Aerosol generator and heating chamber therefor

Abstract

To provide an improved aerosol generation device, and an improved heating chamber therefor.SOLUTION: An aerosol generation device 100 has a heating chamber 108 for receiving a substrate carrier 114 containing an aerosol substrate 128. The heating chamber includes: a first open end 110; a base 112; and a side wall 126 between the open end and the base. The base is connected to the side wall and provides structural support to the side wall. The side wall has a first thickness and the base has a second thickness greater than the first thickness.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] This disclosure relates to an aerosol generator and a heating chamber therefor. This disclosure is particularly applicable to a portable aerosol generator that may be self-contained and low-temperature. Such a device can generate an inhalable aerosol by heating tobacco or other suitable material by conduction, convection, and / or radiation rather than by burning. [Background technology]

[0002] The popularity and use of risk reduction or risk modification devices (also known as vaporizers) have grown rapidly in recent years as a means of helping habitual smokers who wish to quit smoking conventional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. In contrast to burning tobacco in conventional tobacco products, a variety of devices and systems are available that heat or warm aerosolizable substances.

[0003] Commonly available risk reduction or risk modification devices are heated substrate aerosol generators or heat-not-burn devices. These devices typically generate aerosols or vapors by heating an aerosol substrate, usually containing moist tobacco leaves or other suitable aerosolizable material, to a temperature typically in the range of 150°C to 300°C. Heating the aerosol substrate rather than burning or incinerating it releases an aerosol that contains the components desired by the user but does not contain toxic and carcinogenic byproducts of combustion and burning. Furthermore, aerosols produced by heating tobacco or other aerosolizable materials typically do not contain the burnt or bitter taste resulting from combustion and burning, which can be unpleasant to the user. Therefore, the substrate does not require sugars and other additives typically added to such materials to make the smoke and / or vapor more palatable to the user.

[0004] Generally speaking, it is desirable to rapidly heat the aerosol substrate to a temperature at which aerosols can be released from it, and to maintain the aerosol substrate at that temperature. It is clear that aerosols will only be released from the aerosol substrate and delivered to the user if there is an airflow passing through the aerosol substrate. [Overview of the project] [Problems that the invention aims to solve]

[0005] Since this type of aerosol generator is a portable device, energy consumption is an important design consideration. The present invention aims to address the problems of existing devices and to provide an improved aerosol generator and a heating chamber therefor. [Means for solving the problem]

[0006] According to a first aspect of this disclosure, a heating chamber for an aerosol generator is provided, the heating chamber is The first open end and The base and, It comprises a side wall between the open end and the base, The base is connected to the side wall, providing structural support to the side wall. The side walls have a first thickness, and the base has a second thickness that is greater than the first thickness.

[0007] Optionally, the sidewalls and base are formed from the same material, preferably metal, more preferably stainless steel, and even more preferably stainless steel. The steel is 300 series stainless steel, and more preferably selected from the group including 304 stainless steel, 316 stainless steel, and 321 stainless steel.

[0008] Optionally, the base and side walls are formed as a single element, preferably forming a cup-shaped element.

[0009] Optionally, the first thickness is 100 μm or less.

[0010] Optionally, the second thickness is 200 μm to 500 μm.

[0011] Optionally, the base seals the second end of the side wall opposite the open end, and preferably, the side wall extends over the entire periphery of the base.

[0012] Optionally, the heating chamber comprises a flange portion attached to the open end, and the flange portion extends radially outward at the open end of the heating chamber.

[0013] Optionally, the flange portion extends over the entire periphery of the heating chamber.

[0014] Optionally, the flange portion extends obliquely away from the side wall.

[0015] Optionally, the flange portion comprises a first material, the side wall comprises a second material, and the first material has a lower thermal conductivity than the second material.

[0016] Optionally, the side wall comprises a material having a thermal conductivity of 50 W / mK or less.

[0017] Optionally, the heating chamber further comprises a plurality of protrusions formed on the inner surface of the side wall.

[0018] Optionally, the protrusions are formed by recessing the outer surface of the side wall.

[0019] Optionally, the heating chamber further comprises a platform on the inner surface of the base.

[0020] Optionally, the platform is formed by a depression in the outer surface of the base.

[0021] Optionally, the heating chamber is a deep drawn product.

[0022] According to a second aspect of the present disclosure, an aerosol generation device is provided, the aerosol generation device comprising: a power supply, a heating chamber as described above, a heater configured to supply heat to the heating chamber, and a control circuit configured to control the supply of electric power from the power supply to the heater.

[0023] Optionally, the heater is provided on the outer surface of the side wall.

[0024] Optionally, the heater is positioned adjacent to the outer surface of the side wall.

[0025] Optionally, the heating chamber is removable from the aerosol generation device. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] [Figure 1] 1 is a schematic perspective view of an aerosol generation device according to a first embodiment of the present disclosure. [Figure 2] 2 is a schematic cross-sectional view from the side of the aerosol generation device of Figure 1. [Figure 2a] 3 is a schematic cross-sectional view from the top of the aerosol generation device of Figure 1, taken along line X-X shown in Figure 2. [Figure 3] Figure 2 is a schematic perspective view of the aerosol generation device of Figure 1, with a substrate carrier for an aerosol substrate being loaded into the aerosol generation device. [Figure 4] 2 is a schematic cross-sectional view from the side of the aerosol generation device of Figure 1, with a substrate carrier for an aerosol substrate being loaded into the aerosol generation device. [Figure 5] 2 is a schematic perspective view of the aerosol generation device of Figure 1, with a substrate carrier for an aerosol substrate loaded in the aerosol generation device. [Figure 6] 2 is a schematic cross-sectional view from the side of the aerosol generation device of Figure 1, with a substrate carrier for an aerosol substrate loaded in the aerosol generation device. [Figure 6a]Figure 6 is a detailed cross-sectional view of a portion of the image, highlighting the interaction between the substrate support and the protrusions within the heating chamber, and the corresponding effects on the airflow channel. [Figure 7] This is a plan view of the heater separated from the heating chamber. [Figure 8] This is a schematic side cross-sectional view of an aerosol generator according to a second embodiment of the present disclosure, having an alternative airflow configuration. [Figure 9] This is a schematic side cross-sectional view of an aerosol generator according to a third embodiment of the present disclosure, which has a heating chamber with a base formed as a separate part from the side wall portion. [Figure 9a] This is a perspective view from above of the heating chamber of an aerosol generator according to a third embodiment of the present disclosure. [Figure 9b] This is a view from below of the heating chamber of an aerosol generator according to a third embodiment of the present disclosure. [Figure 10] This is a schematic perspective view of an aerosol generator according to a fourth embodiment of the present disclosure, which has a heating chamber without a flange. [Figure 10a] This is a perspective view from above of the heating chamber of an aerosol generator according to a fourth embodiment of the present disclosure. [Figure 10b] This is a view from below of the heating chamber of an aerosol generator according to a fourth embodiment of the present disclosure. [Figure 11] This is a schematic perspective view of an aerosol generator according to a fifth embodiment of the present disclosure, which has a heating chamber without any protrusions on its side walls. [Figure 11a] This is a perspective view from above of the heating chamber of an aerosol generator according to the fifth embodiment of the present disclosure. [Figure 11b] This is a view from below of the heating chamber of an aerosol generator according to a fifth embodiment of the present disclosure. [Modes for carrying out the invention]

[0027] First Embodiment Referring to Figures 1 and 2, according to a first embodiment of this disclosure, the aerosol generator 100 comprises an external casing 102 that houses various components of the aerosol generator 100. In the first embodiment, the external casing 102 is tubular. More specifically, the external casing is cylindrical. Note that the external casing 102 does not have to be tubular or cylindrical in shape, but can be any shape as long as it is sized to fit the components described in the various embodiments described herein. The external casing 102 can be formed of any suitable material, or in fact a layer of material. For example, a metal inner layer can be surrounded by a plastic outer layer. This makes the external casing 102 comfortable for the user to hold. Any heat leaking from the aerosol generator 100 is distributed around the external casing 102 by the metal layer, so hots... While preventing potting, the plastic layer softens the feel of the outer casing 102. In addition, the plastic layer can help protect the metal layer from discoloration or scratching, thus improving the long-term appearance of the aerosol generator 100.

[0028] The first end 104 of the aerosol generator 100, shown at the bottom of each of Figures 1 to 6, is described for convenience as the bottom, base, or lower end of the aerosol generator 100. The second end 106 of the aerosol generator 100, shown at the top of each of Figures 1 to 6, is described as the upper end or upper end of the aerosol generator 100. In the first embodiment, the first end 104 is the lower end of the external casing 102. During use, the user typically orients the aerosol generator 100 with the first end 104 downward and / or distal to the user's mouth, and the second end 106 upward and / or close to the user's mouth.

[0029] As shown in the figures, the aerosol generator 100 holds a pair of washers 107a and 107b in place at the second end 106 by interlocking with the internal portion of the outer casing 102 (only the upper washer 107a is visible in Figures 1, 3, and 5). In some embodiments, the outer casing 102 is folded or bent around the upper washer 107a at the second end 106 of the aerosol generator 100 to hold the washers 107a and 107b in place. The other washer 107b (i.e., the washer furthest from the second end 106 of the aerosol generator 100) is supported on the shoulder or annular ridge 109 of the outer casing 102, thereby preventing the lower washer 107b from seating beyond a predetermined distance from the second end 106 of the aerosol generator 100. Washers 107a and 107b are formed from an insulating material. In this embodiment, the insulating material is, for example, polyetheretherketone (PEEK), which is suitable for use in medical devices.

[0030] The aerosol generator 100 has a heating chamber 108 located toward the second end 106 of the aerosol generator 100. The heating chamber 108 is open toward the second end 106 of the aerosol generator 100. In other words, the heating chamber 108 has a first open end 110 toward the second end 106 of the aerosol generator 100. The heating chamber 108 is held spaced apart from the inner surface of the outer casing 102 by being fitted through the central openings of washers 107a and 107b. In this configuration, the heating chamber 108 is held in a configuration that is approximately coaxial with the outer casing 102. The heating chamber 108 is suspended by a flange 138 of the heating chamber 108, which is located at the open end 110 of the heating chamber 108 and gripped between a pair of washers 107a and 107b. This means that heat conduction from the heating chamber 108 to the external casing 102 generally passes through washers 107a and 107b, and is thus limited by the insulating properties of washers 107a and 107b. In other areas, there is an air gap surrounding the heating chamber 108, so heat transfer from the heating chamber 108 to the external casing 102 other than through washers 107a and 107b is also reduced. In the illustrated embodiment, the flange 138 extends outward from the side wall 126 of the heating chamber 108 for a distance of about 1 mm, forming an annular structure.

[0031] To further enhance the thermal insulation of the heating chamber 108, the heating chamber 108 is also surrounded by an insulating material. In some embodiments, the insulating material is a fibrous or foamed material, such as absorbent cotton. In the illustrated embodiment, the insulator comprises an insulating member 152 in the form of an insulating cup comprising a double-walled tube 154 and a base 156. In some embodiments, the insulating member 152 may comprise a pair of nested cups enclosing a cavity between them. The cavity 158 defined between the walls of the double-walled tube 154 can be filled with an insulating material, such as fibers, foam, gel, or (e.g., low-pressure) gas. In some cases, the cavity 158 may include a vacuum. Good. Advantageously, a vacuum requires very little thickness to achieve high thermal insulation; the walls of the double-walled tube 154 surrounding the cavity 158 can be as thin as 100 μm, and the total thickness (the two walls and the cavity 158 between them) can be as thin as 1 mm. The base 156 is made of an insulating material such as silicone. Because silicone is flexible, the electrical connection 150 of the heater 124 can pass through the base 156, which forms a seal around the electrical connection 150.

[0032] As shown in Figures 1 to 6, the aerosol generator 100 may include an external casing 102, a heating chamber 108, and an insulating member 152, as detailed above. Figures 1 to 6 show an elastically deformable member 160 positioned between the outward-facing surface of the insulating sidewall 154 and the internal surface of the external casing 102 to hold the insulating member 152 in place. The elastically deformable member 160 can provide sufficient friction to form an interlocking fit in order to maintain the insulating member 152 in place. The elastically deformable member 160 may be a gasket, O-ring, or a closed loop of other material that fits the outward-facing surface of the insulating sidewall 154 and the internal surface of the external casing 102. The elastically deformable member 160 may be made of an insulating material such as silicone. This may provide further insulation between the insulating member 152 and the external casing 102. Therefore, this reduces the heat transferred to the external casing 102, allowing the user to comfortably hold the external casing 102 during use. Elastically deformable materials are those that can be compressed and deformed but spring back to their original shape, such as elastic materials or rubber materials.

[0033] Alternatively, the insulating member 152 may be supported by a support column extending between the insulating member 152 and the outer casing 102. The support column may increase rigidity to ensure that the heating chamber 108 is centrally located within the outer casing 102, or that the heating chamber is located in a set position. The support column can be designed to ensure that heat is evenly distributed throughout the outer casing 102 to prevent the formation of hot spots.

[0034] As a further alternative, the heating chamber 108 may be fixed within the aerosol generator 100 by an engaging portion on the external casing 102 that engages with the side wall 126 at the open end 110 of the heating chamber 108. Since the open end 110 is exposed to the greatest flow of cold air and therefore cools the fastest, attaching the heating chamber 108 to the external casing 102 near the open end 110 allows heat to be rapidly dissipated into the environment and ensures a secure fit.

[0035] It should be noted that in some embodiments, the heating chamber 108 is removable from the aerosol generator 100. Therefore, the heating chamber 108 can be easily cleaned or replaced. In such embodiments, the heater 124 and the electrical connection 150 do not have to be removable and may remain in place within the insulating member 152.

[0036] In the first embodiment, the base 112 of the heating chamber 108 is closed; that is, the heating chamber 108 is cup-shaped. In other embodiments, the base 112 of the heating chamber 108 has one or more holes or is perforated, and the heating chamber 108 remains substantially cup-shaped but is not closed at the base 112. In yet another embodiment, the base 112 is closed, but the side wall 126 has one or more holes or is perforated between the area adjacent to the base 112, for example, between the heater 124 (or metal layer 144) and the base 112. The heating chamber 108 also has a side wall 126 between the base 112 and the open end 110. The side wall 126 and the base 112 are connected to each other. In the first embodiment, the side wall 126 is tubular; more specifically, the side wall is cylindrical. However, in other embodiments, the side wall 126 is other preferred shapes, such as a tube with an elliptical or polygonal cross-section. It has. Typically, the cross-section is generally uniform over the length of the heating chamber 108 (without considering the protrusions 140), but in other embodiments, the cross-section may vary, for example, the size of the cross-section may decrease towards one end, such as the tubular shape tapering or becoming a frustoconical shape.

[0037] In the illustrated embodiment, the heating chamber 108 is a single unit, meaning the sidewall 126 and base 112 are formed from a single piece of material, for example, by a deep drawing process. This allows for greater reinforcement of the entire heating chamber 108. In other examples, the base 112 and / or flange 138 may be formed as separate parts and then attached to the sidewall 126. This allows the flange 138 and / or base 112 to be formed from a different material than the material from which the sidewall 126 is manufactured. The sidewall 126 itself is configured to be thin. In some embodiments, the sidewall is up to 150 μm thick. Typically, the sidewall 126 is less than 100 μm thick, for example, about 90 μm, or even about 80 μm. In some cases, the sidewall 126 may be about 50 μm thick, but as the thickness decreases, the rate of failure in the manufacturing process increases. Overall, a range of 50 μm to 100 μm is generally appropriate, with 70 μm to 90 μm being optimal. While the manufacturing tolerance is approximately ±10 μm, the provided parameters are intended to have an accuracy of approximately ±5 μm.

[0038] If the side wall 126 is as thin as defined above, the thermal properties of the heating chamber 108 change significantly. Because the side wall 126 is very thin, the resistance to heat transfer through the side wall 126 is negligible. However, heat transfer along the side wall 126 (i.e., parallel to the central axis or around the circumference of the side wall 126) has small channels along which conduction can occur. Therefore, the heat generated by the heater 124 located on the outer surface of the heating chamber 108 remains localized near the heater 124 in a radially outward direction from the side wall 126 at the open end, but quickly leads to heating of the inner surface of the heating chamber 108. In addition, the thin side wall 126 helps to reduce the thermal mass of the heating chamber 108, resulting in an improved overall efficiency of the aerosol generator 100 because less energy is used to heat the side wall 126.

[0039] The heating chamber 108, specifically the side walls 126 of the heating chamber 108, comprises a material having a thermal conductivity of 50 W / mK or less. In the first embodiment, the heating chamber 108 is a metal, preferably stainless steel. Stainless steel has a thermal conductivity of about 15 to 40 W / mK, the exact value of which varies depending on the specific alloy. As a further example, 300 series stainless steel, suitable for this application, has a thermal conductivity of about 16 W / mK. Preferred examples include 304, 316, and 321 stainless steels, which are approved for medical applications, have high strength, and have sufficiently low thermal conductivity to allow for the localization of heat as described herein.

[0040] Materials with the specified level of thermal conductivity have a reduced ability to conduct heat away from a heated area compared to materials with higher thermal conductivity. For example, the heat remains localized adjacent to the heater 124. Since the transfer of heat to other parts of the aerosol generator 100 is suppressed, the heating efficiency is improved by ensuring that only the parts of the aerosol generator 100 that are intended to be heated are actually heated, and parts that are not intended to be heated remain unheated.

[0041] Metals are suitable materials because they are strong, malleable, and easy to shape and form. In addition, their thermal properties vary greatly from metal to metal and can be adjusted by careful alloying as needed. In this application, “metal” refers to elemental (i.e., pure) metals, as well as alloys of some metals or other elements, such as carbon.

[0042] Accordingly, the configuration of the heating chamber 108 having thin side walls 126, along with the selection of a material having desirable thermal properties from which the side walls 126 are formed, ensures that heat can be efficiently conducted through the side walls 126 into the aerosol substrate 128. Advantageously, this also results in a reduction in the time required to raise the temperature from the ambient temperature to a temperature at which aerosols can be released from the aerosol substrate 128, following the initial operation of the heater.

[0043] The heating chamber 108 is formed by deep drawing. This is an effective method for forming the heating chamber 108 and can be used to provide very thin side walls 126. The deep drawing process involves pressurizing a sheet metal blank with a punch tool and pushing it into a forming die. By using a series of progressively smaller punch tools and dies, a tubular structure is formed, which has a base at one end and a tube, and the tube is deeper than the distance across the tube (the term "deep drawn" comes from the tube having a length that is relatively greater than its width). As a result of being formed in this way, the side walls of the tube formed in this way are the same thickness as the original sheet metal. Similarly, the base formed in this way is the same thickness as the original sheet metal blank. A flange can be formed at the end of the tube by leaving the periphery of the original sheet metal blank extending outward at the end opposite the base of the tubular wall (i.e., by starting with more material in the blank than is needed to form the tube and base). Alternatively, the flange can be formed later in a separate process that includes one or more of the following: cutting, bending, rolling, and stretching (swaging).

[0044] As described above, the tubular sidewall 126 of the first embodiment is thinner than the base 112. This can be achieved by first deep drawing the tubular sidewall 126 and then ironing the wall. Ironing involves heating the tubular sidewall 126 and drawing it, resulting in the tubular sidewall becoming thinner in this process. In this way, the tubular sidewall 126 can be manufactured to the dimensions described herein.

[0045] The thin sidewall 126 may be fragile. This can be mitigated by providing additional structural support to the sidewall 126 and by forming the sidewall 126 in a tubular, preferably cylindrical, shape. In some cases, the additional structural support is provided as a separate feature, but it should be noted that the flange 138 and base 112 also provide a certain degree of structural support. Considering the base 112 first, it should be noted that while tubes with open ends are generally prone to collapse, providing a base 112 in the heating chamber 108 of this disclosure provides additional support. In the illustrated embodiment, it should be noted that the base 112 is thicker than the sidewall 126, for example, 2 to 10 times thicker than the sidewall 126. In some cases, this may result in a base 112 with a thickness of 200 μm to 500 μm, for example, about 400 μm. The base 112 also has the further objective of preventing the substrate carrier 114 from being excessively inserted into the aerosol generator 100. Increasing the thickness of the base 112 helps prevent damage to the heating chamber 108 if the user inadvertently applies too much force when inserting the substrate carrier 114. Similarly, when a user cleans the heating chamber 108, the user may typically insert an object such as an elongated brush through the open end 110 of the heating chamber 108. This means that when the elongated object strikes the base 112, the user is more likely to apply a greater force to the base 112 than to the side wall 126 of the heating chamber 108. Therefore, the thickness of the base 112 relative to the side wall 126 can help prevent damage to the heating chamber 108 during cleaning. In other embodiments, the base 112 has the same thickness as the side wall 126, which results in some of the advantageous effects described above.

[0046] The flange 138 extends outward from the side wall 126 and has an annular shape that extends around the entire periphery of the side wall 126 at the open end 110 of the heating chamber 108. The flange resists bending and shear forces at the side wall 126. For example, lateral deformation of the pipe defined by the side wall 126 is likely to require the flange 138 to buckle. Although the flange 138 is shown extending approximately perpendicularly from the side wall 126, it should be noted that the flange 138 can extend obliquely from the side wall 126, for example, forming a funnel shape with the side wall 126, while retaining the advantageous features described above. In some embodiments, the flange 138 is located only on a portion of the periphery of the side wall 126, rather than being annular. In the illustrated embodiment, the flange 138 is the same thickness as the side wall 126, but in other embodiments, the flange 138 is thicker than the side wall 126 to improve resistance to deformation. Increasing the thickness of specific parts for strength is considered in comparison to the increase in introduced thermal mass, so that the aerosol generator 100 as a whole remains robust but efficient.

[0047] Multiple projections 140 are formed on the inner surface of the side wall 126. The width of the projections 140 around the outer circumference of the side wall 126 is small compared to its length parallel to the central axis of the side wall 126 (i.e., roughly in the direction from the base 112 to the open end 110 of the heating chamber 108). In this example, there are four projections 140. As will become clear from the following discussion, four is usually a preferred number of projections 140 to hold the substrate carrier 114 in a central position within the heating chamber 108. In some embodiments, for example, three projections spaced (evenly) at approximately 120 degrees around the circumference of the side wall 126 may suffice. The projections 140 serve various purposes, and the exact shape of the projections 140 (and corresponding recesses on the outer surface of the side wall 126) is selected based on the desired effect. In any case, the projections 140 extend toward and engage with the substrate carrier 114, and are therefore sometimes called engaging elements. In fact, the terms “projection” and “engaging element” are used interchangeably in this specification. Similarly, if the projection 140 is formed by applying external pressure to the side wall 126, for example by hydraulic molding or pressure molding, the term “recess” is used interchangeably with the terms “projection” and “engaging element.” Forming the projection 140 by recessing the side wall 126 has the advantage that the projection is integral with the side wall 126, and therefore has minimal impact on heat flow. In addition, the projection 140 does not add any thermal mass, as would be the case if an additional element were added to the inner surface of the side wall 126 of the heating chamber 108. In fact, as a result of forming the projection 140 by recessing the side wall 126, the thickness of the side wall 126 remains substantially constant in the circumferential and / or axial directions, even where the projection is provided. Finally, as described, recessing the side wall increases the strength of the side wall 126 by introducing a portion that extends across the side wall 126, thus providing resistance to bending of the side wall 126.

[0048] The heating chamber 108 is configured to accommodate a substrate carrier 114. Typically, the substrate carrier comprises an aerosol substrate 128, such as tobacco or another suitable aerosolizable material that can be heated to generate an aerosol for inhalation. In the first embodiment, the heating chamber 108 is sized to accommodate a single puff of the aerosol substrate 128 in the form of a substrate carrier 114, also known as a “consumable,” as shown, for example, in Figures 3 to 6. However, this is not mandatory, and in other embodiments, the heating chamber 108 is configured to accommodate other forms of the aerosol substrate 128, such as loose tobacco or tobacco packaged in other ways.

[0049] The aerosol generator 100 functions by both conducting heat from the surface of the protrusions 140 that engage with the outer layer 132 of the substrate carrier 114, and by heating the air in the air gap between the inner surface of the side wall 126 and the outer surface of the substrate carrier 114. That is, when a user inhales the aerosol generator 100, there is convective heating of the aerosol substrate 128 as heated air is drawn through the aerosol substrate 128 (as will be described in more detail below). The increased distance (and the distance it extends) increases the surface area of ​​the side wall 126 that transfers heat to the air, so that the aerosol generator 100 can reach its effective temperature more quickly.

[0050] When the substrate carrier 114 is inserted into the heating chamber 108, the projections 140 on the inner surface of the side wall 126 extend toward the substrate carrier 114 and actually come into contact with it (see, for example, Figure 6). As a result, the aerosol substrate 128 is also heated by conduction through the outer layer 132 of the substrate carrier 114.

[0051] It is clear that the surface 145 of the projection 140 must engage with the outer layer 132 of the substrate carrier 114 in order to conduct heat into the aerosol substrate 128. However, manufacturing tolerances may result in small variations in the diameter of the substrate carrier 114. In addition, due to the relatively soft and compressible nature of the outer layer 132 of the substrate carrier 114 and the aerosol substrate 128 held therein, any damage to or rough handling of the substrate carrier 114 may result in a decrease in the diameter or a change in shape to an oval or elliptical cross-section in the area where the outer layer 132 is intended to engage with the surface 145 of the projection 140. Accordingly, any variation in the diameter of the substrate carrier 114 may result in a reduction in thermal engagement between the outer layer 132 of the substrate carrier 114 and the surface 145 of the projection 140, thereby adversely affecting heat conduction from the surface 145 of the projection 140 through the outer layer 132 of the substrate carrier 114 into the aerosol substrate 128. To mitigate the effects of any variations in the diameter of the substrate carrier 114 due to manufacturing tolerances or damage, the projection 140 is preferably sized to extend sufficiently into the heating chamber 108, causing compression of the substrate carrier 114, thereby ensuring an interlocking fit between the surface 145 of the projection 140 and the outer layer 132 of the substrate carrier 114. This compression of the outer layer 132 of the substrate carrier 114 may also produce longitudinal markings on the outer layer 132 of the substrate carrier 114, providing a visual indicator that the substrate carrier 114 has been used.

[0052] Figure 6(a) shows an enlarged view of the heating chamber 108 and the substrate carrier 114. As can be seen from the figure, arrow B indicates the airflow path that brings about the convective heating described above. As described above, the heating chamber 108 may be cup-shaped with a sealed and airtight base 112, which means that since it is impossible for the airflow to pass through the sealed and airtight base 112, the airflow must flow down the side of the substrate carrier 114 in order to enter the first end 134 of the substrate carrier. As described above, the projection 140 extends a sufficient distance into the heating chamber 108 and contacts at least the outer surface of the substrate carrier 114, typically causing at least some compression of the substrate carrier. As a result, in the cross-sectional view of Figure 6(a), there is no air gap along the heating chamber 108 in the plane of the figure, as the projection 140 on the left and right of the figure penetrates through it. Instead, the airflow channels (arrow B) are shown as dashed lines in the region of the protrusions 140, indicating that the airflow channels are located in front of and behind the protrusions 140. In fact, compared to Figure 2(a), it can be seen that the airflow channels occupy four equally spaced gap regions between the four protrusions 140. Of course, in some situations there may be more or fewer than four protrusions 140, in which case the general point that the airflow channels are located within the gaps between the protrusions remains true.

[0053] Furthermore, Figure 6(a) highlights the deformation of the outer surface of the substrate carrier 114, which occurs as the substrate carrier 114 is forced to pass through the protrusion 140 as it is inserted into the heating chamber 108. As described above, the distance the protrusion 140 extends into the heating chamber can be advantageously selected to be large enough to cause compression of any substrate carrier 114. This (sometimes permanent) deformation during heating can help stabilize the substrate carrier 114, in the sense that the deformation of the outer layer 132 of the substrate carrier 114 creates a region of higher density of aerosol substrate 128 near the first end 134 of the substrate carrier 114. In addition, the resulting substrate carrier The undulating outer surface of body 114 provides a gripping effect to the edges of the denser regions of the aerosol substrate 128 near the first end 134 of the substrate carrier 114. Overall, this reduces the likelihood that any loose aerosol substrate will fall from the first end 134 of the substrate carrier 114 and contaminate the heating chamber 108. This is a useful effect because, as mentioned above, heating the aerosol substrate 128 causes it to contract, thereby increasing the likelihood that loose aerosol substrate 128 will fall from the first end 134 of the substrate carrier 114. This undesirable effect is mitigated by the deformation effect described.

[0054] To ensure that the protrusions 140 are in contact with the substrate support 114 (contact is necessary to cause conductive heating, compression, and deformation of the aerosol substrate), the manufacturing tolerances of the protrusions 140, the heating chamber 108, and the substrate support 114 are taken into consideration. For example, the inner diameter of the heating chamber 108 may be 7.6 ± 0.1 mm, the substrate support 114 may have an outer diameter of 7.0 ± 0.1 mm, and the protrusions 140 may have a manufacturing tolerance of ± 0.1 mm. In this example, assuming that the substrate support 114 is mounted in the center of the heating chamber 108 (i.e., a uniform gap remains around the outside of the substrate support 114), the gap that each protrusion 140 must span to contact the substrate support 114 ranges from 0.2 mm to 0.4 mm. In other words, since each projection 140 spans the radial distance, the minimum possible size in this example is half the difference between the minimum possible diameter of the heating chamber 108 and the maximum possible diameter of the substrate support 114, i.e., [(7.6-0.1)-(7.0+0.1)] / 2 = 0.2 mm. The upper limit of the range in this example is (for similar reasons) half the difference between the maximum possible diameter of the heating chamber 108 and the minimum possible diameter of the substrate support 114, i.e., [(7.6+0.1)-(7.0-0.1)] / 2 = 0.4 mm. It is clear that in this example, each projection needs to extend at least 0.4 mm into the heating chamber to ensure that the projection 140 does indeed contact the substrate support. However, this does not take into account the manufacturing tolerances of the projection 140. If a projection of 0.4 mm is required, the range actually produced is 0.4 ± 0.1 mm, i.e., varying between 0.3 mm and 0.5 mm. Some of the protrusions will not span the maximum possible gap between the heating chamber 108 and the substrate support 114. Therefore, the protrusion 140 in this example should be fabricated with a nominal protrusion distance of 0.5 mm, resulting in a value in the range of 0.4 mm to 0.6 mm. This value is sufficient to ensure that the protrusion 140 is always in contact with the substrate support.

[0055] Generally, the inner diameter of the heating chamber 108 is D±δ D The outer diameter of the substrate support 114 is d±δ dAnd the distance over which the protrusion 140 extends into the heating chamber 108 is L±δ L Therefore, the distance over which the protrusion 140 is intended to extend into the heating chamber should be selected as follows:

number

[0056] Furthermore, manufacturing tolerances may result in slight variations in the density of the aerosol substrate 128 within the substrate carrier 114. Such variations in the density of the aerosol substrate 128 are simply The projections can exist both axially and radially within a single substrate carrier 114 or between different substrate carriers 114 manufactured in the same batch. Accordingly, it will also be apparent that the density of the aerosol substrate 128 is relatively constant in order to ensure relatively uniform heat conduction in the aerosol substrate 128 within a particular substrate carrier 114. To mitigate the effects of any density mismatch of the aerosol substrate 128, the projection 140 may be sized to extend sufficiently into the heating chamber 108 to cause compression of the aerosol substrate 128 within the substrate carrier 114, thereby improving heat conduction through the aerosol substrate 128 by eliminating air gaps. In the illustrated embodiment, a projection 140 extending approximately 0.4 mm into the heating chamber 108 is suitable. In other examples, the distance the projection 140 extends into the heating chamber 108 may be defined as a percentage of the distance across the heating chamber 108. For example, the projection 140 may extend for a distance of 3% to 7%, for example, about 5%, of the distance across the heating chamber 108. In another embodiment, the limited diameter to which the projection 140 circumscribes within the heating chamber 108 is 6.0 mm to 6.8 mm, more preferably 6.2 mm to 6.5 mm, and particularly 6.2 mm (±0.5 mm). Each of the multiple projections 140 extends for a radial distance of 0.2 mm to 0.8 mm, most preferably 0.2 mm to 0.4 mm.

[0057] With respect to the projection / recess 140, its width corresponds to the distance around the outer circumference of the side wall 126. Similarly, its length extends perpendicular to its width and runs extensively from the base 112 to the open end of the heating chamber 108 or to the flange 138, and its height corresponds to the distance the projection extends from the side wall 126. Note that the space between adjacent projections 140, the side wall 126, and the outer layer 132 of the substrate carrier 114 defines the area available for airflow. This results in the effect (known as increased draw resistance) that the smaller the distance between adjacent projections 140 and / or the height of the projections 140 (i.e., the distance the projections 140 extend into the heating chamber 108), the stronger the user must suction to draw air through the aerosol generator 100. Assuming that the protrusion 140 is in contact with the outer layer 132 of the substrate support 114, it will be clear that the width of the protrusion 140 determines the reduction of the airflow channel between the side wall 126 and the substrate support 114. Conversely (again, assuming that the protrusion 140 is in contact with the outer layer 132 of the substrate support 114), increasing the height of the protrusion 140 will compress the aerosol substrate more, thereby eliminating the air gap within the aerosol substrate 128, which also increases the pull-in resistance. By adjusting these two parameters, a satisfactory pull-in resistance that is neither too low nor too high can be obtained. The heating chamber 108 can also be made larger to increase the airflow channel between the side wall 126 and the substrate support 114, but there is a practical limitation that the gap will become too large and the heater 124 will begin to become ineffective. Typically, a gap of 0.2 mm to 0.4 mm or 0.2 mm to 0.3 mm around the outer surface of the substrate carrier 114 is a good compromise, allowing for fine-tuning of the pull-in resistance within acceptable limits by changing the dimensions of the protrusions 140. The air gap around the outside of the substrate carrier 114 can also be changed by changing the number of protrusions 140. Any number of protrusions 140 (one or more) provides at least some of the advantages described herein (e.g., increased heating area, provision of compression, provision of conductive heating of the aerosol substrate 128, adjustment of the air gap).The minimum number of protrusions required to securely hold the substrate carrier 114 in alignment with the heating chamber 108 centrally (i.e., coaxially) is four. In another possible design, there are only three protrusions distributed at a distance of 120 degrees from each other. Designs with fewer than four protrusions 140 tend to allow the substrate carrier 114 to be pressed against a portion of the side wall 126 between two protrusions 140. In limited space, providing a very large number of protrusions (e.g., 30 or more) obviously tends to result in a situation where there are little to no gaps between the protrusions, which can completely close the airflow channel between the outer surface of the substrate carrier 114 and the inner surface of the side wall 126, significantly reducing the aerosol generator's ability to provide convective heating. However, Such a design can still be used, in relation to the possibility of providing a hole in the center of the base 112 to define the airflow channel. Typically, the projections 140 may be arranged at equal intervals around the outer circumference of the side wall 126 to help provide uniform compression and heating, but in some variations, they may have an asymmetrical arrangement depending on the desired precise effect.

[0058] It will also become clear that the size and number of the protrusions 140 allow for adjustment of the balance between conductive and convective heating. By increasing the width of the protrusions 140 that contact the substrate carrier 114 (the distance the protrusions 140 extend around the outer circumference of the side wall 126), the available outer circumference of the side wall 126 that functions as an airflow channel (arrow B in Figures 6 and 6(a)) is reduced, thus reducing the convective heating provided by the aerosol generator 100. However, wider protrusions 140 contact the substrate carrier 114 over a larger portion of the outer circumference, thus increasing the conductive heating provided by the aerosol generator 100. A similar effect is observed when more protrusions 140 are added, but this is because the conductive channel is increased by increasing the total contact surface area between the protrusions 140 and the substrate carrier 114, while the available outer circumference of the side wall 126 for convection decreases. It should be noted that increasing the length of the protrusions 140 reduces the volume of air in the heating chamber 108 heated by the heater 124, thus reducing convective heating, while increasing the contact surface area between the protrusions 140 and the substrate support, thus increasing conductive heating. Increasing the distance each protrusion 140 extends into the heating chamber 108 can help improve conductive heating without significantly reducing convective heating. Therefore, the aerosol generator 100 can be designed to balance the types of conductive and convective heating by changing the number and size of the protrusions 140 as described above. The thermal localization effect resulting from the relatively thin sidewalls 126 and the use of a material with relatively low thermal conductivity (e.g., stainless steel) ensures that conductive heating is a suitable means of transferring heat to the substrate support 114 and subsequently to the aerosol substrate 128. This is because the heated portion of the side wall 126 likely corresponds roughly to the location of the protrusion 140, meaning that the generated heat is conducted to the substrate support 114 by the protrusion 140, but not conducted away from the substrate support. In areas that are heated but do not correspond to the protrusion 140, heating of the side wall 126 leads to the convective heating described above.

[0059] As shown in Figures 1 to 6, the projection 140 is elongated; that is, the projection extends to a length greater than its width. In some cases, the projection 140 may have a length five, ten, or even twenty-five times its width. For example, as described above, the projection 140 may extend 0.4 mm into the heating chamber 108, and in one example, it may further be 0.5 mm wide and 12 mm long. These dimensions are suitable for a heating chamber 108 with a length of 30 mm to 40 mm. In this example, the projection 140 does not extend along the entire length of the heating chamber 108 because, in the given example, the projection is shorter than the heating chamber 108. Therefore, the projection 140 has an upper edge 142a and a bottom edge 142b, respectively. The upper edge 142a is the part of the projection 140 that is closest to the open end 110 of the heating chamber 108 and also closest to the flange 138. The bottom edge 142b is the end of the projection 140 that is located closest to the base 112. Above the top edge 142a (closer to the open end than the top edge 142a) and below the bottom edge 142b (closer to the base 112 than the bottom edge 142b), it can be seen that there is no projection 140 on the side wall 126. That is, in these parts the side wall 126 is neither deformed nor recessed. In some examples, the projection 140 is longer and extends all the way to the top and / or bottom of the side wall 126, resulting in one or both of the following: the top edge 142a aligns with the open end 110 of the heating chamber 108 (or flange 138), and the bottom edge 142b aligns with the base 112. In fact, in such cases, the top edge 142a and / or bottom edge 142b may not even be present.

[0060] It may be advantageous that the projection 140 does not extend along the entire length of the heating chamber 108 (for example, from the base 112 to the flange 138). At the upper end, as will be described later, the upper edge 142a of the projection 140 can be used as an indicator to prevent the user from inserting the substrate carrier 114 too far into the aerosol generator 100. However, it may be useful to heat areas other than the area of ​​the substrate carrier 114 containing the aerosol substrate 128. This is because, once the aerosol is generated, it is beneficial to maintain a high temperature (higher than room temperature, but not high enough to burn the user) to prevent recondensation that would impair the user experience. Therefore, the effective heating area of ​​the heating chamber 108 extends beyond the expected position of the aerosol substrate 128 (i.e., to the upper part of the heating chamber 108 near the open end). This means that the heating chamber 108 extends above the upper edge 142a of the projection 140, or similarly, that the projection 140 does not extend all the way to the open end of the heating chamber 108. Similarly, compression of the aerosol substrate 128 at the end 134 of the substrate carrier 114 inserted into the heating chamber 108 could lead to some of the aerosol substrate 128 falling off the substrate carrier 114 and contaminating the heating chamber 108. Therefore, it may be advantageous to position the lower edge 142b of the projection 140 further away from the base 112 than the expected position of the end 134 of the substrate carrier 114.

[0061] In some embodiments, the projection 140 is not elongated and has a width approximately equal to its length. For example, the projection may have a width approximately equal to its height (e.g., having a square or circular contour when viewed radially), or the projection may be 2 to 5 times its width in length. It should be noted that the centering effect provided by the projection 140 can be achieved even if the projection 140 is not elongated. In some examples, there may be multiple sets of projections 140, for example, an upper set near the open end of the heating chamber 108 and a lower set spaced apart from the upper set and located near the base 112. This can help ensure that the substrate carrier 114 is held in a coaxial configuration while reducing the pull resistance introduced by a single set of projections 140 over the same distance. The two sets of projections 140 may be substantially identical, or they may differ in their length or width, or in the number or arrangement of projections 140 configured around the side wall 126.

[0062] In the side view, the projection 140 is shown as having a trapezoidal contour. This means that the contour along the length of each projection 140, for example, the longitudinal cross-section in the center of the projection 140, is approximately trapezoidal. That is, the upper edge 142a is generally flat, tapering, and joins the side wall 126 near the open end 110 of the heating chamber 108. In other words, the upper edge 142a has a chamfered contour. Similarly, the projection 140 has a lower portion 142b, which is generally flat, tapering, and joins the side wall 126 near the base 112 of the heating chamber 108. That is, the lower edge 142b has a chamfered contour. In other embodiments, the upper edge 142a and / or the lower edge 142b do not taper toward the side wall 126, but instead extend from the side wall 126 at an angle of approximately 90 degrees. In yet another embodiment, the upper edge 142a and / or the lower edge 142b have a curved or rounded shape. Bridging the upper edge 142a and the lower edge 142b is a generally planar region that contacts and / or compresses the substrate support 114. The planar contact portion can help provide uniform compression and conductive heating. In another example, the planar portion may instead be a curved portion that curves outward and contacts the substrate support 128, for example, having a polygonal or curved contour (e.g., part of a circle).

[0063] If the protrusion 140 has an upper edge 142a, the protrusion 140 also functions to prevent over-insertion of the substrate carrier 114. As is most clearly shown in Figures 4 and 6, the substrate carrier 114 has a lower portion containing the aerosol substrate 128, which is the substrate carrier 114 The projection terminates prematurely at the boundary of the aerosol substrate 128. The aerosol substrate 128 is typically more compressible than other areas 130 of the substrate carrier 114. Therefore, due to the reduced compressibility of other areas 130 of the substrate carrier 114, the user inserting the substrate carrier 114 will feel increased resistance when the upper edge 142a of the projection 140 aligns with the boundary of the aerosol substrate 128. To achieve this, the portion of the base 112 that the substrate carrier 114 contacts should be spaced at a distance equal to the length of the substrate carrier 114 occupied by the aerosol substrate 128 from the upper edge 142a of the projection 140. In some examples, the aerosol substrate 128 occupies approximately 20 mm of the substrate carrier 114, so the distance between the upper edge 142a of the projection 140 and the base portion that the substrate carrier 114 contacts when the substrate carrier 114 is inserted into the heating chamber 108 is also approximately 20 mm.

[0064] As illustrated, the base 112 also includes a platform 148. The platform 148 is formed in a single step, in which the base 112 is press-formed from below (e.g., hydraulically formed, by mechanical pressure, as part of the formation of the heating chamber 108), leaving a recess on the outer surface (bottom) of the base 112 and the platform 148 on the inner surface (top, inside the heating chamber 108) of the base 112. These terms are used interchangeably when the platform 148 is formed in this way, for example, with a corresponding recess. In other cases, the platform 148 may be formed from a separate part separately attached to the base 112, or by machining a portion of the base 112 to leave the platform 148, in either case the corresponding recess is not required. These latter cases can provide more variety in the shape of the platform 148 that can be realized, because this does not depend on deformation of the base 112, which (conveniently) limits the complexity of the shape that can be chosen. The illustrated shapes are generally circular, but of course, there are a wide variety of shapes that would achieve the desired effects described in detail herein, and these shapes include, but are not limited to, polygonal shapes, curved shapes, and shapes that include one or more of these types. In fact, although shown as a centrally located platform 148, there may be one or more platform elements spaced apart from the center, for example, the edges of the heating chamber 108. Typically, platform 148 has a generally flat top, but hemispherical platforms or platforms with a rounded dome shape at the top are also conceivable.

[0065] As described above, the distance between the upper edge 142a of the projection 140 and the portion of the base 112 in contact with the substrate carrier 114 can be carefully selected to match the length of the aerosol substrate 128, providing the user with an indicator that the substrate carrier 114 has been inserted sufficiently into the aerosol generator 100. If there is no platform 148 on the base 112, this simply means that the distance from the base 112 to the upper edge 142a of the projection 140 must match the length of the aerosol substrate 128. If a platform 148 is present, the length of the aerosol substrate 128 should correspond to the distance between the upper edge 142a of the projection 140 and the top of the platform 148 (i.e., the portion closest to the open end 110 of the heating chamber 108 in some examples). In yet another example, the distance between the upper edge 142a of the projection 140 and the top of the platform 148 is slightly shorter than the length of the aerosol substrate 128. This means that compression of the aerosol substrate 128 must occur at the end 134 of the substrate carrier 114, as the tip 134 of the substrate carrier 114 extends slightly past the top of the platform 148. In fact, this compression effect can occur even in cases where there is no projection 140 on the inner surface of the side wall 126. This compression helps prevent the aerosol substrate 128 at the end 134 of the substrate carrier 114 from falling into the heating chamber 108, thereby reducing the need to clean the heating chamber 108, which can be a complex and difficult task. In addition, this compression is at the end of the substrate carrier 114. This helps to compress 134, thereby mitigating the effects described above. In other words, this effect is unsuitable because compressing this region using the protrusion 140 extending from the side wall 126 tends to increase the likelihood of the aerosol substrate 128 falling off the substrate support 114.

[0066] Platform 148 also provides a region that can collect any aerosol substrate 128 that has detached from the substrate carrier 114 without obstructing the airflow path into the tip 134 of the substrate carrier 114. For example, platform 148 divides the lower end of the heating chamber 108 (i.e., the part closest to the base 112) into an upright portion that forms platform 148 and a lower portion that forms the rest of the base 112. The lower portion can receive loose fragments of aerosol substrate 128 that have detached from the substrate carrier 114, while air can flow over such loose fragments of aerosol substrate 128 into the tip of the substrate carrier 114. To achieve this effect, platform 148 can be raised about 1 mm higher than the rest of the base 112. Platform 148 may have a diameter smaller than the diameter of the substrate carrier 114 so that platform 148 does not obstruct the flow of air through the aerosol substrate 128. Preferably, the platform 148 has a diameter of 0.5 mm to 0.2 mm, most preferably 0.45 mm to 0.35 mm, for example, 0.4 mm (±0.03 mm).

[0067] The aerosol generator 100 has a user-operable button 116. In the first embodiment, the user-operable button 116 is located on the side wall 118 of the casing 102. The user-operable button 116 is configured such that when activated, for example by pressing the user-operable button 116, the aerosol generator 100 is activated, the aerosol substrate 128 is heated, and an aerosol for inhalation is generated. In some embodiments, the user-operable button 116 is also configured to allow the user to activate other functions of the aerosol generator 100 and / or to illuminate to indicate the status of the aerosol generator 100. In other examples, a separate light (e.g., one or more LEDs or other suitable light source) may be provided to indicate the status of the aerosol generator 100. In this regard, status may mean one or more of the following: battery level, heater status (e.g., on, off, error, etc.), device status (e.g., whether it is ready to take a puff), or other indicators of status, such as error mode, number of puffs consumed, whether the entire substrate carrier 114 has been consumed, or the number of puffs remaining until the power is depleted.

[0068] In the first embodiment, the aerosol generator 100 is electrically driven; that is, it is configured to use electricity to heat the aerosol substrate 128. For this purpose, the aerosol generator 100 has a power supply 120, for example, a battery. The power supply 120 is coupled to a control circuit 122. The control circuit 122 is then coupled to a heater 124. A user-operable button 116 is configured to couple and uncouple the power supply 120 to the heater 124 via the control circuit 122. In this embodiment, the power supply 120 is located toward the first end 104 of the aerosol generator 100. This allows the power supply 120 to be positioned at a distance from the heater 124, which is located toward the second end 106 of the aerosol generator 100. In other embodiments, the heating chamber 108 is heated by other means, for example, by burning a flammable gas.

[0069] The heater 124 is mounted on the outer surface of the heating chamber 108. The heater 124 is mounted on a metal layer 144, and the metal layer itself is in contact with the outer surface of the side wall 126. The metal layer 144 forms a band around the heating chamber 108 to match the shape of the outer surface of the side wall 126. The heater 124 is mounted in the center of the metal layer 144. The metal layer 144 extends equally far upward and downward beyond the heater 124. As shown in the figures, the heater 124 is entirely located on the metal layer 144, so that the metal layer 144 covers a larger area than the area occupied by the heater 124. The heater 124, as shown in Figures 1 to 6, is mounted in the middle portion of the heating chamber 108 between the base 112 and the open end 110, and is mounted on the outer surface area covered by the metal layer 114. In other embodiments, the heater 124 may be mounted in other parts of the heating chamber 108, or may be contained within the side wall 126 of the heating chamber 108, and it should be noted that it is not necessary for the outside of the heating chamber 108 to include the metal layer 144.

[0070] The heater 124 comprises a heating element 164, an electrical connection track 150, and a backing film 166, as shown in Figure 7. The heating element 164 is configured such that when current passes through it, it heats up and its temperature rises. The heating element 164 is molded to not contain sharp corners, which may induce hot spots or form melting points on the heater 124. The heating element 164 also has a uniform width, and portions of the element 164 extending close to each other are held at approximately equal distances apart. The heating element 164 in Figure 7 shows two resistive paths 164a and 164b, each taking a winding path over the area of ​​the heater 124, covering as wide an area as possible while adhering to the criteria described above. These paths 164a and 164b are electrically connected in parallel in Figure 7. Note that other numbers of paths, e.g., three paths, one path, or many paths, can be used. The paths 164a and 164b do not cross each other to prevent short circuits. The heating element 164 is configured to have resistance to produce the correct power density for the required heating level. In some examples, the heating element 164 has resistance of 0.4Ω to 2.0Ω, particularly favorably 0.5Ω to 1.5Ω, and more specifically 0.6Ω to 0.7Ω.

[0071] The electrical connection track 150 is shown as part of the heater 124, but in some embodiments it may be replaced by a wire or other connecting element. The electrical connection 150 is used to supply power to the heating element 164 and to form a circuit with the power supply 120. The electrical connection track 150 is shown extending vertically downward from the heating element 164. With the heater 124 in place, the electrical connection 150 extends beyond the base 112 of the heating chamber 108 and through the base 156 of the insulating member 152 to connect to the control circuit 122.

[0072] The backing film 166 may be a single sheet to which the heating element 164 is attached, or may form an envelope that sandwiches the heating element between two sheets 166a and 166b. In some embodiments, the backing film 166 is formed of polyimide. In some embodiments, the thickness of the backing film 166 is minimized to reduce the thermal mass of the heater 124. For example, the thickness of the backing film 166 may be 50 μm, or 40 μm, or 25 μm.

[0073] The heating element 164 is attached to the side wall 108. In FIG. 7, the heating element 164 is configured to wrap once around the periphery of the heating chamber 108 by carefully selecting the size of the heater 124. This ensures that the heat generated by the heater 124 is distributed substantially evenly around the surface covered by the heater 124. Note that in some examples, the heater 124 may be wrapped an integer number of times around the heating chamber 108, rather than exactly one full turn.

[0074] It should also be noted that the height of the heater 124 is about 14 mm to 15 mm. The circumference of the heater 124 (or its length before being applied to the heating chamber 108) is about 24 mm to 25 mm. The height of the heating element 164 may be less than 14 mm. As a result, the add It is possible to position the thermal element 164 completely inside the backing film 166 of the heater 124, with a border around the heating element 164. Accordingly, the area covered by the heater 124, in some embodiments, is about 3.75 cm 2 can be.

[0075] The power used by the heater 124 is supplied in this embodiment by a power supply 120, which is in the form of a cell (or battery). The voltage supplied by the power supply 120 is a regulated voltage or a boosted voltage. For example, the power supply 120 may be configured to generate a voltage in the range of 2.8V to 4.2V. In one example, the power supply 120 is configured to generate a voltage of 3.7V. If the exemplary resistance of the heating element 164 in one embodiment is 0.6Ω and the exemplary voltage is 3.7V, this will result in a power output of approximately 30W for the heating element 164. Note that based on exemplary resistance and voltage, the power output may be 15W to 50W. The cell forming the power supply 120 may be a rechargeable cell, or it may be a single-use cell 120 instead. The power supply is typically configured to power 20 or more thermal cycles. This allows the user to use a full packet of 20 substrate carriers 114 on a single charge of the aerosol generator 100. The cell may be a lithium-ion cell or any other type of commercially available cell. The cell may be, for example, an 18650 cell or an 18350 cell. If the cell is an 18350 cell, the aerosol generator 100 may be configured to store enough charge for 12 thermal cycles or, in fact, 20 thermal cycles, allowing the user to consume 12 or 20 substrate carriers 114.

[0076] One important value for heater 124 is the power per unit area generated by the heater. This is a measure of how much heat can be supplied by heater 124 to the area in contact with the heater (in this case, the heating chamber 108). In the example described, this is 4 W / cm². 2 ~13.5W / cm 2 The range is as follows: The maximum power density rating of the heater is typically 2 W / cm², depending on the design. 2 ~10W / cm 2Therefore, in some of these embodiments, a copper or other conductive metal layer 144 may be provided on the heating chamber 108 to efficiently conduct heat from the heater 124 and reduce the possibility of damage to the heater 124.

[0077] The power supplied by the heater 124 may be constant in some embodiments and not constant in other embodiments. For example, the heater 124 may supply variable power via a duty cycle, or more specifically, via a pulse width modulation cycle. This makes it possible to supply power in pulses and to easily control the time-averaged power output by the heater 124 simply by selecting the ratio of "on" time to "off" time. The level of power output by the heater 124 may also be controlled by additional control means, such as current or voltage manipulation.

[0078] As shown in Figure 7, the aerosol generator 100 has a temperature sensor 170 for detecting the temperature of the heater 124 or the temperature of the environment surrounding the heater 124. The temperature sensor 170 may be, for example, a thermistor, a thermocouple, or any other thermometer. For example, a thermistor may be formed of glass beads containing a resistive material, the resistive material being connected to a voltmeter, and the current flowing through the resistive material is known. Thus, as the temperature of the glass changes, the resistance of the resistive material changes in a predictable manner, and therefore, its temperature can be determined from the voltage drop across the resistive material at a constant current (a constant voltage mode is also possible). In some embodiments, the temperature sensor 170 is located on the surface of the heating chamber 108, for example, in a recess formed on the outer surface of the heating chamber 108. The recess may be as described elsewhere in this specification, for example, part of a projection 140, or a recess specifically provided to hold the temperature sensor 170. In the illustrated embodiment, the temperature sensor 170 is located on the backing layer 166 of the heater 124. It is provided in [location]. In other embodiments, the temperature sensor 170 is integrated with the heating element 164 of the heater 124 in the sense that the temperature is detected by monitoring the change in the resistance of the heating element 164.

[0079] In the aerosol generator 100 of the first embodiment, the time from the start of the aerosol generator 100 to the first puff is a critical parameter. The user of the aerosol generator 100 will understand that it is preferable to minimize the delay time from the start of the aerosol generator 100 to the inhalation of aerosol from the substrate carrier 128, and to start inhaling aerosol from the substrate carrier 128 as quickly as possible. Therefore, during the first stage of heating, the power supply 120 supplies 100% of its available power to the heater 124, for example, by setting the duty cycle to always on, or by manipulating the product of voltage and current to its possible maximum value. This may be a period of 30 seconds, more preferably 20 seconds, or any period until the temperature sensor 170 gives a reading corresponding to 240°C. Typically, the substrate carrier 114 can operate optimally at 180°C. Nevertheless, it may still be advantageous to heat the temperature sensor 170 above this temperature so that the user can extract aerosol from the substrate carrier 114 as quickly as possible. This is because the aerosol substrate 128 is heated by convection of warm air passing through it, and to some extent by conduction between the protrusions 140 and the outer surface of the substrate support 114, so the temperature of the aerosol substrate 128 typically lags behind (i.e., is lower than) the temperature detected by the temperature sensor 170. In contrast, the temperature sensor 170 maintains good thermal contact with the heater 124, so it measures a temperature closer to the heater 124 temperature than to the temperature of the aerosol substrate 128. In fact, accurately measuring the temperature of the aerosol substrate 128 can be difficult, so in many cases the heating cycle is determined experimentally, in which case different heating profiles and heater temperatures are tried, and the various aerosol components formed at those temperatures for the aerosols generated by the aerosol substrate 128 are monitored. In the optimal cycle, the aerosol is supplied as quickly as possible, while the generation of combustion products due to overheating of the aerosol substrate 128 is avoided.

[0080] The level of power delivered by the cell 120 may be set by using the temperature detected by the temperature sensor 170 to form a feedback loop in which the heater power supply cycle is controlled using the temperature detected by the temperature sensor 170. The heating cycle described below may be one in which the user wishes to consume a single substrate carrier 114.

[0081] In the first embodiment, the heater 124 extends around the heating chamber 108; that is, the heater 124 surrounds the heating chamber 108. More specifically, the heater 124 extends around the side wall 126 of the heating chamber 108, but not around the base 112 of the heating chamber 108. The heater 124 does not extend across the entire side wall 126 of the heating chamber 108. Rather, the heater extends across the entire perimeter of the side wall 126, but only over a portion of its length. In this regard, this length is the length from the base 112 to the open end 110 of the heating chamber 108. In other embodiments, the heater 124 extends along the entire length of the side wall 126. In yet another embodiment, the heater 124 comprises two heating portions separated by a gap, thereby leaving the central portion of the heating chamber 108, for example, a portion of the side wall 126 located between the base 112 and the open end 110 of the heating chamber 108, uncovered. In another embodiment, since the heating chamber 108 is cup-shaped, the heater 110 is also cup-shaped, for example, the heater extends entirely around the base 112 of the heating chamber 108. In yet another embodiment, the heater 124 comprises a plurality of heating elements 164 distributed in close proximity to the heating chamber 108. In some embodiments, there is space between the heating elements 164. In other embodiments, the heating elements overlap each other. In some embodiments, the heating elements 164 may be spaced apart around the circumference of the heating chamber 108 or the side wall 126, for example in the lateral direction, and in other embodiments, the heating elements 164 may be spaced apart along the length of the heating chamber 108 or the side wall 126, for example in the longitudinal direction. It will be understood that the heater 124 of the first embodiment is located outside the heating chamber 108, on the outer surface of the heating chamber 108. The heater 124 is provided in good thermal contact with the heating chamber 108, enabling good heat transfer between the heater 124 and the heating chamber 108.

[0082] The metal layer 144 may be formed from copper or any other material having high thermal conductivity (e.g., metal or alloy), such as gold or silver. In this context, high thermal conductivity may refer to a metal or alloy having a thermal conductivity of 150 W / mK or higher. The metal layer 144 can be applied by any suitable method, for example, electroplating. Other methods for applying layer 144 include attaching a metal tape to the heating chamber 108, chemical vapor deposition, physical vapor deposition, etc. Electroplating is a convenient method for applying layer 144, but the portion to which layer 144 is plated must be conductive. Other deposition methods do not require this, and these other methods open up the possibility that the heating chamber 108 may be formed from a non-conductive material such as ceramic, which may have useful thermal properties. Also, when the layer is described as metal, this should generally be interpreted as meaning "formed from a metal or alloy," in which context, metal refers to a material with relatively high thermal conductivity (>150 W / mK). When a metal layer 144 is electroplated onto a sidewall 126, it may be necessary to first form a "strike layer" to ensure that the electroplated layer adheres securely to the outer surface. For example, if the metal layer 144 is copper and the sidewall 126 is stainless steel, a nickel strike layer is often used to ensure good adhesion. The electroplated and deposited layers have the advantage of improving thermal conductivity between the two elements because there is direct contact between the metal layer 144 and the sidewall 126 material.

[0083] Regardless of the method used to form the metal layer 144, the thickness of the layer 144 is usually somewhat thinner than the thickness of the sidewall 126. For example, the thickness of the metal layer can range from 10 μm to 50 μm, or 10 μm to 30 μm, for example, about 20 μm. If a strike layer is used, it is even thinner than the metal layer 144, for example, 10 μm, or even 5 μm. As will be explained in more detail below, the purpose of the metal layer 144 is to distribute the heat generated by the heater 124 to an area larger than the area occupied by the heater 124. Once this effect is sufficiently achieved, there is little benefit in making the metal layer 144 any thicker, because this would simply increase the thermal mass and reduce the efficiency of the aerosol generator 100.

[0084] From Figures 1 to 6, it will be clear that the metal layer 144 extends only over a portion of the outer surface of the side wall 126. This not only reduces the thermal mass of the heating chamber 108 but also allows for the definition of the heating area. Generally, since the metal layer 144 has a higher thermal conductivity than the side wall 126, the heat generated by the heater 124 spreads rapidly throughout the area covered by the metal layer 144. However, because the side wall 126 is thinner and has a relatively lower thermal conductivity than the metal layer 144, the heat remains relatively localized in the area of ​​the side wall 126 covered by the metal layer 144. Selective electroplating is achieved by masking a portion of the heating chamber 108 with a suitable tape (e.g., polyester or polyimide) or silicone rubber mold. Other plating methods may use different tapes or masking methods as appropriate.

[0085] As shown in Figures 1 to 6, the metal layer 144 overlaps with the entire length of the heating chamber 108 along which the protrusion / recess 140 extends. This means that the protrusion 140 is heated by the heat conduction effect of the metal layer 144, and as a result the protrusion 140 provides the aforementioned conductive heating. This means that it becomes possible. The extent of the metal layer 144 generally corresponds to the extent of the heating region, so in many cases it is not necessary to extend the metal layer to the top and bottom of the heating chamber 108 (i.e., the area closest to the open end and base 112). As described above, the region of the substrate support 114 that will be heated starts slightly above the boundary of the aerosol substrate 128 and extends toward the end 134 of the substrate support 114, but in many cases does not include the end 134 of the substrate support 114. As described above, the metal layer 144 has the effect of spreading the heat generated by the heater 124 over a wider area than the area occupied by the heater 124 itself. This is its rated W / cm 2 This means that more power can be supplied to the heater 124 than the nominal power based on the surface area occupied by the heater 124. This is because the generated heat spreads over a wider area, so the effective area of ​​the heater 124 is larger than the surface area actually occupied by the heater 124.

[0086] Since the heating zone can be defined by the portion of the side wall 126 covered by the metal layer 144, it is not so important to position the heater 124 precisely outside the heating chamber 108. For example, instead of needing to position the heater 124 at a specific distance from the top or bottom of the side wall 126, the metal layer 144 could be formed in a very specific area, and the heater 124 could be positioned to cover the top of the metal layer 144, thereby spreading heat across the metal layer 144 area or heating zone as described above. Standardizing the masking process for electroplating or deposition is often simpler than precisely positioning the heater 124.

[0087] Similarly, where there are protrusions 140 formed by recessing the side wall 126, the recesses represent portions of the side wall 126 that do not come into contact with the heater 124 wrapped around the heating chamber 108, and instead the heater 124 tends to bridge over the recesses, leaving gaps. The metal layer 144 can help mitigate this effect because even portions of the side wall 126 that do not directly contact the heater 124 receive heat from the heater 124 through conduction via the metal layer 144. In some cases, the heater element 164 may be configured to minimize the overlap between the heater element 164 and the recess on the outer surface of the side wall 126, for example, by configuring the heating element 164 so that it crosses the recess but does not extend along it. In other cases, the heater 124 is positioned on the outer surface of the side wall 126 such that the portion of the heater 124 that covers the recess becomes a gap between the heater elements 164. Whatever method is chosen to mitigate the effects of the heater 124 covering the recess, the metal layer 144 reduces those effects by conducting heat to the recess. In addition, the metal layer 144 provides additional thickness to the recessed areas of the sidewall 126, thereby providing additional structural support to these areas. In fact, the additional thickness provided by the metal layer 126 reinforces the thin sidewall 126 in all parts covered by the metal layer 144.

[0088] The metal layer 144 can be formed before or after the step in which a recess is formed in the side wall 126 of the outer surface to provide a projection 140 extending into the heating chamber 108. It is preferable to form the recess before the metal layer. This is because once the metal layer 144 is formed, processes such as annealing tend to damage the metal layer 144, and the increased thickness of the side wall 126 when combined with the metal layer 144 makes it more difficult to punch out the side wall 126 to form the projection 140. However, if the recess is formed before the metal layer 144 is formed on the side wall 126, it is much easier to form the metal layer 144 so that it extends beyond the recess (i.e., upward and downward). This is because it is difficult to mask the outer surface of the side wall 126 so that the metal layer extends into the recess. Any gap between the masking and the side wall 126 could cause the metal layer 144 to deposit beneath the masking.

[0089] An insulating layer 146 is wrapped around the heater 124. Because this layer 146 is under tension, it provides compressive force to the heater 124, holding it firmly against the outer surface of the side wall 126. Advantageously, this insulating layer 146 is a heat-shrinkable material. This allows the insulating layer 146 to be tightly wrapped around the heating chamber (over the heater 124, metal layer 144, etc.) before heating. Upon heating, the insulating layer 146 contracts, pressing the heater 124 firmly against the outer surface of the side wall 126 of the heating chamber 108. This eliminates any air gap between the heater 124 and the side wall 126, and the heater 124 is held in very good thermal contact with the side wall. As a result, good efficiency is ensured because the heat generated by the heater 124 results in heating of the side wall (and subsequently the aerosol substrate 128) and is not wasted on heating the air or leaked in any other way.

[0090] In a preferred embodiment, a heat-shrinkable material, such as a treated polyimide tape that shrinks in only one direction, is used. For example, in the case of a polyimide tape, the tape may be configured to shrink only in the longitudinal direction. This means that the tape can be wrapped around the heating chamber 108 and heater 124, and when heated, it shrinks, pressing the heater 124 against the side wall 126. Since the insulating layer 146 shrinks in the longitudinal direction, the force thus generated is uniform and directed inward. If the tape shrinks in the transverse (width) direction, this may cause wrinkles in the heater 124 or the tape itself. This would then introduce gaps and reduce the efficiency of the aerosol generator 100.

[0091] Referring to Figures 3 to 6, the substrate carrier 114 contains a pre-packaged amount of aerosol substrate 128, along with an aerosol collection area 130 enclosed within an outer layer 132. The aerosol substrate 128 is located towards the first end 134 of the substrate carrier 114. The aerosol substrate 128 extends across the entire width of the substrate carrier 114 within the outer layer 132. The aerosol substrate also abuts each other along the substrate carrier 114 and meets at the boundary. Overall, the substrate carrier 114 is substantially cylindrical. In Figures 1 and 2, the aerosol generator 100 is shown without the substrate carrier 114. In Figures 3 and 4, the substrate carrier 114 is shown above the aerosol generator 100 but is not loaded inside the aerosol generator 100. In Figures 5 and 6, the substrate carrier 114 is shown loaded into the aerosol generator 100.

[0092] When a user wishes to use the aerosol generator 100, the user first loads the substrate carrier 114 into the aerosol generator 100. This involves inserting the substrate carrier 114 into the heating chamber 108. The substrate carrier 114 is inserted into the heating chamber 108 with its first end 134, located on the side where the aerosol substrate 128 is situated, oriented so that it enters the heating chamber 108. The substrate carrier 114 is inserted into the heating chamber 108 until its first end 134 comes into contact with the platform 148 extending inward from the base 112 of the heating chamber 108 and comes to rest, that is, until the substrate carrier 114 can no longer be inserted into the heating chamber 108. In the embodiments shown, as described above, there is an additional effect from the interaction between the upper edge 142a of the projection 140 and the boundary of the less compressible adjacent region of the aerosol substrate 128 and the substrate carrier 114, thereby warning the user that the substrate carrier 114 has been inserted sufficiently deep into the aerosol generator 100. From Figures 3 and 4, it can be seen that when the substrate carrier 114 is inserted as deep as possible into the heating chamber 108, only a portion of the length of the substrate carrier 114 is inside the heating chamber 108. The remainder of the length of the substrate carrier 114 protrudes from the heating chamber 108. At least a portion of the remainder of the length of the substrate carrier 114 also protrudes from the second end 106 of the aerosol generator 100. In the first embodiment, the entire remainder of the length of the substrate carrier 114 protrudes from the second end 106 of the aerosol generator 100, i.e., the heating chamber 108 is open. End 110 coincides with the second end 106 of the aerosol generator 100. In other embodiments, all or substantially all of the substrate carrier 114 may be housed within the aerosol generator 100 such that no portion or substantially any portion of the substrate carrier 114 protrudes from the aerosol generator 100.

[0093] When the substrate carrier 114 is inserted into the heating chamber 108, the aerosol substrate 128 within the substrate carrier 114 is configured to be at least partially within the heating chamber 108. In the first embodiment, the aerosol substrate 128 is entirely within the heating chamber 108. In fact, the pre-packaged amount of aerosol substrate 128 within the substrate carrier 114 is configured to extend from the first end 134 of the substrate carrier 114 along the substrate carrier 114 for a distance approximately (or exactly) equal to the internal height of the heating chamber 108 from the base 112 to the open end 110. This is effectively the same as the length of the side wall 126 of the heating chamber 108, which is located inside the heating chamber 108.

[0094] With the substrate carrier 114 loaded into the aerosol generator 100, the user switches on the aerosol generator 100 using the user-operable button 116. This supplies power from the power supply 120 to the heater 124 via (and under the control of) the control circuit 122. The heater 124 conducts heat into the aerosol substrate 128 via the protrusion 140, heating the aerosol substrate 128 to a temperature at which it can begin to release vapor. Once heated to a temperature at which vapor can begin to be released, the user can inhale the vapor by drawing it in through the second end 136 of the substrate carrier 114. That is, the vapor is generated from the aerosol substrate 128 located at the first end 134 of the substrate carrier 114 in the heating chamber 108, drawn along the length of the substrate carrier 114 through the vapor collection area 130 within the substrate carrier 114 to the second end 136 of the substrate carrier, where it enters the user's mouth. This steam flow is indicated by arrow A in Figure 6.

[0095] When a user draws vapor in the direction of arrow A in Figure 6, it will be understood that the vapor flows from the vicinity of the aerosol substrate 128 in the heating chamber 108. This action draws ambient air into the heating chamber 108 from the environment surrounding the aerosol generator 100 (indicated by arrow B in Figure 6, via a flow path shown in more detail in Figure 6(a)). This ambient air is then heated by the heater 124, which in turn heats the aerosol substrate 128 to generate an aerosol. More specifically, in the first embodiment, the air enters the heating chamber 108 through a space provided between the side wall 126 of the heating chamber 108 and the outer layer 132 of the substrate carrier 114. For this purpose, the outer diameter of the substrate carrier 114 is smaller than the inner diameter of the heating chamber 108. More specifically, in the first embodiment, the heating chamber 108 has an inner diameter of 10 mm or less, preferably 8 mm or less, most preferably about 7.6 mm (for example, where there are no protrusions, e.g., where the protrusions 140 are absent or between the protrusions 140). This allows the substrate carrier 114 to have a diameter of about 7.0 mm (±0.1 mm) (where it is not compressed by the protrusions 140). This corresponds to an outer circumference of 21 mm to 22 mm, more preferably 21.75 mm. In other embodiments, the gap between the substrate carrier 114 and the side wall 126 of the heating chamber 108 is most preferably about 0.1 mm. In other variations, the gap is at least 0.2 mm, and in some embodiments up to 0.3 mm. Arrow B in Figure 6 indicates the direction in which air is drawn into the heating chamber 108.

[0096] When the user activates the user-operable button 116 to start the aerosol generator 100, the aerosol generator 100 heats the aerosol substrate 128 to a temperature sufficient to cause partial vaporization of the aerosol substrate 128. More specifically, the control circuit 122 supplies power from the power supply 120 to the heater 124 to heat the aerosol substrate 12 The aerosol substrate 128 is heated to a first temperature. Once the aerosol substrate 128 reaches the first temperature, the components of the aerosol substrate 128 begin to vaporize. That is, the aerosol substrate produces vapor. Once vapor is produced, the user can inhale the vapor through the second end 136 of the substrate carrier 114. In some scenarios, the user may know that it takes a certain amount of time for the aerosol generator 100 to heat the aerosol substrate 128 to the first temperature and for the aerosol substrate 128 to begin producing vapor. This means that the user can decide for themselves when to begin inhaling the vapor. In other scenarios, the aerosol generator 100 is configured to give the user an indicator that the vapor is available for inhalation. In fact, in the first embodiment, the control circuit 122 lights up the user-operable button 116 when the aerosol substrate 128 has been at the first temperature for an initial period of time. In other embodiments, the indicator is provided by another indicator, such as by generating sound or by vibrating a vibrator. Similarly, in other embodiments, the indicator is provided from the activated aerosol generator 100 immediately after the heater 124 reaches its operating temperature, or following some other event, after a fixed period of time.

[0097] The user can continue to inhale vapor as long as the aerosol substrate 128 can continue to generate vapor, for example, as long as vaporizable components remain in the aerosol substrate 128 to vaporize into suitable vapor. The control circuit 122 adjusts the power supplied to the heater 124 to ensure that the temperature of the aerosol substrate 128 does not exceed a threshold level. Specifically, at a certain temperature depending on the composition of the aerosol substrate 128, the aerosol substrate 128 begins to burn. This is not a desirable effect, and temperatures above this point are avoided. To help with this, the aerosol generator 100 is provided with a temperature sensor 170. The control circuit 122 receives an index of the temperature of the aerosol substrate 128 from the temperature sensor and is configured to use that index to control the power supplied to the heater 124. For example, in one scenario, the control circuit 122 provides maximum power to the heater 124 for an initial period until the heater or chamber reaches a first temperature. Next, once the aerosol substrate 128 reaches a first temperature, the control circuit 122 stops supplying power to the heater 124 for a second period until the aerosol substrate 128 reaches a second temperature lower than the first temperature. Subsequently, once the heater 124 reaches the second temperature, the control circuit 122 starts supplying power to the heater 124 for a third period until the heater 124 reaches the first temperature again. This may continue until the aerosol substrate 128 is used up (i.e., all aerosols that can be generated by heating have already been generated) or until the user stops using the aerosol generator 100. In another scenario, once the first temperature is reached, the control circuit 122 maintains the aerosol substrate 128 at the first temperature but reduces the power supplied to the heater 124 so as not to raise the temperature of the aerosol substrate 128.

[0098] A single inhalation by a user is generally referred to as a "puff." In some scenarios, it is desirable to emulate the experience of smoking a cigarette. This means that the aerosol generator 100 is capable of holding enough aerosol substrate 128 to typically provide 10 to 15 puffs.

[0099] In some embodiments, the control circuit 122 is configured to count puffs and turn off the heater 124 after the user has taken 10 to 15 puffs. Puff counting is performed in one of several ways. In some embodiments, the control circuit 122 determines when the temperature drops during puffing. This is because cooling occurs as fresh, cold air flows through the temperature sensor 170, which is detected by the temperature sensor. In other embodiments, the airflow is detected directly using a flow detector. Other preferred methods will be obvious to those skilled in the art. In other embodiments, the control circuit also Alternatively, the heater 124 may be turned off after a predetermined time has elapsed since the first puff. This helps both to reduce power consumption and to provide a backup in case the puff counter fails to correctly register that a predetermined number of puffs have been taken.

[0100] In some examples, the control circuit 122 is configured to power the heater 124 to follow a predetermined heating cycle that takes a predetermined amount of time to complete. Once the cycle is complete, the heater 124 is completely turned off. In some cases, this cycle may utilize a feedback loop between the heater 124 and the temperature sensor 170. For example, the heating cycle may be parameterized by a series of temperatures to which the heater 124 (or more precisely, the temperature sensor) is heated or cooled. The temperature and duration of such a heating cycle can be empirically determined to optimize the temperature of the aerosol substrate 128. This may be necessary because, for example, where the outer layer of the aerosol substrate 128 is at a different temperature from the core, direct measurement of the temperature of the aerosol substrate can be impractical or misleading.

[0101] In the following example, the time to the first puff is 20 seconds. From this point onward, the power level supplied to the heater 124 is reduced from 100% so that the temperature is kept constant at approximately 240°C for approximately 20 seconds. The power supplied to the heater 124 can then be further reduced so that the temperature recorded by the temperature sensor 170 is approximately 200°C. This temperature is maintained for approximately 60 seconds. Next, the power level may be further reduced so that the temperature measured by the temperature sensor 170 drops to the operating temperature of the substrate carrier 114, which in this case is approximately 180°C. This temperature can be maintained for 140 seconds. This time interval may be determined by the length of time the substrate carrier 114 may be used. For example, the substrate carrier 114 may stop generating aerosols after a set period of time, and so a set period in which the temperature is set to 180°C may allow the heating cycle to continue for this duration. After this point, the power supplied to the heater 124 may be reduced to zero. Even when the heater 124 is turned off, aerosols or vapors generated while the heater 124 was on can still be drawn out of the aerosol generator 100 by the user inhaling them. Therefore, even when the heater 124 is turned off, this situation can be warned to the user by the visual indicator remaining on, even though the heater 124 has already been turned off in preparation for the end of the aerosol inhalation session. In some embodiments, this setting period may be 20 seconds. The total duration of the heating cycle may be about 4 minutes in some embodiments.

[0102] The exemplary thermal cycle described above may be modified by the user's use of the substrate carrier 114. When the user extracts an aerosol from the substrate carrier 114, the user's breathing facilitates the flow of cold air through the open end of the heating chamber 108, through the heater 124, and towards the base 112 of the heating chamber 108. The air may then enter the substrate carrier 114 through its tip 134. As the cold air enters the cavity of the heating chamber 108, the previously present hot air is replaced by the cold air, causing the temperature measured by the temperature sensor 170 to decrease. When the temperature sensor 170 senses that the temperature has decreased, this may be used to increase the power supplied to the heater by the cell, thereby heating the temperature sensor 170 back to the operating temperature of the substrate carrier 114. This may be achieved by supplying the heater 124 with the maximum amount of power, or by supplying more power than is necessary to maintain a constant temperature reading for the temperature sensor 170.

[0103] Power supply 120 provides at least the aerosol substrate 128 in a single substrate carrier 114 to a maximum It is sufficient to raise the temperature to a first temperature and maintain it there, supplying enough vapor for at least 10 to 15 puffs. More generally, in line with emulating the smoking experience, the power supply 120 is usually sufficient to repeat this cycle 10 or even 12 times (raising the aerosol substrate 128 to a first temperature and maintaining the first temperature and vapor generation for 10 to 15 puffs), thereby emulating the user experience of smoking a cigarette packet before the power supply 120 needs to be replaced or recharged.

[0104] Generally, the efficiency of the aerosol generator 100 is improved when as much heat as possible generated by the heater 124 leads to the heating of the aerosol substrate 128. To this end, the aerosol generator 100 is configured to provide heat to the aerosol substrate 128 in a controlled manner, while typically reducing heat flow to other parts of the aerosol generator 100. In particular, heat flow to parts of the aerosol generator 100 handled by the user is kept to a minimum, so that these parts remain cool and comfortable to handle, for example, by insulating materials described in more detail herein.

[0105] From Figures 1 to 6 and the accompanying description, it can be seen that, according to the first embodiment, a heating chamber 108 for an aerosol generator 100 is provided, comprising an open end 110, a base 112, and a side wall 126 between the open end 110 and the base 112, wherein the side wall 126 has a first thickness and the base 112 has a second thickness greater than the first thickness. Reducing the thickness of the side wall 126 reduces the energy required to heat the heating chamber 108 to a desired temperature, thus helping to reduce the power consumption of the aerosol generator 100.

[0106] Second Embodiment Here, a second embodiment will be described with reference to Figure 8. The aerosol generator 100 of the second embodiment is identical to the aerosol generator 100 of the first embodiment described with reference to Figures 1 to 6, except as described below, and the same reference numerals are used to refer to similar features. The aerosol generator 100 of the second embodiment has a configuration that allows air to be drawn into the heating chamber 108 during use, which is different from the first embodiment.

[0107] Referring to Figure 8, a channel 113 is provided in the base 112 of the heating chamber 108. The channel 113 is located in the center of the base 112. The channel extends through the base 112 to fluidly communicate with the environment outside the outer casing 102 of the aerosol generator 100. More specifically, the channel 113 is in fluid communication with the inlet 137 of the outer casing 102.

[0108] The inlet 137 extends through the outer casing 102. The channel is located partway along the length of the outer casing 102 between the first end 104 and the second end 106 of the aerosol generator 100. In the second embodiment, the outer casing defines a gap 139 adjacent to the control circuit 122 and between the inlet 137 in the outer casing 102 and the channel 113 at the base 112 of the heating chamber 108. The gap 139 provides fluid communication between the inlet 137 and the channel 113, thereby allowing air to pass from the environment outside the outer casing 102 into the heating chamber 108 through the inlet 137, the gap 139, and the channel 113.

[0109] During use, as vapor is inhaled by the user at the second end 136 of the substrate carrier 114, air is drawn into the heating chamber 108 from the environment surrounding the aerosol generator 100. More specifically, the air enters the void 139 through the inlet 139 in the direction of arrow C. From the void 139, the air passes through the channel 113 in the direction of arrow D. The air then enters the heating chamber 108. This draws the steam first, and then the steam mixed with air, through the substrate carrier 114 in the direction of arrow D, allowing it to be inhaled by the user at the second end 136 of the substrate carrier 114. The air is generally heated as it enters the heating chamber 108, thereby helping the air transfer heat to the aerosol substrate 128 by convection.

[0110] In the second embodiment, the air passage through the heating chamber 108 is substantially linear; that is, the passage extends generally in a straight line from the base 112 of the heating chamber 108 to the open end 110 of the heating chamber 108. The configuration of the second embodiment also allows for a reduction in the gap between the side wall 126 of the heating chamber 108 and the substrate carrier. In fact, in the second embodiment, the diameter of the heating chamber 108 is less than 7.6 mm, and the gap between the substrate carrier 114, which has a diameter of 7.0 mm, and the side wall 126 of the heating chamber 108 is less than 1 mm.

[0111] In a variation of the second embodiment, the position of the inlet 137 is different. In one particular embodiment, the inlet 137 is located at the first end 104 of the aerosol generator 100. This allows the air passage through the entire aerosol generator 100 to be roughly linear, for example, at the first end 104, which is typically directed distal to the user during use, the air enters the aerosol generator 100, flows through (or over, through, etc.) the aerosol substrate 128 within the aerosol generator 100, and enters the user's mouth at the second end 136 of the substrate carrier 114, which is typically directed proximal to the user during use, for example, towards the user's mouth.

[0112] Third Embodiment A third embodiment will now be described with reference to Figures 9, 9(a), and 9(b). The aerosol generator 100 of the third embodiment is identical to the aerosol generator 100 of the first embodiment described with reference to Figures 1 to 6, except as described below, and the same reference numerals are used to refer to similar features. The heating chamber 108 of the third embodiment may also correspond to the heating chamber 108 of the second embodiment, for example, in which a channel 113 is provided in the base 112 of the heating chamber 108, except as described below, which forms a further embodiment of the present disclosure.

[0113] The aerosol generator 100 of the third embodiment has a heating chamber 108 which is formed as a separate element, instead of the base 112 being integrated with the side wall 126, as shown in Figures 1 to 6.

[0114] Establishing a heating chamber 108 with a separate base provides the structural support effect described in relation to the first embodiment. Furthermore, such a base 112 can be formed from a different material than the material on which the sidewall 126 is formed, for example, from a material with lower thermal conductivity than the sidewall 126. Heating the first end 134 of the substrate carrier 114 can be problematic as it may lead to the generation of undesirable aerosol components. By providing an insulating portion in the base 112 of the heating chamber 108, heat conduction to the first end 134 of the substrate carrier 114 can be reduced, thereby mitigating the undesirable effects of heating the first end 134 of the substrate carrier 114. In fact, if a platform 148 is present, the platform 148 can be provided as a separate component from the base 112. This separate platform 148 may have insulating components (relative to the base 112 and / or sidewall 126), thereby reducing undesirable heating of the first end 134 of the substrate carrier 114. In this example, the base 112 can be attached by any suitable means, such as using adhesive, threads, or interference fits.

[0115] Fourth Embodiment A fourth embodiment will now be described with reference to Figures 10, 10(a), and 10(b). The aerosol generator 100 of the fourth embodiment is identical to the aerosol generator 100 of the first embodiment described with reference to Figures 1 to 6, except as described below, and the same reference numerals are used to refer to similar features. The heating chamber 108 of the fourth embodiment may also correspond to the heating chamber 108 of the second embodiment, for example, in which a channel 113 is provided in the base 112 of the heating chamber 108, except as described below, which forms a further embodiment of the present disclosure.

[0116] The aerosol generator 100 of the fourth (and further) embodiment has a heating chamber 108 in which the flange 138 is absent.

[0117] By omitting the flange 138 from the heating chamber 108, the thermal mass of the heating chamber 108 is reduced, at the cost of reduced structural strength provided by the flange 138. In this embodiment, since there is no flange 138 to grip between the washers 106, the heating chamber 108 is attached to the aerosol generator 100 in a different way. More specifically, the heating chamber 108 is sized to form an interference fit with the inner diameter of the washer 107 and is held in that manner. This results in a smaller surface area of ​​the heating chamber 108 in contact with the washer 107, which in turn reduces heat transfer from the heating chamber 108 and improves the overall efficiency of the aerosol generator 100.

[0118] Fifth Embodiment Herein, a fifth embodiment will be described with reference to Figures 11, 11(a), and 11(b). The aerosol generator 100 of the fifth embodiment is identical to the aerosol generator 100 of the first embodiment described with reference to Figures 1 to 6, except as described below, and the same reference numerals are used to refer to similar features. The heating chamber 108 of the fifth embodiment may also correspond to the heating chamber 108 of the second embodiment, for example, in which a channel 113 is provided in the base 112 of the heating chamber 108, except as described below, which forms a further embodiment of the present disclosure.

[0119] The aerosol generator 100 of the fifth (and further) embodiment has a heating chamber 108 in which the protrusion 140 is absent.

[0120] In the fifth embodiment, since the side wall 126 is relatively thin, it is recognized that it is not essential to use the protrusion 140 to form a conduction heating path, as a relatively small amount of air in the heating chamber 108 is heated relatively quickly by the heater 124. Any deformation of the thin side wall 126 could pose a risk of damaging the side wall 126. In other words, manufacturing walls without the protrusion 140 can improve the efficiency of the manufacturing process by reducing the number of heating chambers 108 that would have to be rejected due to manufacturing errors.

[0121] Definitions and Alternative Embodiments From the above description, it will be understood that many features of the various embodiments are interchangeable. This disclosure extends to further embodiments, including features that combine features from the various embodiments in forms not specifically mentioned. For example, the third to fifth embodiments do not have the platform 148 shown in Figures 1 to 6. The inclusion of this platform 148 in the third to fifth embodiments may bring about the advantages of the platform 148 described in relation to those figures.

[0122] Figures 9(a) and 9(b), 10(a) and 10(b), and 11(a) and 11(b) show a heating chamber 108 separated from the aerosol generator 100. This highlights that the advantageous features described with respect to the design of the heating chamber 108 are independent of other features of the aerosol inhalation device 100. In particular, the heating chamber 108 has many applications, not all of which are tied to the vapor inhalation device 100 described herein. Such designs can benefit from the base 112 for providing support to the side wall 126, as described herein. For such applications, the heating chamber described herein is advantageously provided.

[0123] The term “heater” should be understood to mean any device for outputting sufficient thermal energy from the aerosol substrate 128 to form an aerosol. The transfer of thermal energy from the heater 124 to the aerosol substrate 128 may be conductive, convective, radiative, or any combination thereof. In a non-limiting example, a conductive heater may be in direct contact with and pressed against the aerosol substrate 128, or it may be in contact with a separate component, the separate component itself may cause heating of the aerosol substrate 128 by conduction, convection, and / or radiation. Convective heating may involve heating a liquid or gas, resulting in the transfer of thermal energy (directly or indirectly) to the aerosol substrate.

[0124] Radiative heating includes, but is not limited to, transferring energy to the aerosol substrate 128 by emitting electromagnetic radiation in the ultraviolet, visible, infrared, microwave, or radio portion of the electromagnetic spectrum. The radiation thus emitted may be directly absorbed by the aerosol substrate 128 to produce heating, or the radiation may be absorbed by another material such as a susceptor or fluorescent material, and as a result the radiation may be re-emitted at different wavelengths or with a weighted spectrum. In some cases, the radiation may be absorbed by a material, which then transfers heat to the aerosol substrate 128 by conduction, convection, and / or radiation in any combination.

[0125] The heater may be driven electrically, by combustion, or by any other suitable means. The electrically driven heater may include a resistive track element (including optionally an insulating package), an induction heating system (including, for example, an electromagnet and a high-frequency oscillator), etc. The heater 128 may be configured around the outside of the aerosol substrate 128, partially or completely penetrate into the aerosol substrate 128, or any combination thereof.

[0126] The term "temperature sensor" is used to describe an element capable of determining the absolute or relative temperature of a portion of the aerosol generator 100. This may include thermocouples, thermopiles, thermistors, etc. The temperature sensor may be provided as part of another component or as a separate component. In some examples, multiple temperature sensors may be provided to monitor the heating of various parts of the aerosol generator 100, for example, to determine a thermal profile.

[0127] The control circuit 122 is shown throughout to have a single user-operable button 116 for triggering and turning on the aerosol generator 100. This keeps the control simple and reduces the likelihood of the user misusing or failing to properly control the aerosol generator 100. However, in some cases, user-available input controls may be more complex, for example, to control the temperature within a preset limit to alter the flavor balance of the steam, or to switch between a power-saving mode and a rapid heating mode.

[0128] Referring to the embodiments described above, the aerosol substrate 128 contains tobacco, for example, in a dried or cured form, and optionally has additional components for flavor, or to provide a smoother or more enjoyable experience. In some examples, the aerosol substrate 128, such as tobacco, may be treated with a vaporizer. The vaporizer can improve the generation of vapor from the aerosol substrate. The vaporizer may include, for example, a polyol such as glycerol, or a glycol such as propylene glycol. In some cases, the aerosol substrate may not contain tobacco or even nicotine, but instead may contain natural or artificially derived components to provide flavoring, improved volatility, smoothness, and / or other satisfying effects. The aerosol substrate 128 may be provided as a solid or paste-type material in the form of shredded, pelletized, powdered, granular, stripped or sheeted material, or optionally a combination thereof. Similarly, the aerosol substrate 128 may be a liquid or a gel. In fact, in some examples, both a solid portion and a liquid / gel portion may be included.

[0129] Therefore, the aerosol generator 100 can be referred to as a "heated tobacco device," a "heated non-combustion tobacco device," a "tobacco product vaporizer," etc., and is interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol substrate.

[0130] Embodiments of the aerosol generator 100 are described as being configured to house an aerosol substrate 128 in a pre-packaged substrate carrier 114. The substrate carrier 114 may be generally similar to a cigarette having a tubular region with an aerosol substrate configured in a preferred form. Some designs may also include a filter, a vapor collection region, a cooling region, and other structures. An outer layer of paper, or an outer layer of other flexible planar material such as foil, may also be provided to further enhance the similarity to a cigarette, for example, by holding the aerosol substrate in place.

[0131] As used herein, the term “fluid” is to be interpreted as referring collectively to non-solid materials of a flowable type, including but not limited to liquids, pastes, gels, and powders. Accordingly, “fluidized material” is to be interpreted as a material that is essentially a fluid, or a material that has been modified to behave as a fluid. Fluidization may include, but is not limited to, powdering, dissolution in a solvent, gelation, thickening, thinning, and the like.

[0132] As used herein, the term “volatile” means a substance that can readily change from a solid or liquid state to a gaseous state. In non-limiting examples, volatile substances may have a boiling or sublimation temperature close to room temperature at ambient pressure. Therefore, “volatilize” or “volatilise” shall be interpreted as meaning to cause (a material) to volatilize and / or evaporate or disperse into vapor.

[0133] As used herein, the term "vapor" means: (i) a form of liquid that is spontaneously converted by the action of sufficient heat; or (ii) liquid / moisture particles that are suspended in the atmosphere and appear as a cloud of steam / smoke; or (iii) a fluid that fills space like a gas but can be liquefied by pressure alone when below its critical temperature.

[0134] In line with this definition, the term “vaporise” (or “vaporize”) means: (i) to change into vapor, or to cause a change into vapor; and (ii) when particles change their physical state (i.e., liquid) (From a body or solid to a gaseous state).

[0135] As used herein, the term “atomise” (or “atomize”) means: (i) to transform (a substance, especially a liquid) into very small particles or droplets; and (ii) the particles remain in the same physical state (liquid or solid) as they were before being atomized.

[0136] As used herein, the term “aerosol” means a system of particulate matter dispersed in air or gas, such as mist, fog, or smoke. Accordingly, the term “aerosolise” (or “aerosolize”) means to make into an aerosol and / or disperse as an aerosol. Note that the meaning of aerosol / aerosolize is consistent with each of the above-defined terms: volatilize, spray, and vaporize. To avoid misunderstanding, aerosol is used consistently to describe mist or droplets containing atomized, volatilized, or vaporized particles. Aerosol also includes mist or droplets containing any combination of sprayed, volatilized, or vaporized particles.

Claims

1. A heating chamber (108) for an aerosol generator (100), wherein the heating chamber (108) is The first open end (110) and Base (112) and, The side wall (126) between the first open end (110) and the base (112), The side wall (126) comprises a plurality of engaging elements formed on its inner surface, The base (112) is connected to the side wall (126) and provides structural support to the side wall (126). The side wall (126) has a first thickness, and the base (112) has a second thickness that is greater than the first thickness. The base (112) has one or more platform elements (148) arranged at intervals from the center, A heating chamber (108) in which the side wall (126) and the base (112) are formed from the same material.

2. In the heating chamber (108) described in claim 1, The one or more platform elements (148) are heating chambers (108) located on the inner surface of the base (112).

3. In the heating chamber (108) according to claim 1 or 2, The one or more platform elements (148) are positioned at the edge of the heating chamber (108), which is the heating chamber (108).

4. In a heating chamber (108) according to any one of claims 1 to 3, The one or more platform elements (148) are heating chambers (108) having a flat top.

5. In the heating chamber (108) described in claim 1, The engagement element is formed by recessing the outer surface of the side wall (126) into a heating chamber (108).

6. In a heating chamber (108) according to any one of claims 1 to 5, A heating chamber (108) in which the base (112) and the side wall (126) are formed as a single element.

7. In a heating chamber (108) according to any one of claims 1 to 6, A heating chamber (108) having a first thickness of 100 μm or less.

8. In a heating chamber (108) according to any one of claims 1 to 7, The heating chamber (108) has a second thickness of 200 μm to 500 μm.

9. In a heating chamber (108) according to any one of claims 1 to 8, The base (112) is a heating chamber (108) that seals the second end of the side wall (126) opposite to the first open end (110).

10. In a heating chamber (108) according to any one of claims 1 to 9, A heating chamber (108) comprising a flange portion (138) attached to the first open end (110), wherein the flange portion (138) extends radially outward at the first open end (110) of the heating chamber (108).

11. In the heating chamber (108) described in claim 10, The flange portion (138) extends around the entire circumference of the heating chamber (108), which is the heating chamber (108).

12. In the heating chamber (108) according to claim 10 or 11, The flange portion (138) extends diagonally away from the side wall (126) in the heating chamber (108).

13. In a heating chamber (108) according to any one of claims 10 to 12, A heating chamber (108) wherein the flange portion (138) comprises a first material, and the side wall (126) comprises a second material, the first material having a lower thermal conductivity than the second material.

14. In a heating chamber (108) according to any one of claims 1 to 13, The side wall (126) is a heating chamber (108) containing a material having a thermal conductivity of 50 W / mK or less.

15. In a heating chamber (108) according to any one of claims 1 to 14, The heating chamber (108) is a deep-drawn product.

16. Aerosol generator (100), Power supply (120), A heating chamber (108) according to any one of claims 1 to 15, A heater (124) configured to supply heat to the heating chamber (108), Aerosol generator (100) comprising a control circuit (122) configured to control the supply of power from the power source (120) to the heater (124).

17. In the aerosol generator (100) described in claim 16, The heater (124) is provided on the outer surface of the side wall (126) of the aerosol generator (100).

18. In the aerosol generator (100) described in claim 16, The heater (124) is located adjacent to the outer surface of the side wall (126) in the aerosol generator (100).

19. In an aerosol generator (100) according to any one of claims 16 to 18, The heating chamber (108) is removable from the aerosol generator (100), aerosol generator (100).

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