Aerosol generating device with insulating wall and related assembly method

Abstract

The aerosol generating device (10) comprises a housing (12), the housing (12) defining an interior space (30), the device (10) comprising at least one heat source (34) within the interior space (30), the housing (12) comprising at least one insulating wall (40) having an inner surface (41) facing the interior space (30) and an outer surface (42) opposite the inner surface (41), the device (10) further comprising an insulating layer (50) disposed on at least one thermally protected portion of the outer surface (42) of the insulating wall (40), the insulating layer (50) comprising a mesh sublayer, the mesh sublayer comprising a woven structure.

Description

Technical Field

[0001] The present invention relates to an aerosol generating device provided with a heat insulating wall.

[0002] The present invention also relates to a method of assembling such an aerosol generating device.

Background Art

[0003] Different types of aerosol generating devices are already known in the art. Generally, such a device comprises a housing defining an internal space. The internal space comprises, for example, a storage part for storing a vaporizable material which may be liquid or solid. Usually, the internal space also comprises a heat source. For example, this heat source is a heating system made up of one or more electrically operated resistive heating elements arranged to heat the vaporizable material to generate an aerosol. The aerosol is discharged into a flow path extending between an inlet and an outlet of the device. The outlet may be arranged as a mouthpiece for the user to inhale to deliver the aerosol.

[0004] In the case of a large amount of vaping, the heat source may generate a significant amount of heat. This can lead to heating of the housing, which may make it uncomfortable for the user to hold the device. The user may then have to stop vaping in order to cool the device.

Summary of the Invention

Problems to be Solved by the Invention

[0005] One object of the present invention is to provide an aerosol generating device with reduced overheating.

Means for Solving the Problems

[0006] For this purpose, the present invention is an aerosol generating device comprising a housing, the housing defining an internal space, the device comprising at least one heat source within the internal space, The housing comprises at least one insulating wall having an inner surface facing the interior space and an outer surface facing the inner surface, The device further comprises an insulating layer disposed on at least one thermally protected portion of the outer surface of an insulating wall, the insulating layer comprising a mesh sublayer, the mesh sublayer comprising a woven structure, the woven structure comprising through holes through which heat emitted by a heat source flows from the internal space to the outside of the device, the through holes having a size between 20 μm and 100 μm, relating to an aerosol generating device.

[0007] The woven structure of the mesh sublayer forms perforations on the thermal protection portion of the outer surface. These perforations facilitate the flow of heat from within the internal space to the outside of the device.

[0008] According to some embodiments, the mesh sublayer is made of wood or textile.

[0009] Wood and textiles are relatively good insulating materials. Therefore, the mesh sublayer allows heat to flow through its mesh openings but conducts very little heat.

[0010] According to some embodiments, the insulation layer further comprises a backing sublayer fixed to the thermal protection portion and an adhesive sublayer fixed to the backing sublayer, and the mesh sublayer is fixed to the adhesive sublayer.

[0011] Due to these characteristics, the mesh sublayer can be securely attached to the insulated wall.

[0012] According to some embodiments, the aerosol generating device further comprises a thermal diffusion layer disposed between at least one thermal diffusion portion on the inner surface of the insulating wall and the internal space of the device.

[0013] According to some embodiments, the thermal diffusion layer extends substantially parallel to the extended plane of the insulating wall.

[0014] According to some embodiments, the heat diffusion layer is a heat conduction plate.

[0015] According to some embodiments, the heat conductive plate is made of copper.

[0016] Due to these characteristics, the heat generated by the heat source is diffused throughout the entire housing. This prevents heat from accumulating in the narrow space surrounding the heat source. This also increases the heat exchange surface with the thermal protection area. Heat flow through the mesh sublayer is increased.

[0017] According to some embodiments, the aerosol generating device further comprises a support attached to a housing and extending within an internal space, and at least one magnet positioned on the support to fix a heat diffusion layer to the support.

[0018] Due to these characteristics, the thermal diffusion layer is easily attached to the device.

[0019] According to some embodiments, the aerosol generating device further includes a light source within the internal space of the device.

[0020] According to some embodiments, the thermal diffusion layer includes an optical orifice positioned facing the light source.

[0021] Due to these characteristics, despite the presence of a heat diffusion layer, the user can determine whether the device is powered on or not by the light emanating from the light source and passing through the optical orifice.

[0022] According to some embodiments, the insulating wall is a removable wall of the housing.

[0023] Due to these characteristics, the insulated walls are customizable. Device users can select a specific insulated wall based on its thermal insulation properties, or other characteristics such as its appearance or texture.

[0024] According to some embodiments, the heat source is a heating system configured to generate an aerosol from a vaporizable material.

[0025] The heating system of the aerosol generating device can generate a significant amount of heat. Due to these characteristics, the device can discharge a significant amount of heat generated from its heating system.

[0026] The present invention also relates to a method of assembling an aerosol generating device as disclosed above, which includes the step of fixing a heat insulation layer on a heat protection portion on the outer surface of a heat insulation wall.

[0027] According to some embodiments, the heat insulation layer further comprises a backing sub-layer fixed to the heat protection portion and an adhesive sub-layer fixed to the backing sub-layer, the mesh sub-layer is fixed to the adhesive sub-layer, and the fixing step includes - fixing the adhesive sub-layer on the backing sub-layer; - placing the mesh sub-layer on the adhesive sub-layer to form a heat insulation layer; - placing the heat insulation layer in a heat press; - pressurizing and heating the heat insulation layer to fix the mesh sub-layer to the adhesive sub-layer; - cutting the heat insulation layer to a dimension that conforms to the dimension of the heat protection portion; - fixing the backing sub-layer on the heat protection portion.

Brief Description of the Drawings

[0028] [Figure 1] It is a perspective view of an aerosol generating device according to the present invention. [Figure 2] It is a schematic cross-sectional view taken along the vertical plane II-II of the aerosol generating device of FIG. 1. [Figure 3] It is a schematic front view of the aerosol generating device of FIG. 1 with the heat insulation wall removed. [Figure 4] It is a schematic rear view of the heat insulation wall of the aerosol generating device of FIG. 1. [Figure 5] It is a cross-sectional view of the heat insulation wall and the heat insulation layer of the device of FIG. 1, taken perpendicular to the extension plane of the heat insulation wall.

Modes for Carrying Out the Invention

[0029] Before describing the present invention, it should be understood that the present invention is not limited to the structural details described below. Those skilled in the art who are interested in this disclosure will see that other embodiments of the present invention are possible and can be practiced or carried out in a variety of ways.

[0030] As used herein, the terms “aerosol generating device” or “device” may include a vaping device that delivers an aerosol containing an aerosol for vaping to a user by an aerosol generating unit (e.g., an aerosol generating element that generates vapor that condenses into an aerosol before being delivered to the device outlet, for example, in a mouthpiece, for inhalation by the user). The device may be portable. “Portable” may mean a device used when held by a user. The device may be adapted to generate a variable amount of aerosol (as opposed to a fixed amount of aerosol) by, for example, activating a heating system over a variable amount of time, and the generation may be controlled by a trigger. The trigger may be user-activated, such as a vaping button and / or an inhalation sensor. The inhalation sensor may be highly sensitive to inhalation intensity and inhalation duration and may enable the delivery of a variable amount of vapor (to mimic the smoking effect of conventional flammable smoking articles such as cigarettes, cigars, or pipes).

[0031] As used herein, the term “aerosol” may include solid particles, droplets, or a suspension of one or more gaseous precursors. The suspension may be in a gaseous state, including air. In general, the aerosols herein refer to or may include vapor. The aerosols may contain one or more components of the precursors.

[0032] As used herein, the terms “vaporizable material,” “aerosol-forming precursor,” or “precursor,” or “aerosol-forming substance,” or “substance,” may refer to one or more of liquids, solids, gels, mousses, foams, or other substances. The precursor may be treatable by the device’s heating system to form an aerosol, as defined herein. The precursor may contain one or more of nicotine, caffeine, or other active ingredients. The active ingredients may be carried by a carrier, which may be liquid. The carrier may contain propylene glycol or glycerin. A flavoring may be present. The flavoring may contain ethyl vanillin (vanilla), menthol, isoamyl acetate (banana oil), or similar. The solid aerosol-forming substance may be in the form of a rod containing processed tobacco material, corrugated sheets, or aligned strips of re-tobacco (RTB).

[0033] Referring to Figures 1 and 2, the aerosol generating device 10 according to the present invention comprises a housing 12. For example, as shown in Figure 1, the housing 12 has a substantially parallelepiped shape with slightly rounded edges. The housing 12 comprises walls 20 that define the internal space 30 of the device 10. For example, the housing 12 comprises a front wall 21, an opposing rear wall 22, two lateral side walls 23, and two upper and lower side walls 24.

[0034] The device 10 further comprises a support 32 attached to the housing 12, extending into the internal space 30, and configured to support the functional components of the device 10. The support 32 may be formed by a chassis adapted to receive and secure such functional components inside the housing 12. For example, such functional components include electronic components, a battery, or a power supply designed to power the electronic components. In some embodiments, the functional components may further comprise a storage section (not shown) for storing vaporizable material. In these embodiments, the storage section is therefore located inside the housing 12. In this case, it can be refilled directly with vaporizable material or using a removable cartridge designed to be inserted into such section. In some other embodiments, the storage section may be formed outside the housing 12, for example, by a removable cartridge. In this case, the housing 12 defines a fixing means configured to receive and secure the removable cartridge.

[0035] The device 10 further comprises at least one heat source 34 located within the internal space 30. For example, the heat source 34 is included in the heating system of the device 10, which is attached to the support 32 and configured to generate an aerosol by heating a vaporizable material. In this case, the heat source 34 may correspond to a heating element used to heat the vaporizable material contained in the storage section, such as a heating plate, an electrical resistor, or a susceptor. According to other embodiments, the heat source 34 is formed by the device's battery and / or power supply, or any other electrical component of the device. In some embodiments, the heat source 34 is formed by some of the components described above.

[0036] In the event of heavy use of device 10, the heat source 34 may generate a considerable amount of heat. This could lead to overheating of device 10, particularly the walls 20 of the housing. Users of device 10 may then feel this unpleasant heat in their hands. In cases of severe overheating, users may suffer from it, and device 10 may become unsupportable. In such cases, it may be necessary to shut off the heat source 34 to avoid damage to device 10.

[0037] For example, as shown in Figures 2 and 3, the device 10 further includes a light source 36 located within the internal space 30. For example, the light source 36 is mounted on the support 20 and faces the front wall 21 of the housing. For example, it is configured to emit light when the device 10 is turned on, particularly when a battery or power supply provides power to the device's electronic components or heating system to generate an aerosol.

[0038] As can be seen in Figures 2 and 4, the housing 12 is provided with at least one insulated wall 40. For example, the insulated wall 40 is one of the walls 20 of the housing 12, for example, the front wall 21. For example, the insulated wall 40 extends substantially along the extension plane P. The insulated wall 40 comprises an inner surface 41 facing the internal space 30 and an outer surface 42 opposite to the inner surface 41. The insulated wall 40 is a removable wall of the housing 12 that can move between, for example, an installation position (Figure 1) where the insulated wall 40 is attached to the housing 12 and a separation position (Figures 2, 3, and 4) where the insulated wall 40 is separated from the housing 12. In the installation position, the insulated wall 40 protects the internal space 30 from external elements, such as dust or water. As will be described below, in the installation position, the insulated wall 40 also regulates the flow of heat from the heat source 34. In the separation position, a user can access the internal space 30 for, for example, repair or maintenance of the functional elements of the device 10. In some embodiments, the user can access the internal space 30 and refill the storage portion with a vaporizing material directly or by a removable cartridge.

[0039] The insulation wall 40 may also be removed and replaced by another insulation wall 40 exhibiting different features, such as a different aspect of the outer surface 42 or a different texture. For example, the insulation wall 40 may be fixed to other walls of the housing 12 or support 32 by snap fasteners. For example, the lateral side walls 23 and the upper and lower side walls 24 are provided with peripheral snap fastener boxes (not shown) on their leading edges. The insulation wall 40 may be provided with peripheral snap fastener pins on its edges, which are designed to cooperate with the peripheral snap fastener boxes in order to mount the insulation wall 40 to the walls 23, 24 in mounting positions.

[0040] In some embodiments, for example, as shown in the embodiment in Figure 2, the insulating wall 40 includes an optical orifice 43 designed to allow light emitted by the light source 36 to pass through and reach the outside of the device 10. For example, the optical orifice 43 of the insulating wall 40 is filled with a translucent material to allow emitted light to pass through but to prevent external elements from entering the internal space 30.

[0041] The outer surface 42 of the insulated wall 40 includes at least one thermal protection portion. The device 10 includes an insulating layer 50 that is placed on the thermal protection portion, for example, and fixed to the thermal protection portion. As shown in the embodiment of Figure 2, the thermal protection portion corresponds to the entire outer surface 42. According to another embodiment of the present invention, the thermal protection portion corresponds to a portion of the outer surface 42, for example, a portion of the outer surface 42 that faces the heat source 34.

[0042] As shown in Figure 5, the thermal insulation layer 50 includes a mesh sublayer 52. For example, the thermal insulation layer 50 further includes an adhesive sublayer 54 and a backing sublayer 56. For example, the backing sublayer 56 is fixed to the outer surface 42 of the thermal insulation wall 40, the adhesive sublayer 54 is placed on top of the backing sublayer 56, and the mesh sublayer 52 is placed on top of the adhesive sublayer 54.

[0043] The mesh sublayer 52 has a woven structure of materials such as wood or textiles. The mesh sublayer 52 is therefore composed of woven fibers. For example, the mesh sublayer 52 is composed of wood fibers or textile fibers. The wood fibers are composed of cellulose, for example. The textile fibers are composed of cotton, polyester, nylon, acrylic, and / or polyurethane. The woven structure may be a woven or nonwoven structure of wood fibers or textile fibers. Such a woven structure has through holes that allow heat generated by the heat source 34 to flow from the internal space 30 to the outside of the device 10. For example, the mesh sublayer 52 extends facing the entire outer surface 42 of the insulating wall 40. For example, the mesh sublayer 52 is fixed on the adhesive sublayer 54. The through holes in the mesh sublayer 52 also allow light emitted by the light source 36 to pass through and reach the outside of the device 10. For example, the through-hole has a size between 20 μm and 100 μm, preferably between 30 μm and 90 μm, more preferably between 40 μm and 80 μm, even more preferably between 50 μm and 70 μm, and particularly approximately equal to 60 μm. Of course, other ranges of values ​​are also possible for the size of the through-hole.

[0044] The backing sublayer 56 is fixed to the thermal protection portion. For example, the backing sublayer 56 is made of nonwoven fibers. For example, the nonwoven fibers are made of polyester.

[0045] The adhesive sublayer 54 is fixed to the backing sublayer. For example, the adhesive sublayer 54 is composed of a thermoplastic resin adhesive that flexibly changes shape. For example, the adhesive sublayer 54 is composed of a hot melt adhesive such as an acrylic resin adhesive. For example, the mesh sublayer 52 is fixed to the adhesive sublayer 54 and therefore fixed to the thermal insulation wall 40 via the adhesive sublayer 54 and the backing sublayer 56. For example, the backing sublayer 56 and the adhesive sublayer 54 extend facing only a portion of the thermal protection portion and only a portion of the mesh sublayer 52. In this way, the backing sublayer 54 and the adhesive sublayer 56 do not obstruct the flow of heat from the heat source 34 to the outside of the device 10, but still firmly attach the mesh sublayer 52 to the thermal insulation wall 40.

[0046] Referring to Figure 2, the inner surface 41 of the insulating wall 40 has at least one heat diffusion portion. For example, the device 10 further includes a heat diffusion layer 60 positioned between the heat diffusion portion of the inner surface 41 of the insulating wall 40 and the internal space 30 of the device 10. The heat diffusion layer 60 extends substantially parallel to the extension surface P of the insulating wall 40. For example, it is fixed to the inner surface 41 of the insulating wall 40. The heat diffusion layer 60 is made of, for example, copper or any other heat diffusion material, e.g., a heat conductive plate. The heat diffusion layer 60 is configured to diffuse the heat emitted by the heat source 34 throughout its entirety, for example, over the entire extension surface P. The heat diffusion layer 60 diffuses the generated heat onto an increased surface facing the heat protection portion. The heat exchange surface between the internal space 30 and the outside of the device 10 is thus increased. For example, as shown in Figure 2, the heat diffusion layer 60 includes an optical orifice 64 positioned facing the light source 36 when the insulating wall 40 is in its mounting position. At the mounting position of the insulating wall 40, the light emitted by the light source 34 exits the housing 12 through the optical orifice 64 of the heat diffusion layer 60, the optical orifice 43 of the insulating wall 40, and the through-holes of the mesh sub-layer 52.

[0047] For example, as shown in Figures 2 and 3, the device 10 further includes at least one magnet 62 positioned on the support 32 to fix the heat conduction plate to the support 32 when the heat conduction plate is made of a ferromagnetic material such as copper. For example, as shown in Figures 2 and 3, the device 10 includes two magnets 62. The magnets 62 constitute an additional fixing means between the heat insulating wall 40 and the walls 23 and 24.

[0048] It will be apparent to those skilled in the art that the thermal insulation layer 50 and the thermal diffusion layer 60 described above can be placed on any other walls 20 of the housing 12, in particular, depending on the arrangement of the heat source 34 inside the housing. In some embodiments, these layers 50, 60 can be placed on several walls 20 or on a specific side wall 20, for example, if the housing 12 has a cylindrical shape.

[0049] The operation method of the aerosol generating device 10 is described below. The user of device 10 activates the vaping button or inhalation sensor to generate an aerosol. This supplies power to the heat source 34, which generates heat. For example, when the heat source 34 generates heat, the light source 36 emits light. The user of device 10 can then recognize that the heat source 34 is powered on by observing the light emitted through the optical orifices 64 and 43 and through the mesh sublayer 52. The heat diffusion layer 60 diffuses the heat generated by the heat source 34 throughout. The heat is diffused, for example, across the extension surface parallel to the extension plane P. The diffused heat then flows from inside the internal space 30 to the outside of device 10 through the insulating wall 40 and through the through-holes in the mesh sublayer 52. This leads to efficient cooling of the internal space 30 and the housing 12. Even in the case of large amounts of vaping, overheating of the wall 20 is prevented.

[0050] If necessary, the user can remove the insulating wall 40 together with the insulating layer 50 and the heat diffusion layer 60 and replace it with, for example, different layers 50, 60 or different insulating walls having different characteristics or textures.

[0051] Herein, the assembly method of the aerosol generating device 10 will be described. The assembly method includes the step of fixing the insulation layer 50 to the thermal protection portion of the outer surface 42 of the insulation wall 40. The fixing step includes fixing the adhesive sublayer 54 onto the backing sublayer 56. The mesh sublayer 52 is then placed on the adhesive sublayer 54 to form the insulation layer 50. The insulation layer 50 is then placed on a heating press. The insulation layer 50 is pressurized and heated in the heating press to fix the mesh sublayer 52 to the adhesive sublayer 54. The insulation layer is then cut to dimensions that conform to the dimensions of the thermal protection portion. Finally, the backing sublayer 56 is fixed onto the thermal protection portion. Thus, as shown in the figure, the mounting of the insulation layer 50 onto the wall 20 of the housing 12 of a conventional device is facilitated.

Claims

1. An aerosol generating device (10) comprising a housing (12), wherein the housing (12) defines an internal space (30), and the device (10) comprises at least one heat source (34) within the internal space (30), The housing (12) includes at least one insulating wall (40) having an inner surface (41) facing the internal space (30) and an outer surface (42) facing the inner surface (41), The device (10) further comprises an insulating layer (50) disposed on at least one thermally protected portion of the outer surface (42) of the insulating wall (40), the insulating layer (50) comprises a mesh sublayer (52), the mesh sublayer (52) comprises a woven structure, the woven structure comprises through holes that allow heat generated by the heat source (34) to flow from the internal space (30) to the outside of the device (10), and the through holes have a size between 20 μm and 100 μm. Aerosol generating device (10).

2. The aerosol generating device (10) according to claim 1, wherein the mesh sublayer (52) is made of wood or woven fabric.

3. The aerosol generating device (10) according to claim 1 or 2, wherein the heat insulating layer (50) further comprises a backing sublayer (56) fixed to the heat protection portion and an adhesive sublayer (54) fixed to the backing sublayer (56), and the mesh sublayer (52) is fixed to the adhesive sublayer (54).

4. Furthermore, the aerosol generating device (10) according to any one of claims 1 to 3 further comprises a heat diffusion layer (60) disposed between at least one heat diffusion portion of the inner surface (41) of the heat insulating wall (40) and the internal space (30) of the device (10).

5. The aerosol generating device (10) according to claim 4, wherein the heat diffusion layer (60) extends substantially parallel to the extension surface (P) of the insulating wall (40).

6. The aerosol generating device (10) according to claim 4 or 5, wherein the heat diffusion layer (60) is a heat conductive plate.

7. The aerosol generating device (10) according to claim 6, wherein the heat conductive plate is made of copper.

8. Furthermore, the aerosol generating device (10) according to any one of claims 4 to 7 further comprises a support (32) attached to the housing (12) and extending into the internal space (30), and at least one magnet (62) disposed on the support (32) to fix the heat diffusion layer (60) to the support (32).

9. Furthermore, the aerosol generating device (10) according to any one of claims 1 to 8, comprising a light source (36) within the internal space (30) of the device (10).

10. The aerosol generating device (10) according to claim 9, which is used in combination with any one of claims 4 to 8, wherein the heat diffusion layer (60) comprises an optical orifice (64) arranged facing the light source (36).

11. The aerosol generating device (10) according to any one of claims 1 to 10, wherein the heat insulating wall (40) is a detachable wall of the housing (12).

12. The aerosol generating device (10) according to any one of claims 1 to 11, wherein the heat source (34) is a heating system configured to generate an aerosol from a vaporizable material.

13. A method for assembling an aerosol generating device (10) according to any one of claims 1 to 12, comprising the step of fixing the thermal insulation layer (50) onto the thermal protection portion of the outer surface (42) of the thermal insulation wall (40).

14. The thermal insulation layer (50) further comprises a backing sublayer (56) fixed to the thermal protection portion and an adhesive sublayer (54) fixed to the backing sublayer (56), the mesh sublayer (52) being fixed to the adhesive sublayer (54), and the fixing step is, - To fix the adhesive sublayer (54) onto the backing sublayer (56), - The mesh sublayer (52) is placed on the adhesive sublayer (54) to form the heat insulating layer (50), - Placing the aforementioned heat insulating layer (50) inside the heated press, - The insulating layer (50) is pressurized and heated to fix the mesh sublayer (52) to the adhesive sublayer (54), - Cutting the heat insulating layer (50) to a size that matches the dimensions of the heat protection portion, - The backing sublayer (56) is fixed onto the thermal protection portion, The assembly method according to claim 13, including the method described in claim 13.

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