first slot defined by a first circuit board, and a second transverse member positioned within a second slot defined by the first circuit board. Preferably, the second circuit board defines a third slot, and the second transverse member has a third portion positioned within the third slot. Preferably, the first transverse member is in thermal contact only with the first circuit board.

[0056] The thermally conductive assembly is formed from a thermally conductive material. The thermally conductive material preferably has a thermal conductivity of at least about 190 watts / meter Kelvin at 23 degrees Celsius and 50 percent relative humidity, as measured using the improved transient planar heat source (MTPS) method.

[0057] Suitable thermally conductive materials may include metals. Thermally conductive assemblies may also be metal. Suitable metals include aluminum, copper, iron, gold, zinc, or any suitable alloy of these metals. Suitable alloys include some stainless steels, and some copper alloys such as brass, copper-nickel alloys, copper-beryllium alloys, and phosphor bronze.

[0058] The thermal conductive assembly is preferably formed from brass. Advantageously, brass may be sufficiently malleable to facilitate the formation of a thermal conductive assembly having the required shape. Advantageously, a thermal conductive assembly formed from brass may be sufficiently elastic to facilitate the holding of one or more components of the aerosol generator by the thermal conductive assembly. For example, in embodiments where the thermal conductive assembly comprises a thermal conductive frame, a brass thermal conductive assembly may be sufficiently elastic to facilitate the holding of power sources within the thermal conductive frame.

[0059] The aerosol generator may include an inner housing. Advantageously, the inner housing may support one or more components of the aerosol generator.

[0060] The circuit board may be fixed to the inner housing. The circuit board may be fixed to the housing by a press-fit between a portion of the circuit board and the inner housing. In embodiments in which the aerosol generator comprises a first circuit board and a second circuit board, the first circuit board and the second circuit board may be fixed to the inner housing.

[0061] The power supply is preferably located within the internal housing.

[0062] Preferably, the second end of the thermally conductive assembly is in thermal contact with the inner housing. Advantageously, thermal contact between the thermally conductive assembly and the inner housing may facilitate heat dissipation from the circuit board to the inner housing by the thermally conductive assembly.

[0063] In embodiments in which a thermally conductive assembly comprises a thermally conductive frame, it is preferable that the thermally conductive frame is in thermal contact with the inner housing.

[0064] At least a portion of the second end of the thermally conductive assembly may rest on a portion of the inner housing.

[0065] Preferably, a portion of the inner housing is overmolded onto the outside of at least a portion of the second end of the thermal conductive assembly. Advantageously, overmolding a portion of the inner housing onto the outside of at least a portion of the second end of the thermal conductive assembly may embed at least a portion of the second end of the thermal conductive assembly within the material forming the inner housing. Advantageously, embedding at least a portion of the thermal conductive assembly within the material forming the inner housing may facilitate heat transfer from the second end of the thermal conductive assembly to the inner housing.

[0066] In embodiments where the second end of the thermally conductive assembly is equipped with a thermally conductive frame, it is preferable that a portion of the inner housing is overmolded on the outside of at least a portion of the thermally conductive frame.

[0067] The inner housing is preferably formed from a material suitable for molding onto the outside of the thermally conductive assembly. The inner housing may be formed from a polymer material. The inner housing may be formed from a moldable polymer. The inner housing is preferably formed from a material suitable for use in molding processes such as injection molding. Suitable polymer materials include thermoplastics and thermosetting polymers. Suitable polymer materials include polyphthalamide (PPA), polycarbonate (PC), a blend of polycarbonate and acrylonitrile butadiene styrene (PC-ABS), polyphenylsulfone (PPSU), polyether ether ketone (PEEK), polypropylene (PP), polyethylene (PE), polyimide (PI), thermoplastic polyimide (TPI), polyamide imide (PAI), and polyetherimide (PEI). The polymer material may be a composite polymer material. The composite polymer material may contain other materials. The composite polymer material may contain at least one fibrous filler material. The at least one fibrous filler material may contain at least one of carbon fiber and glass fiber.

[0068] A control circuit for controlling the supply of power from the power source to the aerosol generator may include at least one of a microprocessor, a microcontroller, and an application-specific integrated circuit (ASIC).

[0069] In embodiments where the aerosol generator includes a device controller, the device controller may include at least one of a microprocessor, a microcontroller, and an application-specific integrated circuit (ASIC).

[0070] The power source may be a DC power source. In a preferred embodiment, the power source is a battery. The power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery (e.g., lithium cobalt, lithium iron phosphate, or lithium polymer battery). The power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows for the storage of sufficient energy for one or more user operations, such as one or more aerosol generation experiences. For example, the power source may have a capacity that allows for continuous heating of the aerosol-forming substrate for about 6 minutes, or a multiple of 6 minutes, corresponding to the typical time it takes to smoke one conventional cigarette. In another embodiment, the power source may have a capacity that allows for a predetermined number of puffs or discontinuous activation of the heater.

[0071] The aerosol generator preferably has a cavity for receiving an aerosol-forming substrate. In embodiments in which the aerosol generator has an inner housing, the inner housing may define a cavity at least partially.

[0072] The aerosol generator preferably includes an outer housing. In embodiments in which the aerosol generator includes a cavity for receiving an aerosol-forming substrate, the outer housing may define the cavity at least partially.

[0073] The housing may be elongated. The housing may have a cylindrical shape. The housing may contain any suitable material or combination of materials. Suitable materials include metals, alloys, plastics, and composite materials containing at least one of metals, alloys, or plastics. Suitable materials include thermoplastic resins suitable for food or pharmaceutical applications. Suitable thermoplastic resins include polypropylene, polyetheretherketone (PEEK), and polyethylene.

[0074] The aerosol generator is preferably portable. The aerosol generator may have a length of approximately 70 mm to 120 mm. The aerosol generator is preferably a handheld device. In other words, the aerosol generator may be sized and shaped to be held in the user's hand.

[0075] The aerosol generator may be equipped with an electric heater.

[0076] The electric heater may include at least one internal heating element. As used herein, the term “internal heating element” refers to a heating element configured to be inserted into an aerosol-forming substrate. The internal heating element may be at least one of the following forms: a blade, a pin, and a cone. It is preferable that the internal heating element is configured to be insertable into an aerosol-forming substrate. In embodiments in which the aerosol generator includes a cavity for receiving an aerosol-forming substrate, it is preferable that at least one internal heating element extends into the cavity.

[0077] The electric heater may include at least one external heating element. As used herein, the term “external heating element” refers to a heating element configured to heat the outer surface of the aerosol-forming substrate. Preferably, at least one external heating element is configured to at least partially surround the aerosol-forming substrate received by the aerosol generator. In embodiments in which the aerosol generator includes a cavity for receiving the aerosol-forming substrate, preferably at least one external heating element surrounds the cavity at least partially.

[0078] The electric heater may include at least one internal heating element and at least one external heating element.

[0079] In some preferred embodiments, the heater comprises at least one resistance heating element.

[0080] The electric heater may include a resistive heating element. The resistive heating element may include an electrically insulated substrate and one or more conductive tracks or wires provided on the surface of the electrically insulated substrate. The size and shape of the electrically insulated substrate may facilitate the insertion of the electric heater into the aerosol-forming substrate. The electrically insulated substrate is preferably rigid. The aerosol generator may include only one resistive heating element. The aerosol generator may include multiple resistive heating elements.

[0081] The aerosol generator may include a moving element. The moving element may be arranged to move a liquid aerosol forming substrate to an electric heater. The moving element may include a capillary core. The electric heater is preferably in contact with the moving element. The electric heater may include a resistance heating wire. At least a portion of the resistance heating wire may be coiled around the moving element. The electric heater may include a resistance heating mesh.

[0082] The aerosol generator may include an induction heating arrangement. The induction heating arrangement may include an inductor coil. A control circuit for controlling the supply of power from a power source to the aerosol generator is preferably configured to provide a high-frequency oscillating current from the power source to the inductor coil. As used herein, the term “high-frequency oscillating current” refers to an oscillating current having a frequency of 500 kilohertz to 30 megahertz. The aerosol generator may include a DC / AC inverter for converting a DC current supplied by a DC power source into an oscillating current. The inductor coil may be configured to generate a high-frequency oscillating electromagnetic field upon receiving a high-frequency oscillating current from the power source. The inductor coil may be configured to generate a high-frequency oscillating electromagnetic field within a device cavity configured to receive an aerosol-forming substrate. In embodiments in which the aerosol generator includes a cavity for receiving an aerosol-forming substrate, the inductor coil may substantially surround the cavity. The inductor coil may extend at least partially along the length of the cavity.

[0083] In embodiments where the aerosol generator includes an induction heating arrangement, the aerosol generator may include an induction heating element. The induction heating element may be a susceptor element. As used herein, the term “susceptor element” refers to an element comprising a material having the ability to convert electromagnetic energy into heat. When the susceptor element is located in an oscillating electromagnetic field, the susceptor is heated. The heating of the susceptor element may be the result of at least one of hysteresis loss and eddy current induced within the susceptor element, depending on the electrical and magnetic properties of the susceptor material. In embodiments where the aerosol generator includes a cavity for receiving an aerosol-forming substrate, the susceptor element may be arranged such that, when the aerosol-forming substrate is received in the cavity, the oscillating electromagnetic field generated by the inductor coil induces a current within the susceptor element, causing the susceptor element to heat the aerosol-forming substrate. The susceptor element may be located within the cavity. The aerosol generator may comprise only one susceptor element. The aerosol generator may comprise multiple susceptor elements.

[0084] The susceptor element may contain any suitable material. The susceptor element may be formed from any material that can be inductively heated to a temperature sufficient to release volatile compounds from the aerosol-forming substrate. The susceptor element may contain metal or carbon. Suitable materials for the susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composite materials of metallic materials. The susceptor element may also contain ferromagnetic materials such as ferrite iron, ferromagnetic alloys such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite.

[0085] In embodiments where the aerosol generator is equipped with an induction heating arrangement, the aerosol generator may comprise only an inductor coil. In other words, the aerosol generator may not comprise any susceptor element. The aerosol generator may accept an aerosol generating article comprising an aerosol-forming substrate and at least one susceptor element. During use, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element of the aerosol generating article, causing the susceptor element to heat the aerosol-forming substrate.

[0086] The aerosol generator may include an element arranged to vibrate when power is supplied from a power source. The aerosol generator may include a piezoelectric element. The aerosol generator may include at least one nozzle. The piezoelectric element may be arranged to discharge droplets of the liquid aerosol-forming substrate through at least one nozzle. The aerosol generator may include a mesh, which defines at least one nozzle.

[0087] The mesh may be configured to vibrate during use of the aerosol generator. The vibrating mesh may be called an "active mesh." The mesh may be formed from a piezoelectric material. The mesh may also be a piezoelectric element. The piezoelectric element may be formed separately from the mesh and configured to vibrate the mesh during use.

[0088] The mesh may be positioned to remain substantially stationary relative to the vibrating piezoelectric element during use of the aerosol generator. A stationary mesh may be called a “passive mesh.” The aerosol generator may include a storage unit positioned between the mesh and the piezoelectric element. The storage unit may be positioned to receive a liquid aerosol-forming substrate.

[0089] Embodiments of the present invention will be described below with reference to the accompanying drawings, but only as illustrative examples. [Brief explanation of the drawing]

[0090] [Figure 1] Figure 1 shows a schematic cross-sectional view of an aerosol generator according to the first embodiment of the present invention. [Figure 2] Figure 2 illustrates the electrical connections between the electrical components of the aerosol generator shown in Figure 1. [Figure 3] Figure 3 shows a top perspective view of the aerosol generator shown in Figure 1 with the outer housing removed. [Figure 4] Figure 4 shows a bottom perspective view of the aerosol generator shown in Figure 1 with the outer housing removed. [Figure 5] Figure 5 shows a perspective view of the thermally conductive assembly of the aerosol generator shown in Figure 1. [Figure 6] Figure 6 shows an alternative arrangement of the thermally conductive assembly for the inner housing of the aerosol generator shown in Figure 1. [Figure 7] Figure 7 shows a schematic cross-sectional view of an aerosol generator according to a second embodiment of the present invention. [Figure 8] Figure 8 shows a schematic cross-sectional view of an aerosol generator according to a third embodiment of the present invention. [Modes for carrying out the invention]

[0091] Figure 1 shows a schematic cross-sectional view of an aerosol generator 10 according to a first embodiment of the present invention. The aerosol generator 10 comprises an inner housing 12 that defines a cavity 14 for receiving an aerosol-forming substrate at the first end of the aerosol generator 10. The aerosol generator 10 also comprises an outer housing 16 that extends around the inner housing 12.

[0092] The aerosol generator 10 also includes an aerosol generator 18 equipped with an induction heating arrangement. The induction heating arrangement includes an inductor coil 20 surrounding a cavity 14. During use, an aerosol-forming article, including an aerosol-forming substrate and a susceptor element, is inserted into the cavity 14.

[0093] The power supply 24 is located at the second end of the aerosol generator 10 within the inner housing 12. The power supply 24 is a rechargeable battery.

[0094] The aerosol generator 10 also comprises several control components, roughly illustrated by box 26 in Figure 1. The control components and their functional connectivity to one another (illustrated by connection arrows) are shown in more detail in the schematic diagram of Figure 2.

[0095] The aerosol generator 10 comprises a first circuit board 28 on which a control circuit 30 is provided. The control circuit 30 is configured to control the supply of power from a power source 24 to the aerosol generator 18. In particular, the control circuit 30 includes a DC / AC inverter to convert the DC power supplied from the power source 24 into an oscillating current supplied to the inductor coil 20. During use, the oscillating current in the inductor coil 20 generates a high-frequency oscillating electromagnetic field within the cavity 14. The high-frequency oscillating electromagnetic field inductively heats the susceptor element of the aerosol generating article received within the cavity 14, which heats the aerosol-forming substrate of the aerosol generating article.

[0096] The smoke absorption sensor 32 is disposed within or in communication with the cavity 14. The smoke absorption sensor is positioned to detect when a user draws air through the cavity 14 and inhales aerosols generated by the aerosol-forming substrate received within the cavity 14. The smoke absorption sensor 32 includes a pressure sensor. The smoke absorption sensor 32 is electrically connected to the first circuit board 28 and communicates the data generated by the smoke absorption sensor 32 to the control circuit 30.

[0097] The aerosol generator 10 also includes a second circuit board 34 on which a device controller 36 is provided. The device controller 36 communicates with the control circuit 30 and commands the control circuit 30 to control the supply of power from the power supply 24 to the aerosol generator 18, or to stop the supply of power from the power supply 24 to the aerosol generator 18. The device controller 36 may also receive data generated by the smoke absorption sensor 32 via the control circuit 30.

[0098] The charging connector 38 is located at the second end of the aerosol generator 10 and is electrically connected to the second circuit board 34. The charging connector 38 is configured to receive power from an external device such as a main charger or a Universal Serial Bus (USB) charger. The device controller 36 controls the supply of power received by the charging connector 38 for recharging the power supply 24.

[0099] Two feedback devices, each comprising a light-emitting diode (LED) module 40 and a vibration motor 42, are electrically connected to a second circuit board 34. The device controller 36 is configured to provide feedback to the user using the two feedback devices. For example, the device controller 36 may control the LED module 40 to provide the user with the status of the power supply 24. The device controller 36 may also control the vibration motor 42 to indicate at least one of the start of a heating cycle and the end of a heating cycle.

[0100] A user input device, equipped with a push button 44, is electrically connected to a second circuit board 34. The push button 44 enables the user to operate the aerosol generator by providing one or more signals to the device controller 36. For example, the device controller 36 may be configured to allow the user to start a heating cycle, end a heating cycle, generate feedback using at least one of the LED module 40 and vibration motor 42, and modify the configuration of the aerosol generator 10 using a single button press or a combination of button presses.

[0101] Figures 3 and 4 show a top and bottom perspective view of the aerosol generator 10 with the outer housing 16 removed to show the arrangement of the first circuit board 28 and the second circuit board 34 inside the aerosol generator 10. The first circuit board 28 is located on top of the second circuit board 34.

[0102] During use of the aerosol generator 10, the electrical components provided on the first circuit board 28 and the second circuit board 34, including the control circuit 30 and the device controller 36, generate heat. To dissipate the heat generated from the first circuit board 28 and the second circuit board 34, and to prevent thermal damage to the control circuit 30 and the device controller 36, the aerosol generator is equipped with a thermal conductive assembly 46. The integration of the thermal conductive assembly 46 into the aerosol generator 10 is shown in Figures 3 and 4. The thermal conductive assembly 46 is shown in detail, separated from the aerosol generator 10 in Figure 5.

[0103] The thermally conductive assembly 46 comprises a first end 48 positioned between the first circuit board 28 and the second circuit board 34, and a second end 50 spaced apart from the first circuit board 28 and the second circuit board 34.

[0104] The second end 50 of the thermal conductive assembly 46 is defined by a thermal conductive frame 52 positioned to partially surround the power supply 24 in order to provide thermal contact between the second end 50 of the thermal conductive assembly 46 and the power supply 24. In the assembled aerosol generating article 10 shown in Figure 3, the thermal conductive frame 52 is partially embedded within the inner housing 12 during the manufacture of the aerosol generating device 10 by overmolding a portion of the inner housing 12 to the outside of the thermal conductive frame 52.

[0105] The first end 48 of the thermally conductive assembly 46 comprises a first transverse member 54, a first longitudinal arm 56 extending between the first transverse member 54 and the thermally conductive frame 52, a second transverse member 58, and a second longitudinal arm 60 extending between the second transverse member 58 and the thermally conductive frame 52.

[0106] The first transverse member 54 and the second transverse member 58 are positioned within slots defined by the first circuit board 28 and the second circuit board 34, providing thermal contact between the first end 48 of the thermal conductive assembly 46 and each of the first circuit board 28 and the second circuit board 34. The first transverse member 54 includes a first portion 62 positioned within a first slot 64 defined by the first circuit board 28. The second transverse member 58 includes a second portion 66 positioned within a second slot 68 defined by the first circuit board 28. The second transverse member 58 also includes a third portion 70 positioned within a third slot 72 defined by the second circuit board 34.

[0107] Thermal contact between the first transverse members 54 and the second transverse members 58 and the first circuit board 28 and the second circuit board 34 facilitates heat transfer from the first circuit board 28 and the second circuit board 34 to the first end 48 of the thermal conductive assembly 46. The heat transferred to the first end 48 of the thermal conductive assembly 46 is conducted along the first longitudinal arm 56 and the second longitudinal arm 60 to the thermal conductive frame 52, where it is dissipated to the power supply 24 and the inner housing 12. Thermal contact between the first transverse members 54 and the second transverse members 58 and the first circuit board 28 provides a higher heat transfer rate than thermal contact between the second circuit board 34 and the second transverse member 58 alone. The higher heat transfer rate corresponds to a higher heat generation rate by the control circuit 30 compared to the device controller 36.

[0108] Figure 6 shows an alternative arrangement of the thermal conductive frame 52 relative to the inner housing 12. In the embodiment shown in Figure 6, the thermal conductive frame 52 is entirely on top of the inner housing 12 and the power supply 24. In other words, the thermal conductive frame 52 is not partially embedded within the inner housing 12. This arrangement simplifies the assembly of the aerosol generator 10 because it does not require overmolding the inner housing 12 over the thermal conductive frame 52, although the heat transfer rate from the thermal conductive frame 52 to the inner housing 12 may be reduced.

[0109] Figure 7 shows an aerosol generator 100 according to a second embodiment of the present invention. The aerosol generator 100 is substantially the same as the aerosol generator in Figure 1, and the same reference numerals are used to specify similar parts.

[0110] Aerosol generator 100 differs from aerosol generator 10 in that it has an aerosol generator. Although aerosol generator 100 includes an aerosol generator 118 equipped with an inductor coil 20, aerosol generator 118 also includes a susceptor element 222 extending into a cavity 14. During use, the aerosol forming substrate is inserted into the cavity 14, thereby receiving the susceptor element 222 within the aerosol forming substrate.

[0111] The remaining parts of the aerosol generator 100, including the thermally conductive assembly 46, are identical to those of the aerosol generator 10 in Figure 1.

[0112] Figure 8 shows an aerosol generator 200 according to a third embodiment of the present invention. The aerosol generator 200 is substantially the same as the aerosol generator in Figure 1, and the same reference numerals are used to specify similar parts.

[0113] The aerosol generator 200 differs from the aerosol generator 10 in that it has an aerosol generator. Instead of an inductor coil, the aerosol generator 218 of the aerosol generator 200 has an electric heater 220 which has a resistance heating element extending into the cavity 14. During use, the aerosol forming substrate is inserted into the cavity 14, thereby housing the electric heater 220 within the aerosol forming substrate.

[0114] The remaining parts of the aerosol generator 200, including the thermally conductive assembly 46, are identical to those of the aerosol generator 10 in Figure 1.

[0115] 1. An aerosol generator, An aerosol generator for generating aerosols from an aerosol-forming substrate, Power supply and A circuit board comprising a control circuit for controlling the supply of power from the power source to the aerosol generator, A thermally conductive assembly comprising a first end that is in thermal contact with the circuit board and a second end that is separated from the circuit board, The circuit board is a first circuit board, the aerosol generator further comprises a second circuit board, and the first end of the thermally conductive assembly is in thermal contact with the second circuit board, An aerosol generator in which the second circuit board is at least partially located on the first circuit board, the second circuit board is separated from the first circuit board, and the first end of the thermally conductive assembly is positioned between the first circuit board and the second circuit board. 2. The aerosol generating apparatus according to claim 1, wherein the second end of the thermally conductive assembly is in thermal contact with the power supply. 3. The aerosol generator according to claim 1 or 2, wherein the thermally conductive assembly comprises a thermally conductive frame defining the second end of the thermally conductive assembly, and the power supply is at least partially located within the thermally conductive frame. 4. The aerosol generator according to any one of 1 to 3, wherein the thermally conductive assembly is provided with at least one transverse member at the first end of the thermally conductive assembly, and a portion of the at least one transverse member is positioned within a slot defined by the circuit board. 5. An aerosol generating device according to the combination of 3 and 4, wherein the thermal conductive assembly comprises at least one longitudinal arm extending between the at least one transverse member and the thermal conductive frame. 6. The aerosol generator according to 4 or 5, wherein the slot defined by the circuit board is a first slot, the circuit board further defines a second slot, and the at least one transverse member comprises a first transverse member having a first portion located within the first slot, and the at least one transverse member further comprises a second transverse member having a second portion located within the second slot. 7. The aerosol generator according to 3, wherein at least a portion of the at least one transverse member is positioned within a slot defined by the second circuit board. 8. The aerosol generator according to 6, wherein the second circuit board defines a third slot, and the second transverse member has a third portion positioned within the third slot. 9. The aerosol generating apparatus according to 8, wherein the first transverse member is in thermal contact only with the first circuit board. 10. The aerosol generator according to any one of 1 to 9, wherein the aerosol generator comprises at least one additional electrical component, the at least one additional electrical component comprising at least one of a charging connector, a user input device, and a feedback device, and the at least one additional electrical component is electrically connected to the second circuit board. 11. The aerosol generator according to any one of 1 to 10, wherein the aerosol generator comprises an inner housing, the power supply is located within the inner housing, and a portion of the inner housing is overmolded on the outside of at least a portion of the second end of the thermally conductive assembly. 12. The aerosol generator according to any one of 1 to 11, wherein the aerosol generator comprises an inner housing, the power supply is located within the inner housing, and at least a portion of the second end of the thermally conductive assembly is located on a portion of the inner housing. 13. The aerosol generating apparatus according to any one of 1 to 12, wherein the aerosol generator is equipped with an induction heating arrangement.

Claims

1. Aerosol generator, An aerosol generator for generating aerosols from an aerosol-forming substrate, Power supply and The circuit board includes a control circuit for controlling the supply of power from the power source to the aerosol generator, The circuit board is a first circuit board, and the aerosol generator further comprises a second circuit board. An aerosol generator wherein the second circuit board is at least partially located on the first circuit board.

2. The aerosol generating apparatus according to claim 1, comprising a thermally conductive assembly having a first end that is in thermal contact with the circuit board and a second end that is separated from the circuit board.

3. The aerosol generating apparatus according to claim 2, wherein the first end of the thermally conductive assembly is in thermal contact with the second circuit board.

4. The aerosol generating apparatus according to claim 2 or 3, wherein the first end of the thermally conductive assembly is positioned between the first circuit board and the second circuit board.

5. The aerosol generating apparatus according to any one of claims 2 to 4, wherein the second end of the thermally conductive assembly is in thermal contact with the power supply.

6. The aerosol generating apparatus according to any one of claims 2 to 5, wherein the second end of the thermally conductive assembly is separated from the first circuit board and the second circuit board.

7. The aerosol generator according to any one of claims 2 to 6, wherein the thermally conductive assembly comprises a thermally conductive frame defining the second end of the thermally conductive assembly, and the power supply is at least partially located within the thermally conductive frame.

8. The aerosol generator according to any one of claims 2 to 7, wherein the thermally conductive assembly comprises at least one transverse member at the first end of the thermally conductive assembly, and a portion of the at least one transverse member is positioned within a slot defined by the circuit board.

9. The aerosol generating apparatus according to a combination of claims 7 and 8, wherein the thermal conductive assembly comprises at least one longitudinal arm extending between the at least one transverse member and the thermal conductive frame.

10. The aerosol generator according to claim 8 or 9, wherein the slot defined by the circuit board is a first slot, the circuit board further defines a second slot, and the at least one transverse member comprises a first transverse member having a first portion located within the first slot, and the at least one transverse member further comprises a second transverse member having a second portion located within the second slot.

11. The aerosol generator according to claim 8, wherein at least a portion of the at least one transverse member is positioned within a slot defined by the second circuit board.

12. The aerosol generating apparatus according to claim 10, wherein the second circuit board defines a third slot, and the second transverse member has a third portion positioned within the third slot.

13. The aerosol generating apparatus according to claim 12, wherein the first transverse member is in thermal contact only with the first circuit board.

14. The aerosol generator according to any one of claims 2 to 13, wherein the aerosol generator comprises an inner housing, the power supply is located within the inner housing, and a portion of the inner housing is overmolded on the outside of at least a portion of the second end of the thermally conductive assembly.

15. The aerosol generator according to any one of claims 2 to 14, wherein the aerosol generator comprises an inner housing, the power supply is located within the inner housing, and at least a portion of the second end of the thermally conductive assembly is located on a portion of the inner housing.

16. The aerosol generating apparatus according to claim 14 or claim 15, wherein the first circuit board and the second circuit board are fixed to the inner housing.

17. The aerosol generator according to any one of claims 1 to 16, wherein the aerosol generator comprises at least one additional electrical component, the at least one additional electrical component comprising at least one of a charging connector, a user input device, and a feedback device, and the at least one additional electrical component is electrically connected to the second circuit board.

18. The aerosol generating apparatus according to any one of claims 1 to 17, wherein the second circuit board is separated from the first circuit board.

19. The aerosol generating apparatus according to any one of claims 1 to 18, wherein the first circuit board is electrically connected to the second circuit board.

20. The aerosol generating apparatus according to any one of claims 1 to 19, wherein the aerosol generator is equipped with an induction heating mechanism.

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