WO2022207536A1 - Heating assembly for an aerosol generating device - Google Patents

Heating assembly for an aerosol generating device Download PDF

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Publication number
WO2022207536A1
WO2022207536A1 PCT/EP2022/058069 EP2022058069W WO2022207536A1 WO 2022207536 A1 WO2022207536 A1 WO 2022207536A1 EP 2022058069 W EP2022058069 W EP 2022058069W WO 2022207536 A1 WO2022207536 A1 WO 2022207536A1
Authority
WO
WIPO (PCT)
Prior art keywords
electrically insulating
heating
heating assembly
insulating backing
backing film
Prior art date
Application number
PCT/EP2022/058069
Other languages
French (fr)
Inventor
Alec WRIGHT
Original Assignee
Jt International Sa
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jt International Sa filed Critical Jt International Sa
Publication of WO2022207536A1 publication Critical patent/WO2022207536A1/en

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/54—Heating elements having the shape of rods or tubes flexible
    • H05B3/58—Heating hoses; Heating collars
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46—Shape or structure of electric heating means
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/20—Devices using solid inhalable precursors
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/013—Heaters using resistive films or coatings
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/021—Heaters specially adapted for heating liquids
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/022—Heaters specially adapted for heating gaseous material

Definitions

  • the present invention relates to a heating assembly for an aerosol generating 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.
  • reduced-risk or modified-risk devices also known as vaporisers
  • vaporisers have grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit using traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco.
  • Various devices and systems are available that heat or warm aerosolisable substances as opposed to burning tobacco in conventional tobacco products.
  • a commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn (HNB) device.
  • Devices of this type generate an aerosol or vapour by heating an aerosol substrate (i.e. consumable) that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range of 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 undesirable by-products of combustion.
  • the aerosol produced by heating the tobacco or other aerosolisable material does not typically comprise the burnt or bitter taste that may result from combustion that can be unpleasant for the user.
  • a heating assembly for an aerosol generating device comprising: a tubular heating chamber comprising an opening for receiving an aerosol substrate; and a thin film heater that is wrapped around an outer surface of the heating chamber and configured to supply heat to the heating chamber, wherein the thin film heater comprises a flexible heating element and a first electrically insulating backing film comprising mica, wherein the flexible heating element is adhesively coupled to a first side of the first electrically insulating backing film and an opposing second side of the first electrically insulating backing film contacts the outer surface of the heating chamber.
  • the arrangement and composition of the first electrically insulating backing film prevents a short circuit occurring between the metal heating chamber and the heating element, whilst allowing improved heat transfer from the heating element to the aerosol substrate received within the heating chamber.
  • the use of mica as the first electrically insulating backing film provides superior thermal conductivity compared to polyimide films, which are often provided between the heating element and the heating chamber in typical aerosol generating devices.
  • mica has a high electrical breakdown voltage and improved electrical insulating properties compared to polyimide.
  • the thickness of the first electrically insulating backing film to be reduced, thereby further optimising the thermal energy transfer from the heating element to the heating chamber and reducing the bulkiness of the heating assembly.
  • the interfacial heat transfer between the mica and the heating element is improved.
  • the ease of manufacturing of the heating assembly and the reliability of the heating assembly is also improved.
  • the first electrically insulating backing film comprises at least one of: muscovite; and phlogopite.
  • the mica group of sheet silicate (phyllosilicate) minerals includes muscovite and phlogopite. Both such materials provide excellent electrical insulation and high thermal conductivity.
  • muscovite exhibits a dielectric strength of 508 V/mm, a thermal conductivity of 0.54 W/mK, and is able to resist temperatures up to 530°C.
  • muscovite can be produced as a thin film, thereby simplifying the manufacturing process of the heating assembly.
  • the first electrically insulating backing film comprises a mica paper, e.g. a sheet of miniature flakes of musocovite and/or phlogopite.
  • the mica paper provides homogenous properties and the first electrically insulating backing film has improved flexibility and is less susceptible to delamination.
  • the mica paper is impregnated with a binder.
  • the binder comprises: resin; woven cloth or web; or non-woven cloth or web.
  • the binder comprises resin, and the resin comprises: silicone resin, polyester; polytetrafluoroethylene, PTFE; or polyether ether ketone (PEEK).
  • the binder comprises non-woven cloth or web, and the non-woven cloth or web comprises at least one of: glass; and polyester.
  • the first electrically insulating backing film has a thickness of less than 120 pm. More preferably, the first electrically insulating backing film has a thickness of between 90 pm and 120 pm.
  • the thickness of the first electrically insulating film may be 80 pm, 90 pm, 100 pm, 105 pm, 100 pm, 110 pm or 120 pm.
  • the first electrically insulating backing film is a tape of phlogopite mica having a tensile strength of more than 80 N/cm (according to ISO 527) and a thickness between 80 (+/-1.5) pm and 120 (+/-1.5) pm, more preferably between 80 (+/-1.5) pm and 100 (+/-1.5) pm, most preferably of 80 (+/-1.5) pm.
  • the tape has preferably phlogopite mica content between 70 and 106 g/m 2 more preferably between 70 and 80 g/m 2 , a glass content between 21 and 34 g/m 2 , more preferably 21 to 25 g/m 2 and a binder content between 9 and 21 g/m 2 , more preferably 9 and 15 g/m 2 .
  • the first electrically insulating backing film remains flexible while exhibiting high mechanical properties and provides higher electrical insulating properties.
  • the phlogopite mica tape has a dielectric strength of more than 1.1 KV/layer (according to IEC 371-2).
  • the dielectric strength remains constant in the heating range of the device (i.e., up to 350°C) thereby ensuring high electrical insulation properties.
  • the tape of such composition is sufficiently flexible to be easily rolled on the tubular heating element of small diameter.
  • the thin film heater is wrapped around an outer surface of the heating chamber having a diameter of less than 10 mm, more preferably comprised between 6.5 mm and 9 mm, most preferably 7 and 8.5 mm.
  • the thin film heater comprises a second electrically insulating backing film disposed on an opposing side of the heating element to the first electrically insulating backing film such that the heating element is at least partially enclosed between the first electrically insulating backing film and the second electrically insulating backing film.
  • the second electrically insulating backing film electrically insulating other components of the aerosol generating device from the heating element.
  • the second electrically insulating backing insulating film comprises mica.
  • the second electrically insulating backing film comprises at least one of: muscovite; and phlogopite.
  • the second electrically insulating backing film comprises a mica paper.
  • the mica paper is impregnated with a binder.
  • the binder comprises: resin; woven cloth or web; or non- woven cloth or web.
  • the binder comprises resin, and the resin comprises: polyester; polytetrafluoroethylene, PTFE; or polyether ether ketone (PEEK).
  • the binder comprises non-woven cloth or web, and the non-woven cloth or web comprises at least one of: glass; and polyester.
  • the second electrically insulating backing film has a thickness of less than 120 pm. More preferably, the second electrically insulating backing film has a thickness of between 90 pm and 120 pm.
  • the second electrically insulating backing film is a tape of phlogopite having a tensile strength of more than 80 N/cm (according to ISO 527) and a thickness between 80 (+/-1.5) pm and 120 (+/-1.5) pm, more preferably between 80 (+/-1.5) pm and 100 (+/-1.5) pm, most preferably of 80 (+/-1.5) pm.
  • the phlogopite tape has shown higher flexibility than muscovite. Muscovite is also more difficult to roll around a small-diameter tube and is more likely to experience cracking in comparison to phlogopite.
  • the tape has preferably phlogopite mica content between 70 and 106 g/m 2 more preferably between 70 and 80 g/m 2 , a glass content between 21 and 34 g/m 2 , more preferably 21 to 25 g/m 2 and a binder content between 9 and 21 g/m 2 , more preferably 9 and 15 g/m 2 .
  • the thickness is preferably of maximum 100 (+/-1.5), preferably of about 80 (+/-1.5) pm. With such composition and thickness, the second electrically insulating backing film remains flexible to be easily formed into a tubular shape while exhibiting high mechanical properties and providing high electrical insulating properties.
  • the tape of such composition is sufficiently flexible to be easily rolled on the tubular heating element of diameter less than 10 mm, preferably of about 7 to 8.5 mm. More preferably, the phlogopite mica tape has a dielectric strength of more than 1.1 KV/layer (according to I EC 371-2). The dielectric strength remains constant in the heating range of the device (i.e. , up to 350°C or slightly more) thereby ensuring high electrical insulation properties within the full operation heating range of the aerosol generation device.
  • the flexible heating element comprises a metal resistive track.
  • the metal resistive track is a chemically etched metal resistive track.
  • the flexible heating element is adhesively coupled to the first side of the first electrically insulating backing film using a silicon-based adhesive.
  • the heating assembly further comprises: a heat shrink film that is wrapped around the thin film heater to secure the thin film heater to the heating chamber.
  • a heat shrink film that is wrapped around the thin film heater to secure the thin film heater to the heating chamber.
  • the heat shrink film comprises: polyimide; or polyether ether ketone (PEEK).
  • PEEK polyether ether ketone
  • the outer surface of the heating chamber is a circumferential outer surface of the heating chamber.
  • an aerosol generating device comprising a heating assembly according to the first aspect.
  • a thin film heater comprising a flexible heating element and a first electrically insulating backing film comprising mica, preferably muscovite, wherein the flexible heating element is supported on a first side of the first electrically insulating backing film.
  • the flexible heating element is preferably adhesively coupled to the first side of the first electrically insulating backing film.
  • the thin film heater may comprise any combination of the features of the thin film heater described in relation to the first and second aspect of the invention. In this way a general purpose thin film heater is provided which utilises the improved thermal conductivity of the mica film.
  • a heater comprising a heating chamber and a thin film heater according to the third aspect of the invention provided against a surface of the heating chamber.
  • Figure 1 is an exemplary aerosol generating device according to an embodiment of the invention
  • Figure 2 is a perspective view of a heating assembly comprising a thin film heater wrapped around a heating chamber according to an embodiment of the invention
  • Figure 3 is a schematic cross-sectional view of the heating assembly of Figure 2 further comprising a second electrically insulating backing film and a heat shrink film;
  • Figure 4 is schematic view of the thin film heater in a flattened arrangement according to an embodiment of the invention.
  • FIG. 1 illustrates an aerosol generating device 100 according to an embodiment of the invention.
  • the aerosol generating device 100 is illustrated in an assembled configuration with the internal components visible.
  • the aerosol generating device 100 is a heat-not-burn device, which may also be referred to as a tobacco-vapour device, and comprises a heating assembly 200 configured to receive an aerosol substrate such as a rod of aerosol generating material, e.g. tobacco.
  • the heating assembly 200 is operable to heat, but not burn, the rod of aerosol generating material to produce a vapour or aerosol for inhalation by a user.
  • the aerosol generating device 100 depicted in Figure 1 is simply an exemplary aerosol generating device according to the invention.
  • FIG. 2 shows a perspective view of a heating assembly 200 according to an embodiment of the invention.
  • Figure 3 shows a cross-sectional schematic view of the heating assembly 200.
  • the heating assembly 200 comprises a heating chamber 202, also referred to as a thermally conductive shell, configured to hold an aerosol substrate, also referred to as a consumable, therein.
  • the heating chamber 202 defines a cylindrical cavity in which a rod of aerosol substrate may be positioned.
  • the heating chamber 202 is tubular, e.g.
  • the user may insert the aerosol substrate through the opening 204 in the heating chamber 202 such that the aerosol substrate is positioned within the heating chamber 202 and interfaces with an inner surface 201 of the heating chamber 202.
  • the length of the heating chamber 202 may be configured such that a portion of the aerosol substrate protrudes through the opening 204 in the heating chamber 202, i.e. out of the heating assembly 200, and can be received in the mouth of the user.
  • the heating chamber 202 comprises, and preferably consists of, metal such that an efficient transfer of heat is provided through a side wall of the heating chamber 202 to the aerosol substrate whilst also ensuring that the heating chamber 202 has sufficient structural stability and durability.
  • suitable metals include steel or stainless steel.
  • the heating chamber 202 is not limited to being tubular.
  • the heating chamber 202 may be formed as a cuboidal, conical, hemi-spherical or other shaped cavity, and be configured to receive a complementary shaped aerosol substrate.
  • the heating chamber 202 may not entirely surround the aerosol substrate, but instead only contact a limited area of the aerosol substrate.
  • a thin film heater 207 surrounds the heating chamber 202. That is, the thin film heater 207 is wrapped around the heating chamber 202, e.g. in a circumferential direction, such that the thin film heater 207 contacts an outer surface 203 of the heating chamber 202.
  • the thin film heater 207 comprises a first electrically insulating backing film 207, a second electrically insulating backing film 210, and a heating element 208.
  • the heating element 208 is disposed on a first side 209 of the first electrically insulating backing film 206.
  • An opposing second side 211 of the first electrically insulating backing film 206 contacts the outer surface 203 of the heating chamber 202. In this way, the first electrically insulating backing film 206 prevents any contact between the heating chamber 202 and the heating element 208.
  • the heating element 208 is adhesively connected to the first side 209 of the first electrically insulating backing film 206.
  • a silicon-based adhesive may be used to attach the heating element 208 to the first electrically insulating backing film 206.
  • the use of adhesive improves the ease of manufacture by ensuring the components of the thin film heater 207 do not misalign during attachment of the thin film heater 207 to the heating chamber 202.
  • the use of adhesive improves the operational reliability of the heating assembly 200 and enhances the interfacial heat transfer between the first electrically insulating backing film 206 and the heating element 208.
  • the second electrically insulating backing film 210 is located on an opposing side of the heating element 208 to the first electrically insulating backing film 206.
  • the heating element 208 is sandwiched between the first electrically insulating backing film 206 and the second electrically insulating backing film 210.
  • the second electrically insulating backing film 210 is omitted and the heating element 208 is sandwiched between the first electrically insulating backing film 206 and the heat shrink film 212.
  • the heating element 208 comprises a heating material suitable for converting electrical energy into heat (such as stainless steel, titanium, nickel, Nichrome, nickel based alloy, silver etc.).
  • the heating element 208 comprises one or more resistive heater tracks, which may be formed using chemical etching.
  • the heating element 208 may be formed in alternative configurations, e.g. as a heating sheet or mat or a coiled heating wire or a thick film.
  • power may be supplied to the heating element 208 from a power source such as a battery (not depicted) such that the temperature of the heating element 208 increases and heat energy is transferred across the first electrically insulating backing film 206 to the heating chamber 202.
  • a power source such as a battery (not depicted)
  • the aerosol substrate received within the heating chamber 202 is conductively heated by the heating chamber 202 to produce an aerosol for inhalation by the user.
  • the heating chamber 202 is not a resistive heater, and therefore should not receive a current.
  • the first electrically insulating backing film 206 advantageously prevents a short circuit occurring between the heating element 208 and the heating chamber 202, whilst allowing an efficient transfer of heat from the heating element 208 to the heating chamber 202. That it, the first electrically insulating backing film 206 separates the heating element 208 and the heating chamber 202 and ensures that a current does not flow from the heating element 208 to the heating chamber 202.
  • the first electrically insulating backing film 206 comprises mica, i.e. a material selected from the mica group of sheet silicate minerals.
  • the first electrically insulating backing film 206 may comprise muscovite and/or phlogopite.
  • the first electrically insulating backing film 206 may also be referred to as a mica film.
  • Muscovite may be operated up to a maximum temperature of 530°C and exhibits a dielectric strength of 508 V/mm and a thermal conductivity of 0.54 W/mK.
  • muscovite (and other micas) offer superior thermal conduction and electrical insulation compared to polyimide, which is typically provided between the heating element and the heating chamber in conventional aerosol generating devices.
  • mica is phlogopite tape with dielectric strength of more than 1.1 Kv/layer.
  • the first electrically insulating backing film 206 from mica, preferably phlogopite tape, improves the efficiency of heat transfer from the heating element 208 to the heating chamber 202, whilst also ensuring that a short circuit does not occur between the heating element 208 and the heating chamber 202.
  • the properties of mica allow for a thinner layer of the first electrically insulating backing film 206 to be used, which further optimises the heat transfer to the heating chamber and reduces the bulkiness of the heating assembly 200.
  • the first electrically insulating backing film 206 may be formed with a thickness of less than 120 pm, and preferably with a thickness between 90 pm and 120 pm.
  • the first electrically insulating backing film 206 may comprises a mica paper (or a mica tape), such as a muscovite mica paper or a phlogophite mica paper.
  • the mica paper may be impregnated with a high- temperature resistant binder.
  • the binder may comprise a resin such as polyester, polytetrafluoroethylene (PTFE), and/or or polyether ether ketone (PEEK).
  • the binder may comprise a non-woven cloth or web, such as glass and/or polyester.
  • the binder may comprise a woven cloth or web.
  • the second electrically insulating backing film 210 preferably also comprises mica.
  • the second electrically insulating backing film 210 may comprise one of the specific mica materials described above in relation to the first electrically insulating backing film 206. In this way, the second electrically insulating backing film 210 acts as an electrically insulating barrier to prevent electricity from the heating element 208 being conducted to other components of the aerosol generating device 100.
  • the second electrically insulating backing film 210 may be adhesively connected to the heating element 208.
  • second electrically insulating backing film 210 is optional.
  • the heat shrink film 212 is wrapped around the thin film heater 207, e.g. in a circumferential direction, such that the thin film heater 207 is secured against the outer surface 203 of the heating chamber 202.
  • the heat shrink film 212 acts as an external layer which surrounds the exterior of the heating chamber 200, thereby consolidating the structure and ensuring that the heating element 208 maintains contact with the layer of electrically insulating material 206. This removes the requirement for adhesive between the thin film heater 207 and the heating chamber 202 but, in some embodiments, adhesive may still be used.
  • the heat shrink film 212 may comprise polyimide or polyether ether ketone (PEEK).
  • heat may be applied to the heat shrink film 212 such that the heat shrink film 212 contracts around the thin film heater 207 and the thin film heater 207 is secured against the outer surface 203 of the heating chamber 202.
  • the heat shrink film is illustrated as entirely enveloping the thin film heater 207. That is, the heat shrink film 212 extends beyond the extent of the thin film heater 212. However, it will be appreciated that the size and placement of the heat shrink film 212 may vary. Moreover, the skilled person will appreciate that the heat shrink film 212 is optional.
  • FIG 4 shows the thin film heater 207 in a flattened configuration, prior to being wrapped around the heating chamber 202.
  • the thin film heater 207 does not comprise the second electrically insulating backing film 210.
  • the heating element 208 is a metal resistive track that is formed as a meandrous pattern which is adhesively connected to the first side 209 of the first electrically insulating film 206.
  • the heating element 208 is a flexible heating element that is able to be wrapped around the heating chamber 202.
  • the thin film heater 207 is configured such that, when the thin film heater 207 is wrapped around the heating chamber 202, the heating element 208 substantially surrounds the circumference of the heating chamber 202, thereby providing uniform heating to the aerosol substrate received within the heating chamber 202.
  • the heating element 208 preferably comprises two connection elements 214 configured to connect to and form an electrical circuit with a power source (not depicted).
  • connection elements 214 are arranged such that they extend along the length of the heating chamber 202.
  • the thin film heater 207 is configured such that it extends along the entire length of the heating chamber 202. In other embodiments, and as illustrated in Figures 2 and 3, the thin film heater 207 is configured to only extend along a portion of the length of the heating chamber 202.

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  • Surface Heating Bodies (AREA)

Abstract

A heating assembly (200) for an aerosol generating device (100) is disclosed. The heating assembly (200) comprises: a tubular heating chamber (202) comprising an opening (204) for receiving an aerosol substrate; and a thin film heater (207) that is wrapped around an outer surface (203) of the heating chamber (202) and configured to supply heat to the heating chamber (202). The thin film heater (207) comprises a flexible heating element (208) and a first electrically insulating backing film (206) comprising mica. The flexible heating element (208) is adhesively coupled to a first side (209) of the first electrically insulating backing film (206) and an opposing second side (211) of the first electrically insulating backing film (206) contacts the outer surface of the heating chamber (203).

Description

Heating Assembly for an Aerosol Generating Device
The present invention relates to a heating assembly for an aerosol generating 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.
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 using traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat or warm aerosolisable substances as opposed to burning tobacco in conventional tobacco products.
A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn (HNB) device. Devices of this type generate an aerosol or vapour by heating an aerosol substrate (i.e. consumable) that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range of 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 undesirable by-products of combustion. In addition, the aerosol produced by heating the tobacco or other aerosolisable material does not typically comprise the burnt or bitter taste that may result from combustion that can be unpleasant for the user.
Within known heat-not-burn devices, it is desirable to improve the efficiency of the heating process, whilst also ensuring a reliable operation of the device. It is also desirable to improve the compactness of the heating assembly.
According to a first aspect of the invention, there is provided a heating assembly for an aerosol generating device, comprising: a tubular heating chamber comprising an opening for receiving an aerosol substrate; and a thin film heater that is wrapped around an outer surface of the heating chamber and configured to supply heat to the heating chamber, wherein the thin film heater comprises a flexible heating element and a first electrically insulating backing film comprising mica, wherein the flexible heating element is adhesively coupled to a first side of the first electrically insulating backing film and an opposing second side of the first electrically insulating backing film contacts the outer surface of the heating chamber.
In this way, a more efficient heating assembly is provided compared with known aerosol generating devices. The arrangement and composition of the first electrically insulating backing film prevents a short circuit occurring between the metal heating chamber and the heating element, whilst allowing improved heat transfer from the heating element to the aerosol substrate received within the heating chamber. In particular, the use of mica as the first electrically insulating backing film provides superior thermal conductivity compared to polyimide films, which are often provided between the heating element and the heating chamber in typical aerosol generating devices. In addition, mica has a high electrical breakdown voltage and improved electrical insulating properties compared to polyimide. This allows the thickness of the first electrically insulating backing film to be reduced, thereby further optimising the thermal energy transfer from the heating element to the heating chamber and reducing the bulkiness of the heating assembly. Advantageously, by adhesively coupling the flexible heating element to a first side of the first electrically insulating backing film, the interfacial heat transfer between the mica and the heating element is improved. In addition, the ease of manufacturing of the heating assembly and the reliability of the heating assembly is also improved.
Preferably, the first electrically insulating backing film comprises at least one of: muscovite; and phlogopite. The mica group of sheet silicate (phyllosilicate) minerals includes muscovite and phlogopite. Both such materials provide excellent electrical insulation and high thermal conductivity. For example, muscovite exhibits a dielectric strength of 508 V/mm, a thermal conductivity of 0.54 W/mK, and is able to resist temperatures up to 530°C. Moreover, muscovite can be produced as a thin film, thereby simplifying the manufacturing process of the heating assembly.
Preferably, the first electrically insulating backing film comprises a mica paper, e.g. a sheet of miniature flakes of musocovite and/or phlogopite. In this way, the mica paper provides homogenous properties and the first electrically insulating backing film has improved flexibility and is less susceptible to delamination.
Preferably, the mica paper is impregnated with a binder.
Preferably, the binder comprises: resin; woven cloth or web; or non-woven cloth or web. In one example, the binder comprises resin, and the resin comprises: silicone resin, polyester; polytetrafluoroethylene, PTFE; or polyether ether ketone (PEEK). In another example, the binder comprises non-woven cloth or web, and the non-woven cloth or web comprises at least one of: glass; and polyester.
Preferably, the first electrically insulating backing film has a thickness of less than 120 pm. More preferably, the first electrically insulating backing film has a thickness of between 90 pm and 120 pm. For example, the thickness of the first electrically insulating film may be 80 pm, 90 pm, 100 pm, 105 pm, 100 pm, 110 pm or 120 pm.
Preferably, the first electrically insulating backing film is a tape of phlogopite mica having a tensile strength of more than 80 N/cm (according to ISO 527) and a thickness between 80 (+/-1.5) pm and 120 (+/-1.5) pm, more preferably between 80 (+/-1.5) pm and 100 (+/-1.5) pm, most preferably of 80 (+/-1.5) pm.
The tape has preferably phlogopite mica content between 70 and 106 g/m2 more preferably between 70 and 80 g/m2, a glass content between 21 and 34 g/m2, more preferably 21 to 25 g/m2 and a binder content between 9 and 21 g/m2, more preferably 9 and 15 g/m2. With such composition, the first electrically insulating backing film remains flexible while exhibiting high mechanical properties and provides higher electrical insulating properties. More preferably, the phlogopite mica tape has a dielectric strength of more than 1.1 KV/layer (according to IEC 371-2). The dielectric strength remains constant in the heating range of the device (i.e., up to 350°C) thereby ensuring high electrical insulation properties. The tape of such composition is sufficiently flexible to be easily rolled on the tubular heating element of small diameter. Preferably, the thin film heater is wrapped around an outer surface of the heating chamber having a diameter of less than 10 mm, more preferably comprised between 6.5 mm and 9 mm, most preferably 7 and 8.5 mm.
Preferably, the thin film heater comprises a second electrically insulating backing film disposed on an opposing side of the heating element to the first electrically insulating backing film such that the heating element is at least partially enclosed between the first electrically insulating backing film and the second electrically insulating backing film. In this way, the second electrically insulating backing film electrically insulating other components of the aerosol generating device from the heating element.
Preferably, the second electrically insulating backing insulating film comprises mica. Preferably, the second electrically insulating backing film comprises at least one of: muscovite; and phlogopite. Preferably, the second electrically insulating backing film comprises a mica paper. Preferably, the mica paper is impregnated with a binder. Preferably, the binder comprises: resin; woven cloth or web; or non- woven cloth or web. In one example, the binder comprises resin, and the resin comprises: polyester; polytetrafluoroethylene, PTFE; or polyether ether ketone (PEEK). In another example, the binder comprises non-woven cloth or web, and the non-woven cloth or web comprises at least one of: glass; and polyester. Preferably, the second electrically insulating backing film has a thickness of less than 120 pm. More preferably, the second electrically insulating backing film has a thickness of between 90 pm and 120 pm.
Preferably, the second electrically insulating backing film is a tape of phlogopite having a tensile strength of more than 80 N/cm (according to ISO 527) and a thickness between 80 (+/-1.5) pm and 120 (+/-1.5) pm, more preferably between 80 (+/-1.5) pm and 100 (+/-1.5) pm, most preferably of 80 (+/-1.5) pm. The phlogopite tape has shown higher flexibility than muscovite. Muscovite is also more difficult to roll around a small-diameter tube and is more likely to experience cracking in comparison to phlogopite.
The tape has preferably phlogopite mica content between 70 and 106 g/m2 more preferably between 70 and 80 g/m2, a glass content between 21 and 34 g/m2, more preferably 21 to 25 g/m2 and a binder content between 9 and 21 g/m2, more preferably 9 and 15 g/m2. The thickness is preferably of maximum 100 (+/-1.5), preferably of about 80 (+/-1.5) pm. With such composition and thickness, the second electrically insulating backing film remains flexible to be easily formed into a tubular shape while exhibiting high mechanical properties and providing high electrical insulating properties. The tape of such composition is sufficiently flexible to be easily rolled on the tubular heating element of diameter less than 10 mm, preferably of about 7 to 8.5 mm. More preferably, the phlogopite mica tape has a dielectric strength of more than 1.1 KV/layer (according to I EC 371-2). The dielectric strength remains constant in the heating range of the device (i.e. , up to 350°C or slightly more) thereby ensuring high electrical insulation properties within the full operation heating range of the aerosol generation device.
Preferably, the flexible heating element comprises a metal resistive track. Preferably, the metal resistive track is a chemically etched metal resistive track.
Preferably, the flexible heating element is adhesively coupled to the first side of the first electrically insulating backing film using a silicon-based adhesive.
Preferably, the heating assembly, further comprises: a heat shrink film that is wrapped around the thin film heater to secure the thin film heater to the heating chamber. In this way, the heating assembly is consolidated whilst maintaining a compact arrangement of the heating assembly.
Preferably, the heat shrink film comprises: polyimide; or polyether ether ketone (PEEK).
Preferably, the outer surface of the heating chamber is a circumferential outer surface of the heating chamber. According to a second aspect of the invention, there is provided an aerosol generating device comprising a heating assembly according to the first aspect.
According to a third aspect of the invention, there is provided a thin film heater comprising a flexible heating element and a first electrically insulating backing film comprising mica, preferably muscovite, wherein the flexible heating element is supported on a first side of the first electrically insulating backing film. The flexible heating element is preferably adhesively coupled to the first side of the first electrically insulating backing film. The thin film heater may comprise any combination of the features of the thin film heater described in relation to the first and second aspect of the invention. In this way a general purpose thin film heater is provided which utilises the improved thermal conductivity of the mica film.
According to a fourth aspect of the invention, there is provided a heater comprising a heating chamber and a thin film heater according to the third aspect of the invention provided against a surface of the heating chamber.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:
Figure 1 is an exemplary aerosol generating device according to an embodiment of the invention;
Figure 2 is a perspective view of a heating assembly comprising a thin film heater wrapped around a heating chamber according to an embodiment of the invention;
Figure 3 is a schematic cross-sectional view of the heating assembly of Figure 2 further comprising a second electrically insulating backing film and a heat shrink film; and
Figure 4 is schematic view of the thin film heater in a flattened arrangement according to an embodiment of the invention. DETAILED DESCRIPTION
Figure 1 illustrates an aerosol generating device 100 according to an embodiment of the invention. The aerosol generating device 100 is illustrated in an assembled configuration with the internal components visible. The aerosol generating device 100 is a heat-not-burn device, which may also be referred to as a tobacco-vapour device, and comprises a heating assembly 200 configured to receive an aerosol substrate such as a rod of aerosol generating material, e.g. tobacco. The heating assembly 200 is operable to heat, but not burn, the rod of aerosol generating material to produce a vapour or aerosol for inhalation by a user. Of course, the skilled person will appreciate that the aerosol generating device 100 depicted in Figure 1 is simply an exemplary aerosol generating device according to the invention. Other types and configurations of tobacco-vapour products, vaporisers, or electronic cigarettes may also be used as the aerosol generating device according to the invention. Figure 2 shows a perspective view of a heating assembly 200 according to an embodiment of the invention. Similarly, Figure 3 shows a cross-sectional schematic view of the heating assembly 200. For illustration purposes, Figure 2 does not show the second electrically insulating backing film 210 and the heat shrink film 212. The heating assembly 200 comprises a heating chamber 202, also referred to as a thermally conductive shell, configured to hold an aerosol substrate, also referred to as a consumable, therein. In particular, the heating chamber 202 defines a cylindrical cavity in which a rod of aerosol substrate may be positioned. The heating chamber 202 is tubular, e.g. cylindrical, and has an opening 204 positioned at a longitudinal end of the heating chamber 202. In use, the user may insert the aerosol substrate through the opening 204 in the heating chamber 202 such that the aerosol substrate is positioned within the heating chamber 202 and interfaces with an inner surface 201 of the heating chamber 202. The length of the heating chamber 202 may be configured such that a portion of the aerosol substrate protrudes through the opening 204 in the heating chamber 202, i.e. out of the heating assembly 200, and can be received in the mouth of the user. The heating chamber 202 comprises, and preferably consists of, metal such that an efficient transfer of heat is provided through a side wall of the heating chamber 202 to the aerosol substrate whilst also ensuring that the heating chamber 202 has sufficient structural stability and durability. Examples of suitable metals include steel or stainless steel.
The skilled person will appreciate that the heating chamber 202 is not limited to being tubular. For example, the heating chamber 202 may be formed as a cuboidal, conical, hemi-spherical or other shaped cavity, and be configured to receive a complementary shaped aerosol substrate. Moreover, in some embodiments, the heating chamber 202 may not entirely surround the aerosol substrate, but instead only contact a limited area of the aerosol substrate.
A thin film heater 207 surrounds the heating chamber 202. That is, the thin film heater 207 is wrapped around the heating chamber 202, e.g. in a circumferential direction, such that the thin film heater 207 contacts an outer surface 203 of the heating chamber 202. The thin film heater 207 comprises a first electrically insulating backing film 207, a second electrically insulating backing film 210, and a heating element 208. The heating element 208 is disposed on a first side 209 of the first electrically insulating backing film 206. An opposing second side 211 of the first electrically insulating backing film 206 contacts the outer surface 203 of the heating chamber 202. In this way, the first electrically insulating backing film 206 prevents any contact between the heating chamber 202 and the heating element 208.
The heating element 208 is adhesively connected to the first side 209 of the first electrically insulating backing film 206. For example, a silicon-based adhesive may be used to attach the heating element 208 to the first electrically insulating backing film 206. The use of adhesive improves the ease of manufacture by ensuring the components of the thin film heater 207 do not misalign during attachment of the thin film heater 207 to the heating chamber 202. Moreover, the use of adhesive improves the operational reliability of the heating assembly 200 and enhances the interfacial heat transfer between the first electrically insulating backing film 206 and the heating element 208. The second electrically insulating backing film 210 is located on an opposing side of the heating element 208 to the first electrically insulating backing film 206. In this way, the heating element 208 is sandwiched between the first electrically insulating backing film 206 and the second electrically insulating backing film 210. In a possible alternative, the second electrically insulating backing film 210 is omitted and the heating element 208 is sandwiched between the first electrically insulating backing film 206 and the heat shrink film 212.
The heating element 208 comprises a heating material suitable for converting electrical energy into heat (such as stainless steel, titanium, nickel, Nichrome, nickel based alloy, silver etc.). In the depicted embodiment, the heating element 208 comprises one or more resistive heater tracks, which may be formed using chemical etching. However, in other embodiments, the heating element 208 may be formed in alternative configurations, e.g. as a heating sheet or mat or a coiled heating wire or a thick film.
In use, power may be supplied to the heating element 208 from a power source such as a battery (not depicted) such that the temperature of the heating element 208 increases and heat energy is transferred across the first electrically insulating backing film 206 to the heating chamber 202. The aerosol substrate received within the heating chamber 202 is conductively heated by the heating chamber 202 to produce an aerosol for inhalation by the user.
The skilled person will appreciate that the heating chamber 202 is not a resistive heater, and therefore should not receive a current. Thus, the first electrically insulating backing film 206 advantageously prevents a short circuit occurring between the heating element 208 and the heating chamber 202, whilst allowing an efficient transfer of heat from the heating element 208 to the heating chamber 202. That it, the first electrically insulating backing film 206 separates the heating element 208 and the heating chamber 202 and ensures that a current does not flow from the heating element 208 to the heating chamber 202.
The first electrically insulating backing film 206 comprises mica, i.e. a material selected from the mica group of sheet silicate minerals. For example, the first electrically insulating backing film 206 may comprise muscovite and/or phlogopite. The first electrically insulating backing film 206 may also be referred to as a mica film.
Muscovite may be operated up to a maximum temperature of 530°C and exhibits a dielectric strength of 508 V/mm and a thermal conductivity of 0.54 W/mK. In other words, muscovite (and other micas) offer superior thermal conduction and electrical insulation compared to polyimide, which is typically provided between the heating element and the heating chamber in conventional aerosol generating devices. Most preferably, mica is phlogopite tape with dielectric strength of more than 1.1 Kv/layer. Thus, forming the first electrically insulating backing film 206 from mica, preferably phlogopite tape, improves the efficiency of heat transfer from the heating element 208 to the heating chamber 202, whilst also ensuring that a short circuit does not occur between the heating element 208 and the heating chamber 202. Moreover, the properties of mica allow for a thinner layer of the first electrically insulating backing film 206 to be used, which further optimises the heat transfer to the heating chamber and reduces the bulkiness of the heating assembly 200.
For example, the first electrically insulating backing film 206 may be formed with a thickness of less than 120 pm, and preferably with a thickness between 90 pm and 120 pm.
In some embodiments, the first electrically insulating backing film 206 may comprises a mica paper (or a mica tape), such as a muscovite mica paper or a phlogophite mica paper. The mica paper may be impregnated with a high- temperature resistant binder. In one example, the binder may comprise a resin such as polyester, polytetrafluoroethylene (PTFE), and/or or polyether ether ketone (PEEK). In another example, the binder may comprise a non-woven cloth or web, such as glass and/or polyester. In another example, the binder may comprise a woven cloth or web.
The second electrically insulating backing film 210 preferably also comprises mica. In particular, the second electrically insulating backing film 210 may comprise one of the specific mica materials described above in relation to the first electrically insulating backing film 206. In this way, the second electrically insulating backing film 210 acts as an electrically insulating barrier to prevent electricity from the heating element 208 being conducted to other components of the aerosol generating device 100. In some embodiments, the second electrically insulating backing film 210 may be adhesively connected to the heating element 208. The skilled person will appreciate that second electrically insulating backing film 210 is optional.
The heat shrink film 212 is wrapped around the thin film heater 207, e.g. in a circumferential direction, such that the thin film heater 207 is secured against the outer surface 203 of the heating chamber 202. In other words, the heat shrink film 212 acts as an external layer which surrounds the exterior of the heating chamber 200, thereby consolidating the structure and ensuring that the heating element 208 maintains contact with the layer of electrically insulating material 206. This removes the requirement for adhesive between the thin film heater 207 and the heating chamber 202 but, in some embodiments, adhesive may still be used. In some examples, the heat shrink film 212 may comprise polyimide or polyether ether ketone (PEEK).
During manufacture of the heating assembly 200, heat may be applied to the heat shrink film 212 such that the heat shrink film 212 contracts around the thin film heater 207 and the thin film heater 207 is secured against the outer surface 203 of the heating chamber 202.
In Figure 3, the heat shrink film is illustrated as entirely enveloping the thin film heater 207. That is, the heat shrink film 212 extends beyond the extent of the thin film heater 212. However, it will be appreciated that the size and placement of the heat shrink film 212 may vary. Moreover, the skilled person will appreciate that the heat shrink film 212 is optional.
Figure 4 shows the thin film heater 207 in a flattened configuration, prior to being wrapped around the heating chamber 202. In this embodiment, the thin film heater 207 does not comprise the second electrically insulating backing film 210. As illustrated, the heating element 208 is a metal resistive track that is formed as a meandrous pattern which is adhesively connected to the first side 209 of the first electrically insulating film 206. The heating element 208 is a flexible heating element that is able to be wrapped around the heating chamber 202. The thin film heater 207 is configured such that, when the thin film heater 207 is wrapped around the heating chamber 202, the heating element 208 substantially surrounds the circumference of the heating chamber 202, thereby providing uniform heating to the aerosol substrate received within the heating chamber 202. The heating element 208 preferably comprises two connection elements 214 configured to connect to and form an electrical circuit with a power source (not depicted). When the thin film heater 207 is wrapped around the heating chamber 202, the connection elements 214 are arranged such that they extend along the length of the heating chamber 202.
In some embodiments, the thin film heater 207 is configured such that it extends along the entire length of the heating chamber 202. In other embodiments, and as illustrated in Figures 2 and 3, the thin film heater 207 is configured to only extend along a portion of the length of the heating chamber 202.

Claims

1. A heating assembly for an aerosol generating device, comprising: a tubular heating chamber comprising an opening for receiving an aerosol substrate; and a thin film heater that is wrapped around an outer surface of the heating chamber and configured to supply heat to the heating chamber, wherein the thin film heater comprises a flexible heating element and a first electrically insulating backing film comprising mica, and wherein the flexible heating element is adhesively coupled to a first side of the first electrically insulating backing film and an opposing second side of the first electrically insulating backing film contacts the outer surface of the heating chamber.
2. The heating assembly of claim 1 , wherein the first electrically insulating backing film comprises at least one of: muscovite; and phlogopite.
3. The heating assembly of claim 1 or claim 2, wherein the first electrically insulating backing film comprises a mica paper.
4. The heating assembly of claim 3, wherein the mica paper is impregnated with a binder.
5. The heating assembly of claim 4, wherein the binder comprises: resin; woven cloth or web; or non-woven cloth or web.
6. The heating assembly of claim 5, wherein the binder comprises resin, and wherein the resin comprises: silicone resin, polyester; polytetrafluoroethylene (PTFE); or polyether ether ketone (PEEK).
7. The heating assembly of claim 5, wherein the binder comprises non- woven cloth or web, and wherein the non-woven cloth or web comprises at least one of: glass; and polyester.
8. The heating assembly of any preceding claim, wherein the first electrically insulating backing film has a thickness of less than 120 pm.
9. The heating assembly of any preceding claim, wherein the first electrically insulating backing film is a phlogopite mica tape having a thickness between 80 and 120 pm.
10. The heating assembly of claim 9, wherein the tape has a dielectric strength of more than 1.1 KV/layer.
11. The heating assembly of any preceding claim, wherein the thin film heater comprises a second electrically insulating backing film disposed on an opposing side of the heating element to the first electrically insulating backing film such that the heating element is at least partially enclosed between the first electrically insulating backing film and the second electrically insulating backing film.
12. The heating assembly of claim 11 , wherein the second electrically insulating backing film comprises mica.
13. The heating assembly of claim 12, wherein the second electrically insulating backing film is a phlogopite mica tape having a thickness between 80 and 120 pm.
14. The heating assembly of claim 13, wherein the tape has a dielectric strength of more than 1.1 KV/layer.
15. The heating assembly of any preceding claim, wherein the flexible heating element comprises a metal resistive track.
16. The heating assembly of claim 15, wherein the metal resistive track is a chemically etched metal resistive track.
17. The heating assembly of any preceding claim, wherein the flexible heating element is adhesively coupled to the first side of the first electrically insulating backing film using a silicon-based adhesive.
18. The heating assembly of any preceding claim, further comprising: a heat shrink film that is wrapped around the thin film heater to secure the thin film heater to the heating chamber.
19. The heating assembly of claim 18, wherein the heat shrink film comprises: polyimide; or polyether ether ketone (PEEK).
20. The heating assembly of any of the preceding claims, wherein the thin film heater is wrapped around an outer surface of the heating chamber having a diameter of less than 10 mm, preferably comprised between 6.5 mm and 9 mm, more preferably 7 and 8.5 mm.
PCT/EP2022/058069 2021-03-30 2022-03-28 Heating assembly for an aerosol generating device WO2022207536A1 (en)

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EP21165946 2021-03-30

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140305454A1 (en) * 2011-09-28 2014-10-16 Philip Morris Products S.A. Permeable electric thermal resistor foil for vaporizing fluids from single-use mouthpieces with vaporizer membranes
US9055617B2 (en) * 2009-12-30 2015-06-09 Philip Morris Usa Inc. Heater for an electrically heated aerosol generating system
EP3248485B1 (en) * 2009-10-29 2020-04-29 Philip Morris Products S.a.s. An electrically heated smoking system with improved heater
WO2021043691A1 (en) * 2019-09-06 2021-03-11 Jt International Sa Heater assembly

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3248485B1 (en) * 2009-10-29 2020-04-29 Philip Morris Products S.a.s. An electrically heated smoking system with improved heater
US9055617B2 (en) * 2009-12-30 2015-06-09 Philip Morris Usa Inc. Heater for an electrically heated aerosol generating system
US20140305454A1 (en) * 2011-09-28 2014-10-16 Philip Morris Products S.A. Permeable electric thermal resistor foil for vaporizing fluids from single-use mouthpieces with vaporizer membranes
WO2021043691A1 (en) * 2019-09-06 2021-03-11 Jt International Sa Heater assembly

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