RU2765205C2 - Fluid-permeable heating node for aerosol generating system and method for assembling fluid-permeable heater for aerosol generating system - Google Patents

Abstract

FIELD: electrical engineering.SUBSTANCE: fluid-permeable heating node for aerosol generating systems contains a base including a hole through this base, an electric-conductive, essentially flat, thread structure located above the mentioned hole, and mechanical fixation means that mechanically fix the thread structure to the base. The thread structure includes the first part and the second parts forming a combined thread. The first part is provided between the second parts, while the thread structure contains a set of threads forming a mesh. The second parts contain a mesh with a mesh density greater than a mesh density of the first part mesh.EFFECT: simplification of the structure of the fluid-permeable heater.15 cl, 22 dwg

Description

The present invention relates to a fluid-permeable heater assembly for aerosol generating systems and to a method for assembling a fluid-permeable heater. In particular, the present invention relates to a fluid-permeable heater assembly for hand held aerosol generating systems such as electrically controlled smoking systems.

Some aerosol-generating systems, such as electrically controlled smoking devices, may include a battery and control electronics, a cartridge containing an aerosol-forming substrate supply source, and an electrically controlled vaporizer. The substance is evaporated from the aerosol-forming substrate, for example by means of a heating element. The heating element may be an at least partially fluid-permeable heater, such as a flat coil embedded in the ceramic material. However, such heaters are expensive to manufacture.

There is a need for a fluid-permeable heater assembly for aerosol generating systems that is cheap and easy to manufacture. There is also a need for an appropriate method for assembling fluid-permeable heaters.

According to a first aspect of the present invention, a fluid-permeable heater assembly is provided for aerosol generating systems, preferably electrically controlled smoking systems. The fluid-permeable heater assembly comprises a base, preferably an electrically insulating base. This base contains a hole through this base. The heater assembly further comprises an electrically controlled, substantially flat filament structure located over the opening in the base. This thread structure is mechanically fixed to the base by means of fasteners. The attachment means are also electrically conductive and serve as electrical contacts for providing a heating current through the filament structure and also for stabilizing the filament structure fixed to the substrate.

Preferably, the heater assembly is assembled by mechanical means only. The fixation of the thread structure and the base on each other, as well as the provision of electrical contact between the thread structure and the contact of an external power source, for example, a battery, is carried out by mechanical fixation. The fastening means ensure a strong fixation of the thread structure and reliable contact between the thread structure and these fastening means. By mechanically fixing and making electrical contact with the thread structure by mechanical means, there is no need for soldering, welding or etching electrical contacts. Thus, it is possible to facilitate the manufacture and reduce the cost of manufacturing the parts of the heater assembly. Additionally, it is also possible to increase the machinability of the heater unit or its parts. In addition, mechanical fixation allows the reliability of the heater assembly to be improved by eliminating problem areas common to soldering and welding, such as cold brazed solder joints or cold welded welds. These locations are known for their low strength, low load capacity, and electrical resistance instability. In addition, the filament structure does not come into direct contact with the battery connectors of the aerosol generating system, and thus the filament structure does not break when the heater is introduced into the system.

In combination with the method of assembling such a fluid-permeable heater according to the present invention, it is possible to achieve three goals at once in one economical means: fixing the thread structure on the base, stabilizing the thread structure, and providing an electrical connector for a power source, for example, an electronic cigarette battery. The means of attachment, the appropriate mechanism for fixing the thread structure on the substrate, and the corresponding assembly process are economical, resistant to manufacturing manipulations, functionally effective, durable and compatible with the relatively small area of the heater assembly.

The term "substantially flat" is used throughout the present description in relation to the filamentary structure, which has the form of an essentially two-dimensional topological reservoir. Thus, the substantially flat thread structure extends in two directions along the surface much more than in the third direction. In particular, the dimensions of the substantially planar thread structure in two directions along the surface are about 5 times larger than in the third direction, which is the direction normal to that surface. An example of a substantially planar thread structure is a structure between two substantially parallel imaginary planes, in which the distance between the two imaginary planes is significantly less than the extent along these planes. In some embodiments, the substantially flat thread structure is planar. In other embodiments, the substantially flat thread structure is curved along one or more directions, forming, for example, a dome shape or a bridge shape.

The term "filament" (filament) is used throughout this specification to refer to an electrical path located between two electrical contacts. The filament may fork and split into a plurality of paths or filaments, respectively, as needed, or a plurality of electrical paths may converge into a single path. The thread may have a round, square, flat or any other cross section. The thread can be arranged straight or curved.

The term "filament structure" is used throughout the description to refer to a structure of one or, preferably, of multiple threads. The thread structure can be a matrix of threads arranged, for example, parallel to each other. Preferably, the filaments may form a network. This mesh can be woven (woven) or non-woven (non-woven). Preferably, the thread structure has a thickness of from about 0.5 microns to about 500 microns.

As a general rule, when the term "about" is used in conjunction with a specific value throughout this application, it should be understood that the value following the term "about" need not be exactly equal to the specific value for technical reasons. However, the term "about" when used in conjunction with a specific amount should always be understood to include and expressly express the specific amount following the term "about".

For example, the shape of the base and the thread structure fixed to the base can be adapted to the shape of the end of the cartridge containing the aerosol-forming substrate. This end of the cartridge may be planar, but it may also be curved, such as a convex shape.

The hole in the base may have essentially any shape. Preferably, this hole has a simple shape, easy to manufacture, such as a round, oval or rectangular shape, in other words, it is a cylinder having a round, oval or rectangular base extending through the base. Preferably, the hole in the base includes at least the central part of the base. This central part includes the imaginary center of gravity of the base. Alternatively or additionally, said central part may comprise a longitudinal axis, for example an axis of rotation, such as, for example, the axis of rotation of a base made in the form of a round disk.

The substantially flat thread structure is secured over at least a portion of said opening by means of attachment means. The base comprises a fastening surface on which a substantially flat thread structure is placed in the fastened state. Preferably, the fastening surface is part of the top surface of the base. The fastening surface may include said hole, as well as parts of the upper surface of the base adjacent to this hole. Preferably, the mounting surface is planar. The attachment means apply a tensile force to the thread structure. This tensile force is directed at least in a direction coplanar to the fastening surface. Preferably, a tensile force is applied to the thread structure during assembly of the heater, and preferably in the attached state of the thread structure. The tensile force maintains the planar arrangement of the thread structure and contributes to the stabilization of the thread structure in the warp plane. Preferably, the attachment means apply opposing tensile forces to the thread structure, stretching and stabilizing the thread structure in a plane.

The fastening means may comprise several separately located fastening elements, preferably two separately located fastening elements. Preferably, the individual attachment elements are not in direct contact with each other so that these elements are separated from the two contacts for energizing the heater and heating the thread structure. Two or more attachment elements may serve as the first electrical contact for the string structure. Two or more attachment elements can serve as a second electrical contact for the string structure. Preferably, the attachment means are two electrically conductive attachment elements, preferably in the form of clips, clips or staples. Preferably, the attachment means provide attachment action along the line, thus preventing the threads from being damaged or broken due to having only one fixation point. Preferably, the two fastening elements are located one opposite the other, for example, on opposite sides of the base. Preferably, the heater assembly comprises only a few components, such as, for example, a warp, a thread structure, and two attachment elements. The attachment means may also be shaped to match the shape of the external connector in order to simplify the connection and improve the external electrical contact.

Fluid-permeable heater units are suitable for evaporating liquids from various types of cartridges. For example, as an aerosol-forming substrate, the cartridge may contain a liquid or a liquid-containing transport material, such as, for example, a capillary material. Such transport material and capillary material actively transport liquid and are preferably oriented in the cartridge so as to transport liquid towards the heater assembly. The thread structure is positioned adjacent to the liquid or to the capillary material containing the liquid in such a way as to allow the liquid to evaporate under the action of the heat generated by the thread structure. Preferably, the thread structure and the aerosol-forming substrate are arranged to allow liquid to flow into the thread structure by capillary action. The thread structure may also be in physical contact with the capillary material.

The electrically conductive filaments may form spaces between each other, and these spaces may have a width of 10 microns to 100 microns. Preferably, the filaments create a capillary effect in said spaces and thus the liquid to be evaporated is drawn into these spaces in use, increasing the area of contact between the heater assembly and the liquid. The electrically conductive filaments can form a mesh in sizes from 160 US mesh to 600 US mesh (plus or minus 10 percent (in other words, 160 to 600 threads per inch (plus or minus 10 percent))). The width of said gaps is preferably between 75 microns and 25 microns.

The relative open area of the mesh, which is the ratio of the area of the gaps to the total area of the mesh, is preferably 25 to 60 percent. The mesh can be made using various types of woven or lattice structures.

The thread structure can also be characterized by its ability to retain liquid, as is well known in the art.

The electrically conductive filaments may have a diameter of 10 microns to 100 microns, preferably 8 microns to 50 microns, and more preferably 8 microns to 40 microns. The area of the thread structure can be small, preferably not more than 25 square millimeters, allowing the structure to be integrated into a hand held system. The thread structure may, for example, be rectangular and measure 5 millimeters by 2 millimeters in the attached state. Preferably, the filament structure occupies an area of 10 percent to 50 percent of the area of the heater assembly. More preferably, the thread structure occupies an area of 15 to 25 percent of the area of the heater assembly.

The thread structure can be made by etching a sheet material such as foil. This can be particularly advantageous if the heater assembly comprises an array of parallel filaments. If the heater assembly contains a mesh, the threads can be made separately and connected or intertwined with each other.

The heater assembly filaments can be made from any material with suitable electrical properties. Suitable materials include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as molybdenum disilicide, for example), carbon, graphite, metals, metal alloys, and composite materials made from ceramic material and metal material. Such composite materials may contain doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and the platinum group metals. Examples of suitable metal alloys include stainless steel, constantan, nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese - and ferrous alloys, as well as superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, alloys based on iron and aluminum and alloys based on iron, manganese and aluminum. Timetal® is a registered trademark of Titanium Metals Corporation. The filaments may be coated with one or more insulators. Preferred materials for electrically conductive filaments are 304, 316, 304L, 315L stainless steel and graphite.

The electrical resistance of the thread structure is preferably 0.3 ohms to 4 ohms. More preferably, the electrical resistance of the thread structure is from 0.5 ohms to 3 ohms, and even more preferably about 1 ohm. The electrical resistance of the string structure is preferably at least an order of magnitude and more preferably at least two orders of magnitude greater than the electrical resistance of the contact parts. Thus, it is provided that the heat generated by the passage of current through the heater assembly is localized in the filament structure. It is advantageous to have a low total heater node resistance if the system is powered by a battery. A low resistance, high current system allows high power to be delivered to the heating element. Thus, it is possible to rapidly heat the electrically conductive filament structure to the desired temperature with the heating element.

The heater assembly may comprise at least one thread made from a first material and at least one thread made from a second material different from the first material. This may be advantageous for electrical or mechanical reasons. For example, one or more of the filaments may be made from a material whose resistance varies greatly with temperature, such as, for example, an alloy of iron and aluminum. Thus, it is possible to use the resistance value of the filaments to determine temperature or temperature changes. This can be used in a puff detection system. Alternatively or additionally, this can be used to control the temperature of the heater to keep it within the desired temperature range. Rapid temperature changes can also be used as indicators to detect changes in airflow downstream of the heater assembly as a result of a user puff on an electrically controlled smoking system. A preferred variant of this type of thread material is, for example, a matrix of parallel threads of a first material located above a matrix of parallel threads of a second material, these matrices being rotated relative to each other to form a net. The combination of materials can also be used to improve the controllability of the resistance of the substantially flat thread structure. For example, high self-resistance materials can be combined with low self-resistance materials. This may provide an advantage if one of the materials is preferred for other reasons, such as price, workability, or other physical and chemical parameters. For example, one of the materials may be stainless steel.

Preferably, the base of the heater assembly is electrically insulating. This electrically insulating substrate may comprise any suitable material, and preferably the material is capable of withstanding high temperatures (above 300 degrees Celsius) and rapid temperature changes. An example of a suitable material is a film of polyimide material such as Kapton®, polyetheretherketone (PEEK) or ceramic material, preferably an electrically insulating open cell ceramic material. Preferably, the base material is non-brittle. The base material may have capillary action with respect to the liquid to be evaporated.

Preferably, the base is substantially flat. Preferably, the base is a disk, which may be, for example, round, oval or rectangular. This disk may be planar or curved. Preferably, the base also includes a planar mounting surface, when placed oriented towards the cartridge containing the aerosol-forming substrate, such that the heater assembly and the cartridge or cartridge cover, respectively, have a planar contact surface. Thus, the possibility of flush placement of the cartridge and the heater unit is provided.

In accordance with an aspect of the fluid-permeable heater assembly of the present invention, the attachment means mechanically locking the thread structure to the substrate provides a shape-matching or press-fit closure to the substrate. Shape-matching or press-fit closures are two types of mechanical locking that are simple and reliable in mechanically locking components to each other. These two types of closure can be combined. When closing with matching in shape, the fastening means and the base have the corresponding shapes. Fixation can be carried out mainly or exclusively due to frictional forces between the contact surfaces of the fastening means and the base in the area of contact. However, a shape-matching closure can also be achieved, for example by wrapping the threads and the warp around the attachment means. When closed with a press fit, the attachment means and/or the base may comprise resilient parts, such as flexible legs or spring elements. The force applied by the fastening means or parts of the fastening means keeps the thread structure in a state of fixation on the warp.

Shape-matching and press-fit closures can also be combined in the attachment mechanism of the attachment means and the base. For example, the attachment means may include parts made of elastic material. Alternatively or additionally, the attachment means may have a shape that differs from the shape of the corresponding part of the base. For example, the conical leg of the attachment means may be inserted into a base recess having parallel inner walls.

In accordance with another aspect of the fluid-pervious heater assembly of the present invention, the attachment means extend over a portion of the side of the base and comprise resilient legs. These resilient legs press the thread structure against the top surface of the warp. In this case, the thread structure and the base are located between the elastic legs. The thread structure and the warp are fixed between resilient legs, for example legs in the form of leaf springs, attachment means. The elastic force generated by the elastic legs determines the fastening force. The portion of the attachment means protruding from the side of the base can be used as an electrical contact for an external power supply. This makes it possible to make electrical contact with the heating unit from the top or bottom side and at the same time from the side or only from the side. Thus, it is possible to simplify the contact of the heater assembly with electrical connectors located along the inner surface of the walls of the main body of the aerosol generating system. Contact can also be improved by allowing connectors to contact more than one side of the heater assembly.

In accordance with yet another aspect of the fluid-pervious heater assembly of the present invention, the base comprises recesses for receiving a string structure and attachment means therein. The recesses provide the possibility of improving the fixation of the thread structure and contact with it due to the localization of the area of contact with the fastening means on the base or inside it. The notches also provide the ability to help define the contact area, such as the position or size of the contact area. The recesses also make it possible, for example, to limit or prevent displacement, for example sliding, of the attachment means from the warp or along the thread structure during assembly or in the assembled state. Recesses can be made in the surface of the base, preferably in the top surface of the base and the bottom surface of the base. The notches may be made in a portion of the base in depth, or they may extend through the entire base. The recesses may be, for example, grooves, holes or slots.

In accordance with an aspect of the fluid-permeable heater assembly of the present invention, the attachment means are clip-on elements inserted into recesses in the base. These staples are essentially u-shaped and have three legs and a bridge portion between the legs. Bracket elements are easy to manufacture and cheap. The bracket elements can be easily attached to the base, for example, by a linear pressing action. Thus, it is possible to insert the legs of the bracket elements into the holes or recesses of the warp, while finding the thread structure between the warp and the bracket elements. During the assembly process, there is no risk of displacement of the thread structure, since it is fixed in contact with the fasteners and the base. Bracket elements allow various attachment mechanisms or variants thereof. For example, in the case of a shape-matching closure, the legs may be inserted into holes in the base, and the protruding ends of the legs may be bent onto the bottom surface of the base, providing additional fixation of the fastening means on the base. In addition, in the case of using stapled elements, the fixation of the thread structure as well as the surfaces for electrical contact between the thread structure and the fastening means can be improved by simple means. In some preferred embodiments, this is done with recesses and brackets containing appropriate but non-planar contact surfaces. As used herein, the term "non-planar contact surfaces" should be understood to include contact surfaces that are composed of multiple local contact surfaces, and these local contact surfaces may be planar, yet angled to each other such that the resulting contact surface is non-planar.

The increased contact area ensures good electrical contact between the threads and the attachment means. Due to the additional structure on the contact surface, it is also possible to improve the fixation of the thread structure. The possibility of increasing the tensile force acting on the thread structure is provided, which increases the stability of the thread structure. The side of the bracket element facing the recess of the base may have a non-planar shape. The side of the bracket that is to be brought into contact with the battery connector may also have a non-planar shape. In this way, it is possible to increase and optimize the area of contact between the fastening means and the outer connector.

In accordance with another aspect of the fluid-permeable heater assembly of the present invention, said recesses are one or a combination of longitudinal recesses extending through at least a portion of the upper surface of the substrate, individual through holes within the substrate, or recesses in the circumferential surface of the substrate. The different recess types allow for a wide variety of fastening mechanisms and a variety of base shapes and fasteners. Preferably, the longitudinal recesses made in the upper surface of the base provide large areas of contact. The longitudinal recesses may extend through part or all of the top surface of the base. In addition, longitudinal recesses may be provided in the bottom surface. Longitudinal recesses provide the possibility of using flat structures of the heater unit due to the countersinking available for fastening means in the recesses. Longitudinal recesses in the upper surface of the base are particularly preferred for attachment means which extend over the side of the base and for attachment means having protruding resilient legs which are fully inserted into the recesses. In the latter versions, the fastening force acts inside the base. The longitudinal recesses also make it possible to improve the fixation when the longitudinal edges of the fastening means are pressed against the upper surface and the lower surface of the base.

Holes or recesses in the circumferential surface of the base allow for a closure in shape between the attachment means and the base by providing attachment means on the top surface and on the bottom surface, but without adding material to the side of the heater assembly. Thus, the use of a heater assembly will not require size restrictions, for example, the main body of the system.

In some preferred embodiments of the fluid-pervious heater assembly, the attachment means comprise resilient legs that are positioned and locked within the longitudinal recesses. In these embodiments, the fastening force acts in the transverse direction of the base and inside the base. The fastening means, in particular the fastening action of the resilient legs placed inside the recesses, are well protected from the influence of external elements, for example system elements, placed on the upper or lower surface of the heater assembly. Thus, it is possible to prevent the effect of weakening the action of the fastening, for example, by pressing the housing wall against the fastening means. Preferably, the attachment means are recessed into the base, even more preferably substantially completely recessed into the base, except for the flat area of contact. This facilitates manipulation of the substrate during the manufacture of a very compact heater assembly.

The thread structure may partially or completely extend over the opening in the warp. Preferably, the thread structure occupies from about 50 percent to about 95 percent of the area of said hole, for example, it occupies from about 70 percent to about 90 percent of the area of the hole in the warp.

If the filamentary structure occupies the entire area of the opening, the maximum accessible surface area of the liquid or aerosol-forming substrate adjacent to the heater is heated. In this way, strong evaporation is ensured, since the heat affects a large area. In addition, depending on the kind of the aerosol-forming substrate, for example, in the case of a capillary material transporting liquid to the heater, it is possible to support the homogeneous drainage of the aerosol-forming substrate due to the large area to be heated. However, the region not occupied by the substantially flat filament structure may otherwise affect aerosol generation through flow rate and droplet size. This can be useful for optimizing the generation of a predetermined aerosol in a reproducible manner. For example, if the filament structure does not occupy the entire area of the opening, it is possible to more easily pass the evaporated liquid through the heater assembly in those areas that are not occupied by the filament structure. Thus, it is possible to support the formation of an aerosol.

Preferably, the substantially flat thread structure is in direct contact with the capillary material transporting fluid to the heater. This facilitates the creation of a continuous flow of liquid to a substantially flat filamentary structure for generating an aerosol. Preferably, the transport medium is homogeneous.

In some preferred embodiments of the fluid-permeable heater assembly of the present invention, the filament structure comprises a plurality of filaments forming a mesh.

This mesh provides stability and strength to the thread structure. It also allows easier handling during manufacture than, for example, an array of threads arranged parallel to each other. In addition, it is possible to select and vary the ability of the mesh to hold liquid between the threads, for example by varying the type of weave or the structure of the mesh. The mesh is structurally robust: thus the mesh has excellent fail-safe properties due to the redundancy of available electrical paths. Even if one thread of the mesh is broken or not in full contact with the heater, the thread structure can continue to function with only a slight change in the overall electrical and thermal characteristics.

In some preferred embodiments of the fluid-permeable heater assembly of the present invention, the base is an electrically insulating, substantially flat, preferably disc-shaped member. The flat heater assembly is compact and allows for easy handling during fabrication and assembly of the system.

According to another aspect of the present invention, a method for assembling a grid heater for an aerosol generating system is provided. This method comprises the steps of providing a warp, making a hole through the warp, and placing electrically conductive filaments over the hole in the warp. In the following steps of the method, the threads are mechanically fixed to the base using fastening means, thus pressing the threads to the base, and provide electrical contact with the threads through the fastening means.

According to an aspect of the method according to the present invention, the method further comprises making recesses in the base and pressing the fastening means into these recesses. With this indentation, it is possible to apply attachment means to the warp thread structure as a result of linear movement. Thus, it is possible to assemble the heater in one fixation step. The indentation may be substantially perpendicular to the base or substantially parallel to the base. Indentation substantially perpendicular to the base refers to indentation into the top surface from a point above the base. Indentation substantially parallel to the warp refers to the application of the attachment means on the side of the warp or to the application of the attachment means by sliding them over the thread-warp structure.

Preferably, in the step of inserting the attachment means, a tensile force is applied in the direction of the plane of the substantially flat thread structure. This provides the advantage of stretching the substantially flat thread structure to a predetermined degree of tension. In this way, improved surface contact between the substantially flat thread structure and the warp is provided. Additionally, in this way improved surface contact between the thread structure and the transport medium is possible.

In accordance with another aspect of the method according to the present invention, the attachment force is applied in a direction substantially perpendicular to the top surface of the substrate. Typical examples of such variants are the "sandwich" fastening means, when the thread structure and the warp are clamped between parts of the fastening means.

In accordance with another aspect of the method according to the present invention, the attachment force is applied in a direction essentially parallel to the top surface, and inside the base. Examples of such implementations are fastening means that are placed inside the base, preferably inside the recess of the base, made to receive the fastening means or part of the fastening means provided for fixing. The other part of the fastening means provided for electrical contact with the fastening means is then placed outside said recess.

In accordance with another aspect of the method according to the present invention, the thread structure includes a first part and second parts that form a combined thread, with the second parts located at either end of the thread structure, and the first part is located between the second parts. In the context of this description, the term "combined" means that the first part and the second parts form a single body that provides an electrical path from one second part to another second part through the first part.

In such a configuration, the second parts may be made from a material different from that of the first part, or alternatively or additionally, they may be made from the same material but have a different shape. For example, if the thread structure contains a mesh, the second parts may differ in shape from the first part due to the higher mesh density compared to the first part. Alternatively, the thread structure can be made using two different materials for the first part and for the second parts, wherein the material constituting the second parts is more ductile and easier to deform than the material of the first part. In this case, for example, the first part may be made of stainless steel and the second parts may be made of copper. Alternatively, the second parts may be made of foil and the first part may be placed between them so that the first part and the second parts form a combined thread.

If the thread structure comprises first and second parts, this thread structure may be subjected to an additional processing step in which sufficient force is applied to the second parts so that they form a foil-like material. In the context of this description, a "foil-like material" is a material subjected to a force that has flattened the material while maintaining the united thread.

Additional aspects and advantages of the method according to the present invention have been disclosed above in relation to the fluid-permeable heater assembly and will not be described again.

According to another aspect of the present invention, an aerosol generating system is provided, preferably an electrically controlled smoking system. The aerosol generating system comprises a container part (storage) having a housing for storing a liquid aerosol-forming substrate, the housing having an open end. The system further comprises a fluid-permeable heater assembly according to the present invention as described above. This heater assembly is positioned downstream of said housing such that the thread structure of the fluid-permeable heater assembly is positioned over the open end of the housing. The system further comprises a power supply connector for electrically connecting means for attaching the fluid-permeable heater assembly to a power supply.

The advantages and aspects of the aerosol generating system have been described above with respect to the heater assembly and will not be described again. Thanks to the available variants of the fixing means and the corresponding variants of the heater assembly, it is possible to adapt and manufacture the heater assembly, for example, in such a way that it is suitable for the existing main bodies of the said systems. These main bodies may already include a cartridge containing the aerosol-forming substrate, electrical circuitry, a power source, and electrical connectors for contact with the heater assembly.

The container part preferably includes a capillary material. The capillary material may have a fibrous or spongy structure. The capillary material preferably comprises a bundle of capillaries. For example, the capillary material may contain a plurality of fibers or filaments or other thin tubes with channels. The fibers or filaments may be substantially aligned to transfer fluid to the heater. Alternatively, the capillary material may comprise a sponge-like or foam-like material. The structure of the capillary material forms many small channels or tubes through which liquid can be transported by capillary action. The capillary material may comprise any suitable material or combination of materials. Examples of suitable materials are sponge or foam materials, ceramic or graphite based materials in the form of fibers or sintered powders, foamed metal or plastic materials, fibrous material, for example, made from twisted or extruded fibers such as cellulose acetate, polyester, terylene or polypropylene. fibers, nylon fibers, or ceramics. The capillary material may have any suitable capillarity so as to be used for liquids with different physical properties. A liquid has physical properties, including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, that allow the liquid to be transported through a capillary material by capillary action.

Preferably, the capillary material is in contact with the electrically conductive filaments. The capillary material may extend within the spaces between the filaments. The heater assembly can draw the liquid aerosol-forming substrate into said interstices by capillary action. The capillary material may be in contact with the electrically conductive filaments for substantially the entire length of said opening. The cartridge may contain two or more different capillary materials, wherein the first capillary material in contact with the heating element has a higher thermal decomposition temperature, and the second material in contact with the first capillary material, but not in contact with heating element, has a lower thermal decomposition temperature. The first capillary material effectively acts as a spacer separating the heating element from the second capillary material such that the second capillary material is not exposed to temperatures above its thermal decomposition temperature. In the context of this description, the term "thermal decomposition temperature" means the temperature at which the material begins to decompose and lose weight as a result of the formation of gaseous products. The second capillary material provides the advantage of being able to occupy more volume than the first capillary material and being able to hold more of the aerosol-forming substrate than the first capillary material. The second capillary material may have a superior capillary response compared to the first capillary material. The second capillary material may be less expensive than the first capillary material. The second capillary material may be polypropylene.

The first capillary material may separate the heater assembly from the second capillary material by at least 1.5 millimeters, preferably 1.5 millimeters to 2 millimeters, to provide sufficient temperature reduction downstream of the first capillary material.

The container part may be positioned on one side of the conductive filaments and the airflow channel on the opposite side of the conductive filaments relative to the container part, such that the air flow downstream of the conductive filaments entrains the vaporized aerosol-forming substrate.

The system may further comprise an electrical circuit connected to the heater assembly and an electrical power source; this electrical circuit is configured to control the electrical resistance of the heater assembly or one or more filaments of the heater assembly, and to control the power supply to the heater assembly depending on the electrical resistance of the heater assembly or one or more filaments.

The circuitry may include a microprocessor, which may be a programmable microprocessor. The electrical circuit may contain additional electronic components. The electrical circuitry may be configured to control the power supply to the heater assembly. Power may be supplied to the heater assembly continuously after system activation, or may be supplied intermittently, such as from puff to puff.

Power may be supplied to the heater assembly in the form of electrical current pulses.

The advantage of the system is that it contains a power source, usually a battery, inside the main part of the case. Alternatively, the power supply may be another type of charge storage device, such as a capacitor. The power source may have a large enough capacity to allow continuous generation of the aerosol over a period of time of about 6 minutes. In another example, the power supply may have sufficient capacity to enable a predetermined number of activations of the heater assembly.

Hereinafter, the present invention will be described with respect to its embodiments, which are illustrated by the following graphics, where:

Figure 1 shows a variant of the implementation of the node-heater;

Figure 2 shows the heater assembly according to claim 1 in the installed state;

On figa, 3b shows the details of the attachment mechanisms;

On figa-4d shows additional means of attachment and attachment mechanisms.

Figures 5a, 5b show top views of the heater assembly;

On figa-6c shows the node-heater with side sliding means (fig.6a) fastening; details of the mechanism (fig.6b) fastening; and fastening means (Fig. 6c);

Figures 7a, 7b show the heater assembly with staples as clamping means and details of the cross-sectional parts of the base;

Fig. 8 shows another embodiment of a heater assembly with brackets as attachment means;

Figure 9 shows the nodes-heaters with installed brackets;

Figure 10 shows another embodiment of the heater assembly with brackets as attachment means;

Figures 11a-11d show thread structures having first and second portions and methods for making the combined threads.

In the above drawings, like reference numerals are used to refer to the same or similar elements.

Figure 1 and figure 2 shows the node-heater, including an electrically insulating base 1, a heating element, thread structure in the form of a grid 2 and two clips 3 for attaching the grid to the base. The base 1 is in the form of a circular disk and includes a hole 100 located in the center. The base also contains two slots 4 located parallel to each other next to the corresponding sides of the square hole 100. The mesh 2 in the form of a strip is located over the hole and the slots 4. The width of the mesh is less than the width of the opening 100, and thus open portions 101 of said opening not covered by the mesh are formed on both sides of the mesh. The two clips 3 comprise flat contact parts 31 which are to be arranged parallel to the top surface of the base. The contact parts 31 are intended to be in contact with the heater assembly via an electrical connector extending from the battery. Two clamps 3 also contain longitudinal bent fastening parts 30 inserted into the slots 4 of the base 1.

The clamps 3 can be made by bending from a metal blank, such as stainless steel or copper sheet, for example.

Figure 2 shows the heater assembly in the assembled state, while the mesh 2 is pressed into the slots 4 when the clamps 3 are pressed perpendicular to the upper surface of the base in the slot (the direction of the indentation is shown by the arrows in figure 1). The clamps 3 provide a tensile force 5 acting on the mesh 2 in a direction coplanar to the upper surface of the base 1. Both clamps 3 create tensile forces 5 acting in mutually opposite directions. Tensile forces 5 support the planar arrangement of the grid 2 and contribute to the stabilization of the grid in the plane of the base 1.

Fig. 3a shows a detailed view of the clip 3 inserted into the slot 4. The end portions 20 of the net 2 are pressed into the slots by the clip fastening portions 30 and firmly fixed in the slots. The bent attachment portions 30 apply an attachment force 50 to the walls of the slots in a direction parallel to the top surface of the base, inside the base. The edges 301 of the clamps 3 can act as spikes, additionally fixing the grid in the slots and improving the strength of the electrical contact of the clamps 3 with the grid 2.

FIG. 3b shows an alternative variant of the folded fastening portion 30 of the clip 3 inserted into a longitudinal slot 4. The slot has convex walls 6 which press the clip in the narrowest folded region 7 of the inserted fastening part 30. In this embodiment, the narrowest bent part 7 is located approximately in the middle of the height of the base 1. In this way, the bent part 8 (larger), inserted as deep as possible into the slot 4, is additionally protected from leaving the slot.

Figures 4a-4d show variants of clamps 3 that fix the mesh on the upper surface and on the lower surface of the base 1. The upper and lower edges 9, 10 of the attachment are pressed into the upper and lower surface of the base 1. The mesh 2 is located between at least the upper edge 9 fasteners and the top surface of the base. The top edge 9 is slightly inclined towards the rear so as to provide a more stable structure when the mesh 2 is stretched against this rear direction.

The clips 3 comprise side portions 32 located on the side or circumferential side of the base 1. The side portions 32 of the clips provide additional support for the fixation and contact of the mesh 2 through contact with the side of the base 1.

In Figs. 4a and 4b, the mesh 2 is drawn around the circumferential surface of the base 1 and fixed on both sides of the base. The fastening edges 9, 10 of the clamp 3 in FIG. 4b do not extend along the entire length of the clamp in the longitudinal direction. These edges are formed by cutouts in the sheet blank of the clamp and are bent towards the upper and lower surfaces of the base 1, respectively.

The side walls of the clamp 3 in Fig. 4c are smoothly curved, thus changing the elasticity of the clamp. The upper and lower surfaces of the base 1 have longitudinal recesses 12, 13 in the form of grooves for accommodating the edges 9, 10 of the clamp, as well as the mesh 2 (the upper recess 9 exists only in this embodiment).

The side 32 of the clip 3 in Fig. 4d is in close contact with the side of the base as well as part of the bottom surface of the base 1. On the bottom surface of the base the clip forms a triangle 33 in side view. The length of the triangle 33 can be adapted and changed to change the holding force of the clamp 3.

As shown in FIGS. 4a-4d, the clip-on heater assembly can be assembled by placing the mesh 2 over the base 1 and bending the clips at the same time as mounting the heater. When the clamps are bent, a tensile force is applied to the mesh.

Figures 5a and 5b show top views of clip-on heater assemblies having longitudinal attachment portions such as, for example, those shown in the embodiments of Figures 4a-4d and Figures 6a-6c. The clips 3 in FIG. 5 are substantially rectangular in top and bottom views. These clips are easy to make; for example, they are obtained by bending a rectangular blank of sheet material or wire. As shown in fig.5b, the clips have a shape adapted to the shape of the base. Thus, the round base is provided with clips corresponding to the round shape of the circumferential surface of the base. Such a heater assembly is very compact and takes up little space also in the lateral directions.

6a-6c show the heater assembly and clamping brackets; these clamps are able to slide over the prepared structure of the base 1 and mesh 2. The base has longitudinal recesses 12, 13 in the form of grooves in the upper surface and in the lower surface. The recesses 12, 13 are arranged parallel to each other and to the hole 100 in the surface and extend across the entire surface of the base 1. The recesses 12, 13 facilitate the lateral sliding of the clips 3 over the mesh and base structure. Preferably, the mesh 2 is strongly tensioned before the clamp brackets 3 are slid into the base 1. To prevent the mesh from tearing or getting stuck in the mesh as it slides over it, the edges of the clamp bracket 15 are rounded. This can be seen in Fig. 6c, which shows a prefabricated clamp 3 as a fastening means.

7a, 7b, 8 and 10 show fastening means 3 in the form of two staples and corresponding recesses 12 in the base 1. A mesh (not shown) is placed over at least part of the opening 100 of the base. The staples are inserted vertically into recesses 12, 120, 122 of the base. In the fixed position, the bridges of the staples are placed in the longitudinal recesses 12 made in the upper surface of the base 1. These legs have a length greater than the thickness of the base 1. The protruding ends of the legs are bent and sunk into the corresponding recesses 19 in the lower surface of the base. Due to the bending of the legs around the base, secure fixation and contact with the mesh 2 by means of staples is ensured. 7a and 8, four legs of two staples are inserted into four recesses 121 located in the circumferential surface of the disc-shaped base. On figa bridges staples have stamped protrusion 17 roof-shaped form. Such a shape can exactly match the shape of the battery connectors. The longitudinal recesses 12 in the base also have a corresponding roof-shaped protrusion 18 at the bottom, as can be seen in the cross-section shown in detail in Fig. 7b.

8, the staple bridges have an engraved v-shaped recess 20 which corresponds to the engraved v-shaped recess 21 of the recesses 12.

The stretching of the mesh is due to the corresponding protrusions and recesses 17,18; 20, 21 in brackets and notches 12.

Figure 9 shows in the assembled state two heater units shown in Fig.7a and 8. In this case, the heater unit shown in Fig.7a corresponds to the option shown in Fig.9 below, and the heater unit shown in rice. 8 corresponds to the variant shown in Fig. 9 above.

Figure 10 shows another version of the heater assembly with brackets as fastening means 3 . The base has two longitudinal recesses 12 to accommodate the bridge parts of the staples. The base also has one hole 122 at each end of the longitudinal recesses 12. The legs of the staples are pressed into the holes 122 and fix the mesh (not shown) in contact between the recesses 12 and the staples. The staples 3 can be attached to the base 1 by matching the shape between the legs of the staples and the holes 122. However, the bottom surface of the base may also have recesses to accommodate the ends of the legs folded over to the bottom surface of the base.

11a-11d show methods for producing a combined yarn having first and second parts. On figa the first part is shown as a grid 1101, and the second part is shown as a grid 1103 higher density. For example, the first part may comprise a less dense mesh than the second parts, however, both the first and second parts may be made from the same material, such as stainless steel. 11b, the first part is shown as a mesh 1101 containing the first material, and the second parts 1105 are shown as end parts made of a second material different from the first material. In this case, the second material is more plastic than the first material. As an example, the first part 1101 may be made of stainless steel and the second part 1105 may be copper. On figs shows the application of force to the second parts 1108 by pressing elements 1107 so that the second parts 1108 are deformed and turned into a material 1109 type of foil, as shown in fig.11d.

After obtaining the finished combined thread, including the first part 1101 and the second parts 1103, 1105 and 1109, this combined thread can be fixed on the base using one of the above methods by placing the second parts 1103, 1105, 1109 so that the clamps 3 are electrically connected to these second parts.

The present invention has been described in detail based on the embodiments illustrated in the drawings. However, other options for attachment mechanisms and their associated attachment means and base shapes may be considered. For example, the mesh can be fixed to the base with screws. These screws are electrically conductive and serve as electrical contacts for the thread structure and as connectors for the battery. A locking engagement between the fastening means and the base can also be used in the form of, for example, push buttons or latches. In this case, the fastening means form one part of the latch, and the base is equipped with a corresponding other part of the latch.

Claims (23)

1. A fluid-permeable heater assembly for aerosol generating systems, comprising: a base including a hole through this base, an electrically conductive, essentially flat filament structure located over said hole, and mechanical fixation means mechanically fixing the thread structure on said warp, wherein the thread structure includes a first part and second parts forming an integrated thread, the first part being provided between the second parts, while the thread structure contains a plurality of threads forming a grid, and wherein the second parts comprise a mesh with a greater mesh density than the mesh density of the first part. 2. The fluid-permeable heater assembly of claim 1, wherein the first part and the second parts are formed from the same material. 3. A fluid-permeable heater assembly according to any one of the preceding claims, wherein the electrical resistance of the filamentary structure is between 0.3 and 4 ohms. 4. A fluid-permeable heater assembly according to any one of the preceding claims, wherein the thread structure has a thickness of 0.5 microns to 500 microns. 5. A fluid-permeable heater assembly according to any one of the preceding claims, comprising spaces between the threads of the thread structure having a width of 25 to 75 microns. 6. A fluid-permeable heater assembly according to any one of the preceding claims, wherein the open area of the grid is between 25 and 60 percent. 7. A fluid-permeable heater assembly according to any one of the preceding claims, wherein the mesh may or may not be woven. 8. A fluid-permeable heater assembly according to any one of the preceding claims, wherein the mechanical locking means are electrically conductive and serve as electrical contacts to provide heating current through the filamentary structure. 9. A fluid-permeable heater assembly according to any one of the preceding claims, wherein the mechanical locking means is the fastening means. 10. A fluid-permeable heater assembly as claimed in claim 9, wherein the attachment means mechanically locking the thread structure to the warp provide shape-matching closure to the warp or press-fit closure to the warp. 11. A fluid-permeable heater assembly according to any one of claims 9, 10, wherein the attachment means extend over a portion of the side of the warp and comprise resilient legs pressing the thread structure against the top surface of the warp, the thread structure and the warp being located between the elastic legs. 12. A fluid-permeable heater assembly according to any one of claims 9 to 11, wherein the base comprises recesses for receiving the thread structure and attachment means in these recesses. 13. A fluid-permeable heater assembly according to any one of claims 9 to 12, wherein the recesses are one or a combination of longitudinal recesses extending through at least a portion of the top surface of the base, individual through holes in the base, or recesses in the circumferential surface. basics. 14. A fluid-permeable heater assembly according to any one of the preceding claims, wherein the base is an electrically insulating, substantially flat, preferably disc-shaped member. 15. An aerosol generating system, comprising: a container part containing a housing for storing a liquid aerosol-forming substrate having an open end, a fluid-permeable heater assembly according to any one of claims 1 to 14, positioned adjacent said housing such that the thread structure of the fluid-permeable heater assembly is positioned over the open end of the housing, and a power supply connector for electrically connecting the mechanical means of fixing the fluid-permeable heater assembly to the power supply.

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