TWI856241B - Aerosol generation device - Google Patents

Abstract

An aerosol generating device is described. The aerosol generating device includes: a housing; a tubular heating chamber arranged to receive an aerosol substrate, the heating chamber operable to heat the aerosol substrate to generate an aerosol; an elongate battery; a frame within the housing, the frame arranged to hold the battery and heating chamber within the frame such that the heating chamber and the battery are aligned end-on within the housing with a first end of the tubular heating chamber facing a first end of the battery; wherein the frame comprises a dividing wall arranged between the first end of the battery and the adjacent first end of the heating chamber. By providing a tubular heating chamber and an elongate battery which are aligned end-on within the housing, the surface area of the thermal interface between the heating chamber and battery is significantly reduced, thereby reducing heat transfer to the battery. This further allows for a more compact, user-friendly arrangement but without increasing heat transfer to the battery, as would usually be associated with reducing the size of the device.

Description

Aerosol Generating Device

The present disclosure relates to an aerosol generating device. The present disclosure is particularly applicable to a portable aerosol generating device that can be self-contained and cryogenic. Such a device can heat tobacco or other suitable aerosol base material by conduction, convection and/or radiation rather than ignition to generate an aerosol for inhalation.

Over the past few years, there has been a rapid growth in the popularity and use of reduced-risk or modified-risk devices, also known as vaporizers, which have helped to help habitual smokers who want to quit traditional tobacco products such as cigarettes, cigars, cigarillos, and roll-ups. Various devices and systems are available that heat an aerosolizable substance to release a vapor for inhalation, rather than relying on burning tobacco.

A commonly available, reduced risk or modified risk device is a heated substrate aerosol generating device or heat-not-burn device. This type of device generates an aerosol or vapor by heating an aerosol substrate, typically comprising moistened tobacco or other suitable aerosolizable material, to a temperature typically in the range of 150°C to 300°C. Heating the aerosol substrate, but not burning or igniting it, releases an aerosol that includes the components sought by the user, but without the toxic, carcinogenic byproducts of combustion and ignition. Furthermore, aerosols produced by heating tobacco or other aerosolizable materials generally do not include burnt or bitter flavors produced by combustion and ignition that may be unpleasant to the user, so the base does not require sugars and other additives that are typically added to such materials to make the smoke and/or vapor taste better to the user.

Known aerosol generating devices typically include a heating chamber for receiving an aerosol generating substrate for consumption, a power source, and control circuitry for controlling the supply of power from the power source to the heating chamber. A known problem with such devices is that the unavoidable proximity of the heating chamber to the power source and control circuitry within the device can result in unnecessary heating of the power source and electronic circuitry. Such heating can damage such heat-sensitive electronic components and, in certain circumstances, can even be dangerous when components not designed to be heated become overheated, posing a risk of fire or explosion.

There is an increasing motivation to provide more compact, user-friendly aerosol generating devices, but reducing the size of such devices inevitably brings sensitive electronic components closer to heat sources and exacerbates the thermal management problems described above.

It is an object of the present invention to solve the above problems and to provide an aerosol generating device in which heat management is improved while still providing a compact, user-friendly device.

In a first aspect of the present invention, an aerosol generating device is provided, comprising: a housing; a tubular heating chamber, the tubular heating chamber being arranged to receive an aerosol matrix, the heating chamber being operable to heat the aerosol matrix to generate an aerosol; an elongated battery; a frame within the housing, the frame being arranged to hold the battery and the heating chamber within the frame, so that the heating chamber and the battery are aligned end-to-end within the housing, wherein the first end of the tubular heating chamber faces the first end of the battery; wherein the frame comprises a partition wall, the partition wall being arranged between the first end of the battery and the adjacent first end of the heating chamber. By providing a tubular heating chamber and an elongated battery aligned end-to-end within a housing, the surface area of the thermal interface between the heating chamber and the battery is significantly reduced, thereby reducing heat transfer to the battery. This further allows for a more compact, user-friendly layout, but without the increased heat transfer to the battery that is typically associated with reducing the size of the device.

The phrase "aligned end-to-end" is intended to be defined as substantially aligning the elongated battery with the tubular heating chamber along the length of the housing. The elongation axes of the tubular heating chamber and the battery may be axially aligned, or they may deviate from axial alignment, such as the elongation axes being displaced in a direction perpendicular to the elongation axes. The elongation axes may be equally angled relative to each other, although preferably the elongation axes are parallel.

Preferably, the first end of the tubular heating chamber is adjacent to the first end of the battery. In some examples, a gap separates the first end of the tubular heating chamber from the first end of the battery.

The tubular heating chamber preferably has an open end, the open end being arranged to receive the aerosol generating matrix, and the first end of the heating chamber is preferably the end opposite the open end. Preferably, the first end is closed. Preferably, the first end of the heating chamber faces the first end of the battery.

In the following disclosure, "heating chamber" may be used to refer to a composite article comprising an inner tubular heating chamber (or heating cup) and an outer insulating shell, wherein the tubular heating chamber is sleeved in the outer insulating shell. The tubular heating chamber preferably comprises a heating cup having an open end for receiving a consumable product and a closed end. Preferably, the film heater is wrapped around the outer surface of the heating cup, and the heating cup and the film heater are positioned within an insulating sleeve, preferably within a vacuum tube (or other form of insulating tube).

Preferably, the aerosol generating device includes a frame within the housing, the frame being arranged to retain one or both of the battery and the heating chamber within the frame. In this way, the tubular heating chamber and/or the heating chamber can be securely held in place within the housing of the device. In addition, providing a frame allows components to be held in precise, reproducible positions that aid in thermal management by precisely holding the components in positions that reduce heat transfer to sensitive electronic components (such as batteries).

The frame preferably retains the heating chamber and/or the battery so that they are not in contact with the housing of the device. Preferably, the frame is configured to provide a gap between a first end of the heating chamber and a first end of the battery.

The frame includes a partition wall disposed between the first end of the battery and the adjacent first end of the heating chamber. The partition wall preferably includes a thermal barrier positioned between the first end of the battery and the adjacent first end of the heating chamber. Preferably, the partition wall is a planar structural element extending across the interior cross-section of the housing to separate the first end of the battery from the adjacent first end of the heating chamber. The partition wall increases the restriction of heat transfer from the heating chamber to the battery.

Preferably, the partition wall comprises an insulating material. In some examples, the device further comprises an insulating layer disposed on the partition wall, such as aerogel or ceramic fiber or wool.

Preferably, the dividing wall extends across the interior cross-section of the housing to provide a thermal barrier between the heating chamber and the battery.

Preferably, the partition wall meets the inner surface of the housing, preferably at least around a majority of the circumference of the cross section. Preferably, the partition wall is arranged to provide a barrier or obstruction between the first end of the tubular heating chamber and the first end of the adjacent battery. This arrangement further helps to minimize heat exchange by convection between the heating chamber and the battery. In addition, in the event of a battery outgassing event, the passage of the jet of fluid from the battery towards the mouth end of the device is restricted. In particular, the velocity of the gas or liquid discharged from the battery in the direction of the mouth end of the device is reduced by the partition wall, and the safety of the device is thereby improved.

Preferably, the frame includes: a battery frame arranged to hold a battery; and a heating chamber frame arranged to hold a heating chamber; wherein a first end of the battery frame is connected against a first end of the heating chamber frame so that the heating chamber frame and the battery frame are aligned end-to-end within the housing. Preferably, the first end of the battery frame is configured to support a first end of the battery; and the first end of the heating chamber frame is configured to support a first end of the heating chamber. Providing a multi-component frame design improves ease of assembly because the heater element can be pre-assembled in the heater chamber frame and the battery can be pre-assembled in the battery frame before the two frames are connected together.

Preferably, the aerosol generating device includes a partition wall extending across the interior cross-section of the housing to provide a thermal barrier between the heating chamber and the battery; wherein the partition wall includes one or both of the first end of the battery frame and the first end of the heating chamber frame. Preferably, the partition wall includes the open and closed end of the battery frame and the (at least partially) closed end of the heater frame. In this way, the frame not only serves to support the heating chamber and the battery in place, but also inhibits heat transfer to the battery and increases safety in the event of battery degassing.

Preferably, the heating chamber frame is configured to hold the heating chamber such that a gap exists between the first end of the tubular heating chamber and the partition wall. Preferably, the heating chamber frame is configured such that a gap exists between the cylindrical outer surface of the heating chamber and the heating chamber frame. Such arrangements further reduce heat transfer to the battery by providing an air gap around the outer and lower surfaces of the heating chamber, thereby further enhancing thermal management within the device.

Preferably, the heating chamber frame has an L-shaped structure. Preferably, the heating chamber frame includes a base surface connected to the battery frame and a longitudinal portion extending along the length of the assembled heating chamber. The longitudinal portion is preferably substantially perpendicular to the base surface to form an L-shaped structure. Preferably, the longitudinal portion (vertically extending portion) is placed along the outer side of the heating chamber. This L-shaped arrangement facilitates assembly, ensures that the heating chamber can be accurately positioned and aligned relative to the battery, and further minimizes heat transfer between the heating chamber and the surrounding support structure.

Preferably, the heating chamber includes a heater cup, a thin film heater wrapped around an outer surface of the heater cup, and an insulation tube, wherein the heater cup is sleeved within the insulation tube. Preferably, the heater cup is supported within the insulation tube by one or more heating chamber supports configured to hold the heater cup and engage the surrounding insulation tube. Preferably, the one or more heating chamber supports are each positioned at one end of the heater cup. Preferably, the heating chamber supports are annular supports positioned around each end of the heater cup, and one or both heating chamber supports extend outside the insulation tube to engage the frame so that the heating chamber is held within the housing of the device by the heater frame. This arrangement facilitates assembly and reduces heat transfer from the heater cup to the frame.

Preferably, the battery frame includes: a closed first end extending across the interior cross-section of the housing; and one or more longitudinal struts running along the length of the battery, the one or more longitudinal struts being arranged to expose a majority of the side surface of the battery within the housing. In this way, the battery frame provides space around the battery to contain any fluid released during degassing.

Preferably, the aerosol generating device further comprises flexible electrical connectors arranged to bend around the portion of the wall positioned between the heating chamber and the battery to connect electronic components on either side of this portion of the partition wall. In particular, a PCB may be arranged between a first end of the battery frame and a first end of the heating chamber frame, wherein the partition wall comprises a closed first end of the battery frame and a (at least partially) closed first end of the heating chamber frame; and the PCB may be connected to a heater arranged to heat the heating chamber using a flexible connector that passes around the closed first end of the heater chamber frame. In this way, the number of through holes in the partition wall is minimized to further improve resistance to heat transfer through the partition wall.

Preferably, the aerosol generating device comprises a first PCB extending across a cross section of the housing and arranged between a first end of the battery and a first end of an adjacent heating chamber. In this way, the first PCB provides an additional thermal barrier between the heating chamber and the battery. Preferably, the first PCB is provided with a recess in the closed first end of the battery frame. Preferably, the first PCB is a power board comprising electronic components for controlling the supply of power from the battery to the heating chamber. Preferably, the battery and the heating chamber, in particular a heater arranged to heat the heating chamber, are connected to the first PCB.

More specifically, preferably, the aerosol generating device comprises a frame within the housing, the frame being arranged to retain the battery and the heating chamber within the frame, wherein the frame comprises a partition wall extending across an interior cross-section of the housing between a first end of the battery and an adjacent first end of the heating chamber; wherein the first PCB is received within a recessed portion of the partition wall.

Preferably, the aerosol generating device further comprises a second PCB extending along the length of the housing, wherein the first PCB is connected to the second PCB by a flexible connector, the flexible connector is bent around a portion of a partition wall, and the partition wall extends across the cross-section of the housing between the first end of the tubular heating chamber and the first end of the adjacent battery. In particular, preferably, the first PCB is disposed between the first end of the heating chamber frame and the first end of the battery frame, and the second PCB is connected along the length of the heating chamber frame, and the first PCB and the second PCB are connected by a flexible connector, which is arranged around the first end of the heating chamber frame.

Preferably, the device includes a battery frame arranged to hold a battery, and a heating chamber frame arranged to hold a heating chamber, wherein a first end of the battery frame is connected to a first end of the heating chamber frame; and the first end of the battery frame and the first end of the heating chamber frame are closed, and the first PCB is positioned between the open and closed end of the battery frame and the open and closed end of the heating chamber frame; so that the battery is thermally isolated from the heating chamber by a partition wall, which includes the open and closed end of the battery frame, the first PCB, and the open and closed end of the heating chamber frame.

Preferably, the aerosol generating device further comprises a heater arranged to heat the inner volume of the tubular heating chamber, wherein the heater is positioned outside the tubular heating chamber. Particularly preferably, the heater is a thin film heater wrapped around the outer surface of the heating chamber. In the case where the heater is located outside the heating chamber, the need for thermal management of the battery is more important.

In another aspect of the present invention, a method for assembling an aerosol generating device is provided, the method comprising: installing an elongated battery in a battery frame; connecting a first end of a heating chamber frame to a first end of the battery frame; installing a tubular heating chamber in the heating chamber frame to form a modular frame assembly; inserting a drop-down list box frame assembly into the elongated housing.

1:Aerosol generating device

10: Shell

11: First end

12: Base end

13: Open mouth

14: Sliding parts

15: The remaining part

20: Heating chamber

21: First end

22: Vacuum tube

23: Heating chamber support

24: Heating chamber support

30:Battery

31: First end

32: Second end

40: Heating chamber frame

41: First end

42: Screws

43: Vertical part

44: Screws

50:Battery frame

51: First end

52: End plate

53: Second end

54: Open mouth

55: Vertical support

57: protruding part

58: Recessed part

60:Framework

61: Partition wall

65:Mounting cap

70:Multi-part PCB

71:PCB

72: Flexible connector

73: Flexible connector

74: Motherboard

75:USB board

76:USB board

77: Motherboard PCB

80:Assembly fixture

81: First concave portion

82: Support surface

[Figure 1A] and [Figure 1B] are schematic diagrams of an aerosol generating device; [Figure 2A], [Figure 2B] and [Figure 2C] are schematic diagrams of a battery frame assembly; [Figure 3A] and [Figure 3B] are schematic diagrams showing the connection between a battery frame and a heating chamber frame; [Figure 4A] and [Figure 4B] are schematic diagrams of a modular frame subassembly; [Figure 5] is a schematic diagram of a multi-component PCB; [Figure 6A], [Figure 6B], [Figure 6C], [Figure 6D] and [Figure 6E] are schematic diagrams showing the assembly process of the aerosol generating device.

Figures 1A and 1B schematically illustrate an aerosol generating device 1 according to the present invention. The device 1 comprises a housing 10, a tubular heating chamber 20 arranged to receive an aerosol generating substrate, the heating chamber 20 being operable to heat the aerosol substrate to generate an aerosol. The aerosol generating device 1 further comprises an elongated battery 30, and the heating chamber 20 and the battery are aligned end-to-end in the housing 10, wherein the first end 21 of the tubular heating chamber 20 faces the first end 31 of the battery 30. Since the heating chamber 20 in the battery 30 is aligned end-to-end in the housing 10, the thermal interface between the heating chamber and the battery is reduced, thereby reducing heat transfer to the battery during use of the device 1. This arrangement also allows for a more compact aerosol generating device 1 in which the size of the housing 10 can be reduced, thereby taking advantage of the efficient use of space achieved by the end-to-end configuration of the tubular heating chamber 20 and the battery 30.

As shown in the external view of the device 1 in FIG. 1A and the cross-sectional view in FIG. 1B , the aerosol generating device 1 has an elongated housing 10 extending between a first mouth end 11 and an opposite base end 12. The housing 10 has an opening 13 positioned at the first end 11 of the housing 10 through which a consumable product can be introduced into a tubular heating chamber 20. Power can be selectively provided by a battery 30 using control circuitry within the device to heat the consumable product received in the chamber 20 to produce vapor that can be inhaled by the user.

In this example, the device 1 is arranged to receive an elongated consumable received in the chamber 20, while a portion of the consumable still protrudes from the opening 13 and serves as a nozzle through which the user can inhale the generated aerosol, although other examples are envisioned in which the consumable is fully contained within the device and the aerosol is inhaled through the nozzle. The device 1 further includes a slider 14 that can be used to selectively open and close the opening 13 at the first end 11 of the device 1.

During use, the heating chamber 20 is raised to an elevated temperature typically between 150°C and 300°C. Given that the internal components of the device 1 are in close proximity to one another, it is necessary to take steps to reduce heat transfer to the battery 30 and control circuitry. As described above, the end-to-end arrangement of the heating chamber 20 and the battery 30 provides a reduced thermal interface to minimize the transfer of high temperatures to the battery. In addition, the first end 21 of the heating chamber 20 generally has a reduced temperature compared to the rest of the heating chamber, which means that the lowest temperature portion of the heating chamber is located near the battery, which in turn reduces the amount of heat transferred to precision control components and the power supply 30 itself. Many other features of the aerosol generating device 1 according to the present invention further enhance thermal management within the device 1.

As shown in FIG. 1B , the aerosol generating device 1 further includes a frame 60 within the housing 10, which is arranged to hold the battery 30 and the tubular heating chamber 20. In particular, the frame 60 is configured to engage with the inner surface of the housing 10 within the device 1 to provide a secure support to which the heating chamber 20 and the battery 30 can be mounted. Thus, the frame 60 is used to securely hold the heating chamber 20 and the battery 30 in a desired position within the device 1, which minimizes heat transfer therebetween.

The frame 60 further includes a partition wall 61 extending across the interior volume of the housing 10 between the first end 21 of the heating chamber 20 and the first end 31 of the battery 30. Thus, the partition wall 61 serves as another thermal barrier to isolate the first end 31 of the battery 30 from the first end 21 of the heating chamber 20. The partition wall 61 preferably meets the interior surface of the housing 10 to provide a barrier between the heating chamber 20 and the battery 30. In addition to providing an improved thermal barrier, the barrier wall 61 also serves to separate the upper portion of the heating chamber and device 1 from the lower portion of the device containing the battery 30, thereby serving to restrict the passage of fluid released from the battery in the event of a battery degassing event.

In the example shown in the accompanying drawings, the frame 60 is a modular component including two sub-frames: a battery frame 50 and a heating chamber frame 40. The battery frame 50 and the heating chamber frame 40 are connected at corresponding longitudinal ends so that they are longitudinally aligned within the housing 10, wherein the first end 41 of the heating chamber frame 40 is connected to the first end 51 of the battery frame 50. This modular two-part frame design significantly improves the ease of assembly by allowing the internal components of the device 1 to be assembled in a modular manner, wherein the battery 30 and the battery frame 50 are assembled to the heating chamber 20 and the heating chamber frame 40, respectively, before being connected to the interface between the first end 41 of the heating chamber frame 40 and the first end 51 of the battery frame 50.

As shown in FIG. 1B , in this example, the partition wall 61 includes a portion 41 of the heating chamber frame 40 and a portion 51 of the battery frame 50. In particular, both the battery frame 50 and the heating chamber frame 40 include a portion at the respective first end 41, 51 that extends radially across the cross-section of the device to provide a partition between the heating chamber 20 and the battery 30. This arrangement can provide enhanced thermal protection for the battery by providing multiple insulation layers forming the barrier wall 60 between the heating chamber and the battery 30.

2A to 2C schematically illustrate a battery frame 50 in a particular example of the present invention. As can be seen in FIG. 2A , the battery frame 50 comprises a substantially open structure, providing a rigid enclosure that partially encloses the battery 30, while providing an open space that exposes portions of the outer surface of the battery 30. The battery frame 50 comprises a closed first end 51 that includes an end plate 52 that is arranged to extend across a cross section of the inner housing 10. The battery frame 50 comprises a second end 53 opposite the first end 51 that is used to support the second end 32 of the battery 30. The second end 53 of the battery frame comprises a support surface to support the second end 32 (i.e., the base end) of the battery, but also comprises a plurality of gaps 54 that provide an opening in the second end 53 of the battery frame 50. The battery frame 50 also includes a plurality of longitudinal struts 55 arranged to extend along the length of the battery connecting the first end 51 to the second end 53.

In the example shown in FIG. 2 , the battery frame 50 includes two longitudinal struts 55 positioned on opposite longitudinal edges of the battery, connecting the closing plate 52 at the first end 51 with the open support member at the second end 53. In this way, when the battery 30 is received in the battery frame 50 as shown in FIG. 2B , the end plate 52 at the first end 51 provides a barrier across the first end 31 of the battery 30, while the longitudinal struts 55 and the second end 53 (i.e., the base end) having the opening 54 mean that a portion of the outer surface of the battery is exposed. The structure is optimized to provide increased safety in the event of a degassing event of the battery 30. In particular, if the battery 30 ruptures or vents during degassing, the first end 51 reduces the speed of any jet fluid as it travels toward the mouth end 11. Instead, the fluid is allowed to fill the exposed area left by the longitudinal struts 55 and the openings 54 in the base of the battery frame 50, so that the fluid is directed downward through the openings 54 and out of a vent point provided in the bottom surface of the device's housing 10. Thus, the battery frame 50 structure provides increased thermal resistance to the battery 30 at the first end 51 adjacent to the heated chamber 20, but also provides space to contain any fluid released from the battery 30 and direct it out of the base 12 of the device 1.

As shown in FIG. 2C , in a cross-sectional view taken through the end plate 52 of the battery frame 50, the first end 51 formed by the end plate 52 radially extends to contact the inner surface S of the housing 10. Although in this example, the connection is not continuous all the way around the interface between the device housing 10 and the battery frame 50, the portion along the interface corresponding to the open portion 56 formed by the longitudinal support 55 is complete.

As shown in FIG. 2C , the battery frame 50 is shaped so as to be nested within the housing 10 so as to meet the inner surface, thereby allowing it to be securely supported within the housing 10 to provide stable support for the battery 30. The battery frame 50 also includes a protrusion 57 extending away from the second end 53 (i.e., the base end), which is arranged to engage with the inner surface of the base end 12 of the housing 10. The protrusion 57 means that the remaining portion 15 of the housing 10 is provided at the base end 12 of the device, and the remaining portion can accommodate the fluid released from the battery 30 during degassing. The protrusion 57 can also accommodate a charging port and related electronic control components to allow connection with a charging cable to charge the battery 30.

As shown in FIGS. 2A and 2B , the top end plate 52 of the closed first end 51 of the battery frame 50 includes a recessed portion 58. In particular, in the first end 51 of the battery frame 50 adjacent to the heating chamber 20 and the heating chamber frame 40, there is a recessed portion 58 arranged to receive the PCB 71, as shown in FIG. 3A . This allows both providing additional thermal shielding for the battery 30 and allowing both the battery 30 and the heating chamber 20 to be easily connected to the intervening PCB.

As described in more detail below, this example of a device 1 according to the present invention includes a multi-part PCB having multiple different PCB parts that are connected by flexible connectors to allow a compact layout, wherein the various parts of the PCB are connected in different orientations around multiple different internal components of the device 1.

The first PCB portion 71 received in the recessed portion 58 of the battery frame 50 is preferably a power board 71 which includes high power components associated with controlling the supply of current from the battery 30 to the heater of the heating chamber 20. Placing the power board 71 in this orientation (spanning the internal cross-section of the device 1 between the heating chamber and the battery 30) provides many advantages. It allows both the heating chamber 20 and the battery 30 to be connected to the power board 71 while minimizing the required connection length. Since these connections carry high currents between the battery 30 and the heater of the heating chamber 20, it is advantageous that these components are kept as short as possible to minimize losses. It also allows all high power components to be located on the same portion 71 of the PCB layout 70. In this way, the power panel 71 can be optimized to include such higher power components.

Another important advantage associated with the thermal management characteristics of the present invention is that the power plate 71 provides additional thermal shielding between the heating chamber 20 and the battery 30. In particular, the power plate 71 spans the partition wall 61 provided by the end 51 of the battery frame 50 so that they provide a multi-layer barrier to enhance the thermal shielding between the heating chamber 20 and the battery 30. The recessed portion 58 can be configured to receive and securely retain the power plate 71 (as shown in FIG. 3A) to allow connection between the power plate and the battery 30 and the heater component of the heating chamber 20.

3B shows how the heating chamber frame 40 is then connected to the battery frame 50, wherein the first end 41 of the heater frame is connected against the first end 51 of the adjacent battery frame 50. The heating chamber frame 40 has an L-shaped structure having a base surface forming a connection with the first end 41 of the battery frame and an extended vertical portion 43 extending in a lengthwise direction along the longitudinal length of the assembled heating chamber to retain the heating chamber within the housing 10. The first end 41 of the heating chamber frame 40 includes a substantially closed surface extending in a radial direction across the interior cross-section of the housing 10 of the device 1. In this way, as shown in FIG. 3B , the first end 51 of the battery frame 50, the PCB 71, and the first end 41 of the heating chamber frame 14 together provide a multi-layer partition wall 61 to isolate the battery 30 from the heating chamber 20. This provides a good thermal shield while making it easy to connect the power board 71, the battery, and the heating chamber.

In this example, the battery frame 50 is connected to the heating chamber frame 40 with screws 42, thereby providing a direct and strong means of assembling the frame components. This allows the modular construction of the aerosol generating device 1 to be further described below.

FIG4A shows an assembled heating chamber frame 40 holding a heating chamber 20, which is connected to a battery frame 50 holding a battery 30. As more clearly shown in the cross-sectional view of FIG4B, the heating chamber 20 includes a heating cup 21, a thin film heater 26 wrapped around the outer surface of the heater cup 21, and an insulating tube 22 (e.g., a vacuum insulation tube) in which the heating cup 21 is mounted. The heater cup 21 is supported within the vacuum tube 22 by two heating chamber supports 23, 24, which are configured to hold the ends of the heater cup 21 and engage the surrounding vacuum tube 22 to hold the heater cup 21 in place within the heating tube 22. The heating chamber supports 23, 24 are also configured to engage with the heating chamber frame 40 so that the heating chamber 20 is held in the housing 10 of the device 1 by the heating chamber frame 40.

As shown in FIG4B , the heating chamber 20 assembly includes a first heating chamber support 23 at the second open end 25 of the heating chamber and a second support 24 at the first end (closed end) 21 of the heating cup of the heating chamber 20. The heating chamber supports 23, 24 extend at least partially around the circumference of the heater cup 21 and slightly along the length of the heating chamber to clamp the heating chamber at one end and connect to the surrounding vacuum tube 22. In this example, the heating chamber support 24 at the base end includes a plurality of pillars 27 arranged around the circumference of the support 24, which extend along a portion of the length of the heating chamber to clamp it. In this way, the heating cup 21 is held only at the end of the heating chamber 20 to minimize heat transfer to surrounding components.

As shown in FIG. 4A , the heater supports 23 , 24 extend outside the insulation tube 22 of the heating chamber 20 and interface with the surrounding heating chamber frame 40. The heating chamber supports 23 , 24 are connected to the heating chamber frame 40 to hold the heating chamber 20 (including the heater cup and the surrounding vacuum chamber 22) within the heating frame. In this way, heat transfer is from the heater cup 23 to the heating chamber frame 40 and all the way to the battery 30. In particular, the heater supports 23 , 24 contact the coolest areas of the heater cup 23 only at the ends, and the contact between the heater chamber supports 23 , 24 and the frame is minimized to reduce heat transfer between these components.

The base heating chamber support 24 is configured to have a second open end 25 to block direct heat flow in the axial direction toward the battery 30, but only allow heat to be transferred out and transferred to the inner surface side of the housing 10, thereby further reducing heat transfer to the power source 30. The heating chamber frame 40 is also configured to provide a space between the base of the heating chamber 20 and the partition wall 61 composed of the ends 41, 51 of the heating chamber frame 40 and the battery frame 50. By configuring the heating chamber frame 40 in this way to provide an empty gap below the heating chamber, heat transfer to the partition wall 61 and all the way to the power source 30 is further reduced. The heating chamber frame 40 and the heater supports 23, 24 are also configured to leave a gap between the outer surface of the insulation tube 22 and the surrounding heating chamber frame 40, which helps to distribute any hot spots and further reduce heat transfer between the heater tube and the heating chamber frame 40.

The arrangement of the present invention also utilizes flexible connectors 72, 73 that connect various electronic components around portions of the partition wall 61. In particular, the flexible connector 72 connects the power board 71 enclosed between the heater chamber frame 40 and the battery frame 50 to the second PCB portion 74, wherein the flexible connector 72 bends around a portion of the end surface 41 of the heating chamber frame 40 that forms the partition wall 61. Similarly, the electrical connector connecting the thin film heater wrapped around the heater cup 23 to the power board 71 is also flexible so as to pass around and around the end 41 of the heating chamber frame 40. This reduces the number of openings that must be formed through portions of the partition wall 61, which will increase the degree of heat transfer through the partition wall 61. By instead bending the flexible connectors 72, 73 around the base 41 of the heater support, no additional openings are required to allow the connectors to pass, thereby improving thermal management within the device 1.

As described above, the aerosol generating device 1 according to the present invention uses a multi-part PCB 70 arrangement as shown in Figure 5. The multi-part PCB includes a power board 71, which is positioned between the first end of the heating chamber 20 and the first end 31 of the battery 30, and between the corresponding ends 41, 51 of the heating chamber frame 40 and the battery frame 50. In this example, the PCB arrangement further includes a motherboard or CPU board 74, a USB board 75, a user interface board 76, and a Hall sensor board 77, each of which is connected by a flexible connector. By providing a multi-part PCB board in this manner, multiple different PCB parts can be adapted to be arranged in a vertically opposed arrangement of the ends of the heating chamber 20 and the battery 30, and can be positioned folded around the multiple different components to allow a compact arrangement in which heat transfer is minimized. In particular, returning to Figure 4B, the power board is positioned as part of the partition wall between the ends 41, 51 of the frame components, with the flexible connector 72 connected to the vertically arranged motherboard PCB 77 running along the length of the heating chamber 20.

The flexible connector 72 is also used to connect a Hall sensor for sensing the position of the slider 14 and the user interface panel 76, which includes user interface buttons and an LED display. The end-to-end straight-to-vertical arrangement provided by the frame 60 together with the multi-part PCB arrangement 70 configured to bend around various components of the frame 60 provides a particularly compact arrangement while minimizing heat transfer between the heating chamber and the battery 30.

As shown in FIG. 4B , the recess 58 in the open end of the battery frame 50 receives at least a portion of the power board 71. In some examples of the present invention, further isolation can be provided around the PCB within the recess 58 to further increase the thermal barrier performance between the heating chamber 20 and the battery 30.

In addition to significantly reducing the degree of heat transfer between the heating chamber and the battery, the present invention, while providing a compact aerosol generating device 1, also greatly assists the assembly process by utilizing the end-to-end arrangement and frame structure. FIG. 6 illustrates how the modular frame assembly may be constructed using an assembly fixture 80.

First, the battery 30 is installed in the battery frame 50. Then the power board 71 of the PCB assembly 70 is positioned in the recess in the end plate 52 of the first end 51 of the battery frame 50 to hold the power board 71 in the recess 58. The USB board 75 is connected to the protrusion 57 at the base of the battery frame 50. The assembled battery frame 50 is then positioned in the assembly fixture 80, as shown in FIG6A. The contact surface of the power board 71 is provided with point contacts to prepare it for connection between the heater 26 and the battery 30. The battery connection wire is then soldered to the connector on the power board 71, as shown in FIG6A.

With the assembled battery frame held in the first recess 81 of the assembly fixture, the assembled heating chamber 20 is held on the support surface 82 of the assembly fixture. Once the connector is welded to the power plate 71, the heating chamber frame 40 is connected to the battery frame 50, as shown in FIG6B. In particular, there are corresponding mechanical connectors on the end surface 41 of the heating chamber frame 40 and on the opposite end surface 51 of the battery frame. The mechanical connection portion on the heating chamber frame 40 is connected to a corresponding feature such as a hook on the battery frame 50, and the heating chamber frame 40 is then connected together by screws 42 (as shown in FIG6C), and the battery frame 50 and the heating chamber frame 40 provide a stable spine for the internal components of the device to be securely mounted.

The main PCB board 74 is then bent and connected to the hook on the heating chamber frame 40 via the flexible connector 72. The main board 74 is fixed to the heating chamber frame 40 by the clamping ribs provided on the heating chamber frame 40. The USB board 76 and the Hall center plate 77 are then bent to the appropriate position and fixed to the heating chamber frame 40 by the flexible connector 72. As shown in FIG. 6D, the heating chamber 20 is then connected to the heating chamber frame 40. Finally, the mounting cap 65 is positioned on the top of the heater frame (as shown in FIG. 6E) and fixed to the heater frame with screws 44 (as shown in FIG. 6E). The mounting cap, while not required, serves to secure the heating chamber 20 in place within the heating chamber frame 40 so that the opening remains free to receive consumables through the opening 13 in the first end 11 of the device 1. The assembled frame with all internal components mounted as shown in FIG. 6E can then be nested within the outer device housing 10 to form the assembled product shown in FIG. 1A.

By providing an aerosol generating device 1 in which the tubular heating chamber 20 and the elongated battery are aligned end-to-end within the device, the thermal interface between the components is minimized, thereby reducing the amount of heat transferred from the heating chamber to the battery, while achieving a very compact and user-friendly layout. By additionally providing a frame 60 that secures the components within a surrounding housing, the assembly process is further significantly improved, while further reducing the amount of heat between the heating chamber 20 and the battery 30.

Definitions and alternative implementations

It will be appreciated from the above description that many of the features of the described embodiments perform independent functions with independent benefits. Thus, each of these independent features in the embodiments of the invention defined in the claims may be independently selected for inclusion or omission.

The term "heater" should be understood to mean any device for outputting heat energy sufficient to form an aerosol from an aerosol matrix. The transfer of heat energy from the heater to the aerosol matrix may be conductive, convective, radiative, or any combination thereof. As non-limiting examples, conductive heaters may directly contact and press the aerosol matrix, or the heaters may contact a separate component, such as a heating chamber, which itself causes heating of the aerosol matrix by conduction, convection, and/or radiation.

The heater may be electrically driven, driven by combustion, or driven in any other suitable manner. Electrically driven heaters may include resistive track elements (optionally including insulated packaging), inductive heating systems (e.g. including electromagnetics and high frequency oscillators), etc. The heater may be arranged around the outside of the aerosol matrix, may partially or completely penetrate into the aerosol matrix, or any combination of such methods. For example, in addition to the heater of the above-mentioned embodiment, the aerosol generating device may have a blade heater that extends into the aerosol matrix in the heating chamber.

Aerosol bases include, for example, tobacco in dried or smoked form, in some cases with additional ingredients for flavoring or producing a smoother or otherwise more pleasurable experience. In some examples, aerosol bases such as tobacco may be treated with a vaporizer. The vaporizer may improve the generation of vapor from the aerosol base. For example, the vaporizer may include a polyol (such as glycerol) or a glycol (such as propylene glycol). In some cases, the aerosol base may not contain tobacco or even nicotine, but may contain natural or artificially obtained ingredients for flavoring, volatility, improving smoothness, and/or providing other pleasurable effects. The aerosol base may be provided as a solid or paste-type material in the form of shredded, pelletized, powdered, granulated, stripped or sheeted forms, or combinations thereof as desired. Likewise, the aerosol base may be a liquid or a gel. In fact, some examples may include both a solid portion and a liquid/gel portion.

Therefore, the aerosol generating device 1 may also be referred to as a "heated tobacco device", a "heating but not igniting tobacco device", a "device for vaporizing tobacco products", etc., which is interpreted as a device suitable for achieving such effects. The features disclosed herein are also applicable to devices designed to vaporize any aerosol matrix.

The aerosol generating device may be arranged to receive the aerosol substrate in a pre-packaged substrate carrier. The substrate carrier may be broadly similar to a cigarette, having a tubular region in which the aerosol substrate is arranged in a suitable manner. Filters, vapor collection regions, cooling regions and other structures may also be included in some designs. An outer layer of paper or other flexible planar material such as foil may also be provided, for example to hold the aerosol substrate in place to further resemble a cigarette or the like. The substrate carrier may fit within the heating chamber or may be longer than the heating chamber so that the flap remains open while the aerosol generating device 1 is provided with the substrate carrier. In such an embodiment, the aerosol can be provided directly from a matrix carrier, which serves as a nozzle of the aerosol generating device.

As used herein, the term "aerosol" shall refer to a system of particles dispersed in air or a gas such as mist, dust or smoke. Thus, the term "aerosolized" shall refer to making and/or dispersing into an aerosol. Note that the meaning of aerosol/aerosolization is consistent with each of volatility, atomization and vaporization. For the avoidance of doubt, aerosol is used to consistently describe mist or droplets including atomized, volatilized or vaporized particles. Aerosol also encompasses mist or droplets including any combination of atomized, volatilized or vaporized particles.

1:Aerosol generating device

10: Shell

13: Open mouth

20: Heating chamber

21: First end

22: Vacuum tube

30:Battery

31: First end

40: Heating chamber frame

41: First end

50:Battery frame

51: First end

60:Framework

61: Partition wall

Claims (17)

An aerosol generating device comprises: a housing; a tubular heating chamber arranged to receive an aerosol matrix, the heating chamber being operable to heat the aerosol matrix to generate an aerosol; an elongated battery; a frame within the housing, the frame being arranged to hold the battery and the heating chamber within the frame, so that the heating chamber and the battery are aligned end-to-end within the housing, wherein the first end of the tubular heating chamber faces the first end of the battery; wherein the frame comprises a partition wall arranged between the first end of the battery and the adjacent first end of the heating chamber; wherein the partition wall extends across an inner cross-section of the housing to provide a thermal barrier between the heating chamber and the battery. An aerosol generating device as described in claim 1, wherein the partition wall meets the inner surface of the housing. An aerosol generating device as claimed in claim 1 or 2, wherein the frame comprises: a battery frame arranged to hold the battery; and a heating chamber frame arranged to hold the heating chamber; wherein the first end of the battery frame is connected against the first end of the heating chamber frame so that the heating chamber frame and the battery frame are aligned end-to-end in the housing. The aerosol generating device as described in claim 3 comprises: a partition wall extending across the inner cross section of the housing to provide a thermal barrier between the heating chamber and the battery; wherein the partition wall includes one or both of the first end of the battery frame and the first end of the heating chamber frame. An aerosol generating device as described in claim 4, wherein the heating chamber frame is configured to hold the heating chamber so that a gap exists between the first end of the tubular heating chamber and the partition wall. An aerosol generating device as described in claim 4, wherein the battery frame comprises: a closed first end extending across the inner cross section of the housing; and one or more longitudinal struts extending along the length of the battery, the one or more longitudinal struts being arranged so that most of the side surface of the battery is exposed within the housing. An aerosol generating device as described in claim 3, wherein the heating chamber frame has an L-shaped structure, the L-shaped structure includes a base surface and a longitudinal portion, the base surface is connected to the battery frame, and the longitudinal portion extends in the longitudinal direction of the heating chamber to keep the heating chamber in the housing. An aerosol generating device as described in claim 3, wherein the heating chamber includes a heating cup, a thin film heater wrapped around the outer surface of the heating cup, and an insulating tube. The aerosol generating device as described in claim 8 further comprises: one or more heating chamber supports arranged to hold the heater cup and extend outside the insulation tube of the heating chamber and connected to the heating chamber frame to hold the heating chamber within the frame. The aerosol generating device as claimed in claim 1 or 2 further comprises: flexible electrical connectors arranged to bend around the portion of the wall positioned between the heating chamber and the battery to connect electronic components on either side of the portion of the partition wall. The aerosol generating device as described in claim 3 comprises: a first PCB extending across the cross section of the housing and arranged between the first end of the battery and the first end of the adjacent heating chamber. An aerosol generating device as described in claim 11, wherein the first PCB is a power PCB connected to the heating chamber and the battery. An aerosol generating device as described in claim 11, wherein the first PCB is received in a recessed portion of the partition wall. The aerosol generating device as claimed in claim 13 further comprises: a second PCB extending along the length of the housing, wherein the first PCB is connected to the second PCB by a flexible connector, the flexible connector is bent around a portion of a partition wall, and the partition wall extends across the cross-section of the housing between the first end of the tubular heating chamber and the first end of the adjacent battery. An aerosol generating device as described in claim 11, wherein the first end of the battery frame and the first end of the heating chamber frame are closed, and the first PCB is positioned between the open and closed ends of the battery frame and the open and closed ends of the heating chamber frame; so that the battery and the heating chamber are thermally isolated by a partition wall, and the partition wall includes the closed end of the battery frame, the first PCB and the open and closed end of the heating chamber frame. An aerosol generating device as described in claim 15, wherein the battery frame includes a top end plate at a first end of the battery frame, the top end plate having a recessed portion arranged to receive the first PCB. The aerosol generating device as described in claim 1 or 2 further includes a heater, which is arranged to heat the internal volume of the tubular heating chamber, wherein the heater is positioned outside the tubular heating chamber.