Aerosol generating device with insulating material

Abstract

The aerosol generating device (1) comprises: an insulator (102) having an inner wall (104) and an outer wall (106) separated from each other; a cavity (110) defined in the inner wall (104) capable of receiving an aerosol-forming substrate; and a heater (112) positioned to heat the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity (110); a casing (10) surrounding the insulator (102); and electrical contacts (116) connected to the heater (112), at least one of the electrical contacts (116) being mechanically connectable to the casing (10) to hold the insulator (102) in place.

Description

Technical Field

[0001] The present invention relates to an aerosol generating device, and more particularly, to an aerosol generating device provided with a heat insulator such as a vacuum heat insulator.

Background Art

[0002] (Also known as vaporizers) The popularity and use of aerosol generating devices and systems have grown rapidly in recent years as an alternative to traditional tobacco products such as cigarettes, cigars, cigarillos, and roll-your-own tobacco. In contrast to burning tobacco in traditional tobacco products, various devices and systems are available for heating or warming aerosolizable substances, which may or may not contain nicotine or other active substances.

[0003] Generally available aerosol generating systems are of the base material heating type of aerosol generation or heat-not-burn type. This type of system generates an aerosol or vapor by heating a consumable (i.e., a "heat-not-burn stick") containing an aerosol-forming base material such as reconstituted tobacco to a temperature typically in the range of 150°C to 350°C. By heating rather than burning or igniting the aerosol-forming base material, an aerosol containing the components desired by the user but free of undesirable by-products due to combustion is released. In addition, the aerosol produced by heating tobacco or other aerosolizable materials typically does not contain the burnt or bitter taste that can be unpleasant to the user and can result from combustion.

[0004] Typically, for example, a stick-shaped heat-not-burn consumable is inserted into the cavity of a heat-not-burn device, and the end of the stick protrudes from the device to form an inhalation mouthpiece. Thereafter, a heater within the heat-not-burn device supplies heat to the stick to aerosolize the aerosolizable material contained in the aerosol-forming base material within the stick, and the generated aerosol is supplied to the user from the protruding end of the stick.

[0005] Typically, not all of the heat generated by the heater is transferred to the consumables, creating aerosols. This reduces the overall efficiency of the device and shortens battery life. Furthermore, the loss can lead to overheating of other components within the device, which can lead to damage and discomfort for the user when holding the device. [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] The objective of this invention is to address these problems. [Means for solving the problem]

[0007] According to one aspect of the present invention, an aerosol generating device is provided, comprising: an insulating body having an inner wall and an outer wall separated from each other; a cavity defined within the inner wall capable of receiving an aerosol-forming substrate; and a heater positioned to heat the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity; a casing surrounding the insulating body; and electrical contacts connected to the heater, at least one of which is mechanically connectable to the casing to hold the insulating body in place.

[0008] Advantageously, since the electrical contacts also provide a mechanical connection between the insulator and the casing, the number of heat conduction paths between them is reduced. By reducing the amount of heat conducted from the insulator to the casing, a greater proportion of heat can be transferred to the aerosol-forming substrate, thus increasing the efficiency of the heater. Furthermore, the heating of the casing is also reduced, which may reduce damage to other components of the device installed within the casing, which may also be desirable from the perspective of the user holding the casing.

[0009] The insulator and heater are sometimes collectively referred to as the heating device. The heating device may be housed within a chamber of the casing, such as a chamber defined by the side portion of the casing extending from the base portion of the casing. The heating device may be housed within the chamber such that a gap is provided between the outer wall of the insulator and the casing. The region between the inner and outer walls of the insulator is sometimes referred to as the insulating region.

[0010] Preferably, the electrical contacts provide the sole connection between the insulator and the casing. Advantageously, this reduces the heat transferred between the insulator and the casing by minimizing the number of heat conduction paths between them. In other words, preferably, the only way heat can be conducted between the insulator and the casing is through the electrical contacts.

[0011] Preferably, the inner and outer walls of the insulator are separated from each other by a vacuum, thereby providing a vacuum insulator. In this way, heat conduction and / or convection between the inner and outer walls of the insulator are further suppressed, thereby further reducing heat transfer from the insulator to the casing. Alternatively, the inner and outer walls of the insulator may be separated from each other by voids, aerogel, foam material, fibrous material, and / or any combination thereof.

[0012] Preferably, the insulator is removable from within the casing. In other words, at least one of the electrical contacts can be mechanically disconnected from the casing. For example, the heating device providing the insulator and heater may be removable from the casing, such as from within the chamber. In this way, the insulator can be replaced, cleaned, and / or repaired. Alternatively, the insulator may be permanently fixed within the casing, which may allow for a stronger connection between the insulator and the casing.

[0013] The cavity may have at least one opening where the inner wall is joined to the outer wall, and one or more electrical contacts may be located on the insulator in a location that minimizes heat flow between at least one opening and the electrical contact. In this way, the electrical contacts are made in the portion of the outer wall that remains the coldest during use of the aerosol generating device. This reduces heat transfer between the insulator and the casing. For example, the electrical contacts may be located in a location that maximizes the shortest distance between at least one opening and the electrical contact. In other words, if there are multiple openings to the cavity, the electrical contacts are not placed close to any of them. The distance may be determined along the direct path between the opening and the electrical contact. Preferably, the distance is determined along the thermal path between the opening and the electrical contact. Since heat flow is suppressed through the insulating portion of the insulator, the distance can be measured along the thermal path through the air surrounding the insulator and / or along the outer wall of the insulator.

[0014] The insulator may be cup-shaped, with a cavity having a single opening where the inner wall joins the outer wall, and the electrical contacts located at the base of the insulator opposite the opening in the cavity. In other words, the insulator may be mounted to the casing in a cantilever configuration, with only one end of the insulator connected to the casing. By placing the electrical contacts at the base of the insulator, the electrical contacts are made on the coldest part of the outer wall during use, thereby reducing heat transfer from the insulator to the casing. In other words, the distance between the electrical contacts and the opening in the cavity is maximized.

[0015] Alternatively, the insulator may be tubular such that the cavity has two openings into which the inner wall joins the outer wall, and the electrical contacts are located on the sides of the insulator spaced apart from both openings. The electrical contacts may also be positioned equidistant from both openings into the cavity, thereby maximizing the shortest distance to both openings. Alternatively, if one opening is determined to generate more heat than the other, the electrical contacts may be moved further away from that opening. In this way, the electrical contacts are made in the coldest part of the outer wall during use, thereby reducing heat transfer from the insulator to the casing.

[0016] The electrical contacts may be mechanically connectable to the base portion of the casing. Connecting the electrical contacts to the base portion of the casing reduces heat transfer to the side portion of the aerosol generating device (which may be held by the user). Alternatively, the electrical contacts may be mechanically connectable to the side portion of the casing. The side portion of the casing may have an inner wall and an outer wall, and the electrical contacts may be mechanically connectable to the inner wall. Insulation material may be installed between the inner wall and the outer wall to further reduce heat transfer from the insulator to the casing.

[0017] The electrical contacts may comprise a pair of pins. These pins may be connectable to the casing by a lockable coupling. These pins may be connectable to the casing using a bayonet connection or threads.

[0018] The electrical contact may comprise a pin and a threaded outer surface that can engage with the casing to hold the insulating material in place.

[0019] It will be understood by those skilled in the art that any feature of any device or apparatus described herein may be provided as a feature of a method. It will also be understood that any particular combination of the various features described and defined in any embodiment described herein may be independently implemented and / or supplied and / or used. Furthermore, it will be understood that the present invention is described herein merely as an example, and modifications of details may be made within the scope of the invention.

[0020] Here, with reference to the attached drawings, one or more embodiments will be described simply as examples. [Brief explanation of the drawing]

[0021] [Figure 1A] A schematic cross-section of a first embodiment of an aerosol generating device equipped with a heating device is shown. [Figure 1B]Shows a cross-section of the heating device of the embodiment shown in FIG. 1A. [Figure 2A] Shows a schematic cross-section of a second embodiment of an aerosol generating device comprising a heating device. [Figure 2B] Shows a cross-section of the heating device of the embodiment shown in FIG. 2A. [Figure 3-4] Shows an alternative heating device that can be used in one embodiment of an aerosol generating device.

Mode for Carrying Out the Invention

[0022] In the following description and the accompanying drawings, corresponding features can preferably be identified using corresponding reference numerals so that the common features need not be described in detail for every embodiment.

[0023] FIG. 1A depicts a schematic cross-section of a first embodiment of an aerosol generating device 1. The device 1 has a casing 10 with a base portion 12 and a side portion 14. More specifically, the side portion 14 extends from the base portion 12 and defines a chamber 15. In this embodiment, the side portion 14 comprises an outer wall 14a and an inner wall 14b, although it will be understood that the side portion 14 may comprise only a single wall.

[0024] The device 1 comprises a heating device 100 held within the casing 10, such as within the chamber 15. In this way, the casing 10 surrounds the heating device 100. Further details of the heating device 100 are shown in the cross-section of FIG. 1B. The heating device 100 comprises a heat insulator 102. The heat insulator 102 comprises an inner wall 104 and an outer wall 106 which are spaced apart from each other such that a heat insulating region 108 is enclosed in the space between them. Preferably, the heat insulating region 108 contains a vacuum, thereby providing a vacuum heat insulator 102. Alternatively or additionally, the heat insulating region 108 may contain a void, an aerogel, a foamed material, a fibrous material, and / or any combination of the above.

[0025] The heating device 100 includes a cavity 110 provided adjacent to the inner wall 104 and configured to receive an aerosol-forming substrate. For example, a consumable 5 may be inserted into the cavity 110, where the consumable 5 includes an aerosol-forming substrate such as a cigarette 6. The consumable 5 is typically an elongated rod or stick that can be inserted into the cavity 110 by the user through an opening 111 to the cavity 110. The insulator 102 is substantially cylindrical in shape, thereby allowing the insulator 102 to completely surround the consumable 5 and maximize the insulating effect. In this example, the insulator 102 has an opening 111 at one longitudinal end for receiving the consumable 5, and the opposite end is closed. Thus, the insulator 102 has a cup-shaped cross-section when viewed perpendicular to its longitudinal axis. In other words, the cavity 110 has a single opening 111 into which the inner wall 104 is joined to the outer wall 106.

[0026] A heater 112 is provided within the insulated region 108 and on the inner wall 104. The heater 112 heats the inner wall 104 by conduction, thereby configuring the inner wall 104 to heat the consumables 5 and the air in the cavity 110 by conduction and radiation. The heater 112 is powered by a power source such as a battery (not shown) installed in the base portion 12 of the casing 10 of the device 1.

[0027] By providing the insulating material 102 in the heating device 100, the insulating region 108 suppresses direct heat conduction or convection from the heater 112 to the outer wall 106, thereby reducing the amount of wasted heat. Nevertheless, during use of the device 1, the outer wall 106 may still be heated due to convection of air from the opening 111 of the cavity 110, or conduction between the inner wall 104 and the outer wall 106 at the opening 111. By providing the heating device 100 inside the chamber 15 of the device 1, a gap is created between the outer wall 106 of the heating device 100 and the casing 10 of the device 1. Advantageously, this reduces heating of the casing 10, thereby increasing the efficiency of the device 1 and preventing discomfort for the user holding the casing 10 of the device 1.

[0028] The heating device 100 includes one or more electrical contacts 116 connected to the heater 112 by a first wire connector 114a and a second wire connector 114b, etc. The electrical contacts 116 are mechanically connectable to the casing 10 of the device 1. In this embodiment, the electrical contacts 116 are mechanically connectable to the base portion 12 of the casing 10. By using the same means to provide both mechanical and electrical connections between the insulator 102 and the casing 10, the number of heat conduction paths is reduced. Advantageously, this can further reduce heating of the casing 10, thereby increasing the efficiency of the device 1 and preventing discomfort to the user holding the casing 10 of the device 1.

[0029] Preferably, the electrical contact 116 provides the only connection between the insulator 102 and the casing 10. In this way, the number of heat conduction paths is minimized, and heat transfer between the insulator 102 and the casing 10 is further reduced. To achieve this, the material and shape of the electrical contact 116 are selected to provide sufficient strength to keep the heating device 100 in place within the chamber 15 during use of the device 1 without requiring any additional contacts between the heating device 100 and the casing 10. In other words, the electrical contact 116 provides a robust connection, thereby suppressing the movement of the insulator 102 relative to the casing 10.

[0030] Preferably, the electrical contact 116 is also mechanically detachable from the casing 10 so that the heating device 100 is removable from the casing 10. Advantageously, by providing a heating device 100 that is removable from the casing 10, components of the heating device 100 can be easily repaired and / or replaced without having to replace the entire device 1.

[0031] In this example, the electrical contact 116 comprises a pair of pins. The pins may be connectable to the casing 10 by a lockable coupling. The pins are inserted into the base portion 12 and can be locked in place via a small rotation or translation.

[0032] In one implementation configuration, the connection between the pin and the base portion 12 may correspond to the connection used between the fluorescent starter and its corresponding socket. More specifically, the pin may have a flange portion that holds the pin in a protruding groove of the base portion 12, and the movement of the pin through the groove (e.g., by the rotation of the heating device 100) allows the pin to be removed from the base portion 12 at the opening. Electrical and mechanical connections between the heating device 100 and the casing 10 may be provided in other ways. For example, the heating device 100 may be connected to the casing 10 using a bayonet connector, and radial pins connected to the heating device 100 engage in a pair of L-shaped slots on the casing 10. Alternatively, a screw connector may be provided, and the heating device 100 has a threaded outer surface that can engage with the corresponding threads on the base portion 12 of the casing 10. In a further alternative configuration, the electrical contact 116 may comprise a (single) pin and a threaded outer surface that can engage with the casing 10 to hold the insulator 102 in place. Such a configuration allows for a strong mechanical connection between the heating device 100 and the casing 10, while also providing a stable supply of power to the heating device 100 via the electrical contacts 116.

[0033] The electrical contacts 116 are preferably positioned on the insulator 102 to minimize heat flow between the opening 111 and the electrical contacts 116. In this way, the electrical contacts 116 are made in the portion of the outer wall 106 that remains the coldest during use of the aerosol generating device 1. This reduces heat transfer between the insulator 102 and the casing 10. The electrical contacts 116 may be positioned on the insulator 102 to maximize their distance from the opening 111 of the cavity 110. The maximum distance may correspond to a direct path between the opening 111 and the electrical contacts 116. Preferably, the maximum distance is determined to be the maximum distance along the heat path between the opening 111 and the electrical contacts 116. Since heat flow is suppressed through the insulating region 108 of the insulator 102, this distance may be measured along the heat path through the air surrounding the insulator 102 and / or along the outer wall 106 of the insulator 102.

[0034] In the cup-shaped insulator 102 shown in Figures 1A and 1B, the electrical contact 116 can be located at the base of the insulator 102 opposite the opening 111 of the cavity 110. In other words, the insulator 102 is attached to the casing 10 in a cantilever configuration, with only one end of the insulator 102 connected to the casing 10. In this way, the distance along the heat path between the opening 111 and the electrical contact 116 is maximized, thereby reducing heat transfer between them. In other words, the electrical contact 116 is made on the coldest part of the outer wall 106 during use, thereby reducing the amount of heat transferred from the insulator 102 to the casing 10 of the device 1.

[0035] Figure 2A shows a schematic cross-section of a second embodiment of the aerosol generating device 1. Device 1 is similar to device 1 described above in that it comprises a casing 10 having a base portion 12 and side portions 14 surrounding a chamber 15. However, device 1 includes an alternative heating device 200, which is shown in more detail in Figure 2B. In Figure 2B, the heating device 200 is depicted with consumables 5 inserted, which include a tobacco 6 and a filter 7.

[0036] Unlike the embodiments shown in Figures 1A and 1B, the thermal insulator 202 in this embodiment has both longitudinal ends open such that it has a tubular cross-section when viewed perpendicular to its longitudinal axis. More specifically, the cavity 210 has a first opening 211a at a first longitudinal end and a second opening 211b at a second longitudinal end. The first opening 211a is configured to receive the consumable 5. A plug 236 may be provided in the second opening 211b to prevent the consumable 5 from being inserted excessively into the cavity 210. The plug 236 may include PEEK, rubber, or other suitable heat-resistant material.

[0037] The insulator 202 also includes one or more electrical contacts 216 connected to the heater 212. The electrical contacts 216 are mechanically connectable to the casing 10 of the device 1. In this embodiment, the electrical contacts 216 are mechanically connectable to a side portion 14 of the casing 10. More specifically, the electrical contacts 216 are mechanically connectable to the inner wall 14b of the side portion 14 of the casing 10. If the side portion 14 has only a single wall, it will be understood that the electrical contacts 216 may be mechanically connectable to a single wall (e.g., an outer wall). By providing both mechanical and electrical connections between the insulator 202 and the casing 10 using the same means, the number of heat conduction paths is reduced. Preferably, the electrical contacts 216 provide the only connection between the insulator 202 and the casing 10. In this way, the number of heat conduction paths is minimized, and heat transfer between the insulator 202 and the casing 10 is further reduced. To achieve this, the material and shape of the electrical contact 216 are selected to provide sufficient strength to hold the heating device 200 in place within the chamber 15 during use of the device 1 without requiring additional contacts between the heating device 200 and the casing 10. In other words, the electrical contact 216 provides a solid connection, thereby suppressing the movement of the insulator 202 relative to the casing 10.

[0038] Preferably, the electrical contact 216 is also mechanically detachable from the casing 10 so that the heating device 200 is removable from the casing 10. Advantageously, by providing a heating device 200 that is removable from the casing 10, components of the heating device 200 can be easily repaired and replaced without the need to replace the entire device 1.

[0039] In this example, the electrical contact 216 comprises a pair of pins. The pins may be connectable to the casing 10 by a lockable coupling. The pins are inserted into the side portion 14 of the casing 10 and can be locked in place via small rotations or translations. As previously described with respect to the heating device 100, various connection configurations can be used to provide both strong mechanical and electrical connections between the heating device 200 and the casing 10 via the electrical contact 216.

[0040] The electrical contacts 216 are preferably positioned on the insulating material 202 to minimize heat flow between the openings 211a, 211b and the electrical contacts 216. In this way, the electrical contacts 216 are made in the portion of the outer wall 206 that remains the coldest during use of the aerosol generating device 1. This reduces heat transfer between the insulating material 202 and the casing 10.

[0041] In the tubular insulator 202 shown in Figures 2A and 2B, the electrical contacts 216 may be located on the side of the insulator 202, spaced apart from the first opening 211a and the second opening 211b of the cavity 210. For example, the electrical contacts 216 may be located on the side of the insulator 202 substantially equidistant from both the first opening 211a and the second opening 211b of the cavity 210. In this location, the shortest distance between the electrical contacts 216 and either of the openings 211a or 211b is maximized, thereby reducing heat transfer from either of the openings 211a or 211b to the electrical contacts 216. Alternatively, if one of the openings 211a or 211b is determined to generate more heat than the other (e.g., due to the thermal insulation properties of the plug 236), the position of the electrical contacts 216 may be adjusted accordingly (e.g., by moving them closer to the opening 211b containing the plug 236). In other words, the electrical contacts 216 are formed in the coldest part of the outer wall 206 during use, thereby reducing the amount of heat transferred from the insulator 202 to the casing 10 of the device 1. In any of the embodiments described herein, the coldest part of the outer wall 206 may be calculated by computer simulation or the like to determine the optimal placement of the electrical contacts 216.

[0042] It will be understood that the aforementioned electrical contacts 116, 216 may be located at other positions on the insulators 102, 202 to provide a mechanical connection of the device 1 to the casing 10. Figures 3 and 4 show alternative embodiments of heating devices 300, 400 that may be used in the device 1. Heating device 300 is similar to the cup-shaped heating device 100 described above, except that the electrical contacts 316 are located on the end of the insulator 302 adjacent to the opening 311 of the cavity 310. Heating device 400 is similar to the cup-shaped heating devices 100, 300 described above, except that the electrical contacts 416 are located on the side of the insulator 402 near the opening 411 of the cavity 410. This may allow for easier inspection and / or repair of the heating devices 300, 400, which may be preferable for certain types of device 1. As described above, the electrical contacts 316 and 416 are mechanically connectable to the casing 10 of device 1, preferably providing the only connection between the insulators 302 and 402 and the casing 10.

[0043] While the foregoing describes exemplary embodiments of the present invention, it will be understood that the present invention is described merely as an example herein, and modifications of details can be made within the scope of the invention. Furthermore, those skilled in the art will understand that the present invention is not limited to the embodiments disclosed herein, nor is it limited to any details shown in the accompanying drawings that are not described in detail herein and are not defined in the claims.

[0044] Furthermore, other further embodiments of the present invention will become apparent to those skilled in the art by considering this specification and can be devised without departing from the basic scope of the invention as defined by the following claims.

Claims

1. Aerosol generating device, An insulating body comprising: an inner wall and an outer wall separated from each other; a cavity defined within the inner wall capable of receiving an aerosol-forming substrate; and a heater positioned to heat the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity. A casing surrounding the aforementioned insulating body, An electrical contact connected to the heater, wherein at least one of the electrical contacts is mechanically connectable to the casing to hold the heat insulating body in a predetermined position, An aerosol generating device equipped with the following features.

2. The aerosol generating device according to claim 1, wherein the electrical contact provides the only connection between the heat insulating body and the casing.

3. The aerosol generating device according to claim 1, wherein the inner wall and the outer wall of the insulating body are separated from each other by a vacuum, thereby providing a vacuum insulating body.

4. The aerosol generating device according to claim 1, wherein the heat insulating body is removable from inside the casing.

5. The aerosol generating device according to claim 1, wherein the cavity comprises at least one opening whose inner wall is joined to the outer wall, and the one or more electrical contacts are located on the insulating material in a location that minimizes heat flow between the at least one opening and the electrical contacts.

6. The aerosol generating device according to claim 5, wherein the insulating body is cup-shaped such that the cavity has a single opening into which the inner wall is joined to the outer wall, and the electrical contacts are located at the base of the insulating body opposite the opening of the cavity.

7. The aerosol generating device according to claim 5, wherein the insulating body is tubular such that the cavity has two openings into which the inner wall is joined to the outer wall, and the electrical contacts are located on the side of the insulating body spaced apart from both of the two openings.

8. The aerosol generating device according to any one of claims 1 to 7, wherein the electrical contacts are mechanically connectable to the base portion of the casing.

9. The aerosol generating device according to any one of claims 1 to 7, wherein the electrical contacts are mechanically connectable to the side portion of the casing.

10. The aerosol generating device according to claim 9, wherein the side portion of the casing comprises an inner wall and an outer wall, and the electrical contacts are mechanically connectable to the inner wall.

11. The aerosol generating device according to any one of claims 1 to 7, wherein the electrical contact comprises a pair of pins.

12. The aerosol generating device according to claim 11, wherein the pair of pins can be connected to the casing by a lockable coupling.

13. The aerosol generating device according to claim 12, wherein the pair of pins can be connected to the casing using a bayonet connection or a screw thread.

14. The aerosol generating device according to any one of claims 1 to 7, wherein the electrical contact comprises a pin and a threaded outer surface that can engage with the casing to hold the insulating body in place.

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