Aerosol generating device, heater for aerosol generating device, and manufacturing method

Abstract

The present application provides an aerosol generating device, a heater for an aerosol generating device, and a manufacturing method. The aerosol generating device comprises a heater configured to be inserted into an aerosol generating product for heating. The heater comprises: a housing, comprising a free front end and a distal end facing away from each other along the length direction, and a cavity extending between the free front end and the distal end; a heating element, assembled in the cavity and extending along the longitudinal direction of the cavity; and a positioning element, located in the cavity and configured to provide positioning when the heating element is assembled in the cavity, so as to maintain the heating element at a predetermined position in the cavity. According to the aerosol generating device, in the heater, providing the positioning of the heating element within the housing by means of the positioning element is advantageous for the manufacturing of the heater.

Description

Aerosol-generating device, heater for an aerosol-generating device, and method of manufacture

[0001] CROSS REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application No. 202411105669.7, filed on August 12, 2024, and entitled “Aerosol-generating device, heater for an aerosol-generating device, and method of manufacture”, the content of which is incorporated herein by reference in its entirety. TECHNICAL FIELD

[0003] Embodiments of the present application relate to the field of aerosol-generating technology, and in particular to an aerosol-generating device, a heater for an aerosol-generating device, and a method of manufacture. BACKGROUND

[0004] Tobacco products, such as cigarettes, cigars, and the like, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these burning tobacco products by creating products that release compounds without burning.

[0005] Examples of such products are heat-not-burn devices that release compounds by heating, rather than burning, a material. The material may, for example, be tobacco or another non-tobacco product, which may or may not contain nicotine. Known heat-not-burn devices heat by inserting a pin or needle-like heater into the tobacco or other non-tobacco product; the applicant has proposed in Chinese patent CN116268569A a heater configuration comprising a pin-like outer shell and a heating coil inside the outer shell; wherein the two ends of the heating coil are welded with conductive leads for power supply, and a tubular support element is arranged inside the heating coil to support the heating coil. In the assembly of the heating coil and the outer shell, the heating coil is easily deformed by extrusion and the like, and cannot be accurately positioned longitudinally inside the outer shell.

[0006] SUMMARY

[0007] One embodiment of the present application provides an aerosol-generating device configured to heat an aerosol-generating article to generate an aerosol; comprising: a heater for insertion into the aerosol-generating article to heat; the heater comprising:

[0008] an outer shell comprising a free front end and a terminal end facing away from each other along a length direction, and a cavity extending between the free front end and the terminal end;

[0009] a heating element assembled in the cavity and extending longitudinally along the cavity;

[0010] a positioning element located in the cavity and configured to provide positioning to maintain the heating element at a predetermined position in the cavity when the heating element is assembled in the cavity.

[0011] In some embodiments, the housing is heated by receiving heat from the heating element, which in turn heats the aerosol generating article.

[0012] In some embodiments, the heating element is a helical heating coil.

[0013] In some embodiments, the cavity has an opening at the distal end; the heating element is fitted into the cavity via the opening.

[0014] In some embodiments, the heating element is longitudinally abutted against the positioning element.

[0015] In some embodiments, the positioning element is located between the heating element and the free distal end.

[0016] In some embodiments, the heating element is 1-3.5 mm away from the free distal end when at the predetermined position.

[0017] In some embodiments, the positioning element is configured to be spherical.

[0018] In some embodiments, the ratio of the diameter of the positioning element to the maximum inner diameter of the cavity is between 0.15-0.97;

[0019] Alternatively, the ratio of the diameter of the positioning element to the maximum inner diameter of the cavity is between 0.5-0.8;

[0020] Alternatively, the diameter of the spherical positioning element is between 0.8-1.5 mm.

[0021] In some embodiments, the positioning element is electrically insulating;

[0022] and / or, the positioning element is rigid;

[0023] and / or, the positioning element is dense;

[0024] and / or, the positioning element is solid.

[0025] In some embodiments, the cavity has a tapered section with a reduced inner diameter near the free distal end; the positioning element is substantially contained or held in the tapered section with the reduced inner diameter.

[0026] In some embodiments, the housing comprises:

[0027] a substrate, and a protective coating formed on or coated on the outer surface of the substrate;

[0028] the outer surface of the substrate is a rough surface and has a surface roughness of 0.2-3.0 µm.

[0029] In some embodiments, the ratio of the thickness of the protective coating to the surface roughness of the outer surface of the substrate is greater than 2:1.

[0030] In some embodiments, the heating element is configured as a helical heating coil extending longitudinally along the cavity, and has a first end proximate to the free front end, and a second end proximate to the distal end.

[0031] The heating coil has an abutment at the first end, and is longitudinally abutted against the positioning element by the abutment.

[0032] In some embodiments, the abutment is formed or defined by inwardly bending the wire material of the heating coil.

[0033] In some embodiments, the heater further comprises:

[0034] a support element positioned at least partially inside the heating coil, and configured to provide support to the heating coil from inside the heating coil; the support element is longitudinally abutted against the abutment.

[0035] In some embodiments, the heater further comprises:

[0036] a support element positioned at least partially inside the heating element, and configured to provide support to the heating element from inside the heating element.

[0037] At least one or both ends of the support element are smoothly curved or chamfered.

[0038] In some embodiments, the heating element has a first end proximate to the free front end, and a second end proximate to the distal end.

[0039] The heater further comprises:

[0040] a first conductive pin and a second conductive pin for conducting electric current on the heating element; the first conductive pin is connected to the first end of the heating element, and extends at least partially outside the distal end and through the support element; the second conductive pin is connected to the second end of the heating element, and extends at least partially outside the distal end.

[0041] In some embodiments, the first end and / or the abutment of the heating element is non-contacting with the housing.

[0042] In some embodiments, the heater further comprises:

[0043] a flange at least partially surrounding the housing and arranged to provide structural support to the housing to hold the housing to the aerosol-generating device; the flange having at least one aperture arranged therein.

[0044] Yet another embodiment of the present application also proposes an aerosol-generating device configured to heat an aerosol-generating article to generate an aerosol; comprising: a heater for insertion into the aerosol-generating article to heat; the heater comprising:

[0045] a housing comprising a free front end and a distal end facing away from each other in a length direction, and a cavity extending between the free front end and the distal end; the cavity having an opening at the distal end;

[0046] a heating element fitted in the cavity and extending in a longitudinal direction of the cavity;

[0047] a support element positioned at least partially inside the heating element and configured to provide support to the heating element from inside the heating element;

[0048] a positioning element positioned in the cavity and configured to provide positioning when the support element is fitted in the cavity via the opening.

[0049] Yet another embodiment of the present application also proposes an aerosol-generating device configured to heat an aerosol-generating article to generate an aerosol; comprising: a heater for insertion into the aerosol-generating article to heat; the heater comprising:

[0050] a housing comprising a free front end and a distal end facing away from each other in a length direction, and a cavity extending between the free front end and the distal end;

[0051] a heating element fitted in the cavity and extending in a longitudinal direction of the cavity;

[0052] a positioning element positioned in the cavity;

[0053] the positioning element is positioned between the heating element and the free front end, and the heating element is longitudinally abutted against the positioning element.

[0054] Yet another embodiment of the present application also proposes a heater for an aerosol-generating device; comprising:

[0055] a housing configured in a pin or needle shape and comprising a free front end and a distal end facing away from each other in a length direction, and a cavity extending between the free front end and the distal end;

[0056] a heating element fitted in the cavity and extending in a longitudinal direction of the cavity;

[0057] a positioning element positioned in the cavity;

[0058] The positioning element is located between the heating element and the free front end, and the heating element is longitudinally abutted against the positioning element.

[0059] Yet another embodiment of the present application also proposes a preparation method of a heater for an aerosol generating device, the preparation method comprising:

[0060] obtaining a housing, a positioning element and a heating element; the housing comprises a free front end and a terminal end facing away from each other along a length direction, and a cavity extending between the free front end and the terminal end, the cavity having an opening at the terminal end;

[0061] assembling the positioning element into the cavity from the opening;

[0062] assembling the heating element into the cavity from the opening, and longitudinally abutting the heating element against the positioning element to keep the heating element at a predetermined position in the cavity.

[0063] In some embodiments, the heating element is configured as a spiral heating coil extending along a longitudinal direction of the cavity, and comprises a first end and a second end facing away from each other. The heating coil has an abutment portion at the first end, which is formed or defined by inwardly bending the wire material of the heating coil.

[0064] In some embodiments, the assembling the heating element into the cavity from the opening further comprises, before the assembling:

[0065] forming an insulating layer on a surface of the heating element to provide insulation. In some embodiments, the insulating layer comprises glass glaze, ceramic film or the like.

[0066] In some embodiments, the assembling the heating element into the cavity from the opening further comprises, before the assembling:

[0067] obtaining a support element, and extending the support element into the heating element from the second end of the heating element to provide support to the heating element from the inside of the heating element.

[0068] In some embodiments, the support element is longitudinally abutted against the abutment portion.

[0069] In some embodiments, the assembling the heating element into the cavity from the opening further comprises, before the assembling:

[0070] obtaining a first conductive pin and a second conductive pin;

[0071] connecting the first electrically conductive lead to the second end of the heating element.

[0072] connecting the second electrically conductive lead to the second end of the heating element.

[0073] In some embodiments, the method further comprises, before the step of fitting the heating element into the cavity from the opening:

[0074] injecting a precursor slurry for forming a heat storage medium or a heat conducting medium into the cavity from the opening.

[0075] In some embodiments, the heat storage medium or the heat conducting medium is, for example, a ceramic or a glass frit, or an inorganic glass glue.

[0076] In some embodiments, the method further comprises:

[0077] baking or sintering the precursor slurry to solidify the precursor slurry into a heat storage medium or a heat conducting medium.

[0078] The above aerosol generating device, in which the positioning of the heating element in the housing is provided by the positioning element in the heater, is advantageous for the preparation of the heater. BRIEF DESCRIPTION OF DRAWINGS

[0079] One or more embodiments are illustrated by way of example in the figures that are part of this disclosure and which are illustrative, but not restrictive, of the embodiments, wherein elements having the same reference number designates like elements. Figures in the drawings are not necessarily to scale, except if so expressly indicated.

[0080] Figure 1 is a schematic view of an aerosol generating device according to an embodiment;

[0081] Figure 2 is a schematic view of a heater according to an embodiment, from one perspective;

[0082] Figure 3 is a schematic view of a heater according to an embodiment, from one perspective and in cross-section;

[0083] Figure 4 is a schematic view of a heater according to an embodiment, from one perspective and in cross-section, in exploded view;

[0084] Figure 5 is a schematic view of a heater according to an embodiment, from one perspective and in cross-section, with electrically conductive leads arranged at the ends of the heating coil;

[0085] Figure 6 is a schematic view of a heater according to an embodiment, from another perspective and in cross-section;

[0086] Figure 7 is a schematic view of a heater according to an embodiment, during the assembly of the support element and the heating coil;

[0087] Figure 8 is a schematic view of the assembly of the electrically conductive pins and the insulating tube with the heating coil in the preparation of the heater of one embodiment in sequence;

[0088] Figure 9 is a schematic view of the assembly of the flange and the positioning element with the housing in the preparation of the heater of one embodiment in sequence;

[0089] Figure 10 is a schematic view of the injection of the slurry for forming the heat storage medium or the heat conduction medium into the cavity of the housing by the injection device in the preparation of the heater of one embodiment;

[0090] Figure 11 is a schematic view of the assembly of the heating module including the heating coil into the cavity of the housing in the preparation of the heater of one embodiment.

[0091] Reference Signs

[0092] 10, electric core;

[0093] 20, electric circuit;

[0094] 30, heater; 31, housing; 311, free front end; 312, end; 313, cavity; 3131, conical section; 314, conical part; 32, heating coil; 321, first electrically conductive pin; 3210, abutment; 322, second electrically conductive pin; 33, support element; 331, upper end; 332, lower end; 333, through hole; 334, first chamfered part; 335, second chamfered part; 34, flange; 341, notch; 35, positioning element; 36, heat storage medium or heat conduction medium; 36a, precursor slurry; 381, insulating tube;

[0095] 40, opening;

[0096] 400, injection device;

[0097] 1000, aerosol generating article. Embodiments of the present application

[0098] In order to facilitate the understanding of the present application, the present application will be described in more detail below in conjunction with the drawings and specific embodiments.

[0099] One embodiment of the present application proposes an aerosol generating device, the configuration of which can be seen from Figure 1, comprising:

[0100] The chamber has an opening 40; in use, the aerosol generating article 1000 can be removably received in the chamber through the opening 40 of the chamber;

[0101] A heater 30 extending at least partially within the chamber, when the aerosol generating article 1000 is received within the chamber, is inserted into the aerosol generating article 1000 to heat, thereby causing the aerosol generating article 1000 to release a plurality of volatile compounds, and the volatile compounds are formed only by the heating process;

[0102] An electric cell 10 for supplying power;

[0103] A circuit 20 for guiding electric current between the electric cell 10 and the heater 30.

[0104] In a preferred embodiment, the electric cell 10 supplies a direct current voltage in a range of about 2.5 V to about 9.0 V, and the electric cell 10 can supply a direct current in a range of about 2.5 A to about 20 A.

[0105] In a preferred embodiment, the heater 30 has a shape of a pin or a needle or a rod or a bar or a column or a sheet or a plate, which is advantageous for insertion into the aerosol generating article 1000. In some embodiments, the heater 30 can have a length of about 10 to 18 mm and an outer diameter of about 2 to 4 mm.

[0106] In some alternative embodiments, the aerosol generating article 1000 preferably employs a tobacco-containing material that releases volatile compounds from a substrate upon heating; or can also be a non-tobacco material suitable for electrically heated smoking after heating. The aerosol generating article 1000 preferably employs a solid substrate, which can include one or more of a powder, a granule, a fragment, a strip, a band, or a sheet of one or more of a vanilla leaf, a tobacco leaf, a homogenized tobacco, and an expanded tobacco; or the solid substrate can contain additional volatile flavor compounds of tobacco or non-tobacco to be released upon heating of the substrate.

[0107] In some embodiments, the heater 30 can generally include a resistance heating element, and an auxiliary substrate for fixing the resistance heating element and the like. For example, in some embodiments, the resistance heating element is in the shape or form of a spiral coil. Or in yet other embodiments, the resistance heating element is in the form of a conductive track combined on a carrier. Or in yet other embodiments, the resistance heating element is in the shape of a sheet.

[0108] Or in yet other alternative embodiments, the heater 30 is an electromagnetic induction heater that can be heated by penetration of a varying magnetic field. Or in yet other alternative embodiments, the heater 30 is an infrared heater that heats the aerosol generating article 1000 to generate an aerosol by radiating infrared rays to the aerosol generating article 1000.

[0109] Figures 2 to 6 show schematic views of a heater 30 according to an embodiment; the heater 30 according to the embodiment includes a free front end 311 and a terminal end 312 opposite to each other along a length direction; wherein the free front end 311 is configured as a tapered tip, and has a tapered portion 314 with a decreasing outer diameter at the free front end 311 for insertion into the aerosol generating article 1000. In the views shown in Figures 2 to 6, the heater 30 includes:

[0110] a housing 31 defining at least a portion of an outer surface of the heater 30. In the views shown in Figures 2 to 6, the housing 31 is configured as a pin or needle or column or rod shape. In the views shown in Figures 2 to 6, the housing 31 defines the free front end 311 and the terminal end 312 of the heater 30 at opposite ends along the length direction, respectively; and the housing 31 has a cavity 313 formed or arranged therein extending between the free front end 311 and the terminal end 312. The cavity 313 is open at the terminal end 312 to facilitate assembly of functional components inside the cavity 313.

[0111] In some embodiments, the housing 31 is heat conductive. The housing 31 is made of a heat conductive material; for example, the housing 31 can be made of ceramic such as alumina ceramic, zirconia ceramic, or glass, or can be made of metal or alloy such as iron-aluminum alloy, stainless steel, and the like. In some alternative embodiments, the housing 31 includes a metal or alloy having a thermal conductivity of at least 20 W / m.k, such as stainless steel or aluminum alloy.

[0112] In some embodiments, a protective coating is formed on the surface of the housing 31 by spraying or deposition, or the like. The protective coating is used to form a protection on the surface of the housing 31 to prevent or reduce the adhesion of residues or aerosol condensate originating from the aerosol generating article 1000 on the surface of the housing 31. In some specific embodiments, the protective coating can include a glass glaze layer, a ceramic film, or the like. In some embodiments, the housing 31 includes a substrate in the form of a pin or needle or sheet, and a protective coating formed on the outer surface of the substrate. In some embodiments, the outer surface of the substrate is a rough surface treated by surface roughening, which is advantageous for improving the adhesion of the protective coating.

[0113] In some embodiments, the protective coating is more corrosion resistant than the substrate. For example, the substrate is made of metal or alloy; and the protective coating is a glass glaze, a ceramic film, or the like.

[0114] In some alternative embodiments, the outer surface of the substrate is formed to have a rough surface with surface roughness by sandblasting, chemical etching, laser etching, or the like surface treatment. In some alternative embodiments, the surface roughness Ra of the outer surface of the substrate is between 0.2 and 3.0 pm. In some more preferred embodiments, the surface roughness Ra of the outer surface of the substrate is between 0.6 and 1.2 pm. In one specific embodiment, the surface roughness Ra of the outer surface of the substrate is about 0.8 pm.

[0115] In the present disclosure, the "surface roughness" is a term in the field of machining, which refers to the unevenness of the machined surface with small pitch and tiny peaks and valleys. In actual provisions and uses, the surface roughness has multiple characterization parameters, such as the national standard GB / T 1031-2009 "Surface Texture Profile Method Surface Roughness Parameters and Their Numerical Values", which details the terms and evaluation parameter standards related to surface roughness. Among them, the height characteristic parameter, the pitch characteristic parameter, and the shape characteristic parameter can all be used to measure the surface roughness. The "Ra, i.e., the profile arithmetic mean deviation" is one of the height characteristic parameters of the surface roughness; in the national standard GB / T 1031-2009 "Surface Texture Profile Method Surface Roughness Parameters and Their Numerical Values", it is detected and calculated by the arithmetic mean of the profile deviation absolute value within the sampling length lr.

[0116] In some embodiments, the thickness of the protective coating is greater than the surface roughness Ra of the outer surface of the substrate. In more preferred embodiments, the ratio of the thickness of the protective coating to the surface roughness Ra of the outer surface of the substrate is greater than 2:1; more preferably, the ratio is greater than 5:1; or more preferably, the ratio is greater than 10:1. In some embodiments, the thickness of the protective coating is approximately between 10 and 50 pm; in some alternative embodiments, the thickness of the protective coating is approximately between 20 and 30 pm. It is advantageous for the protective coating to have good bonding force on the outer surface of the substrate without falling off.

[0117] In some embodiments, the outer shell 31 has an outer diameter of about 2.0-3.2 mm and a wall thickness of about 0.1-0.3 mm; then the inner diameter of the cavity 313 of the outer shell 31 is about 1.5-2.5 mm, and the length of the cavity 313 is about 12-15 mm.

[0118] In the embodiments shown in FIG. 2 to FIG. 6, the cavity 313 is closed on one side near or towards the free front end 311; and, the cavity 313 is open on one side at the end 312. In the embodiments shown in FIG. 2 to FIG. 6, the cavity 313 has a tapered section 3131 with a reduced inner diameter near the free front end 311. Thus, the cavity 313 is tapered in shape with a gradually reduced inner diameter in the section near the free front end 311. In some embodiments, the tapered section 3131 with a reduced inner diameter has a length of about 0.5 to 3.0 mm in the longitudinal direction of the housing 31.

[0119] According to FIG. 2 to FIG. 6, the heater 30 further comprises:

[0120] A heating coil 32, such as a helical solenoid coil, is located in the cavity 313 of the housing 31. In some embodiments, the heating coil 32 has about 4 to 12 windings or turns. In some embodiments, the heating coil 32 has an extended length of 8 to 12 mm. In some embodiments, the heating coil 32 has an outer diameter of 1.2 to 2 mm, and an inner diameter of 0.6 to 1.6 mm.

[0121] According to FIG. 2 to FIG. 6, the heater 30 further comprises:

[0122] First and second electrically conductive pins 321 and 322 for conducting an electric current, such as a direct or alternating current, through the heating coil 32 to cause the heating coil 32 to generate heat for heating. The first and second electrically conductive pins 321 and 322 are respectively connected to the two ends of the heating coil 32; specifically, the first electrically conductive pin 321 is connected to a first end of the heating coil 32 near the free front end 311 by welding or the like, and the second electrically conductive pin 322 is connected to a second end of the heating coil 32 near the end 312 by welding or the like. Further, the first and second electrically conductive pins 321 and 322 at least partially extend from the cavity 313 to the outside of the end 312, which is advantageous for connection to the circuit 20. Further, the first electrically conductive pin 321 is connected to the upper end of the heating coil 32 by welding or the like, and penetrates through the heating coil 32 to the outside of the end 312; the second electrically conductive pin 322 is directly connected to the lower end of the heating coil 32 by welding or the like. The first and second electrically conductive pins 321 and 322 have a diameter of about 0.1 to 0.5 mm. Or in some specific embodiments, the first and second electrically conductive pins 321 and 322 have a diameter of 0.3 mm. The first electrically conductive pin 321 penetrates through the heating coil 32 in the longitudinal direction.

[0123] In embodiments, the heating portion for insertion into the aerosol generating article 1000 for heating is constituted by the housing 31 and the heating coil 32 held within the housing 31. Then in some embodiments, the heating coil 32 is for generating electric resistance Joule heat, and the housing 31 is heated by receiving the heat of the heating coil 32, which in turn heats the aerosol generating article 1000. Alternatively, the heating coil 32 is for generating a varying magnetic field when an alternating current flows therethrough; the housing 31 is made of a metal or alloy that is susceptible to the varying magnetic field, and the housing 31 is heated by the varying magnetic field penetrating therethrough to heat the aerosol generating article 1000. Or in yet other alternative embodiments, the heating portion for insertion into the aerosol generating article 1000 for heating is constituted by a rod-shaped heating member; for example, the heating member can further include a rod-shaped electrically insulating carrier such as ceramic, polymer, etc., and an electrically resistive heating track formed on or bonded to the electrically insulating carrier, etc.

[0124] In an alternative embodiment, the heating coil 32 is made of a metal material, a metal alloy, graphite, carbon, an electrically conductive ceramic, or a composite of a metal material and another ceramic material having a suitable resistance. Among them, the suitable metal or alloy material includes at least one of nickel, cobalt, zirconium, titanium, a nickel alloy, a cobalt alloy, a zirconium alloy, a titanium alloy, a nickel-chromium alloy, a nickel-iron alloy, a ferro-chromium alloy, a ferro-chromium-aluminum alloy, a ferro-manganese-aluminum-based alloy, or stainless steel, etc. Of course, after assembly, the heating coil 32 and the inner wall of the cavity 313 of the housing 31 are insulated from each other. And in use, the housing 31 is heated by receiving or transferring the heat of the heating coil 32 to heat the aerosol generating article 1000. In some embodiments, the heating coil 32 is surface-dipped, sprayed, or deposited with an insulating layer, or surface-oxidized, etc., to provide insulation between the heating coil 32 and the inner wall of the cavity 313 of the housing 31. The insulating layer is, for example, a glass glaze layer, a ceramic film layer, etc.

[0125] In some embodiments, the first conductive pin 321 and / or the second conductive pin 322 has a diameter of about 0.1-0.5 mm; and the first conductive pin 321 and / or the second conductive pin 322 has a length of about 20-40 mm. And the first conductive pin 321 and / or the second conductive pin 322 is made of a metal or alloy with low resistivity, such as gold, silver, copper, or an alloy containing the same; or in yet other embodiments, the first conductive pin 321 and / or the second conductive pin 322 is made of a copper wire or a copper filament with a plating layer such as a nickel layer on the surface. Or in yet other embodiments, the first conductive pin 321 and / or the second conductive pin 322 can be further sprayed or coated with an insulating layer, such as a ceramic layer, a glaze layer, an organic layer, etc., which is beneficial for insulation.

[0126] For example, in some embodiments, the first conductive pin 321 and / or the second conductive pin 322 is sheathed with an insulating tube 381, which is advantageous for providing insulation. In some embodiments, the insulating tube 381 is made of an organic polymer material, such as Teflon, polyimide, etc.

[0127] In embodiments, the heating coil 32 is not in contact with the aerosol- generating article 1000.

[0128] According to the embodiments shown in Figs. 2 to 6, the cross-sectional shape of the wire material of the heating coil 32 is different from a conventional circular shape. According to the embodiments shown in Figs. 2 to 6, the cross-section of the wire material of the heating coil 32 has an axial direction extending dimension that is greater than a radial direction extending dimension perpendicular to the axial direction, so that the cross-section of the wire material of the heating coil 32 is in a flattened rectangular shape. In simple terms, the above configured heating coil 32 is completely or at least flattened in form of the wire material compared to a conventional spiral-shaped heating coil formed by a circular cross-section wire. Thus, the wire material extends to a lesser extent along the radial direction. By this measure, energy loss in the heating coil 32 can be reduced. In particular, the transfer of heat generated by the heating coil 32 towards the housing 31 in the radial direction can be facilitated.

[0129] Alternatively, in yet other embodiments, the wire material of the heating coil 32 can be in a circular cross-sectional shape.

[0130] Referring to Figs. 2 to 6, the heater 30 further comprises:

[0131] A flange 34 at least partially surrounds or is coupled to the housing 31. The flange 34 is arranged proximate to the end 312, and the aerosol-generating device holds or retains the flange 34 so that the heater 30 is stably mounted and fixed in the device. Also, the flange 34 is substantially away from the heating coil 32; in some embodiments, the flange 34 is kept at a distance of at least 2 mm from the heating coil 32. Alternatively, the flange 34 is substantially located between the heating coil 32 and the end 312. Alternatively, in yet other embodiments, the flange 34 is closer to the end 312 than the heating coil 32. The flange 34 can comprise ceramic, PEEK, alloy, etc.

[0132] In the embodiments shown in Figs. 2 to 6, the flange 34 is arranged in a sheet shape. The sheet-shaped flange 34 has a thickness of about 0.1 to 1.2 mm. In some embodiments, the flange 34 is made of metal or alloy. In some embodiments, the flange 34 and the housing 31 are fixedly connected by welding, riveting, tight fitting, etc. Also, the flange 34 and the housing 31 are not detachable.

[0133] In the embodiments shown in FIGS. 2-6, the flange 34 is configured in a circular ring shape. At least one notch 341 is arranged on the flange 34. The notch 341 can be used to provide angular alignment or positioning of the flange 34 with the housing 31 during assembly by the equipment or production personnel.

[0134] Referring to FIGS. 2-6, the heater 30 further includes:

[0135] A support element 33 configured to extend within the heating coil 32 along the length of the heater 30; the support element 33 is configured in a tubular shape; the support element 33 is made of an insulating material, such as ceramic, glass, etc.; the heating coil 32 is wrapped around and bonded to the support element 33 and is supported by the support element 33 within the heating coil 32.

[0136] Referring to FIGS. 2-6, the support element 33 has a through hole 333 extending longitudinally therethrough; the through hole 333 extends from the upper end 331 to the lower end 332 of the support element 33. After assembly, the first conductive pin 321 extends through or passes through the through hole 333 of the support element 33; the first conductive pin 321 extends from the first end of the heating coil 32, through the through hole 333 of the support element 33, and then extends out of the terminal end 312.

[0137] In some embodiments, the support element 33 is configured to restrict the first conductive pin 321 within the support element 33 by arranging separate and spaced apart through holes 333, so as to separate the first conductive pin 321 and the second conductive pin 322 / heating coil 32, to prevent them from contacting and shorting.

[0138] In some embodiments, the support element 33 has a length of about 10-12 mm. According to the embodiments shown in FIGS. 2-6, the length of the support element 33 is slightly less than the length of the heating coil 32. Also, the length of the support element 33 is less than the length of the cavity 313 of the housing 31; as shown in FIG. 2, after assembly, the support element 33 located within the housing 31 has a spacing with the terminal end 312 of the housing 31. In some embodiments, the spacing between the lower end 332 of the support element 33 and the terminal end 312 is greater than 2 mm. In some embodiments, the through hole 333 of the support element 33 has a diameter of about 0.5 mm.

[0139] Referring to Figs. 2-6, the wire material of the heating coil 32 has a contact portion 3210 formed by inwardly bending at the first end. The contact portion 3210 is inwardly bent into the heating coil 32. In some embodiments, the contact portion 3210 is flatly bent inwardly; or, the contact portion 3210 is arcuately curved. In assembly, the support element 33 extends into the heating coil 32 from the second end of the heating coil 32 and longitudinally abuts against the contact portion 3210 to form a stop. According to Figs. 2-6, the upper end 331 of the support element 33 longitudinally abuts against the contact portion 3210.

[0140] Referring to Figs. 2-6, the upper end 331 and / or the lower end 332 of the support element 33 is cut or ground to form a smooth curve or arc. In Figs. 2-6, the support element 33 has a first chamfer portion 334 at the upper end 331; the first chamfer portion 334 makes the upper end 331 of the support element 33 and the outer surface to be smoothly transitioned. In Figs. 2-6, the support element 33 has a second chamfer portion 335 at the lower end 332; the second chamfer portion 335 makes the lower end 331 of the support element 33 and the outer surface to be smoothly transitioned. The support element 33 with the first chamfer portion 334 and / or the second chamfer portion 335 is advantageous in assembly for extending the support element 33 into the heating coil 32.

[0141] Referring to Figs. 2-6, the heater 30 further comprises:

[0142] a positioning element 35 located in the cavity 313 of the housing 31. More preferably, the positioning element 35 is located in the tapered section 3131 with the reduced inner diameter. After assembly, the positioning element 35 is arranged between the first end of the heating coil 32 and the housing 31. The first end of the heating coil 32 longitudinally abuts against the positioning element 35. In assembly, the heating coil 32 is stopped by abutting against the positioning element 35 when extending into the cavity 313 from the free end 312, thereby keeping the heating coil 32 at a predetermined position in the longitudinal direction in the cavity 313. Or more specifically, the contact portion 3210 of the heating coil 32 abuts between the positioning element 35 and the support element 33.

[0143] In some embodiments, the heating coil 32 has a distance of 1-3.5 mm from the free end 311 at the predetermined position. Or, the predetermined position represents a position of the heating coil 32 with respect to the free end 311 that satisfies a heating temperature field of the heater 30 in use.

[0144] In some embodiments, the positioning element 35 is electrically insulating.

[0145] In some embodiments, the positioning element 35 is rigid.

[0146] In some embodiments, the positioning element 35 is made of a material such as glass or ceramic. For example, the positioning element 35 is made of a glass or ceramic material such as alumina, zirconia, silica, carbide, nitride, etc.

[0147] In some embodiments, the positioning element 35 is dense. Or in yet other embodiments, the positioning element 35 is porous or is a foam.

[0148] In some embodiments, the positioning element 35 is solid. Or in yet other embodiments, the positioning element 35 is hollow, such as a hollow sphere.

[0149] In some embodiments, the positioning element 35 is configured to be spherical. In some embodiments, the ratio of the diameter of the positioning element 35 to the maximum inner diameter of the cavity 313 is between 0.15 and 0.97. In more preferred embodiments, the ratio of the diameter of the positioning element 35 to the maximum inner diameter of the cavity 313 is between 0.5 and 0.8. In more specific embodiments, the ratio of the diameter of the positioning element 35 to the maximum inner diameter of the cavity 313 is 0.6.

[0150] In some embodiments, the diameter of the spherical positioning element 35 is between 0.8 and 1.5 mm.

[0151] In some embodiments, the positioning element 35 is a spheroid. In yet other embodiments, the positioning element 35 is an ellipsoid, a baseball, or an oval, etc. Or in more embodiments, the positioning element 35 is configured to be a cuboid. Or in more embodiments, the positioning element 35 is configured to be a polyhedron, such as a regular pentagonal polyhedron, a regular octahedron, a regular dodecahedron, etc. Or, the positioning element 35 is configured to be a regular polyhedron.

[0152] Or in yet other variant embodiments, the positioning element 35 is conical in shape. The conical positioning element 35 is more advantageous for fitting with the conical section 3131 having a decreasing inner diameter.

[0153] Or in yet other variant embodiments, the heating coil 32 is supported by the support element 33; and is provided with a stop and / or assembly positioning by the support element 33 against the positioning element 35 longitudinally.

[0154] Referring to Figs. 2 to 6, the cavity 313 of the housing 31 is further arranged with:

[0155] A heat storage medium or a heat conducting medium 36 is at least partially filled or arranged between the heating coil 32 and the inner surface of the shell 31. The heat storage medium or the heat conducting medium 36 is arranged to eliminate the gap between the heating coil 32 and the inner surface of the shell 31, etc., so as to improve the heat conduction therebetween. Alternatively, the heat storage medium or the heat conducting medium 36 at least partially provides heat conduction between the heating coil 32 and the shell 31. Alternatively, the heat storage medium or the heat conducting medium 36 at least partially provides heat storage within the shell 31.

[0156] In some embodiments, the heat storage medium or the heat conducting medium 36 comprises a heat conducting ceramic or glass enamel, etc. In some embodiments, the heat storage medium or the heat conducting medium 36 is formed by sintering or solidifying a slurry injected into the cavity 313. For example, in some specific embodiments, the heat storage medium or the heat conducting medium 36 is formed by sintering or solidifying a glass enamel slurry or a ceramic slurry injected into the cavity 313. For example, in some specific embodiments, the glass enamel slurry or the ceramic slurry can comprise a slurry formed by mixing at least one of glass powder, barium oxide powder, silicon dioxide powder, boron oxide powder, aluminum oxide powder, magnesium oxide powder, etc. with an organic solvent, etc.

[0157] In some embodiments, the heat storage medium or the heat conducting medium 36 has a thermal conductivity of 1-25 W / m·K. For example, the thermal conductivity of glass enamel is about 1 W / m·K, and the thermal conductivity of aluminum oxide ceramic is about 20 W / m·K. In some specific embodiments, the material of the heat storage medium or the heat conducting medium 36 has a starting melting point of not less than 500°C. In some specific embodiments, the heat storage medium or the heat conducting medium 36 has a thermal expansion coefficient of not less than 8 ppm / °C, preferably 10-13 ppm / °C.

[0158] In some specific embodiments, the heat storage medium or the heat conducting medium 36 can comprise inorganic glass glue such as sodium silicate sol, aluminum silicate sol, etc. The inorganic glass glue such as sodium silicate sol, aluminum silicate sol, etc. is injected into the cavity 313 by gluing and then solidified to form the heat storage medium or the heat conducting medium 36.

[0159] FIGS. 7-11 show a mass production process of the heater 30 in an embodiment, which in the embodiment comprises:

[0160] S10, as shown in FIG. 7, the heating coil 32 and the support element 33 are obtained, the support element 33 is inserted into the heating coil 32 from the second end of the heating coil 32, and the support element 33 is longitudinally abutted on the abutting portion 3210 of the first end of the heating coil 32.

[0161] S20, as shown in FIG. 8, the first conductive pin 321 and the second conductive pin 322 are obtained; the first conductive pin 321 is passed through the through hole 333 of the support element 33, and then welded / electrically connected with the first end / abutting portion 3210 of the heating coil 32; the second conductive pin 322 is welded / electrically connected with the second end of the heating coil 32.

[0162] S30, as shown in FIG. 8, the insulating tube 381 is obtained, and the insulating tube 381 is wrapped outside the first conductive pin 321 and the second conductive pin 322 to provide insulation.

[0163] S40, an insulating layer is formed on the surface of the heating coil 32; for example, the heating coil 32 is immersed in the slurry precursor of the glass enamel by dip coating, and then baking and / or sintering are performed, so that the slurry precursor of the glass enamel is uniformly wrapped and solidified on the surface of the heating coil 32, and then the insulating layer is formed; or for another example, the ceramic slurry is sprayed on the outside of the heating coil 32 by plasma spraying, and then baking and / or sintering are performed to uniformly wrap and solidify the ceramic slurry on the surface of the heating coil 32, and then the insulating layer is formed; that is, the heating module is obtained.

[0164] S50, as shown in FIG. 9, the shell 31 and the flange 34 are obtained; the flange 34 is combined with the shell 31 through the end 312 of the shell 31, and the shell 31 and the flange 34 are connected and fastened by laser welding or the like.

[0165] S60, as shown in FIG. 9, the positioning element 35 is obtained and placed into the cavity 313 from the end 312 of the shell 31, and abuts against the tapered section 3131 with a reduced inner diameter.

[0166] S70, as shown in FIG. 10, the precursor slurry 36a of the glass enamel or ceramic forming the heat storage medium or heat conduction medium 36 is injected into the cavity 313 from the end 312 of the shell 31 by the injection device 400.

[0167] S80, as shown in FIG. 11, the heating module including the heating coil 32 in FIG. 7 is placed into the cavity 313 from the end 312 of the shell 31, and the abutting portion 3210 of the heating coil 32 abuts against the positioning element 35 to form a stop and then provide positioning.

[0168] S90, the precursor slurry 36a is baked or sintered to solidify the precursor slurry 36a to form the heat storage medium or heat conduction medium 36, that is, the heater 30 is obtained.

[0169] It should be noted that the above-mentioned embodiments illustrate rather than limit the application, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims.

Claims

1. An aerosol-generating device configured to heat an aerosol-generating article to generate an aerosol; characterised in that, Comprise: a heater for insertion into an aerosol-generating article for heating; the heater comprising: a housing comprising a free front end and a terminal end facing away from each other in a length direction, and a cavity extending between the free front end and the terminal end; a heating element fitted in the cavity and extending in a longitudinal direction of the cavity; a positioning element located in the cavity and configured to provide positioning and thereby maintain the heating element in a predetermined position in the cavity when the heating element is fitted in the cavity.

2. An aerosol-generating device according to claim 1, wherein, The heating element longitudinally abuts against the positioning element.

3. An aerosol-generating device according to claim 1 or 2, wherein, The positioning element is located between the heating element and the free front end; the heating element is 1-3.5 mm away from the free front end when in the predetermined position.

4. An aerosol-generating device according to claim 1 or 2, wherein, The positioning element is configured to be spherical.

5. An aerosol-generating device according to claim 4, wherein the heater is arranged to heat the aerosol-forming substrate to a temperature of 150-250°C. The ratio of the diameter of the positioning element to the maximum inner diameter of the cavity is between 0.15-0.97; or, the ratio of the diameter of the positioning element to the maximum inner diameter of the cavity is between 0.5-0.8; or, the diameter of the spherical positioning element is between 0.8-1.5 mm.

6. An aerosol-generating device according to claim 4, wherein the heater is arranged to heat the aerosol-forming substrate to a temperature of 150-250°C. The positioning element is electrically insulating; and / or, the positioning element is rigid; and / or, the positioning element is dense; and / or, the positioning element is solid.

7. An aerosol-generating device according to claim 1 or 2, wherein The cavity has a tapered section with a reduced inner diameter near the free front end; the positioning element is substantially contained or maintained in the tapered section with the reduced inner diameter.

8. An aerosol-generating device according to claim 1 or 2, wherein, The housing comprises: a substrate, and a protective coating formed or coated on an outer surface of the substrate; The outer surface of the substrate is a rough surface and has a surface roughness of 0.2-3.0 µm.

9. An aerosol-generating device according to claim 8, wherein The ratio of the thickness of the protective coating to the surface roughness of the outer surface of the substrate is greater than 2:

1.

10. An aerosol-generating device according to claim 1 or 2, wherein, The heating element is configured to be a spiral heating coil extending in the longitudinal direction of the cavity, and has a first end near the free front end and a second end near the terminal end; The heating coil has an abutment located at the first end and longitudinally abuts against the positioning element from the abutment.

11. An aerosol-generating device according to claim 10, wherein, The abutment is formed or defined by inwardly bending the wire material of the heating coil.

12. An aerosol-generating device according to claim 10, wherein, The heater further comprises: a support element at least partially positioned inside the heating coil and configured to provide support to the heating coil from inside the heating coil; the support element longitudinally abuts against the abutment.

13. An aerosol-generating device according to claim 1 or 2, wherein, The heater further comprises: a support element at least partially positioned inside the heating element and configured to provide support to the heating element from inside the heating element; At least one end or both ends of the support element are smoothly arced or chamfered.

14. An aerosol-generating device according to claim 1 or 2, wherein, The first end and / or abutment of the heating element are non-contacting with the housing.

15. An aerosol-generating device configured to heat an aerosol-generating article to generate an aerosol; characterised in that, Comprise: a heater for insertion into an aerosol-generating article for heating; the heater comprising: a housing comprising a free front end and a terminal end facing away from each other in a length direction, and a cavity extending between the free front end and the terminal end; the cavity has an opening at the terminal end; a heating element fitted in the cavity and extending in a longitudinal direction of the cavity; a positioning element located in the cavity and configured to provide positioning and thereby maintain the heating element in a predetermined position in the cavity when the heating element is fitted in the cavity. a support element positioned at least partially inside the heating element and configured to provide support to the heating element from inside the heating element; a positioning element positioned inside the cavity and configured to provide positioning when the support element is fitted inside the cavity via the opening.

16. An aerosol-generating device configured to heat an aerosol-generating article to generate an aerosol; characterised in that, comprising: a heater for insertion into an aerosol generating article for heating; the heater comprising: a housing comprising a free front end and a terminal end facing away from each other in a length direction, and a cavity extending between the free front end and the terminal end; a heating element fitted inside the cavity and extending in a longitudinal direction of the cavity; a positioning element positioned inside the cavity; the positioning element is positioned between the heating element and the free front end, and the heating element is longitudinally abutted against the positioning element.

17. A heater for an aerosol generating device, characterized in that, comprising: a housing configured as a pin or needle and comprising a free front end and a terminal end facing away from each other in a length direction, and a cavity extending between the free front end and the terminal end; a heating element fitted inside the cavity and extending in a longitudinal direction of the cavity; a positioning element positioned inside the cavity; the positioning element is positioned between the heating element and the free front end, and the heating element is longitudinally abutted against the positioning element.

18. A method of making a heater for an aerosol-generating device, the method comprising: providing a heater element; providing a heater support; and coupling the heater element to the heater support. the preparation method comprising: obtaining a housing, a positioning element and a heating element; the housing comprising a free front end and a terminal end facing away from each other in a length direction, and a cavity extending between the free front end and the terminal end, the cavity having an opening at the terminal end; fitting the positioning element from the opening into the cavity; fitting the heating element from the opening into the cavity and longitudinally abutting the heating element against the positioning element to keep the heating element at a predetermined position inside the cavity.

19. The method of claim 18, wherein the heater for an aerosol-generating device is prepared by, the heating element is configured as a spiral heating coil extending in a longitudinal direction of the cavity, and comprises a first end and a second end facing away from each other; the heating coil has an abutment portion at the first end, the abutment portion being formed or defined by inwardly bending the wire material of the heating coil; the fitting the heating coil from the opening into the cavity further comprises, before the fitting: obtaining a support element; inserting the support element into the heating coil from the second end of the heating coil and abutting the support element against the abutment portion.

20. The preparation method of the heater for the aerosol generating device according to claim 18 or 19, the fitting the heating element from the opening into the cavity further comprising, before the fitting: injecting a precursor slurry for forming a heat storage medium or a heat conduction medium into the cavity from the opening; the fitting the heating element from the opening into the cavity further comprising, after the fitting: baking or sintering the precursor slurry to solidify the precursor slurry into a heat storage medium or a heat conduction medium.

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