Aerosol generation device and manufacturing method

Abstract

[Problem] To provide a mechanism that allows appropriate detection of insertion of a base material into an aerosol generation device. [Solution] Provided is an aerosol generation device comprising: a storage part for storing, in an internal space, a base material containing an aerosol source; a load for generating energy for heating the aerosol source of the base material stored in the storage part; and a capacitance sensor which includes a plurality of electrodes for detecting an electrostatic capacitance of the internal space of the storage part. The electrode includes a body configured from metal; and a first section of a surface of the body of the electrode is covered with an insulation layer configured from a ceramic material.

Description

Aerosol generating device and manufacturing method

[0001] The present disclosure relates to an aerosol generating device and a method of production.

[0002] Aerosol generating devices that generate aerosols to be inhaled by users are widely used. For example, an aerosol generating device generates aerosols imparted with flavor components using a base material containing an aerosol source for generating aerosols and a flavor source for imparting flavor components to the generated aerosol. A user can enjoy the flavor by inhaling the aerosol imparted with flavor components generated by the aerosol generating device. The action of a user inhaling the aerosol is hereinafter also referred to as a puff or a puffing action. An example of a device classified as an aerosol generating device is a heated tobacco product, which is used instead of a so-called cigarette. Note that a heated tobacco product is a type of aerosol generating device that generates aerosol by heating an aerosol source.

[0003] Regarding an aerosol generating device of the type that heats an inserted substrate, a technology for detecting the insertion of the substrate has been developed. For example, Patent Document 1 below discloses a technology for detecting the insertion of the substrate using a capacitance sensor. Furthermore, regarding the capacitance sensor, Patent Document 2 below discloses a technology for configuring electrodes using an anodized aluminum material.

[0004] Patent No. 6348985 Publication Special Publication No. 04-037366

[0005] However, there is still room for further improvement in the substrate detection technology using a capacitance sensor as disclosed in Patent Document 1. The technology disclosed in Patent Document 2 is intended to measure liquid levels, and the size of the device is far different from that of an aerosol generator, so it can be said that it is difficult to directly apply this technology to the field of aerosol generators.

[0006] Therefore, the present disclosure has been made in consideration of the above problems, and the purpose of the present disclosure is to provide a mechanism that can appropriately detect the insertion of a substrate into an aerosol generating device.

[0007] In order to solve the above problem, according to one aspect of the present disclosure, there is provided an aerosol generating device comprising: a storage section that stores a substrate containing an aerosol source in an internal space; a load that generates energy for heating the aerosol source of the substrate stored in the storage section; and a capacitance sensor that includes a plurality of electrodes that detect the capacitance of the internal space of the storage section, wherein the electrodes include a body made of metal, and a first portion of the surface of the body of the electrodes is covered with an insulating layer made of ceramic.

[0008] The electrode may be arranged so that a portion of the electrode is exposed to the internal space of the housing, and the portion of the electrode exposed to the internal space of the housing may be covered by the insulating layer.

[0009] The storage section may be a cylindrical body having an opening on the upper side through which the base material can be inserted and removed in the vertical direction, and 100% of the side surface of the electrode body facing the central axis of the storage section and 50% or more of the upper and lower surfaces facing the central axis of the storage section may be covered by the insulating layer.

[0010] The insulating layer may have a relative dielectric constant of 3 or more.

[0011] The body of the electrode may be made of aluminum, and the insulating layer may be an alumina film.

[0012] The insulating layer may consist of a coating of silicon carbide or glass.

[0013] The insulating layer may have a thickness of 1 μm or more and less than 20 μm.

[0014] The thickness of the main body of the electrode may be equal to or greater than 0.1 mm and less than 4 mm.

[0015] A second portion of the surface of the body of the electrode may be coated with a soldering assist layer comprising a coating material that assists soldering.

[0016] The area of ​​the second portion may be equal to or greater than 0.01 mm^2 and less than 16 mm^2.

[0017] The electrode may be configured in a ring shape, and a plurality of the electrodes may be arranged spaced apart in the vertical direction.

[0018] A part of the housing portion may be the insulating layer made of ceramic, and the electrode may be disposed in contact with the outer surface of the housing portion that is the insulating layer made of ceramic.

[0019] The aerosol generating device may further include a control unit that controls the operation of the load based on the capacitance detected by the capacitance sensor.

[0020] In addition, in order to solve the above-mentioned problems, according to another aspect of the present disclosure, there is provided a manufacturing method for manufacturing an electrode that constitutes a capacitance sensor used in an aerosol generation device, the manufacturing method including: a first step of processing a plate-shaped base material made of aluminum as a workpiece into a shape having a first annular member, a second annular member surrounding the outside of the first annular member, and two connecting portions that connect the first annular member and the second annular member at different positions; a second step of anodizing the workpiece after the first step is completed; a third step of forming a through hole in the second annular member of the workpiece after the second step is completed and cutting one of the two connecting portions; a fourth step of plating the inner surface of the through hole and the cut surface of the cut connecting portion of the workpiece after the third step is completed; and a fifth step of cutting the uncut connecting portion of the workpiece after the fourth step is completed.

[0021] As described above, the present disclosure provides a mechanism that can appropriately detect the insertion of a substrate into an aerosol generating device.

[0022] 10 is a schematic diagram showing an example of the configuration of an aerosol generating device. FIG. 11 is an end view of a storage unit according to this embodiment cut in the vertical direction. FIG. 12 is an end view of a storage unit according to this embodiment cut along the cutting line A-A shown in FIG. 2. FIG. 13 is a perspective view showing a specific example of the electrode shown in FIG. 2 and FIG. 3. FIG. 14 is a diagram for explaining a first step of a method for manufacturing an electrode. FIG. 15 is a diagram for explaining a second step of a method for manufacturing an electrode. FIG. 16 is a diagram for explaining a third step of a method for manufacturing an electrode. FIG. 17 is a diagram for explaining a fourth step of a method for manufacturing an electrode. FIG. 18 is a diagram for explaining a fifth step of a method for manufacturing an electrode. FIG. 19 is an end view of a storage unit according to a first modified example cut in the vertical direction. FIG. 19 is an end view of a storage unit according to a first modified example cut along the cutting line B-B shown in FIG. 10. FIG. 19 is an end view of a storage unit according to a second modified example cut in the vertical direction. FIG. 20 is an end view of a storage unit according to a second modified example cut along the cutting line C-C shown in FIG. 12.

[0023] Preferred embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings. In this specification and drawings, components having substantially the same functional configurations are designated by the same reference numerals, and redundant description will be omitted.

[0024] 1. Configuration Example of Aerosol Generating Device The aerosol generating device is a device that generates an aerosol to be inhaled by a user.

[0025] 1 is a schematic diagram showing an example of the configuration of an aerosol generating device. As shown in FIG. 1, the aerosol generating device 100 according to this example configuration includes a power supply unit 111, a sensor unit 112, a notification unit 113, a storage unit 114, a communication unit 115, a control unit 116, a heating unit 121, a storage unit 140, and a heat insulating unit 144.

[0026] The power supply unit 111 stores electric power. Then, the power supply unit 111 supplies electric power to each component of the aerosol generating device 100 based on the control of the control unit 116. The power supply unit 111 can be configured, for example, by a rechargeable battery such as a lithium ion secondary battery.

[0027] The sensor unit 112 acquires various information related to the aerosol generating device 100. As an example, the sensor unit 112 is configured with a pressure sensor such as a condenser microphone, a flow rate sensor, a temperature sensor, or the like, and acquires values ​​associated with inhalation by the user. As another example, the sensor unit 112 is configured with an input device such as a button or a switch that accepts information input from the user.

[0028] The notification unit 113 notifies the user of information. The notification unit 113 is configured by, for example, a light emitting device that emits light, a display device that displays an image, a sound output device that outputs sound, or a vibration device that vibrates.

[0029] The storage unit 114 stores various types of information for the operation of the aerosol generating device 100. The storage unit 114 is configured by a non-volatile storage medium such as a flash memory.

[0030] The communication unit 115 is a communication interface capable of performing communication conforming to any wired or wireless communication standard, such as Wi-Fi (registered trademark), Bluetooth (registered trademark), BLE (Bluetooth Low Energy (registered trademark)), NFC (Near Field Communication), or LPWA (Low Power Wide Area).

[0031] The control unit 116 functions as an arithmetic processing unit and a control unit, and controls the overall operation of the aerosol generation device 100 in accordance with various programs. The control unit 116 is realized by an electronic circuit such as a CPU (Central Processing Unit) or a microprocessor.

[0032] The storage unit 140 has an internal space 141 and holds the stick-shaped substrate 150 while accommodating a portion of the stick-shaped substrate 150 in the internal space 141. The storage unit 140 has an opening 142 that connects the internal space 141 to the outside and accommodates the stick-shaped substrate 150 inserted into the internal space 141 through the opening 142. For example, the storage unit 140 is a cylindrical body with the opening 142 and a bottom 143 as its bottom surface, and defines a columnar internal space 141. An air flow path that supplies air to the internal space 141 is connected to the storage unit 140. An air inlet, which is an air inlet to the air flow path, is arranged, for example, on a side surface of the aerosol generation device 100. An air outlet, which is an air outlet from the air flow path to the internal space 141, is arranged, for example, on the bottom 143.

[0033] The stick-shaped substrate 150 includes a substrate portion 151 and a mouthpiece portion 152. The substrate portion 151 includes an aerosol source. The aerosol source includes a tobacco-derived or non-tobacco-derived flavor component. When the aerosol generating device 100 is a medical inhaler such as a nebulizer, the aerosol source may include a medicament. The aerosol source may be, for example, a liquid such as a polyhydric alcohol, such as glycerin or propylene glycol, or water, containing a tobacco-derived or non-tobacco-derived flavor component, or a solid containing a tobacco-derived or non-tobacco-derived flavor component. When the stick-shaped substrate 150 is held in the storage portion 140, at least a portion of the substrate portion 151 is housed in the internal space 141, and at least a portion of the mouthpiece portion 152 protrudes from the opening 142. When a user holds the mouthpiece portion 152 protruding from the opening 142 in their mouth and inhales, air flows into the internal space 141 via an air flow path (not shown) and reaches the user's mouth along with the aerosol generated from the substrate portion 151.

[0034] The heating unit 121 generates aerosol by heating the aerosol source and atomizing the aerosol source. In the example shown in FIG. 1 , the heating unit 121 is configured in a film shape and is arranged to cover the outer periphery of the storage unit 140. When the heating unit 121 generates heat, the substrate unit 151 of the stick-shaped substrate 150 is heated from the outer periphery, generating aerosol. The heating unit 121 generates heat when power is supplied from the power supply unit 111. As an example, power may be supplied when the sensor unit 112 detects that the user has started inhaling and / or that predetermined information has been input. Power supply may be stopped when the sensor unit 112 detects that the user has stopped inhaling and / or that predetermined information has been input.

[0035] The heat insulating section 144 prevents heat transfer from the heating section 121 to other components. For example, the heat insulating section 144 is made of a vacuum heat insulating material, an aerogel heat insulating material, or the like.

[0036] The above describes an example of the configuration of the aerosol generation device 100. Of course, the configuration of the aerosol generation device 100 is not limited to the above, and various configurations such as those exemplified below may be used.

[0037] As one example, the heating unit 121 may be configured in a blade shape and disposed so as to protrude from the bottom 143 of the storage unit 140 into the internal space 141. In this case, the blade-shaped heating unit 121 is inserted into the substrate 151 of the stick-shaped substrate 150 and heats the substrate 151 of the stick-shaped substrate 150 from the inside. As another example, the heating unit 121 may be disposed so as to cover the bottom 143 of the storage unit 140. Furthermore, the heating unit 121 may be configured as a combination of two or more of a first heating unit covering the outer periphery of the storage unit 140, a blade-shaped second heating unit, and a third heating unit covering the bottom 143 of the storage unit 140.

[0038] As another example, the storage unit 140 may include an opening / closing mechanism such as a hinge that opens and closes a portion of the outer shell that forms the internal space 141. The storage unit 140 may then open and close the outer shell to hold and store the stick-shaped substrate 150 inserted into the internal space 141. In this case, the heating unit 121 may be provided at the holding location in the storage unit 140, and may heat the stick-shaped substrate 150 while pressing it.

[0039] Furthermore, the means for atomizing the aerosol source is not limited to heating by the heating unit 121. For example, the means for atomizing the aerosol source may be induction heating. In that case, the aerosol generation device 100 has at least an electromagnetic induction source such as a coil that generates a magnetic field, instead of the heating unit 121. A susceptor that generates heat by induction heating may be provided in the aerosol generation device 100, or may be included in the stick-shaped substrate 150.

[0040] 2. Technical Issues The technical issues involved in detecting a substrate using a capacitance sensor will be described below.

[0041] To increase the sensitivity of a capacitance sensor, it is desirable to place the electrodes as close as possible to the object to be detected. However, if the electrode body is placed close to the substrate while it is exposed, the electrodes may be shorted out via aerosol generated from the substrate. For example, the aerosol generated from the substrate may wet the wrapping paper that forms the outermost shell of the substrate, causing a short circuit between the electrodes via the wrapping paper. In this case, it becomes difficult to accurately detect capacitance.

[0042] Furthermore, in capacitance sensors mounted on small devices such as the aerosol generating device 100, electrode insulation has been achieved by forming electrodes on flexible printed circuits (FPCs). However, resins that make up FPCs, such as polyimide, polyethylene naphthalate (PEN), or polyethylene terephthalate (PET), have low dielectric constants, which can reduce the sensitivity of capacitance sensors. Furthermore, it is difficult to wrap an FPC around a small cylindrical body such as the housing 140, and there is a risk that the sensitivity of the capacitance sensor will decrease depending on the wrapping accuracy.

[0043] 3. Technical Features 3.1. Configuration of Capacitive Sensor 10 A configuration for detecting the stick-shaped substrate 150 based on capacitance will now be described with reference to FIGS. 2 to 4. FIG.

[0044] Fig. 2 is an end view of the housing portion 140 according to this embodiment cut in the vertical direction. Fig. 3 is an end view of the housing portion 140 according to this embodiment cut along the cutting line A-A shown in Fig. 2. Fig. 4 is a perspective view showing a specific example of the electrode 11 shown in Figs. 2 and 3.

[0045] In the following, the direction in which the stick-shaped substrate 150 is inserted and removed is also referred to as the up-down direction. The stick-shaped substrate 150 is inserted downward and removed upward. The storage section 140 has an opening 142 on the upper side and a bottom 143 on the lower side.

[0046] 2, the storage section 140 is configured by connecting an upper first storage section 140a and a lower second storage section 140b. Specifically, the first storage section 140a is a cylindrical body with openings on both ends, and the second storage section 140b is a cylindrical body with a bottom. The edge of the lower opening of the first storage section 140a is connected to the edge of the opening of the second storage section 140b, thereby configuring the storage section 140.

[0047] The first housing portion 140a may be made of a material with low thermal conductivity, such as a resin such as PEEK (Polyether Ether Ketone). The second housing portion 140b may be made of a material with high thermal conductivity, such as a metal such as SUS (stainless steel). The heating portion 121 described with reference to FIG. 1 is disposed around the second housing portion 140b and heats the stick-shaped substrate 150 via the second housing portion 140b. Furthermore, the first housing portion 140a may include a shielding layer for blocking noise that may affect the electrode 11, covering the periphery of the electrode 11 (e.g., the upper, lower, and outer surfaces).

[0048] 2 and 3, the capacitance sensor 10 is disposed in the housing portion 140 (particularly, the first housing portion 140a). The process of connecting the first housing portion 140a and the housing portion 140b to form the housing portion 140 and the process of disposing the capacitance sensor 10 in the first housing portion 140a can be achieved by insert molding.

[0049] The capacitance sensor 10 detects the capacitance of the internal space 141 of the housing portion 140. The capacitance sensor 10 includes two electrodes 11, and detects the capacitance of the space between the two electrodes 11, which overlaps with a portion of the internal space 141 of the housing portion 140.

[0050] As shown in Figures 2 to 4, the electrode 11 is configured in a ring shape. The electrode 11 is arranged so that the hollow portion of the electrode 11 overlaps the internal space 141 of the housing 140 and the outer surface of the electrode 11 is embedded in the housing 140. In particular, the two electrodes 11 are arranged spaced apart in the vertical direction. With this configuration, the capacitance sensor 10 can detect a change in capacitance when the stick-shaped substrate 150 passes through the hollow portion of the electrode 11. Furthermore, with this configuration, unlike a capacitance sensor configured using an FPC, a process of wrapping an FPC around the housing 140 is not required, and therefore the capacitance sensor can be mounted on the aerosol generation device 100 without sacrificing sensitivity.

[0051] The capacitance detected by the capacitance sensor 10 changes depending on whether or not the stick-shaped substrate 150 is present between the electrodes 11. In particular, the aerosol source contained in the stick-shaped substrate 150 has a high relative dielectric constant, and therefore the capacitance changes significantly depending on whether or not the aerosol source is present between the electrodes 11. Based on this change in capacitance, the control unit 116 can determine whether or not the stick-shaped substrate 150 has been inserted into the storage unit 140.

[0052] The control unit 116 may control the operation of the heating unit 121 based on the capacitance detected by the capacitance sensor 10. For example, the control unit 116 may start heating by the heating unit 121 when it determines, based on the capacitance detected by the capacitance sensor 10, that the stick-shaped substrate 150 has been inserted into the housing unit 140. This function is also referred to as an auto-start function.

[0053] 2 and 3 , the electrode 11 includes a conductive body 12. A first portion 12a, which is a part of the surface of the body 12 of the electrode 11, is covered with an insulating layer 13. The body 12 of the electrode 11 may be made of, for example, any metal. The insulating layer 13 may be made of, for example, any ceramic.

[0054] 2 and 3 , the electrode 11 is arranged so that a portion of the electrode 11 is exposed to the internal space 141 of the housing 140. With this configuration, it is possible to shorten the distance from the electrode 11 to the stick-shaped substrate 150, which is the detection target, as much as possible. This makes it possible to improve the sensitivity of the capacitance sensor 10.

[0055] 2 and 3, the portion of the electrode 11 exposed to the internal space 141 of the housing 140 is covered with the insulating layer 13. That is, only the first portion 12a of the electrode 11 covered with the insulating layer 13 is exposed to the internal space 141 of the housing 140. This configuration makes it possible to prevent short-circuiting between the electrodes 11 via the aerosol.

[0056] The dielectric constant of the insulating layer 13 is preferably higher than that of the FPC made of resin. Specifically, the dielectric constant of the insulating layer 13 is preferably equal to or greater than 3. This configuration makes it possible to improve sensitivity compared to a capacitance sensor made of an FPC.

[0057] As an example, the main body 12 of the electrode 11 may be made of aluminum such as A1050. The insulating layer 13 may be an alumina film such as an oxalic acid anodized aluminum film, or may be formed by anodizing. This configuration allows the electrode 11 to withstand the heat generated during insert molding while satisfying the dielectric constant requirements. Furthermore, anodizing makes it easier to achieve a thin and uniform film thickness compared to other film formation methods such as coating. In other words, employing an alumina film formed by alumina treatment as the insulating layer 13 can improve the sensitivity of the capacitance sensor 10. Furthermore, because the alumina film has high abrasion resistance, it can exhibit high durability against abrasion when the stick-shaped substrate 150 is inserted and removed.

[0058] The thickness of the insulating layer 13 is preferably 1 μm or more and less than 20 μm. The insulating layer 13 can exhibit appropriate insulating properties as long as the thickness is at least 1 μm. On the other hand, if the insulating layer 13 is excessively thick, it may be difficult to properly form the insulating layer 13, especially at the edge portions of the main body 12, and cracks may occur. Such cracks may cause various usability problems, such as the accumulation of dust and other foreign matter, reducing the sensitivity of the capacitance sensor 10, or generating a foul odor. In this regard, by making the insulating layer 13 less than 20 μm, it is possible to avoid cracks and prevent usability from being impaired.

[0059] On the other hand, the thickness of the main body 12 of the electrode 11 may be 0.1 mm or more and less than 4 mm. With this configuration, the capacitance sensor 10 can be made small enough to be mounted on a small device such as the aerosol generation device 100.

[0060] As shown in Fig. 4, the second portion 12b of the surface of the main body 12 of the electrode 11 is covered with a soldering auxiliary layer 14 made of a coating material that assists soldering. Examples of coating materials that make up the soldering auxiliary layer 14 include Ni, Sn, and Au. A conductor for supplying power to the electrode 11 is soldered to the soldering auxiliary layer 14. This configuration makes it possible to strengthen the connection between the electrode 11 and the conductor.

[0061] 4, the electrode 11 may have a stalk 26 that protrudes outward. The soldering auxiliary layer 14 may be provided at the tip of the stalk 26. The soldering auxiliary layer 14 provided at the tip of the stalk 26 may protrude outside the housing portion 140 when the electrode 11 is placed in the housing portion 140. This configuration makes it possible to easily connect the electrode 11 and the conductor after insert molding.

[0062] The thickness of the soldering auxiliary layer 14 is preferably 1 μm or more and less than 10 μm. With this configuration, it is possible to ensure that the strength of the connection between the electrode 11 and the conductor wire is sufficient.

[0063] The width of the second portion 12b covered by the soldering auxiliary layer 14 is preferably 0.1 mm or more and less than 4 mm. Considering the thickness of the main body 12 of the electrode 11, the area of ​​the second portion 12b covered by the soldering auxiliary layer 14 is preferably 0.01 mm^2 or more and less than 16 mm^2. This configuration makes it possible to miniaturize the electrode 11 while maintaining the necessary and sufficient soldering strength.

[0064] Of the surface of the body 12 of the electrode 11, a third portion 12c that does not belong to either the first portion 12a or the second portion 12b may be exposed and not covered. This is because the third portion 12c is buried in the first housing portion 140a and insulated by the first housing portion 140a, and is not exposed to the internal space 141 of the housing portion 140. As shown in Fig. 4, the third portion 12c may be provided on the opposite side of the outer circumferential surface of the electrode 11 from the second portion 12b.

[0065] 4 illustrates an example in which most of the body 12 of the electrode 11 is covered with the insulating layer 13. However, the present disclosure is not limited to this example. It is sufficient that at least the portion of the body 12 of the electrode 11 exposed to the internal space 141 of the housing 140 is covered with the insulating layer 13. For example, it is preferable that 100% of the side surface (i.e., inner peripheral surface) 12d of the body 12 of the electrode 11 facing the central axis of the housing 140 and 50% or more of the region 12e of the upper and lower surfaces facing the central axis of the housing 140 are covered with the insulating layer 13. Here, the central axis of the housing 140 is an axis that passes through the center of the internal space 141 of the housing 140 and extends in the vertical direction. With this configuration, when less than 50% of the inner surface of the electrode 11 is exposed to the internal space 141 of the housing 140, the entire exposed portion is covered with the insulating layer 13.

[0066] <3.2. Manufacturing Method of Electrode 11> Hereinafter, a manufacturing method for manufacturing the electrode 11 constituting the capacitance sensor 10 used in the aerosol generation device 100 shown in FIG. 4 will be described with reference to FIGS. 5 to 9.

[0067] Fig. 5 is a diagram for explaining a first step S11 of the manufacturing method of the electrode 11. Fig. 6 is a diagram for explaining a second step S12 of the manufacturing method of the electrode 11. Fig. 7 is a diagram for explaining a third step S13 of the manufacturing method of the electrode 11. Fig. 8 is a diagram for explaining a fourth step S14 of the manufacturing method of the electrode 11. Fig. 9 is a diagram for explaining a fifth step S15 of the manufacturing method of the electrode 11.

[0068] 5 to 9 are performed using a plate-shaped base material as the workpiece 20 to manufacture the electrode 11. The base material may be a plate material made of aluminum such as A1050 and having a uniform thickness. The thickness of the base material corresponds to the thickness of the main body 12 of the electrode 11 and may be, for example, 0.1 mm or more and less than 4 mm.

[0069] 5 , in a first step S11, a plate-shaped base material is used as the workpiece 20, which is machined into a shape having a first annular member 21, a second annular member 22 surrounding the outside of the first annular member 21, and two connecting portions 23 (23a and 23b) connecting the first annular member 21 and the second annular member 22 at different positions. The first annular member 21 corresponds to the main body 12 of the electrode 11. The machining method used in the first step S11 may be, for example, cutting, pressing, or laser machining.

[0070] As shown in Fig. 6 , in the second step S12, the workpiece 20 after the first step S11 is completed is anodized, and the surface of the workpiece 20 is coated with an alumina film. The alumina film may be made of, for example, oxalic acid anodized aluminum. This alumina film corresponds to the insulating layer 13 of the electrode 11. That is, the thickness of the alumina layer corresponds to the thickness of the insulating layer 13 of the electrode 11 and is preferably, for example, not less than 1 µm and less than 20 µm. The portion of the body 12 of the electrode 11 that is coated with the insulating layer 13 corresponds to the first portion 12a of the surface of the body 12 of the electrode 11 described above.

[0071] As shown in FIG. 7 , in the third step S13, a through hole 24 is formed in the second annular member 22 of the workpiece 20 after the second step S12 is completed, and one of the two connecting portions 23, the connecting portion 23a, is cut. A portion of the connecting portion 23a remains connected to the first annular member 21, forming a stalk 26 protruding outside the first annular member 21. The base material is exposed at the inner surface 25 of the through hole 24 and at two cut surfaces 27 (27a and 27b) of the connecting portion 23a. Of the two cut surfaces 27 of the connecting portion 23a, the cut surface 27a on the stalk 26 side corresponds to the second portion 12b of the surface of the main body 12 of the electrode 11 described above. Examples of the processing method used in the third step S13 include cutting, pressing, and laser processing.

[0072] As shown in FIG. 8 , in the fourth step S14, the inner surface 25 of the through hole 24 and the cut surface 27 of the severed connecting portion 23a of the workpiece 20 after the third step S13 are plated. In particular, the plating may be electroplating, such as Ni—Sn plating. The aluminum base material is exposed on the inner surface 25 of the through hole 24 and the cut surface 27 of the connecting portion 23a. Therefore, by passing an electric current between the inner surface 25 of the through hole 24 and the cut surface 27 (27a and 27b) of the connecting portion 23a, a soldering auxiliary layer 14 can be formed on these surfaces as a plating layer. In particular, the plating layer formed on the cut surface 27a of the tip of the stalk 26 corresponds to the soldering auxiliary layer 14 that covers the second portion 12b of the surface of the body 12 of the electrode 11 described above. That is, the thickness of the plating layer corresponds to the thickness of the soldering auxiliary layer 14, and is preferably, for example, not less than 1 μm and less than 10 μm.

[0073] 9 , in a fifth step S15, the uncut connecting portion 23b of the workpiece 20 after the completion of the fourth step S14 is cut. The first annular member 21 after the completion of the fifth step S15 is the electrode 11. Of the two cut surfaces 28 (28a and 28b) of the connecting portion 23b, the cut surface 28a on the first annular member 21 side corresponds to the third portion 12c that is exposed and not covered on the surface of the main body 12 of the electrode 11. The processing method used in the fifth step S15 may be, for example, cutting, pressing, or laser processing.

[0074] Each of the steps described above may be performed by controlling each processing device with a computer.

[0075] According to the manufacturing method described above, it is possible to suitably manufacture the electrodes 11 that constitute the capacitance sensor 10 according to this embodiment.

[0076] According to the above manufacturing method, an alumina film is formed as the insulating layer 13 by anodizing. Therefore, compared to forming the insulating layer 13 by coating, it is easier to control the film thickness of the insulating layer 13, and it is possible to form the insulating layer 13 thin and uniformly. Furthermore, since the alumina film has a higher dielectric constant than an FPC, it is possible to improve the sensitivity of the capacitance sensor 10 compared to capacitance sensors formed with FPCs. Furthermore, since the alumina film has high abrasion resistance, it is possible to demonstrate high durability against abrasion when the stick-shaped substrate 150 is inserted and removed.

[0077] Alumina films are difficult to solder and are inherently insulating. Therefore, it is difficult to form the soldering auxiliary layer 14 on the alumina film. Another possible method for forming the soldering auxiliary layer 14 is to mask the desired area before anodizing and then perform plating after the anodizing. However, with this method, it is difficult to ensure manufacturing precision, as the masking can peel off during the anodizing.

[0078] In this regard, in the third step S13 and the fourth step S14, the soldering auxiliary layer 14 is formed by plating on the aluminum portion of the base material exposed at the cut surface 27a of the tip of the stalk 26 formed by cutting the connecting portion 23a. As a result, it is possible to ensure conductivity and form the soldering auxiliary layer 14 with high precision in an area of ​​sufficient size required for soldering the electrode 11 and the conductor wire.

[0079] Another possible plating method is electroless plating, but with electroless plating, the entire surface including the alumina layer is plated, making it difficult to ensure the insulation of the electrode 11.

[0080] In this regard, in the third step S13, the formation of the through-hole 24 and the cutting of the connecting portion 23a form an exposed surface of the base material as an electrode contact for plating, which makes it possible to perform electroplating and form the soldering auxiliary layer 14 in a small area such as the cut surface 27a at the tip of the stalk 26.

[0081] <4. Supplementary Information> Although preferred embodiments of the present disclosure have been described in detail above with reference to the accompanying drawings, the present disclosure is not limited to such examples. It is clear that a person skilled in the art to which the present disclosure pertains can conceive of various modified or altered examples within the scope of the technical ideas described in the claims, and it is understood that these also naturally fall within the technical scope of the present disclosure.

[0082] (1) First Modification In the above embodiment, an example in which the electrodes 11 are configured in an annular shape and arranged spaced apart from each other above and below has been described, but the present disclosure is not limited to such an example. The two electrodes 11 may be configured in a plate shape and arranged so that the plate surfaces face each other. This modification will be described with reference to FIGS. 10 and 11 .

[0083] FIG. 10 is an end view of the housing 140 according to the first modified example, cut in the vertical direction. FIG. 11 is an end view of the housing 140 according to the first modified example, cut along the cutting line B-B shown in FIG. 10. As shown in FIGS. 10 and 11, the two electrodes 11 may be configured as curved plates that curve along the shape of the inner periphery of the housing 140 and may be arranged to face each other across the internal space 141 of the housing 140. The electrodes 11 are configured, for example, by coating a main body 12, which is an aluminum curved plate, with an insulating layer 13, which is an alumina film. A portion of the electrode 11 may be exposed to the internal space 141 of the housing 140, as long as the entire exposed portion is covered with the insulating layer 13. The modified example described above can also solve the above-mentioned technical problem, as with the above embodiment.

[0084] (2) Second Modification Example Although the case where the housing portion 140 and the electrode 11 are integrally molded has been described in detail above, the present disclosure is not limited to such an example. The electrode 11 may be formed on an FPC and disposed in the housing portion 140. This modification example will be described with reference to FIGS. 12 and 13 .

[0085] FIG. 12 is an end view of the housing 140 according to the second modified example, cut in the vertical direction. FIG. 13 is an end view of the housing 140 according to the second modified example, cut along the cutting line C-C shown in FIG. 12. As shown in FIGS. 12 and 13, the two electrodes 11 are configured as curved plates that curve along the outer periphery of the housing 140. The two electrodes 11 are arranged so that the inner sides of the electrodes 11 overlap the outer sides of the housing 140 and face each other across the housing 140. In particular, the two electrodes 11 are arranged spaced apart in a direction perpendicular to the vertical direction (i.e., the radial direction of the housing 140).

[0086] The electrode 11 is attached to an FPC substrate 15 made of a resin such as polyimide or liquid crystal polymer, and then the electrode 11 is fixed to the outside of the first housing portion 140a through a process of wrapping the FPC substrate 15 around the first housing portion 140a. Here, the first housing portion 140a is made of ceramic, specifically, a highly dielectric and insulating ceramic such as alumina or zirconia.

[0087] That is, in this modification, the first housing portion 140a is the insulating layer 13 made of ceramic. The electrode 11 is arranged in contact with the outside of the first housing portion 140a, which is the insulating layer 13 made of ceramic. In particular, it is desirable that the electrode 11 and the first housing portion 140a, which has a high dielectric constant and insulating properties, be arranged in close contact with each other.

[0088] With this configuration, even when the electrodes 11 are formed on the FPC substrate 15, the capacitance sensor 10 can detect a change in capacitance when the stick-shaped substrate 150 passes through the space between the two electrodes 11. In particular, with this configuration, it becomes possible to mount the capacitance sensor 10 on the aerosol generation device 100 while suppressing a decrease in sensitivity that can occur when the first storage section 140a is made of a resin material.

[0089] Furthermore, with this configuration, as described above, a shielding layer for blocking noise that affects the electrodes 11 can be formed integrally with the electrodes 11 on the FPC substrate 15. This configuration is effective when the electrodes 11 are susceptible to noise and noise blocking by the shielding layer is important.

[0090] An example of noise is radiation noise from the heating unit 121. In order to block radiation noise, it is desirable to place an annular metallic shield layer below the electrode 11 in Fig. 12 (i.e., between the electrode 11 and the heating unit 121 arranged on the outer periphery of the second housing portion 140b).

[0091] Another example of noise is noise from a person on the opening 142 side that occurs when inserting or sucking the stick-shaped substrate 150. In order to block noise from people, it is desirable to place a circular metal shield layer above the electrode 11 in Fig. 12 (i.e., between the electrode 11 and the opening 142).

[0092] In order to shield these noises, it is more preferable to dispose a cylindrical metallic shield layer so as to cover the outside of the electrode 11 in addition to the shield layers on the top and bottom of the electrode 11.

[0093] (3) Others In the above embodiment, an example in which the capacitance sensor 10 is configured with two electrodes 11 has been described, but the present disclosure is not limited to such an example. The number of electrodes 11 that configure the capacitance sensor 10 may be three or more.

[0094] In the above embodiment, the body 12 of the electrode 11 is made of aluminum, but the present disclosure is not limited to this example. The body 12 of the electrode 11 may be made of other metals such as stainless steel (SUS). Alternatively, the body 12 of the electrode 11 may be made of non-metals such as indium tin oxide or conductive polymer.

[0095] In the above embodiment, the insulating layer 13 is an alumina film formed by alumina treatment, but the present disclosure is not limited to this example. The insulating layer 13 may be formed by coating silicon carbide or glass.

[0096] The heating unit 121 described in the above embodiment is an example of a load that generates heat, which is energy for heating the aerosol source of the stick-shaped substrate 150 housed in the housing unit 140. The load is not limited to the heating unit 121. When the means for heating the aerosol source is induction heating, the load may be an induction coil that generates a magnetic field, which is energy for induction heating a susceptor that is thermally close to the aerosol source.

[0097] In the above embodiment, an example has been described in which the auto-start function is executed using the detection of the insertion of the stick-shaped substrate 150 as a trigger, but the present disclosure is not limited to such an example. The detection of the insertion of the stick-shaped substrate 150 may also be used as a trigger to execute a wake-up function (return from a low-power standby mode).

[0098] Although the above describes an example in which the control unit 116 detects the insertion of the stick-shaped substrate 150 based on a change in capacitance, the present disclosure is not limited to such an example. The control unit 116 may also detect the state or suction of the stick-shaped substrate 150 based on a change in capacitance during suction.

[0099] The series of processes performed by each device described herein may be implemented using software, hardware, or a combination of software and hardware. The software programs may be stored in advance, for example, on a recording medium (more specifically, a non-transitory computer-readable storage medium) internal or external to each device. Each program is then loaded into a random access memory (RAM) and executed by a processing circuit such as a central processing unit (CPU). The recording medium may be, for example, a magnetic disk, an optical disk, a magneto-optical disk, or a flash memory. The computer program may also be distributed, for example, via a network, without using a recording medium. The computer may be, for example, an application-specific integrated circuit (ASIC), a general-purpose processor that executes functions by loading a software program, or a computer on a server used in cloud computing. The series of processes performed by each device described herein may be centrally processed by a single computer or distributed across multiple computers. Furthermore, in each of the above embodiments, two or more communication means present in a single device may be physically implemented on a single medium.

[0100] Furthermore, the processes described herein using flowcharts or sequence diagrams do not necessarily have to be performed in the order shown. Some process steps may be performed in parallel. Furthermore, additional process steps may be employed, and some process steps may be omitted.

[0101] Note that the following configurations also fall within the technical scope of the present disclosure: (1) An aerosol generation device comprising: a storage unit that stores a substrate containing an aerosol source in an internal space; a load that generates energy for heating the aerosol source of the substrate stored in the storage unit; and a capacitance sensor including a plurality of electrodes that detects the capacitance of the internal space of the storage unit, wherein the electrode includes a body made of metal, and a first portion of a surface of the body of the electrode is covered with an insulating layer made of ceramic. (2) The aerosol generation device according to (1), wherein the electrode is arranged so that a portion of the electrode is exposed to the internal space of the storage unit, and the portion of the electrode that is exposed to the internal space of the storage unit is covered with the insulating layer. (3) The aerosol generation device according to (2), wherein the storage section is a cylindrical body having an opening on the upper side through which the base material can be inserted and removed in the vertical direction, and wherein 100% of the side surface of the electrode body facing the central axis of the storage section and 50% or more of the upper and lower surfaces facing the central axis of the storage section are covered with the insulating layer. (4) The aerosol generation device according to any one of (1) to (3), wherein the insulating layer has a relative dielectric constant of 3 or more. (5) The aerosol generation device according to (4), wherein the electrode body is made of aluminum, and the insulating layer is an alumina film. (6) The aerosol generation device according to (4), wherein the insulating layer is formed by coating silicon carbide or glass. (7) The aerosol generation device according to any one of (1) to (6), wherein the insulating layer has a thickness of 1 μm or more and less than 20 μm. (8) The aerosol generating device according to any one of (1) to (7), wherein the thickness of the main body of the electrode is equal to or greater than 0.1 mm and less than 4 mm. (9) The aerosol generating device according to any one of (1) to (8), wherein a second portion of the surface of the main body of the electrode is covered with a soldering auxiliary layer made of a coating material that assists soldering. (10) The aerosol generating device according to (9), wherein the area of ​​the second portion is equal to or greater than 0.01 mm^2 and less than 16 mm^2.(11) The aerosol generation device according to any one of (1) to (10), wherein the electrode is configured in a ring shape, and the plurality of electrodes are arranged spaced apart in the vertical direction. (12) The aerosol generation device according to (1), wherein a part of the storage unit is the insulating layer made of ceramic, and the electrode is arranged in contact with the outer side of the storage unit which is the insulating layer made of ceramic. (13) The aerosol generation device according to any one of (1) to (12), further comprising a control unit that controls operation of the load based on the capacitance detected by the capacitance sensor. (14) A manufacturing method for manufacturing an electrode that constitutes a capacitance sensor used in an aerosol generating device, the manufacturing method including: a first step of processing a plate-shaped base material made of aluminum as a workpiece into a shape having a first annular member, a second annular member surrounding the outside of the first annular member, and two connecting portions that connect the first annular member and the second annular member at different positions; a second step of anodizing the workpiece after the first step is completed; a third step of forming a through hole in the second annular member and cutting one of the two connecting portions of the workpiece after the second step is completed; a fourth step of plating the inner surface of the through hole and the cut surface of the cut connecting portion of the workpiece after the third step is completed; and a fifth step of cutting the uncut connecting portion of the workpiece after the fourth step is completed.

[0102] DESCRIPTION OF SYMBOLS 100 Aerosol generating device 111 Power supply unit 112 Sensor unit 113 Notification unit 114 Memory unit 115 Communication unit 116 Control unit 121 Heating unit 140 Storage unit (140a: first storage unit, 140b: second storage unit) 141 Internal space 142 Opening 143 Bottom 144 Heat insulating unit 150 Stick-shaped substrate 151 Substrate unit 152 Suction nozzle 10 Capacitive sensor 11 Electrode 12 Main body 12a First portion 12b Second portion 12c Third portion 13 Insulating layer 14 Soldering auxiliary layer 15 FPC substrate 20 Workpiece 21 First annular member 22 Second annular member 23 Connection portion 24 Through hole 25 Inner surface 26 Stalk 27, 28 Cut surface

Claims

1. An aerosol generating device comprising: a storage unit that stores a substrate containing an aerosol source in an internal space; a load that generates energy for heating the aerosol source of the substrate stored in the storage unit; and a capacitance sensor including a plurality of electrodes that detects the capacitance of the internal space of the storage unit, wherein the electrodes include a body made of metal, and a first portion of a surface of the body of the electrodes is covered with an insulating layer made of ceramic.

2. The aerosol generating device according to claim 1, wherein the electrode is arranged so that a portion of the electrode is exposed to the internal space of the storage unit, and the portion of the electrode exposed to the internal space of the storage unit is covered with the insulating layer.

3. The aerosol generating device described in claim 2, wherein the storage section is a cylindrical body having an opening on the upper side through which the base material can be inserted and removed in the vertical direction, and 100% of the side surface of the electrode body facing the central axis of the storage section and 50% or more of the upper and lower surfaces facing the central axis of the storage section are covered by the insulating layer.

4. The aerosol generating device according to any one of claims 1 to 3, wherein the insulating layer has a relative dielectric constant of 3 or more.

5. The aerosol generating device according to claim 4, wherein the main body of the electrode is made of aluminum, and the insulating layer is an alumina film.

6. The aerosol generating device according to claim 4, wherein the insulating layer is formed by coating silicon carbide or glass.

7. The aerosol generating device according to any one of claims 1 to 6, wherein the insulating layer has a thickness of 1 μm or more and less than 20 μm.

8. The aerosol generating device according to any one of claims 1 to 7, wherein the thickness of the main body of the electrode is 0.1 mm or more and less than 4 mm.

9. An aerosol generating device according to any one of claims 1 to 8, wherein a second portion of the surface of the main body of the electrode is covered with a soldering assist layer made of a coating material that assists soldering.

10. The aerosol generating device according to claim 9, wherein the area of ​​the second portion is equal to or greater than 0.01 mm^2 and less than 16 mm^2.

11. The aerosol generating device according to any one of claims 1 to 10, wherein the electrode is configured in a ring shape, and the plurality of electrodes are arranged spaced apart in the vertical direction.

12. The aerosol generating device according to claim 1, wherein a part of the container is the insulating layer made of ceramic, and the electrode is arranged in contact with the outside of the container, which is the insulating layer made of ceramic.

13. The aerosol generating device according to any one of claims 1 to 12, further comprising a control unit that controls the operation of the load based on the capacitance detected by the capacitance sensor.

14. A manufacturing method for manufacturing an electrode that constitutes a capacitance sensor used in an aerosol generating device, comprising: a first step of processing a plate-shaped base material made of aluminum into a shape having a first annular member, a second annular member surrounding the outside of the first annular member, and two connecting portions that connect the first annular member and the second annular member at different positions; a second step of anodizing the workpiece after the first step is completed; a third step of forming a through hole in the second annular member of the workpiece after the second step is completed and cutting one of the two connecting portions; a fourth step of plating the inner surface of the through hole and the cut surface of the cut connecting portion of the workpiece after the third step is completed; and a fifth step of cutting the uncut connecting portion of the workpiece after the fourth step is completed.

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