Aerosol generator, induction coil, and method for manufacturing the same

Abstract

This application discloses an aerosol generator and an induction coil. The aerosol generator includes an induction coil for generating a changing magnetic field, and a susceptor that generates an aerosol by inductively heating an aerosol generating substrate, such as a liquid substrate, in the changing magnetic field. Here, the conductor material of the induction coil includes two or more bundles of wire cores, and the wire core includes two or more conductive threads, thereby suppressing the induction coil itself from forming a current offset and reducing the internal loss of the induction coil itself. Alternatively, the conductor material of the induction coil includes multiple bundles of wire cores, and each bundle of wire cores is formed by twisting multiple conductive threads once or multiple times, and the number of conductive threads used in the first twisting of the multiple conductive threads is 3 to 20, thereby avoiding the occurrence of a thread breakage phenomenon, lowering the AC impedance of the induction coil itself, reducing losses due to the internal proximity effect, and increasing the heat generation efficiency of the aerosol generator.

Description

Technical Field

[0001] (Cross - reference to Related Applications) This application claims the priority of a Chinese patent application with an application number of 202111318784.9 and an invention title of "Aerosol Generator and Induction Coil", which was filed with the China National Intellectual Property Administration on November 9, 2021, and all of its contents are incorporated herein by reference.

[0002] This application further claims the priority of a Chinese patent application with an application number of 202211351480.7 and an invention title of "Electronic Atomization Device, Induction Coil and Method Thereof", which was filed with the China National Intellectual Property Administration on October 31, 2022, and all of its contents are incorporated herein by reference.

[0003] Embodiments of the present invention relate to the technical field of electronic atomization, particularly to aerosol generators, induction coils and their manufacturing methods.

Background Art

[0004] Cigarette products (such as tobacco, cigars, etc.) generate tobacco smoke by burning tobacco during use. As an alternative to these products that burn tobacco, attempts have been made to manufacture products that release compounds without combustion. Examples of such products include heating devices that release compounds by heating rather than burning materials. For example, the material may be a tobacco product or other non - tobacco products, and these non - tobacco products may or may not contain nicotine.

[0005] As a known heating device, an aerosol generator can generate a magnetic field by an induction coil and induce the susceptor to generate heat, thereby heating the atomized liquid substrate to release compounds and generate an aerosol for the user to inhale.

[0006] However, conventional aerosol generators use induction coils made of one or more fine conductive threads, which makes them prone to thread breakage during the twisting process during manufacturing. This results in high AC impedance in the coils and low heat generation efficiency in the aerosol generators. [Overview of the project]

[0007] A first aspect of this application provides an aerosol generating device comprising an induction coil for generating a changing magnetic field and a susceptor for generating an aerosol by inductively heating an aerosol generating substrate in the changing magnetic field, wherein the conductor material of the induction coil includes two or more bundles of wire cores, and the wire cores include two or more conductive threads.

[0008] In a more preferred embodiment, the conductive material of the induction coil has a circular or rectangular cross-section.

[0009] In a more preferred embodiment, the induction coil is constructed as a solenoid coil or a planar spiral coil.

[0010] In a more preferred embodiment, the conductor material of the induction coil includes 3 to 10 bundles of the wire cores.

[0011] In a more preferred embodiment, the conductive thread has a diameter of 0.02 to 0.2 mm.

[0012] In a more preferred embodiment, the conductive yarn has a break elongation percentage of 1-6%.

[0013] In a more preferred embodiment, the wire core has an ultimate tensile strength exceeding 50 MPa.

[0014] In a more preferred embodiment, two or more of the conductive threads in the core are twisted together, and / or two or more bundles of the cores in the conductor material of the induction coil are twisted together.

[0015] In a more preferred embodiment, the core further comprises a first coating layer for covering two or more of the conductive threads, and / or the induction coil further comprises a second coating layer for covering two or more bundles of the cores.

[0016] In a more preferred embodiment, the aerosol generating substrate comprises a liquid substrate, the susceptor is configured to generate an aerosol by heating the liquid substrate, and the core per bundle is formed by twisting a plurality of conductive threads once or multiple times, wherein the number of conductive threads used in the first twist of the plurality of conductive threads is 3 to 20.

[0017] In a more preferred embodiment, the core is formed by twisting a plurality of conductive threads three or four times.

[0018] In a more preferred embodiment, the diameter of the conductive thread is 0.01 mm to 0.05 mm.

[0019] In a more preferred embodiment, the conductor material of the induction coil includes 500 to 2000 of the conductive threads.

[0020] In a more preferred embodiment, the operating frequency provided to the induction coil is 500 kHz to 3 MHz.

[0021] In a more preferred embodiment, the induction coil is constructed as a solenoid coil, and the solenoid coil has 4 to 20 turns.

[0022] In a more preferred embodiment, the solenoid coil has an elliptical cross-section in its hollow portion.

[0023] In a more preferred embodiment, the solenoid coil has a spacing of 0.1 to 2 mm between adjacent windings.

[0024] A second aspect of the present application is an induction coil for an aerosol generator configured to generate a changing magnetic field, wherein the conductor material of the induction coil includes a plurality of bundles of wire cores, and each wire core per bundle is formed by twisting a plurality of conductive filaments once or multiple times, and the number of conductive filaments used in the first twisting of the plurality of conductive filaments is 3 to 20. An induction coil for an aerosol generator is provided.

[0025] A third aspect of the present application provides a method for manufacturing an induction coil for an aerosol generator, including the steps of preparing 3 to 20 conductive filaments and obtaining a first-stage wire core through the first twisting; preparing a plurality of bundles of the first-stage wire cores, and obtaining a second-stage wire core after performing a second twisting on the plurality of bundles of the first-stage wire cores; and preparing a plurality of bundles of the second-stage wire cores, and forming the conductor material of the induction coil after performing a third twisting on the plurality of bundles of the second-stage wire cores.

[0026] In a more preferred implementation, a third-stage wire core is obtained after performing a third twisting on a plurality of bundles of the second-stage wire cores, a plurality of bundles of the third-stage wire cores are prepared, and the conductor material of the induction coil is formed after performing a fourth twisting on the plurality of bundles of the third-stage wire cores.

[0027] The above induction coil is advantageous for suppressing the formation of its own current offset and reducing the internal loss of the induction coil itself. Moreover, the induction coil of the aerosol generator can avoid the occurrence of filament breakage, reduce the AC impedance of the induction coil itself, reduce the loss due to the internal proximity effect, and improve the heat generation efficiency of the aerosol generator.

Brief Description of the Drawings

[0028] One or more embodiments are exemplarily described by the figures in the corresponding drawings. However, these exemplary descriptions do not limit the embodiments. Elements / modules and processes with the same reference numerals in the drawings indicate similar elements / modules and processes. Unless otherwise specified, the figures in the drawings do not limit the proportion. [Figure 1]It is a structural schematic diagram of the aerosol generator provided in Example 1 in the specific embodiment of the present application. [Figure 2] It is a structural schematic diagram of the induction coil in FIG. 1 from one angle. [Figure 3] It is a cross-sectional schematic diagram of the conductor material of the induction coil in FIG. 2. [Figure 4] It is a cross-sectional schematic diagram of the conductor material of the induction coil of another example provided in Example 1 in the specific embodiment of the present application. [Figure 5] It is a cross-sectional schematic diagram of the induction coil of another example provided in Example 1 in the specific embodiment of the present application from one angle. [Figure 6] It is a cross-sectional schematic diagram of the conductor material of the induction coil in FIG. 5. [Figure 7] It is a structural schematic diagram of the induction coil of another example provided in Example 1 in the specific embodiment of the present application. [Figure 8] It is a structural schematic diagram of the induction coil of another example provided in Example 1 in the specific embodiment of the present application. [Figure 9] It is a structural schematic diagram of the aerosol generator of another example provided in Example 1 in the specific embodiment of the present application. [Figure 10] It is the self-temperature change curve during the use of the induction coil provided in Example 1 and the induction coil of the comparative example in the specific embodiment of the present application. [Figure 11] It is a schematic diagram of the aerosol generator provided in Example 2 in the specific embodiment of the present application. [Figure 12] It is a schematic diagram of the induction coil provided in Example 2 in the specific embodiment of the present application. [Figure 13] It is a cross-sectional schematic diagram of the conductor material of the induction coil provided in Example 2 in the specific embodiment of the present application. [Figure 14] It is a cross-sectional schematic diagram of another conductor material of the induction coil provided in Example 2 in the specific embodiment of the present application. [Figure 15]This is a schematic diagram of another induction coil provided in Example 2 of a specific embodiment of this application. [Figure 16] This is a schematic diagram of the induction coil formation method provided in Example 2 of a specific embodiment of this application. [Modes for carrying out the invention]

[0029] For ease of understanding of this application, the application will be described in more detail below, along with the drawings and specific embodiments. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art. The terms used in the specification of this application are for the purpose of describing specific embodiments and are not intended to limit this application. The terms "and / or" used herein include any and all combinations of one or more related enumerated items.

[0030] The aerosol generator provided in this application is for generating an aspirable aerosol by heating an aerosol generating substrate. The aerosol generating substrate may be a solid substrate or a liquid substrate, and the carrier supporting the aerosol generating substrate may be a rod-shaped or rod-shaped aerosol generating product, which includes at least one volatile solid substrate, and the carrier may be a pod capable of containing a certain volume of liquid substrate, and the pod has a reservoir chamber or holding medium for storing the liquid substrate. To facilitate understanding of this application, the application will be described in more detail below with reference to the drawings and specific embodiments. Example 1

[0031] One embodiment of this application provides an aerosol generator, the structure of which can be seen in Figure 1. A cavity into which aerosol-generating substrate A can be removed and accepted, An induction coil 50 for generating a magnetic field that changes under alternating current, A susceptor 30, at least a portion of which extends within the cavity, is inductively coupled to an induction coil 50, is penetrated by a changing magnetic field and generates heat, and further heats an aerosol generating substrate A, such as a rolled cigarette, causing at least one component of the aerosol generating substrate A to be released, thereby forming an aerosol for smoking. A battery cell 10 is a rechargeable DC battery cell capable of outputting DC current, The system includes a circuit 20 that is properly electrically connected to a rechargeable battery cell 10, converts the DC current output from the battery cell 10 into an alternating current having an appropriate frequency, and then supplies it to an induction coil 50.

[0032] Depending on the settings for product use, the induction coil 50 may include a spirally wound cylindrical inductor coil, as shown in Figure 1. The spirally wound cylindrical induction coil 50 may have a radius r in the range of approximately 5 mm to approximately 10 mm, and in particular, the radius r may be approximately 7 mm. The spirally wound cylindrical induction coil 50 may have a length in the range of approximately 8 mm to approximately 14 mm and a number of turns in the range of approximately 8 to 15 turns. Accordingly, the internal volume is approximately 0.15 cm³. 3 ~Approx. 1.10cm 3 It may be within the range.

[0033] In a more preferred embodiment, the frequency of the alternating current supplied by the circuit 20 to the induction coil 50 is 80 kHz to 500 kHz, and more specifically, the frequency may be in the range of approximately 200 kHz to 300 kHz.

[0034] In a preferred embodiment, the DC power supply voltage provided by the battery cell 10 is in the range of approximately 2.5V to approximately 9.0V, and the amperage of the DC current that can be provided by the battery cell 10 is in the range of approximately 2.5A to approximately 20A.

[0035] In one preferred embodiment, the susceptor 30 has a substantially pin-like, needle-like, rod-like, or blade-like shape, which is further advantageous for insertion into the aerosol-generating substrate A. The susceptor 30 may also have a length of about 12 mm, a width of about 4 mm, and a thickness of about 0.5 mm, and may be manufactured from grade 430 stainless steel (SS430). In an alternative embodiment, the susceptor 30 may have a length of about 12 mm, a width of about 5 mm, and a thickness of about 0.5 mm, and may be manufactured from grade 430 stainless steel (SS430). In other modified embodiments, the susceptor 30 may be constructed in a cylindrical or tubular shape, and when in use, its internal space forms a cavity for receiving the aerosol-generating substrate A, and generates an aerosol for smoking by heating the outer circumference of the aerosol-generating substrate A. These susceptors 30 may further be manufactured from grade 420 stainless steel (SS420) and iron / nickel-containing alloy materials (e.g., permalloy).

[0036] In the embodiment shown in Figure 1, the aerosol generator further includes a holder 40 for arranging the induction coil 50 and the susceptor 30, and the material of the holder 40 may include, for example, a high-temperature resistant nonmetallic material such as PEEK or ceramics. In the embodiment, the induction coil 50 is wound around and fixed to the outer wall of the holder 40. Also, as shown in Figure 1, the holder 40 has a hollow tubular shape, and a portion of its tubular hollow space forms a cavity for receiving the aerosol generating substrate A.

[0037] In selective implementations, the susceptor 30 may be manufactured from the susceptible material described above, or a susceptible material coating may be formed on the outer surface of a heat-resistant substrate such as ceramics by electroplating, deposition, or the like.

[0038] Furthermore, Figure 2 shows a schematic diagram of the structure of the induction coil 50 in one embodiment. The induction coil 50 is a solenoid coil wound with an elongated wire material, and after assembly, is placed around the cavity and / or susceptor 30. In this embodiment, the induction coil 50 has a circular cross-sectional profile of the wire material.

[0039] Furthermore, Figure 3 shows a schematic cross-sectional view of one embodiment of the conductor material for the induction coil 50 in Figure 2. In an embodiment, the conductor material for the induction coil 50 includes at least two bundles of wire cores 51, and each wire core 51 includes at least two conductive threads 511. In a more preferred embodiment, the conductor material for the induction coil 50 may include 3 to 10 bundles of wire cores 51, and each wire core 51 may include about 10 to 50 conductive threads 511.

[0040] Accordingly, in practice, the induction coil 50 generates a magnetic field that varies in frequency from 80 kHz to 500 kHz, and it is appropriate to set the maximum diameter of each conductive thread 511 to one-third or less of the skin depth. In practice, based on the fact that the skin depth is approximately 0.12 to 0.25 mm when operating at the above frequencies, it is desirable to set the maximum diameter of each conductive thread 511 to approximately 0.02 to 0.07 mm.

[0041] In some embodiments, the conductive thread 511 is manufactured from a low-resistivity metal or alloy such as copper, gold, silver or their alloys, and carbon material (carbon fiber or other conductive carbon material). In embodiments, based on the need to satisfy the above-mentioned skin depth requirements as much as possible and to enable the conductive thread 511 to be manufactured easily in terms of strength and production, in preferred embodiments, each conductive thread 511 is suitable to have a diameter of about 0.05 to 0.2 mm.

[0042] Specifically, when the conductive thread 511 is made of copper wire of the above diameter, it has a break elongation percentage of approximately 1-6%, which is advantageous in terms of ease of production and manufacturing, as well as strength. Furthermore, the conductive thread 511 is distributed almost uniformly within the wire core 51.

[0043] Furthermore, in a more preferred embodiment, the induction coil 50 may include a total of 12 to 200 conductive threads 511. In a specific embodiment, the induction coil 50 has 5 bundles of wire cores 51, each wire core 51 containing 24 conductive threads 511, each conductive thread 511 having a diameter of 0.08 mm, and the conductive threads 511 are copper wires.

[0044] The induction coil 50 constructed from the multiple bundles of wire cores 51 described above helps to eliminate the "internal proximity effect" (i.e., an alternating magnetic field generated by a single wire generates eddy currents in adjacent wires) that occurs in the operation of an induction coil 50 made from a single wire. This is advantageous in suppressing the formation of current offset by the induction coil 50 itself, and further reduces the internal resistance and internal losses of the induction coil 50.

[0045] Furthermore, in a more preferred embodiment, an insulating material layer, such as an insulating coating / insulating film, is formed on the surface of each conductive thread 511 in the core 51 by deposition, spraying, or the like, so that each conductive thread 511 in the core 51 is substantially insulated from one another. In a selective embodiment, the insulating material includes, but is not limited to, Teflon, polytetrafluoroethylene, polyimide, polyurethane, aromatic amide polymer, etc.

[0046] In some embodiments, the core 51 is formed by twisting together a plurality of conductive threads 511. In a more preferred embodiment, the plurality of conductive threads 511 are twisted together clockwise or counterclockwise.

[0047] In some other implementations, the conductive threads 511 in each core 51 are arranged in parallel in a spiral, or wound or braided together as a whole, so that they are wound stably without dispersion.

[0048] Each core 51 further includes a first covering layer 512 for covering the twisted conductive threads 511 to prevent or inhibit the dispersion of the conductive threads 511 within the core 51. In a preferred embodiment, the first covering layer 512 is made of silk-wound wire (e.g., acetate fiber yarn, polyester fiber yarn, etc.) commonly used in ordinary cable manufacturing.

[0049] In a preferred embodiment, the core 51, which is formed by twisting conductive threads 511 and then covering them with a first coating layer 512, has an outer diameter of approximately 0.25 to 1 mm.

[0050] In a more preferred embodiment, the core 51, which is twisted as described above and then wound in silk, has an ultimate tensile strength exceeding 50 MPa.

[0051] Alternatively, in some other modified implementations, the center of the wire 51 has a substantially rectangular cross-sectional area.

[0052] Alternatively, in several other modified embodiments, the conductive thread 511 is a thin strip of thread with a rectangular cross-section, for example, an elongated strip of thin strip of thread obtained by cutting copper foil.

[0053] In one specific implementation, the first coating layer 512 on each wire core 51 is formed after bonding a material such as an acetate fiber yarn or a polyester fiber yarn to the outside of the twisted conductive yarn 511 by a hot air self-adhesion or acetone self-adhesion process and curing. Here, the hot air self-adhesion process involves heating the mold with hot air so that the mold temperature becomes the bonding temperature of the wire when winding the acetate fiber yarn or polyester fiber yarn, etc., around the outside of the twisted conductive yarn 511, thereby bonding and molding the acetate fiber yarn or polyester fiber yarn to the outside of the conductive yarn 511 to form the first coating layer 512. The acetone self-adhesion process involves applying or spraying acetone onto the surface of the yarn using felt or a nozzle during the process of winding the acetate fiber yarn around the twisted conductive yarn 511, bonding the acetate fiber yarn with acetone, and forming the first coating layer 512 after curing.

[0054] Alternatively, in other modified embodiments, the first coating layer 512 on the core 51 is obtained in a manner similar to the method used in manufacturing optical fibers / cables, where the internal layer is filled and then the surface is coated. In some specific embodiments, the gaps between the conductive threads 511 are filled with a filler such as polyethylene, polyvinyl chloride (PVC), or nylon during the twisting process, and then coated with a coating material such as phenolic resin, alkyd resin, nitrile rubber, or ethylene propylene rubber. This is advantageous in preventing the dispersion and shedding of the conductive threads 511 in the core 51 after manufacturing.

[0055] Furthermore, the conductor material of the induction coil 50 is made by twisting together multiple bundles of wire cores 51, or the conductor material of the induction coil 50 is made by arranging multiple bundles of wire cores 51 in parallel in a spiral, winding them together as a single unit, or braiding them together.

[0056] Furthermore, in practice, the induction coil 50 further includes a second coating layer 52 for covering the twisted bundles of cores 51 to prevent or prevent the bundles of cores 51 from dispersing. Similarly, the second coating layer 52 is also manufactured by the same materials and processes as the first coating layer 512.

[0057] In a more preferred embodiment, the induction coil 50, which is further formed by twisting together multiple bundles of wire cores 51 and covering them with a second coating layer 52, has an outer diameter of approximately 1 to 3 mm in cross-section.

[0058] Similarly, the first coating layer 512 and the second coating layer 52 are basically insulating materials, and after manufacturing is complete, the wire cores 51 are insulated from each other.

[0059] Furthermore, Figure 4 shows a schematic cross-sectional view of the conductor material of the induction coil 50a according to another embodiment. The induction coil 50a according to this embodiment is It includes two or more conductors 51a, at least two bundles of cores 511a contained within each conductor 51a, and multiple conductive threads 5111a contained within each core 511a.

[0060] In one preferred embodiment, the conductor material of the induction coil 50a according to the embodiment shown in Figure 4 is obtained by further twisting or winding the conductor materials according to multiple embodiments shown in Figure 3.

[0061] Alternatively, in other modified embodiments, the conductor material of the induction coil 50a according to the multiple embodiments shown in Figure 4 may be further twisted or wound to obtain a better induction coil.

[0062] Furthermore, Figure 5 shows a schematic diagram of an induction coil 50b according to another embodiment. In this embodiment, the induction coil 50b is of the form of a solenoid coil, and the conductor material of the induction coil 50b has a broad or flattened cross-section, which is different from the general circular shape.

[0063] Furthermore, Figure 6 shows a schematic cross-sectional view of the conductor material of the induction coil 50b in Figure 5. The cross-section of the conductor material of the induction coil 50b has a first dimension d1 extending in the longitudinal direction and a second dimension d2 extending in the radial direction perpendicular to the longitudinal direction, and the first dimension d1 extending in the longitudinal direction is larger than the second dimension d2 extending in the radial direction, thereby giving the cross-section of the conductor material of the induction coil 50b a substantially flattened rectangular shape. In one preferred embodiment, the first dimension d1 is about 1 mm and the second dimension d2 is about 0.1 to 0.5 mm. In some embodiments, the cross-section of the conductor material of the induction coil 50b is formed such that the maximum dimensions in the two directions are different, for example, it is elliptical.

[0064] Simply put, in the induction coil 50b, where the cross-section of the conductor material is flattened, the shape of the conductor material is completely or at least flattened. Therefore, the radial elongation of the conductor material is small. This reduces energy loss in the induction coil 50b. At the same time, the induction coil 50b can be made thinner in the radial direction, which is advantageous in reducing the skin effect.

[0065] Furthermore, referring to Figure 6, the conductor material of the induction coil 50b includes at least two bundles of wire cores 51b, each wire core 51b containing multiple twisted or wound conductive threads 511b. In a more preferred embodiment, the wire cores 51b are arranged or positioned along the longitudinal direction of the cross-section of the conductor material.

[0066] Alternatively, in the embodiment shown in Figure 7, the induction coil 50c is constructed in a solenoid shape with a square cross-section.

[0067] Figures 8 and 9 show schematic diagrams of an induction coil 50d and an aerosol generator having the induction coil 50d in another modified embodiment. In this embodiment, the induction coil 50d is constructed as a planar spiral coil.

[0068] In some implementations, the cross-section of the conductor material of the induction coil 50d is generally circular. Alternatively, in some other modified implementations, the cross-section of the conductor material of the induction coil 50d is flattened or rectangular. Specifically, for example, the radial extension dimension of the conductor material of the induction coil 50d is greater than the axial extension dimension, resulting in a roughly rectangular cross-section.

[0069] Furthermore, the conductor material of the induction coil 50d may be formed by twisting or winding the above-mentioned at least two bundles of conductors, and similarly, each bundle of conductors contains at least two twisted or wound conductive threads.

[0070] Furthermore, as shown in Figure 9, the aerosol generator according to this embodiment is A holder 40d in which a cavity for receiving aerosol-generating substrate A is defined, A susceptor 30d, at least a portion of which is located within the cavity, is penetrated by a changing magnetic field and generates heat, heating the aerosol-generating substrate A accepted within the cavity, The aerosol generator includes a planar induction coil 50d positioned substantially perpendicular to the longitudinal direction for generating a changing magnetic field.

[0071] In a more preferred implementation, the planar induction coil 50d is positioned between the susceptor 30d / holder 40d and the circuit 20.

[0072] In a more preferred implementation, the planar induction coil 50d is positioned coaxially with the susceptor 30d. Alternatively, the central axis of the susceptor 30d generally coincides with the central axis of the planar induction coil 50d.

[0073] In a preferred embodiment, the planar induction coil 50d is supported and fixed by a first support member 60d and a second support member 70d.

[0074] In some implementations, the first support member 60d and / or the second support member 70d are sheet-like or plate-like, parallel to the planar induction coil 50d.

[0075] Furthermore, Figure 10 shows the temperature change curve of the induction coil 50 itself, measured when an alternating current with an amplitude of 6A and a frequency of 200KHz to 300KHz is supplied to the induction coil 50 made of conductive material with the structure shown in Figure 3. In this measurement example, the induction coil 50 is made by first dividing 120 copper wires with a diameter of 0.08 mm into 5 bundles, and then twisting 24 wires in each bundle in sequence.

[0076] Similarly, Figure 10 further shows the temperature change curve of the induction coil in the comparative example, measured when an alternating current with an amplitude of 6A and a frequency of 200KHz to 300KHz is supplied to the induction coil. In this comparative example, the induction coil is manufactured from a conductor material in which 120 copper wires with a diameter of 0.08 mm are all twisted together as a single bundle.

[0077] According to the measurement results in Figure 10, the heat generated by the induction coil in the comparative example is always higher than that of the induction coil 50 in the embodiment. When the copper wire material and quantity are the same, and the alternating current supplied by the power supply is also the same, the higher temperature of the induction coil in the comparative example compared to the embodiment is less due to the material or internal resistance and more due to the internal proximity effect. In contrast, the induction coil in the embodiment is advantageous in suppressing the formation of current offset by itself and reducing the internal losses of the induction coil itself. Example 2

[0078] Figure 11 is a schematic diagram of an aerosol generator provided in an embodiment of this application.

[0079] As shown in Figure 11, the aerosol generator 100 includes an atomizer 10 and a power supply assembly 20. The atomizer 10 is detachably connected to the power supply assembly 20, and the atomizer 10 and the power supply assembly 20 may be connected by a buckle connection, a magnetic connection, or the like.

[0080] The atomizer 10 includes a susceptor 11 and a reservoir chamber (not shown). The reservoir chamber is used to store a liquid substrate that can be atomized, and the susceptor 11 is inductively coupled to an induction coil 21 and is heated by a changing magnetic field, further heating the liquid substrate to generate an aerosol for smoking.

[0081] The liquid substrate is preferably a tobacco-containing material, and the tobacco-containing material contains volatile tobacco flavor compounds released from the liquid substrate during heating. Alternatively, or in addition to the above, the liquid substrate may contain non-tobacco materials. The liquid substrate may contain water, ethanol or other solvents, plant extracts, nicotine solutions, natural or artificial flavorings. The liquid substrate is preferably further to contain an aerosol-forming agent. Examples of suitable aerosol-forming agents include glycerin and propylene glycol.

[0082] Generally, the susceptor 11 may be made of at least one material selected from aluminum, iron, nickel, copper, bronze, cobalt, ordinary carbon steel, stainless steel, ferritic stainless steel, martensitic stainless steel, or austenitic stainless steel.

[0083] In some exemplary embodiments, the susceptor 11 can release heat and evaporate the liquid substrate by directly or indirectly contacting it. Furthermore, the atomizer 10 further includes a liquid transfer unit, through which the susceptor 11 indirectly contacts the liquid substrate. The liquid transfer unit may be, for example, cotton fibers, metal fibers, ceramic fibers, glass fibers, porous ceramics, etc., and can transfer the liquid substrate stored in the reservoir chamber to the susceptor 11 by capillary action. In some optional embodiments, the susceptor 11 may heat the liquid substrate by radiant heat while remaining in non-contact with it.

[0084] In some exemplary implementations, the susceptor 11 is constructed in a closed-loop or open-loop tubular shape and is supported by being wrapped around the inner surface of the liquid transfer unit with a sheet of wire mesh.

[0085] In some exemplary embodiments, the susceptor 11 may further include a radial portion extending radially from one end of the tube, the radial portion of which may be bonded to the end of the liquid transport unit.

[0086] In some exemplary implementations, the susceptor 11 is embedded within a liquid transfer unit and fired simultaneously with the liquid transfer unit to form an atomizing core. Thus, the liquid substrate does not transfer to the surface of the susceptor 11 before atomizing, but rather begins to atomize due to heat near the susceptor 11. On the one hand, there is thermal conduction contact between the susceptor 11 and the liquid transfer unit, preventing dry firing, and on the other hand, most of the liquid substrate does not come into direct contact with the susceptor 11 when atomizing, thus avoiding metal contamination by the susceptor 11.

[0087] In some exemplary implementations, the susceptor 11 may include a number of spaced closed loops, each containing the same or different metallic material, for example, having different Curie temperature points for the materials of the different closed loops.

[0088] In some exemplary implementations, the susceptor 11 may be a plate-like structure. The plate-like susceptor 11 may have multiple meshes.

[0089] In some exemplary embodiments, the weight of suscepta 11 is 10 mg to 30 mg. Preferably, it is 10 mg to 25 mg, more preferably 10 mg to 23 mg, even more preferably 15 mg to 23 mg, and still more preferably 18 mg to 23 mg. In specific examples, the weight of suscepta 11 may be 20 mg, 21 mg, etc.

[0090] The power supply assembly 20 includes an induction coil 21, a circuit 22, and a battery cell 23.

[0091] The induction coil 21 is configured to generate a magnetic field that changes under an alternating current.

[0092] Circuit 22 can control the overall operation of the aerosol generator 100. Circuit 22 controls not only the operation of the battery cell 23 and the induction coil 21, but also the operation of other elements in the aerosol generator 100.

[0093] In one example, the frequency of the alternating current supplied by circuit 22 to the induction coil 21 is 500 kHz to 3 MHz, preferably 500 kHz to 2.5 MHz, more preferably 500 kHz to 2 MHz, even more preferably 500 kHz to 1.5 MHz, and even more preferably 500 kHz to 1 MHz. For example, the frequency of the alternating current supplied by circuit 22 to the induction coil 21 is 500 kHz, or 600 kHz, or 800 kHz, or 1.2 MHz.

[0094] The battery cell 23 supplies power to operate the aerosol generator 100. The battery cell 23 may be a rechargeable battery cell or a disposable battery cell.

[0095] Figure 12 is a schematic diagram of an induction coil provided in an embodiment of this application.

[0096] As shown in Figure 12, the induction coil 21 includes a main body 211, an electrical connection part 212, and an electrical connection part 213, the electrical connection parts 212 and 213 are used to electrically connect to the battery cell 23.

[0097] After assembly, the main body 211 is positioned around the susceptor 11 and may be fitted into a holder (not shown), the holder having a shape similar to that of the main body 211.

[0098] The main body 211 is a solenoid coil wound with a long, thin wire material, and is formed by winding, for example, 500 to 2000 wires, or 500 to 1900 wires, or 700 to 1900 wires, or 900 to 1900 wires, or 1000 to 1900 wires, or 1200 to 1900 wires, or 1400 to 1900 wires, or 1600 to 1900 wires.

[0099] The cross-section of the conductor material may be rectangular, circular, or elliptical. A rectangular shape is preferable, and it is also preferable to have a flattened structure for the conductor material of the induction coil 21, which is advantageous for increasing the number of turns of the induction coil 21 per unit length and further increasing the inductance value.

[0100] The overall length of the main body 211 in the axial direction is approximately 5 to 20 mm, and in one specific embodiment, the overall length of the induction coil 21 in the axial direction is 12.2 mm.

[0101] The cross-section of the hollow portion of the main body 211 is non-circular, for example, elliptical, and the cross-section of the main body 211 is racetrack-shaped. In some examples, the difference between the major axis and minor axis of the ellipse is 0.5 mm to 2 mm. Specifically, the length of the major axis of the ellipse is 8 mm to 15 mm (preferably 8 mm to 12 mm, more preferably 8 mm to 10 mm, and even more preferably 9 mm to 10 mm), and the length of the minor axis of the ellipse is 8 mm to 13 mm (preferably 8 mm to 11 mm, more preferably 8 mm to 10 mm, and even more preferably 8 mm to 9 mm). In one specific embodiment, the ellipse has a major axis length of 9.7 mm and a minor axis length of 8.9 mm. A main body 211 having this shape is advantageous for manufacturing the induction coil 21 and assembling it into the power supply assembly 20.

[0102] The number of turns or windings of the solenoid coil is 4 to 20 turns, preferably 6 to 20 turns, more preferably 6 to 15 turns, even more preferably 6 to 12 turns, and even more preferably 6 to 10 turns. An induction coil 21 having this number of turns can provide an effective magnetic field for heating the susceptor 11.

[0103] The spacing between adjacent windings may be the same or different. The spacing between adjacent windings is approximately 0.1 to 2 mm, or 0.1 mm to 1.5 mm, or 0.1 mm to 1 mm, or 0.1 mm to 0.5 mm. In one specific embodiment, the spacing between adjacent windings is 0.2 or 0.4 mm. These specific spacings have been found to ensure efficient heating of the susceptor 11 and, therefore, efficient heating of the liquid substrate.

[0104] Figure 13 is a schematic cross-sectional view of the conductor material of an induction coil provided in an embodiment of this application.

[0105] It should be explained that the twisted wires 30b and 30c described in this embodiment are the same wire cores as described in Example 1, and the wire 30a described in this embodiment is the same conductive yarn as described in Example 1; they are just different names for the same object.

[0106] As shown in Figure 13, the conductor material 30 of the induction coil 21 includes multiple bundles of twisted wires 30c, and each bundle of twisted wires 30c also includes multiple bundles of twisted wires 30b. Each bundle of twisted wires 30b contains 3 to 20 wires 30a, or 3 to 18 wires 30a, or 3 to 16 wires 30a, or 3 to 14 wires 30a, or 3 to 12 wires 30a, or 5 to 12 wires 30a, or 8 to 12 wires 30a. In one specific embodiment, each bundle of twisted wires 30b may contain 10 wires 30a.

[0107] In one embodiment, the conductor 30a is made from a low-resistivity metal or alloy such as copper, gold, silver or an alloy thereof, and a carbon material (carbon fiber or other conductive carbon material).

[0108] In one embodiment, the cross-section of the conductor 30a may be circular or rectangular. In a preferred embodiment, the cross-section of the conductor 30a is circular, which helps to avoid the occurrence of the wire breakage phenomenon and is advantageous in reducing the AC impedance of the induction coil itself.

[0109] The real part of the equivalent impedance of the induction coil 21 when the cross-sectional shape of the conductor 30a is circular (corresponding to "Equivalent Impedance 1" in the table below) and the real part of the equivalent impedance of the induction coil 21 when the cross-sectional shape of the conductor 30a is rectangular (corresponding to "Equivalent Impedance 2" in the table below) can be measured and verified using an impedance analyzer, provided that conditions such as the operating frequency, the number of twists, and the number of conductors 30a at the time of the first twist (corresponding to "Number of Conductors" in the table below) are the same. In this measurement, the number of twists was 2, and the number of conductors 30a at the time of the first twist was 45. The measurement results are shown in the table below.

[0110] JPEG0007897310000001.jpg39164

[0111] From the measurement results above, it was found that, under the same conditions, even at high operating frequencies, the value of equivalent impedance 1 is smaller than the value of equivalent impedance 2. That is, the real part of the equivalent impedance of the induction coil 21 when the cross-sectional shape of the conductor 30a is circular is smaller than the real part of the equivalent impedance of the induction coil 21 when the cross-sectional shape of the conductor 30a is rectangular. Therefore, when the cross-sectional shape of the conductor 30a is circular, it is advantageous for reducing the AC impedance of the induction coil itself.

[0112] In one embodiment, corresponding to the above-mentioned fact that the induction coil 21 generates a magnetic field that changes at a frequency of 500 kHz to 3 MHz in practice, it is desirable that the diameter of the conductor 30a be 0.01 mm to 0.05 mm. In a specific embodiment, the diameter of the conductor 30a may be 0.03 mm or 0.04 mm. A smaller diameter of the conductor 30a is advantageous in reducing the skin effect of the induction coil 21, improving the heating efficiency of the susceptor, improving the atomization rate of the liquid substrate, and also in reducing the size and weight of the susceptor and the volume of the atomizer used in conjunction with the power supply assembly.

[0113] In one embodiment, each of the multiple bundles of twisted wires 30b may have the same number of wires or different numbers of wires. For example, one bundle of twisted wires 30b may have 10 wires 30a, while another bundle of twisted wires 30b may have 15 wires 30a.

[0114] In one embodiment, first, 3 to 20 strands of wire 30a are twisted once to obtain one bundle of twisted wire 30b, then multiple bundles of twisted wire 30b are twisted a second time to obtain one bundle of twisted wire 30c, and finally, multiple bundles of twisted wire 30c are twisted a third time to form the wire material 30 for the induction coil 21.

[0115] Here, the number of bundles of twisted wire 30b and the number of bundles of twisted wire 30c are not limited and can generally be determined by the total number of wires 30a in the induction coil 21. For example, if the main body 211 is formed by winding 1600 wires, first, 10 wires 30a are twisted once to obtain one bundle of twisted wire 30b, then 16 bundles of twisted wire 30b are twisted a second time to obtain one bundle of twisted wire 30c, and finally, 10 bundles of twisted wire 30c are twisted a third time to obtain the final product.

[0116] In the above twisting process, the yarn may be twisted clockwise or counterclockwise.

[0117] The induction coil 21 with the above structure can avoid the occurrence of thread breakage, reduce the AC impedance of the induction coil itself, reduce losses due to the proximity effect, and improve the heat generation efficiency of the aerosol generator.

[0118] In further implementations, an insulating material layer, such as an insulating coating / insulating film, can be formed on the surface of each conductor 30a in the stranded conductor 30b by deposition, spraying, etc., so that the conductors 30a in the stranded conductor 30b are substantially insulated from each other. In optional implementations, the insulating material includes, but is not limited to, Teflon, polytetrafluoroethylene, polyimide, polyurethane, aromatic amide polymer, etc.

[0119] Each stranded conductor 30b further includes a covering layer (not shown) for covering the stranded conductor 30a to prevent or inhibit the dispersion of the conductor 30a in the stranded conductor 30b. In a preferred embodiment, the covering layer is made of silk windings (e.g., acetate fiber yarn, polyester fiber yarn, etc.) commonly used in ordinary cable manufacturing.

[0120] In one specific implementation, the coating layer on each twisted wire 30b is formed after bonding a material such as acetic acid fiber yarn or polyester fiber yarn to the outside of the twisted wire 30a by a hot air self-adhesion or acetone self-adhesion process and curing. Here, the hot air self-adhesion process involves heating the mold with hot air so that the mold temperature reaches the bonding temperature of the wire when winding the acetic acid fiber yarn or polyester fiber yarn around the outside of the twisted wire 30a, thereby bonding and molding the acetic acid fiber yarn or polyester fiber yarn to the outside of the wire 30a to form a coating layer. The acetone self-adhesion process involves applying or spraying acetone onto the surface of the yarn using felt or a nozzle during the process of winding the acetic acid fiber yarn around the outside of the twisted wire 30a, bonding the acetic acid fiber yarn with acetone, and forming a coating layer after curing.

[0121] Alternatively, in other modified embodiments, the coating layer on the twisted conductor 30b is obtained in a manner similar to the method used in the manufacturing of optical fibers / cables, where the internal filling is followed by surface coating. In some specific embodiments, the gaps between the conductors 30a are filled with a filler such as polyethylene, polyvinyl chloride (PVC), or nylon during the twisting process, and then coated with a coating material such as phenolic resin, alkyd resin, nitrile rubber, or ethylene propylene rubber. This is advantageous in preventing the dispersion and detachment of the conductors 30a in the twisted conductor 30b after manufacturing.

[0122] Furthermore, in the implementation, a similar coating layer is used to insulate multiple bundles of twisted wires 30b or multiple bundles of twisted wires 30c from each other.

[0123] Figure 14 is a schematic cross-sectional view of another conductive material for an induction coil provided in an embodiment of this application.

[0124] The conductor material 40 shown in Figure 14 differs from that in Figure 13 in that it includes multiple bundles of twisted conductors 40a, and the conductor material 40 of the induction coil 21 is formed after the multiple bundles of twisted conductors 40a are twisted a fourth time. Here, each twisted conductor 40a is similar to the conductor material 30 shown in Figure 13, i.e., it is formed after three twists.

[0125] The conductor material 40 formed after four twisting processes can further avoid the occurrence of thread breakage and reduce the AC impedance of the induction coil itself. It has been found that conductor materials formed after three or more twisting processes can all achieve the above objectives. Considering the cost of the twisting process, it is preferable to form the conductor material by a three or four twisting process.

[0126] To further investigate the effects of the number of twists and the number of conductors 30a during the first twist, the inventors measured the real part of the equivalent impedance under two different measurement conditions. One condition involved two twists and 45 conductors 30a during the first twist (corresponding to "Equivalent Impedance 3" in the table below), while the other involved four twists and 10 conductors 30a during the first twist (corresponding to "Equivalent Impedance 4" in the table below). Other measurement conditions were the same, for example, the operating frequency was 500KHz to 3MHz, and the cross-sectional shape of the conductors 30a was circular in both cases. The measurements were performed using an impedance analyzer, and the results are shown in the table below.

[0127] JPEG0007897310000002.jpg35164

[0128] From the measurement results above, it was found that when the number of twists is 4 and the number of conductors 30a in the first twist is 10, the AC impedance is small, and the decrease in AC impedance is very large compared to the case where "the number of twists is 2 and the number of conductors 30a in the first twist is 45". Therefore, by using a small number of conductors (e.g., 3 to 20) in the first twist of the induction coil's twisted conductors and increasing the number of twists (e.g., 3 or more), the efficiency of electromagnetic coupling can be promoted, the heating rate during susceptor operation can be increased, and the aerosol generator can generate aerosol in a very short time after startup, thereby meeting the usage requirement that an aerosol generator containing a liquid substrate can be smoked with almost no waiting time after startup.

[0129] Furthermore, when "the number of twists is 4 and the number of wires 30a in the first twist is 10", no yarn breakage occurred during the twisting process, whereas when "the number of twists is 2 and the number of wires 30a in the first twist is 45", yarn breakage occurred.

[0130] Figure 15 is a schematic diagram of another induction coil provided in the embodiments of this application.

[0131] As shown in Figure 15, the induction coil 21a is constructed as a planar spiral coil. The conductor material of the planar spiral coil is also formed after twisting multiple conductors 30a multiple times, where the number of conductors 30a in the first twist is 3 to 20. It is preferable to have a twisting process of 3 or 4 twists.

[0132] The planar spiral coil may be arranged along a direction perpendicular to the longitudinal direction of the aerosol generator 100, or along the longitudinal direction of the aerosol generator 100. The planar spiral coil may be supported by a sheet-like or plate-like support member parallel to the planar induction coil 21a, or it may be incorporated into other members.

[0133] Figure 16 is a schematic diagram of the induction coil formation method provided in the embodiment of this application.

[0134] As shown in Figure 16, the method described above is Step S11 involves preparing 3 to 20 wires, performing the first twist, and obtaining the first twisted wire. Step S12 involves preparing multiple bundles of first-stage twisted wires, and performing a second twist on the multiple bundles of first-stage twisted wires to obtain second-stage twisted wires, wherein each of the multiple bundles of first-stage twisted wires may have the same number of wires or a different number of wires. The method includes step S13, which involves preparing multiple bundles of second-stage twisted conductors, and then forming the conductor material for the induction coil after performing a third twist on the multiple bundles of second-stage twisted conductors.

[0135] In one example, the above method further, The steps include obtaining a third twisted wire after twisting a third time through a bundle of second-stage twisted wires, The process includes the steps of preparing multiple bundles of third-stage twisted conductors, and forming the conductor material for the induction coil after performing a fourth twist on the multiple bundles of third-stage twisted conductors.

[0136] It should be explained that while preferred embodiments of this application are shown in the specification and drawings, this application can be realized in many different forms and is not limited to the embodiments described herein. These embodiments are not additional limitations on the content of this application, but are provided to provide a more detailed, deeper, and complete understanding of the disclosure. Furthermore, any combination of the above technical features to form various embodiments not listed herein shall all be considered within the scope of the specification of this application. In addition, those skilled in the art may make improvements or modifications based on the above description, and such improvements and modifications shall all fall within the scope of protection of the claims attached to this application.

Claims

1. An induction coil for generating a changing magnetic field, It includes a susceptor for generating aerosols by inducing heat in a changing magnetic field and heating an aerosol-generating substrate, An aerosol generator wherein the conductor material of the induction coil includes two or more bundles of wire cores, each wire core includes two or more conductive threads, each wire core is formed by twisting multiple conductive threads three or four times, the number of conductive threads used in the first twist of the multiple conductive threads is 3 to 20, and the diameter of each conductive thread is 0.01 mm or more and less than 0.05 mm.

2. The aerosol generating apparatus according to claim 1, wherein the conductor material of the induction coil has a circular or rectangular cross-section.

3. The aerosol generating apparatus according to claim 1 or 2, wherein the induction coil is constructed as a solenoid coil or a planar spiral coil.

4. The aerosol generating apparatus according to claim 1, wherein the conductor material of the induction coil includes 3 to 10 bundles of the wire cores.

5. The aerosol generating device according to claim 1, wherein the conductive thread has a break elongation percentage of 1 to 6%.

6. The aerosol generator according to claim 1, wherein the wire core has an ultimate tensile strength of more than 50 MPa.

7. The aerosol generating apparatus according to claim 1, wherein two or more bundles of the wire cores in the conductor material of the induction coil are twisted together.

8. The wire core further includes a first coating layer for covering two or more of the conductive threads, and / or The aerosol generating apparatus according to claim 1, wherein the induction coil further comprises a second coating layer for covering two or more bundles of the wire cores.

9. The aerosol generating apparatus according to claim 1, wherein the aerosol generating substrate comprises a liquid substrate, and the susceptor is configured to generate an aerosol by heating the liquid substrate.

10. The aerosol generating apparatus according to claim 1, wherein the conductor material of the induction coil includes 500 to 2000 of the conductive threads.

11. The aerosol generator according to claim 1, wherein the operating frequency provided to the induction coil is 500 kHz to 3 MHz.

12. The aerosol generating device according to claim 1, wherein the induction coil is structured as a solenoid coil, and the solenoid coil has 4 to 20 turns.

13. The aerosol generating device according to claim 12, wherein the solenoid coil has an elliptical cross-section in its hollow portion.

14. The aerosol generating device according to claim 12, wherein the solenoid coil has a spacing of 0.1 to 2 mm between adjacent windings.

15. An induction coil for an aerosol generator configured to generate a changing magnetic field, wherein the conductor material of the induction coil includes a plurality of bundles of wire cores, each bundle of wire cores is formed by twisting a plurality of conductive threads three or four times, the number of conductive threads used in the first twist of the plurality of conductive threads is 3 to 20, and the diameter of the conductive threads is 0.01 mm or more and less than 0.05 mm.

16. A method for manufacturing an induction coil for an aerosol generator, Prepare 3 to 20 conductive threads, and obtain the first stage core after the first twisting process. Prepare multiple bundles of first-stage core yarn, and after twisting the multiple bundles of first-stage core yarn a second time, obtain a second-stage core yarn. This includes preparing multiple bundles of second-stage wire cores, twisting the multiple bundles of second-stage wire cores a third time, and then forming the conductor material for the induction coil, A method for manufacturing an induction coil for an aerosol generator, wherein the diameter of the conductive thread is 0.01 mm or more and less than 0.05 mm.

17. A method for manufacturing an induction coil for an aerosol generator, Prepare 3 to 20 conductive threads, and obtain the first stage core after the first twisting process. Prepare multiple bundles of first-stage core yarn, and after twisting the multiple bundles of first-stage core yarn a second time, obtain a second-stage core yarn. Prepare multiple bundles of second-stage core yarn, and after twisting the multiple bundles of second-stage core yarn for the third time, obtain a third-stage core yarn. This includes preparing multiple bundles of third-stage core wires, twisting the multiple bundles of third-stage core wires a fourth time, and then forming the conductor material for the induction coil, A method for manufacturing an induction coil for an aerosol generator, wherein the diameter of the conductive thread is 0.01 mm or more and less than 0.05 mm.

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