WO2021170832A1

WO2021170832A1 - Aerosol generation device

Info

Publication number: WO2021170832A1
Application number: PCT/EP2021/054894
Authority: WO
Inventors: Ernst Hupkes
Original assignee: Jt International Sa
Priority date: 2020-02-28
Filing date: 2021-02-26
Publication date: 2021-09-02
Also published as: TW202139868A; CN115209752A; JP2023516948A; EP4110111A1

Abstract

An aerosol generating device (1) is described. The aerosol generating device includes: a housing (10); a tubular heating chamber (20) arranged to receive an aerosol substrate, the heating chamber operable to heat the aerosol substrate to generate an aerosol; an elongate battery (30); a frame (60) 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 (21) of the tubular heating chamber facing a first end (31) of the battery; wherein the frame comprises a dividing wall (61) 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 GENERATION DEVICE

The present disclosure relates to an aerosol generation device. The disclosure is particularly applicable to a portable aerosol generation device, which may be self- contained and low temperature. Such devices may heat, rather than burn, tobacco or other suitable aerosol substrate materials by conduction, convection, and/or radiation, to generate an aerosol for inhalation.

BACKGROUND

The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat aerosolisable substances to release a vapour for inhalation, rather than relying on burning of tobacco.

A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn device. Devices of this type generate an aerosol or vapour by heating an aerosol substrate that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range 150°C to 300°C. Heating an aerosol substrate, but not combusting or burning it, releases an aerosol that comprises the components sought by the user but not the toxic and carcinogenic by-products of combustion and burning. Furthermore, the aerosol produced by heating the tobacco or other aersolisable material does not typically comprise the burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and so the substrate does not therefore require the sugars and other additives that are typically added to such materials to make the smoke and/or vapour more palatable for the user.

Known aerosol generating devices typically include a heating chamber for receiving a consumable aerosol generating substrate, a power source and control circuitry for controlling the supply of power to the heating chamber from the power source. One known issues with such devices is that the inevitable proximity of the heating chamber to the power source and control circuitry within the device can cause unwanted heating of the power source and electronic circuitry. This heating may damage these heat-sensitive electronic components and, in some cases, this may even be dangerous with a risk of fire or explosion when components that are not designed to be heated become too hot.

There is also an increasing motivation to provide more compact, user friendly aerosol generating devices but reducing the size of such devices inevitably brings the delicate electronic components into closer proximity with the heat source and exacerbates the heat management issues described above.

It is an object of the present invention to address the above mentioned issues and provide an aerosol generating device in which heat management is improved whilst still providing a compact user friendly device.

SUMMARY

In a first aspect of the invention there is provided an aerosol generating device comprising: 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. The phrase “aligned end-on” is intended to define the fact that the elongate battery and tubular heating chamber are aligned substantially lengthwise within the housing. The elongate axes of the tubular heating chamber and battery may be axially aligned or they may be displaced from axial alignment, for example with the elongate axes displaced in a direction perpendicular to the elongate axes. The elongate axes may equally be angled relative to each other, although preferably the elongate 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 and the first end of the battery.

The tubular heating chamber preferably has an open end arranged to receive the aerosol generating substrate and the first end of the heating chamber is preferably the opposing end to 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 the “heating chamber” may be used to refer to the composite item comprising an inner tubular heating chamber (or heating cup) and an outer insulating housing within which the tubular heating chamber is sleeved. The tubular heating chamber preferably comprises a heating cup having an open end for receiving the consumable and a closed end. Preferably a thin film heater is wrapped around an outer surface of the heating cup and the heating cup and thin film heater are positioned within a heat insulating sleeve, preferably a vacuum tube (or other form of insulating tube).

Preferably the aerosol generating device comprises a frame within the housing, the frame arranged to hold one or both of the battery and heating chamber within the frame. In this way, the tubular heating chamber and/or heating chamber may be held securely in position within the housing of the device. Furthermore, the provision of a frame allows the components to be held in a precise, reproducible position which assists with heat management by allowing the components to be precisely held in a position which reduces heat transfer to sensitive electronic components, such as the battery.

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

The frame comprises a dividing wall arranged between the first end of the battery and the adjacent first end of the heating chamber. The dividing wall preferably comprises a thermal barrier positioned between the first end of the battery and the adjacent first end of the heating chamber. Preferably the dividing wall is a planar structural element which extends across the internal cross-section of the housing, dividing the first end of the battery and the adjacent first end of the heating chamber. The dividing wall provides an increased restriction to heat transfer from the heating chamber to the battery.

Preferably the dividing wall comprises a heat insulating material. In some examples the device further comprises a layer of insulation provided on the dividing wall, for example an aerogel or ceramic fiber or wool.

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

Preferably the dividing wall meets the internal surface of the housing, preferably around at least a majority of the circumference of the cross-section. Preferably the dividing wall is arranged to provide a barrier or hurdle between the first end of the tubular heating chamber and the adjacent first end of the battery. This arrangement further aides in minimising heat exchange by convection between the heating chamber and the battery. Furthermore, in the event of a battery degassing event, the passage of ejected fluid from the battery towards the mouth end of the device is restricted. In particular, the velocity of gas or liquids expelled from the battery is reduced by the dividing wall, in direction of the mouth end of the device and therefore improves the safety of the device.

Preferably the frame comprises a battery frame arranged to hold the battery; and a heating chamber frame arranged to hold the heating chamber; wherein a first end of the battery frame is connected against a first end of the heating chamber frame such that the heating chamber frame and battery frame are aligned end-on within the housing. Preferably a first end of the battery frame is configured to support the first end of the battery; and a first end of the heating chamber frame is configured to support the first end of the heating chamber. Providing a multi part frame design improves the ease of assembly since the heater components can be pre-assembled within 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 comprises a dividing wall extending across the internal cross section of the housing to provide a thermal barrier between the heating chamber and the battery; wherein the dividing wall comprises one or both of the first end of the battery frame and the first end of the heating chamber frame. Preferably the dividing wall comprises a closed end of the battery frame and a (at least partially) closed end of the heater frame. In this way the frame both acts to support the heating chamber and battery in position and also to inhibit thermal transfer to the battery and increase safety in the event of battery degassing.

Preferably the heating chamber frame is configured to hold the heating chamber such that there is a gap between the first end of the tubular heating chamber and the dividing wall. Preferably the heating chamber frame is configured such that there is a gap between the cylindrical outer surface of the heating chamber and the heating chamber frame. These provisions further enhance the thermal management within the device by providing an air gap around the outer and lower surfaces of the hating chamber to further reduce heat transfer to the battery.

Preferably the heating chamber frame has an L-shaped structure. Preferably the heating chamber frame comprises a base surface connected to the battery frame and a longitudinal portion extending lengthwise along the assembled heating chamber. The longitudinal portion is preferably substantially perpendicular to the base surface to form the L-shaped structure. Preferably the longitudinal portion (a vertically extending portion) lies along an outer side of the heating chamber. This L-shaped arrangement facilitates ease of assembly, ensuring the heating chamber can be accurately positioned, aligned relative to the battery, and further minimise heat transfer between the heating chamber and surrounding support structure. Preferably the heating chamber comprises a heater cup, a thin film heater wrapped around an outer surface of the heater cup and an insulating tube, wherein heater cup is sleeved within the insulating tube. Preferably the heater cup is supported within the insulating tube by one or more heating chamber supports configured to hold the heater cup and engage with the surrounding insulating tube. Preferably the one or more heating chamber supports are each positioned at an 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 out of the insulating tube to engage with the frame, such that the heating chamber is held by the heater frame within the housing of the device. This arrangement facilitates ease of assembly and reduces heat transfer from the heater cup to the frame. Preferably the battery frame comprises: a closed first end which extends across the internal cross section of the housing; and one or more longitudinal struts running along the length of the battery which are arranged to leave a majority of a side surface of the battery exposed within the housing. In this way, the battery frame provides space around the battery to accommodate any fluids released during degassing.

Preferably the aerosol generating device further comprises flexible electrical connections which are arranged to bend around a portion of the wall positioned between the heating chamber and battery to connect electrical components either side of the portion of the dividing wall. In particular, a PCB may be provided between the first end of the battery frame and the first end of the heating chamber frame, where the dividing 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 with a flexible connection which passes around the closed first end of the heater chamber frame. In this way, the number of through holes within the dividing wall are minimised to further improve the resistance to thermal transfer through the dividing wall. Preferably the aerosol generating device comprises a first PCB extending across the cross section of the housing and arranged between the first end of the battery and the adjacent first end of the 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 electrical components for controlling the provision 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 arranged to hold the battery and heating chamber within the frame, wherein the frame comprises a dividing wall which extends across the internal cross section of the housing between the first end of the battery and the adjacent first end of the heating chamber; wherein the first PCB is received within a recessed portion of the dividing wall.

Preferably the aerosol generating device further comprising a second PCB extending along the length of the housing wherein the first PCB is connected to the second PCB by a flexible connection which bends around a portion of a dividing wall, the dividing wall extending across the cross section of the housing between the first end of the tubular heating chamber and the adjacent first end of the battery. In particular, preferably the first PCB is provided between a first end of the heating chamber frame and a 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 second PCB are connected by a flexible connection which is arranged around the first end of the heating chamber frame.

Preferably the device comprises a battery frame arranged to hold the battery and a heating chamber frame arranged to hold the heating chamber, where 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 closed end of the battery frame and the closed end of the heating chamber frame; such that the battery is thermally insulated from the heating chamber by a dividing wall comprising the closed end of the battery frame, the first PCB and the closed end of the heating chamber frame.

Preferably the aerosol generating device further comprising a heater arranged to heat the internal volume of the tubular heating chamber, wherein the heater is positioned external to the tubular heating chamber. In particular preferably the heater is a thin film heater wrapped around an outer surface of the heating chamber. Where the heater is positioned external to the heating chamber, the need for heat management of the battery is more significant.

In a further aspect of the invention there is provided a method for assembling an aerosol generating device comprising mounting an elongate battery within a battery frame; connecting a first end of a heating chamber frame to a first end of the battery frame; mounting a tubular heating chamber within the heating chamber frame to form a combined frame assembly; inserting the combined frame assembly into an elongate housing.

BRIEF DESCRIPTION OF THE DRAWINGS

Figures 1 A and 1 B are schematic views of an aerosol generating device; Figures 2A, 2B and 2C are schematic views of a battery frame assembly; Figures 3A and 3B are schematic views illustrating the connection of the battery frame and heating chamber frame;

Figures 4A and 4B are schematic views of the combined frame sub- assembly;

Figure 5 is a schematic view of a multi-part PCB;

Figures 6A, 6B, 6C, 6D and 6E are schematic views illustrating an assembly process of the aerosol generating device.

DETAILED DESCRIPTION

Figures 1A and 1 B schematically illustrate an aerosol generating device 1 according to the present invention. The device 1 includes a housing 10, a tubular heating chamber 20 arranged to receive an aerosol generating substrate, the heating chamber 20 operable to heat the aerosol substrate to generate an aerosol. The aerosol generating device 1 further includes an elongate battery 30 and the heating chamber 20 and the battery are aligned end-on within the housing 10 with a first end 21 of the tubular heating chamber 20 facing a first end 31 of the battery 30. Since the heating chamber 20 in the battery 30 are aligned end-on within the housing 10, there is a reduced thermal interface between the heating chamber and the battery, which reduces thermal transfer to a battery during use of the device 1. This arrangement also allows for a more compact aerosol generating device 1 in which the dimensions of the housing 10 can be reduced, utilising the efficient use of space achieved with the end-on configuration of the tubular heating chamber 20 and the battery 30.

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

In this example, the device 1 is arranged to accept an elongate consumable which is received in the chamber 20 whilst a portion of the consumable remains protruding from the opening 13 and acts as a mouthpiece through which a user can inhale the generated aerosol, although other examples are envisaged where the consumable is contained fully within the device and the aerosol inhaled through a mouthpiece. The device 1 further comprises a slider 14 which 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 rises to an elevated temperature, typically between 150 and 300°C. Given that the internal components of the device 1 lie in close proximity to each other, it is necessary to take steps to reduce the thermal transfer to the battery 10 and control circuitry. As described above, the end-on arrangement of the heating chamber 20 and battery 30 provide a reduced thermal interface to minimise the conduction of the high temperatures to the battery. Furthermore, the first end 21 of the heating chamber 20 is generally of a reduced temperature in comparison to other portions of the heating chamber meaning that the lowest temperature portion of the heating chamber is positioned adjacent to the battery, which again reduces the amount of heat transferred to the delicate control components and to the power source 30 itself. A number of other features of the aerosol generating device 1 according to the present invention further enhance the heat management within the device 1.

As shown in Figure 1 B, 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 internal surfaces of the housing 10 within the device 1 to provide a secure support to which the heating chamber 20 and battery 30 can be mounted. The frame 60 therefore acts to securely hold the heating chamber 20 and the battery 30 in the required position within the device 1 which minimised heat transfer between them.

The frame 60 further includes a dividing wall 61 which extends across the internal volume of the housing 10 between the first end 21 of the heating chamber 20 and the first end 31 of the battery 30. The dividing wall 61 therefore acts as a further thermal barrier insulating the first end 31 of the battery 30 from the first end 21 of the heating chamber 20. The dividing wall 61 preferably meets the internal surface of the housing 10 to provide a barrier between the heating chamber 20 and the battery 30. As well as providing an improved thermal barrier, a barrier wall 61 also acts to separate the heating chamber and the upper portion of the device 1 from the lower portion of the device containing the battery 30 and thus act to restrict the passage of fluids released from the battery in the event of a battery degassing event.

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

As can be shown in Figure 1 B, in this example the dividing wall 61 comprises a portion 41 of the heating chamber frame 40 and the portion 51 of the battery frame 50. In particular, both the battery frame 50 and the heating chamber frame 40 comprise a portion at the respective first ends 41 , 51 which extends radially across the cross section of the device to provide a division between the heating chamber 20 and the battery 30. This arrangement can provide increased thermal protection to the battery by providing a number of thermally insulating layers forming the barrier wall 60 between the heating chamber and battery 30.

Figures 2Ato 2C schematically illustrate the battery frame 50 in a specific example of the invention. As can be seen in Figure 2A, the battery frame 50 comprises substantially open structure, providing a rigid surround which partially encloses the battery 30 within, whilst providing open spaces which leave portions of the outer surface of the battery 30 exposed. The battery frame 50 comprises a closed first end 51 comprising an end plate 52 which is arranged so as to extend across the cross section of the internal housing 10. The battery frame 50 comprises a second end 53 opposite the first end 51 which acts to support the second end 32 of the battery 30. The second end 53 of the battery frame comprises supporting surfaces to support the base end 32 of the battery but also a number of gaps 54 providing openings in the second end 53 of the battery frame 50. The battery frame 50 also includes a number of longitudinal struts 55 which are arranged to extend along the length of the battery connecting the first end 51 and the second end 53.

In the example shown in Figure 2, the battery frame 50 includes two longitudinal struts 55 positioned on opposing longitudinal edges of the battery connecting the closed plate 52 at the first end 51 and the open support of the second end 53. In this way, when the battery 30 is received within the battery frame 50 as shown in Figure 2B, the end plate 52 of the first end 51 provides a barrier across the first end 31 of the battery 30 whilst the longitudinal struts 55 and the base end 53 with the openings 54 mean that portions of the external surface of the battery are exposed. This structure is optimised to provide increased safety in the event of a degassing event of the battery 30. In particular, if the battery 30 were to rupture or vent during degassing the first end 51 reduces the velocity of any ejected fluids velocity as they travel towards the mouth end 11. Instead, the fluids are allowed to fill the exposed areas left by the longitudinal struts 55 and the openings 54 in the base of the battery frame 50 such that fluid is directed downwards through the openings 54 and out of a vent point provided in a bottom surface of the house 10 of the device. The battery frame 50 structure therefore provides increased thermal resistance to the battery 30 at the first end 51 adjacent to the heating chamber 20 but also provides space to accommodate any fluids released from the battery 30 and direct these out of the base 12 of the device 1.

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

As shown in Figure 2C the battery frame 50 is shaped so as to be sleeved within the housing 10 so as to meet the internal surfaces allowing it to be securely supported within the housing 10 to provide a robust support for the battery 30. The battery frame 50 also includes a protruding portion 57 extending away from the base end 53 which is arranged to engage the inner surface of the base end 12 of the housing 10. This protruding portion 57 means that a vacant portion 15 of the housing 10 is provided at the base end 12 of the device which can accommodate fluids released from the battery 30 during degassing. The protruding portion 57 can also accommodate the charging port and associated electronic control components to allow the connection of a charging cable in order to charge the battery 30. As shown in Figures 2A and 2B the top end plate 52 which provides the closed first end 51 of the battery frame 50 comprises a recessed portion 58. In particular, in the first end 51 of the battery frame 50 which is adjacent to the heating chamber 20 and the heating chamber frame 40, there is a recessed portion 58 which is arranged to receive a PCB 71 as shown in Figure 3A. This allows for both additional thermal shielding for the battery 30 and ease of connection of both the battery 30 and heating chamber 20 to the intervening PCB.

As described in more detail below, this example of the device 1 according to the present invention includes a multipart PCB with a number of different PCB parts which are connected by flex connections to allow a compact arrangement in which the various portions of the PCB are connected in different orientations around the various internal components of the device 1.

The first PCB portion 71 which is received in the recess portion 58 of the heater frame 50 is preferably a power board 71 comprising the high power components associated with the control of the provision of current from the battery 30 to the heater of the heating chamber 20. Providing the power board 71 in this orientation lying across the internal cross section of the device 1 between the heating chamber and battery 30 provides a number of advantages. It allows for the heating chamber 20 and battery 30 to both be connected to the power board 71 whilst minimising the length of connections required. Since these connections are carrying high current 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 minimise losses. It also allows all high power components to be provided on the same portion 71 of the PCB arrangement 70. In this way the power board 71 can be optimised for the inclusion of these higher power components.

A further important advantage associated with the heat management properties of the present invention is that the power board 71 provides additional thermal shielding between the heating chamber 20 and the battery 30. In particular, the power board 71 lies across the dividing wall 61 provided by the end 51 of the battery frame 50 such 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 may be configured to receive the power board 71 and hold it securely as shown in Figure 3A to allow for connection between the power board and the battery 30 and the heater component of the heating chamber 20.

Figure 3B shows how the heating chamber frame 40 is then connected to the battery frame 50, with the first end 41 of the heater frame connected against the adjacent first end 51 of the heater frame 50. The heating chamber frame 40 has an L shaped structure with the base surface forming the first end 41 connected to the battery frame and an extending vertical portion 43 which extends lengthwise up the longitudinal length of the assembled heating chamber to hold the heating chamber within the housing 10. The first end 41 of the heater frame 40 comprises a substantially closed surface extending in a radial direction across the internal cross section of the housing 10 of the device 1. In this way, as shown in Figure 3B, the first end 51 of the heater frame 50, the PCB 71 and the first end 41 of the heating chamber frame 14 together provide a multilayer dividing wall 61 shielding the battery 30 from the heating chamber 20. This provides good thermal shielding whilst allowing ease of connection between the power board 71 , the battery and the heating chamber.

In this example, the battery frame 50 and heating chamber frame 40 are connected with screws 42 providing a straightforward and sturdy means of assembling the frame assemblies. This allows for the modular construction of the aerosol generating device 1 described further below.

Figure 4A shows the assembled heater frame 40 holding the heating chamber 20 connected to the battery frame 50 holding the battery 30. As shown more clearly in the cross section view of Figure 4B, the heating chamber 20 comprises the heating cup 21 , a thin film heater 26 wrapped around the outer surface of the heater cup 21 and a heat insulation tube 22, for example a vacuum insulation tube, within 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 with the surrounding vacuum tube 22 to hold the heater cup 21 in position within the heating tube 22. The heating chamber supports 23, 24 are also configured to engage with the heater frame 40 such that the heating chamber 20 is held by the heater frame 40 within the housing 10 of the device 1.

As shown in Figure 4B 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 circumference of the heater cup 21 and extend slightly along the length of the heating chamber to grip 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 comprises a plurality of struts 27, disposed around the circumference of the support 24, which extend along a portion of the length of the heating chamber to grip it. In this way, the heating cup 21 is only held at the end points of the heating chamber 20 minimising the thermal transfer to the surrounding components.

As shown in Figure 4A the heater supports 23, 24 extend out of the insulating tube 22 of the heating chamber 20 and interface with the surrounding heating chamber support frame 40. The heating chamber supports 23, 24 connect into the heating frame 40 to hold the heating chamber 20 (comprising the heater cup and surrounding vacuum chamber 22) within the heating frame. In this way, the thermal transfer from the heater cup 23 to the heater frame 40 and onwards to the battery 30. In particular, the heater supports 23, 24 are only in contact with the coolest regions of the heater cup 23 at the ends and the contact between the heater chamber supports 23, 24 and the frame is minimised to reduce the thermal transfer between these components.

The base heating chamber support 24 is configured so as to have a horizontal side opening 25 to block direct heat flow in an axial direction towards the battery 30 but instead only allow heat to pass out and towards the side of the internal surface of the housing 20, reducing heat transfer to the power source 30 further. The heater frame 40 is also configured to provide space between the base of the heating chamber 20 and the dividing wall 61 made up of the ends 41 , 51 of the heater chamber support 40 and the battery support 50. By configuring the heater frame 40 in this way to provide empty void under the heating chamber, the heat transfer to the dividing wall 61 and onwards to the power source 30 is further reduced. The heating chamber frame 40 and heater supports 23, 24 are also configured to leave a gap between the outer surface of the insulation tube 22 and the surrounding heater frame 40 which aids in distributing any hot spots and further reducing thermal transfer between the heater tube and the surrounding frame 40.

The arrangement of the present invention also makes use of flexible connections 72, 73 which connect various electronic components around portions of the dividing wall 61. In particular, a flex connection 72 connects the power board 71 , enclosed between the heater frame 40 and the battery frame 50, to a second PCB portion 74, wherein the flexible connection 72 bends around a portion of the end surface 41 of the heat support 40 forming the dividing wall 61. Similarly, the electrical connections connecting the thin film heater wrapped around the heater cup 23 to the power board 71 are also flexible, so as to pass out and round the end portion 41 of the heater frame 40. This reduces the number of openings that must be made through portions of the dividing wall 61 which would increase the degree of thermal transfer through the dividing wall 61. By instead bending the connections 72, 73 around the base portion 41 of the heater support, no further openings are required to allow for the connections to pass through, thus improving thermal management within the device 1.

As described above the aerosol generating device 1 according to the present invention uses a multipart PCB 70 arrangement as shown in Figure 5. The multipart PCB includes the power board 71 which is positioned between the first end of the heating chamber 20 and the first end 31 of the battery 30, between the corresponding end portions 41 , 51 of the heater frame 40 and battery frame 50. In this example, the PCB arrangement further comprises a main or CPU board 74, a USB board 75, a user interface board 76 and a hall sensor board 77, each of which are connected by flex connectors. By providing a multipart PCB board in this way, the various PCB portions may be adapted to the vertical end-on arrangement of the heating chamber 20 and battery 30 and may be positioned folded around these various components to allow for the compact arrangement in which heat transfer is minimised. In particular, returning to Figure 4B, the power board is positioned as part of the dividing wall between the end portions 41, 51 of the frame components with the flex connector 72 connecting to the vertically arranged main board PCB 77 running along the length of the heating chamber 20.

Flex connections 72 are also used to connect to a hall sensor used to sense the position of the slider 14 and a user interface board 76, comprising a user interface button and LED display. The end-on vertical arrangement provided by the frame 60 together with the multipart PCB arrangement 70 which is configured to bend around the various components of the frame 60 provides a particularly compact arrangement whilst minimising the thermal transfer between the heating chamber and battery 30.

As shown in Figure 4B the recess 58 in the closed end of the battery frame 50 receives at least a portion of the power board 71. In some examples of the invention further insulation may be provided within this recess 58 around the PCB to further increase the thermal barrier properties between the heating chamber 20 and the battery 30.

As well as significantly reducing the degree of thermal transfer between the heating chamber and battery, whilst providing a compact aerosol generating device 1 , the present invention utilising an end-on arrangement and frame structure also significantly assists with the assembly process. Figure 6 illustrates how an assembly jig 80 can be used to construct the modular frame assembly.

Firstly, the battery 30 is mounted within the battery frame 50. The power board 71 of the PCB assembly 70 is then positioned within the recess within the end plate 52 of the first end 51 of the battery frame 50 such that the power board 71 is held within the recess 58. The USB board 75 is connected within the protruding portion 57 at the base of the battery frame 50. The assembled battery frame 50 is then positioned in the assembly jig 80 as shown in Figure 6A. The contact surfaces of the power board 71 are provided with point contacts to prepare them for connection of the heater 26 and battery 30. The battery connection wires are then soldered to the connections on the power board 71 as shown in Figure 6A.

With the assembled battery frame held in a first recess 81 of the assembly jig, the assembled heating chamber 20 is held on a supporting surface 82 of the assembly jig. Once the connections are soldered to the power board 71 the heater frame 40 is then connected to the battery frame 50 as shown in Figure 6B. In particular, there are corresponding mechanical connections on the end surface 41 of the heater frame 40 and on the opposing end surface 51 of the battery frame. Mechanical connection potion on the heater frame 40 are connected into corresponding features, such as hooks, on the battery frame 50 and the heater frame 40 is then connected by screws 42, shown in Figure 6C together the battery frame 50 and heater frame 40 provide a robust spine to the internal components of the device to which they can be mounted securely.

The main PCB board 74 is then bent via the flexible connections 72 and connected into hooks on the heater frame 40. The main board 74 is secured to the heater frame 40 with clamping ribs provided on the heater frame 40. The USB board 76 and hall centre board 77 are then bent into position by the flexible connections 72 and secured to the heater frame 40. The heating chamber 20 is then connected within the heating frame 40 as shown in Figure 6D. Finally a mounting cap 65 is positioned on top of the heater frame as shown in Figure 6E and fixed to the heater frame using screws 43 as shown in Figure 6E. The mounting cap, although not essential, acts to secure the heating chamber 20 in position within the heating chamber frame 40 allowing the opening to remain free to accept a consumable through the opening 13 in the first end 11 of the device 1. The assembled frame which mounts all of the internal components as shown in Figure 6E can then be sleeved within the outer device housing 10 to form the assembled product shown in Figure 1A. By providing an aerosol generating device 1 in which the tubular heating chamber 20 and the elongate battery are aligned end-on within the device the thermal interface between the components is minimised thus reducing the amount of heat transferred from the heating chamber to the battery whilst achieving a very compact and user friendly arrangement. By providing a frame 60 in addition which holds these components in place within the surrounding housing, the assembly process is further significantly improved whilst further reducing the amount of heat flow between the heating chamber 20 and battery 30.

Definitions and Alternative Embodiments

It will be appreciated from the description above that many features of the described embodiment perform independent functions with independent benefits. Therefore the inclusion or omission of each of these independent features from embodiments of the invention defined in the claims can be independently chosen.

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

Heaters may be electrically powered, powered by combustion, or by any other suitable means. Electrically powered heaters may include resistive track elements (optionally including insulating packaging), induction heating systems (e.g. including an electromagnet and high frequency oscillator), etc. The heater may be arranged around the outside of the aerosol substrate, it may penetrate partway or fully into the aerosol substrate, or any combination of these. For example, instead of the heater of the above-described embodiment, an aerosol generation device may have a blade-type heater that extends into an aerosol substrate in the heating chamber.

Aerosol substrate includes tobacco, for example in dried or cured form, in some cases with additional ingredients for flavouring or producing a smoother or otherwise more pleasurable experience. In some examples, the aerosol substrate such as tobacco may be treated with a vaporising agent. The vaporising agent may improve the generation of vapour from the aerosol substrate. The vaporising agent may include, for example, a polyol such as glycerol, or a glycol such as propylene glycol. In some cases, the aerosol substrate may contain no tobacco, or even no nicotine, but instead may contain naturally or artificially derived ingredients for flavouring, volatilisation, improving smoothness, and/or providing other pleasurable effects. The aerosol substrate may be provided as a solid or paste type material in shredded, pelletised, powdered, granulated, strip or sheet form, optionally a combination of these. Equally, the aerosol substrate may be a liquid or gel. Indeed, some examples may include both solid and liquid/gel parts.

Consequently, the aerosol generating device 1 could equally be referred to as a “heated tobacco device”, a “heat-not-burn tobacco device”, a “device for vaporising tobacco products”, and the like, with this being interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices which are designed to vaporise any aerosol substrate.

The aerosol generation device may be arranged to receive the aerosol substrate in a pre-packaged substrate carrier. The substrate carrier may broadly resemble a cigarette, having a tubular region with an aerosol substrate arranged in a suitable manner. Filters, vapour collection regions, cooling regions, and other structure 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 the resemblance of a cigarette, etc. The substrate carrier may fit within the heating chamber or may be longer than the heating chamber such that the lid remains open while the aerosol generation device 1 is provided with the substrate carrier. In such embodiments, the aerosol may be provided directly from the substrate carrier which acts as a mouthpiece for the aerosol generation device. As used herein, the term “aerosol” shall mean a system of particles dispersed in the air or in a gas, such as mist, fog, or smoke. Accordingly the term “aerosolise” means to make into an aerosol and/or to disperse as an aerosol. Note that the meaning of aerosol/aerosolise is consistent with each of volatilise, atomise and vaporise. For the avoidance of doubt, aerosol is used to consistently describe mists or droplets comprising atomised, volatilised or vaporised particles. Aerosol also includes mists or droplets comprising any combination of atomised, volatilised or vaporised particles.

Claims

1. An aerosol generating device comprising: 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

2. The aerosol generating device of claim 1 wherein the dividing wall extends across the internal cross section of the housing to provide a thermal barrier between the heating chamber and the battery.

3. The aerosol generating device of claim 2 wherein the dividing wall meets the internal surface of the housing.

4. The aerosol generating device of any of claims 1 to 3 wherein the frame comprises: a battery frame arranged to hold the battery; and a heating chamber frame arranged to hold the heating chamber; wherein a first end of the battery frame is connected against a first end of the heating chamber frame such that the heating chamber frame and battery frame are aligned end-on within the housing.

5. The aerosol generating device of claim 4 comprising a dividing wall extending across the internal cross section of the housing to provide a thermal barrier between the heating chamber and the battery; wherein the dividing wall comprises one or both of the first end of the battery frame and the first end of the heating chamber frame.

6. The aerosol generating device of claim 5 wherein the heating chamber frame is configured to hold the heating chamber such that there is a gap between the first end of the tubular heating chamber and the dividing wall.

7. The aerosol generating device of claim 5 or 6 wherein the battery frame comprises: a closed first end which extends across the internal cross section of the housing; and one or more longitudinal struts running along the length of the battery which are arranged to leave a majority of a side surface of the battery exposed within the housing.

8. The aerosol generating device of claims 4 to 7 wherein the heating chamber frame has an L shaped structure comprising a base surface connected to the battery frame and a longitudinal portion which extends lengthwise up the longitudinal length of the assembled heating chamber to hold the heating chamber within the housing.

9. The aerosol generating device of claims 4 to 8 wherein the heating chamber comprises a heating cup, a thin film heater wrapped around the outer surface of the heating cup and a heat insulation tube.

10. The aerosol generating device of claim 9 further comprising one or more heating chamber supports, the heating chamber supports arranged to hold the heater cup and extend out of the insulating tube of the heating chamber and connect into the heating chamber frame to hold the heating chamber within the frame.

11. The aerosol generating device of any preceding claim further comprising: flexible electrical connections which are arranged to bend around a portion of the wall positioned between the heating chamber and battery to connect electrical components either side of the portion of the dividing wall.

12. The aerosol generating device of any preceding claim comprising a first PCB extending across the cross section of the housing and arranged between the first end of the battery and the adjacent first end of the heating chamber.

13. The aerosol generating device of claim 12 wherein the first PCB is a power PCB to which the heating chamber and the battery are connected.

14. The aerosol generating device of claim 12 or 13 wherein the first PCB is received within a recessed portion of the dividing wall.

15. The aerosol generating device of claim 14 further comprising a second PCB extending along the length of the housing wherein the first PCB is connected to the second PCB by a flexible connection which bends around a portion of a dividing wall, the dividing wall extending across the cross section of the housing between the first end of the tubular heating chamber and the adjacent first end of the battery.

16. The aerosol generating device of any of claims 12 to 15 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 closed end of the battery frame and the closed end of the heating chamber frame; such that the battery is thermally insulated from the heating chamber by a dividing wall comprising the closed end of the battery frame, the first PCB and the closed end of the heating chamber frame.

17. The aerosol generating device of claim 16 wherein the battery frame comprises a top end plate at the first end of the battery frame having a recessed portion arranged to receive the first PCB.

18. The aerosol generating device of any preceding claim further comprising a heater arranged to heat the internal volume of the tubular heating chamber, wherein the heater is positioned external to the tubular heating chamber.