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WO2024068538A1 - Aerosol-generating device with a heater module holder - Google Patents

Aerosol-generating device with a heater module holder Download PDF

Info

Publication number
WO2024068538A1
WO2024068538A1 PCT/EP2023/076384 EP2023076384W WO2024068538A1 WO 2024068538 A1 WO2024068538 A1 WO 2024068538A1 EP 2023076384 W EP2023076384 W EP 2023076384W WO 2024068538 A1 WO2024068538 A1 WO 2024068538A1
Authority
WO
WIPO (PCT)
Prior art keywords
heater
upstream part
heater casing
aerosol
module holder
Prior art date
Application number
PCT/EP2023/076384
Other languages
French (fr)
Inventor
Michel BESSANT
Jun Jie HOW
Andrew Antonio Dorot JAYAG
Eva SAADE LATTORE
Enrico TURRINI
Jun Wei Yim
Original Assignee
Philip Morris Products S.A.
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 Philip Morris Products S.A. filed Critical Philip Morris Products S.A.
Publication of WO2024068538A1 publication Critical patent/WO2024068538A1/en

Links

Classifications

    • 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
    • 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
    • A24F40/70—Manufacture
    • 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

Definitions

  • the present disclosure relates to an aerosol-generating device with a heater module holder.
  • the present disclosure further relates to a method of assembling an aerosol-generating device using a heater module holder.
  • an aerosol-generating device for generating an inhalable vapor. Such devices may heat an aerosol-forming substrate contained in an aerosol-generating article without burning the aerosol-forming substrate.
  • the aerosol-generating device may comprise a heating module comprising a heating element and including a heating chamber for receiving the aerosol-generating article.
  • the heating module may be housed in a heater casing.
  • the aerosol-forming substrate Upon heating to a target temperature, the aerosol-forming substrate vaporises to form an aerosol.
  • an aerosol-generating device which may comprise a heater casing having a heater casing downstream part and a heater casing upstream part.
  • the heater casing may house a heater module.
  • the heater module may be mounted in the heater casing on a heater module holder.
  • the heater module holder may be connected to the heater casing upstream part.
  • an aerosol-generating device comprising a heater casing having a heater casing downstream part and a heater casing upstream part.
  • the heater casing houses a heater module.
  • the heater module is mounted in the heater casing on a heater module holder.
  • the heater module holder is connected to the heater casing upstream part.
  • the heater module may easily be mounted within the heater casing owing to the heater module holder.
  • the heater module holder may provide a reliable connection between the heater module and the heater casing upstream part.
  • the heater module holder may reliably position the heater module within the heater casing.
  • the heater module holder may allow an easy positioning of the heater module in relation to the heater casing upstream part.
  • Aerosol generating devices comprise a proximal end through which, in use, an aerosol exits the device.
  • the proximal end of the aerosol generating device may also be referred to as the mouth end or the downstream end.
  • the mouth end is downstream of the distal end.
  • the distal end of the aerosol generating article may also be referred to as the upstream end.
  • Components, or portions of components, of the aerosol generating device may be described as being upstream or downstream of one another based on their relative positions with respect to the airflow path of the aerosol generating device.
  • the heater module holder may comprise a protruding upstream connection section.
  • the protruding upstream connection section may be configured for connection to the heater casing upstream part.
  • the heater casing upstream part may comprise a mounting recess.
  • the mounting recess may be configured for receiving the protruding upstream connection section.
  • connection system may allow a reliable connection between the heater module holder and the heater casing upstream part. This may allow an easy connection between the heater module holder and the heater casing upstream part. Owing to the protruding upstream connection section, the heater module holder may simply be placed in the mounting recess of the heater casing upstream part in order to provide a reliable connection.
  • An inner surface of the mounting recess of the heater casing upstream part may be spaced apart from an opposing outer surface of the protruding upstream connection section. This may create a mounting gap.
  • the inner surface of the mounting recess of the heater casing upstream part may be spaced apart from the opposing outer surface of the protruding upstream connection section when the protruding upstream connection section is received in the mounting recess.
  • the mounting gap may be formed when the heater module holder is received in the mounting recess of the heater casing upstream part.
  • the mounting gap may provide a tolerance when connecting the heater module holder to the heater casing upstream part. This may allow to produce the heater module holder and the heater casing upstream part with greater manufacturing tolerances. This may allow the heater module holder being correctly aligned to the heater casing upstream part despite large manufacturing tolerances.
  • the mounting gap may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part.
  • the relative movement of the heater module holder in relation to the heater casing upstream part may advantageously allow more tolerance when positioning the heater module holder in the heater casing upstream part.
  • the mounting gap may allow a relative movement of the heater module holder in relation to the heater casing upstream part during the assembly of the aerosol-generating device.
  • the correct position may be fixed by employing connection elements. This may reliably position the heater module holder in the correct position with regard to the heater casing upstream part. This may also allow an easy and correct positioning of the heater module in relation to the heater casing upstream part. This may be due to the heater module being mounted on the heater module holder during the assembly of the aerosol-generating device.
  • a width of the protruding upstream connection section of the heater module holder may be between 6 percent to 15 percent smaller than a width of the mounting recess of the heater casing upstream part.
  • the width of the protruding upstream connection section may be between 8 percent to 12 percent more preferably 10 percent smaller than the width of the mounting recess of the heater casing upstream part.
  • the aerosol-generating device may comprise a longitudinal axis.
  • the mounting gap may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part perpendicular to the longitudinal axis of the aerosol-generating device.
  • a flexible sealing element may be arranged between the protruding upstream connection section and the mounting recess.
  • the flexible sealing element may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part.
  • the flexible sealing element may be located at a downstream end of the protruding upstream connection section of the heater module holder.
  • the heater module holder may comprise the flexible sealing element.
  • the flexible sealing element may also be configured to provide an additional movement of the protruding upstream connection section of the heater module holder in the recess of the heater casing upstream part owing to the flexibility of the flexible sealing element.
  • the flexible sealing element may also be compressible. This may allow an additional movement of the heater module holder relative to the heater casing upstream part. This may allow a tilt of the heater module holder in relation to the heater casing upstream part. In particular, the tilt of the heater module holder may be a relative to the longitudinal axis of the aerosol-generating device. This may provide an additional way of movement of the heater module holder relative to the heater casing upstream part.
  • the flexible sealing element may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part.
  • the flexible sealing element may also be configured to seal the mounting gap at the downstream part of the mounting gap. This may provide the possibility to render the heater casing airtight despite the mounting gap.
  • the flexible sealing element may be formed of one of rubber or an elastomer, in particular silicone rubber.
  • the heater casing upstream part may comprise an air-flow path for providing air into the heater casing.
  • the heater casing downstream part may comprise an air-flow path for providing air to the heater casing.
  • the heater module holder may comprise a through hole for providing an air-flow path through the heater module holder into the heater module mounted on the heater module holder.
  • the heater casing downstream part, the heater casing upstream part and the heater module holder may be tubular.
  • This may provide a tubular heater casing with a heater module which may be configured to receive an aerosol-generating article which is also tubular or which is formed as a rod.
  • the aerosol-generating article may have the overall shape of a cigarette.
  • an aerosol-generating article refers to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol.
  • an aerosol-generating article may be a smoking article that generates an aerosol that is directly inhalable into a user’s lungs through the user's mouth.
  • An aerosolgenerating article may be disposable.
  • an ‘aerosol-generating device’ relates to a device that interacts with an aerosol-forming substrate to generate an aerosol.
  • the aerosol-forming substrate may be part of an aerosol-generating article, for example part of a smoking article.
  • An aerosol-generating device may be a smoking device that interacts with an aerosol-forming substrate of an aerosolgenerating article to generate an aerosol that is directly inhalable into a user’s lungs thorough the user's mouth.
  • An aerosol-generating device may be a holder.
  • the device is preferably a portable or handheld device that is comfortable to hold between the fingers of a single hand.
  • aerosol-forming substrate refers to a substrate capable of releasing volatile compounds that can form an aerosol.
  • the volatile compounds may be released by heating or combusting the aerosol-forming substrate.
  • the aerosol-forming substrate may be solid or liquid or may comprise both solid and liquid components.
  • An aerosolforming substrate may be part of an aerosol-generating article.
  • the mounting gap may be a radial mounting gap. This may allow an easy way to rotate the heater module holder relative to the heater casing upstream part. This may allow an easy way to allow a relative movement of the heater module holder in relation to the heater casing upstream part perpendicular to the longitudinal axis of the aerosol-generating device.
  • the flexible sealing element may comprise an O-ring.
  • the flexible sealing element may be formed as an O-ring. This may allow an easy alignment between the flexible sealing element and a radial mounting gap. This may allow the flexible sealing element to reliably seal a downstream end of the radial mounting gap.
  • a diameter of the protruding upstream connection section of the heater module holder may be between 6 percent to 15 percent smaller than a diameter of the mounting recess of the heater casing upstream part.
  • the diameter of the protruding upstream connection section may be between 8 percent to 12 percent, more preferably 10 percent smaller than the diameter of the mounting recess of the heater casing upstream part.
  • This may provide a radial mounting gap with sufficient dimensions to reliably position the heater module holder relative to the heater casing upstream part.
  • One or both of the heater casing upstream part and the heater casing downstream part may comprise connections.
  • the connections may be configured for mounting the heater casing downstream part to the heater casing upstream part. This may block a position of the heater module holder relative to the heater casing upstream part.
  • the connections may comprise holes in both of the heater casing upstream part and the heater casing downstream part.
  • a connection element may be positioned in both the holes of the heater casing upstream part and the heater casing downstream part for locking both parts together. This also may block a further movement of the heater module holder inside of the heater casing relative to the heater casing downstream part.
  • the connection elements may for example comprise screws which may be configured for screwing the heater casing downstream part to the heater casing upstream part.
  • One or both of the holes in the heater casing upstream part and the heater casing downstream part may comprise threads for accommodating the connection elements, in particular the screws.
  • the heater module may be mounted on the heater module holder by protruding elements and corresponding grooves configured for receiving the protruding elements.
  • the heater module may comprise a heating element.
  • the heating element may at least partially circumscribe a heating chamber.
  • the heating chamber may be located within the heater casing.
  • the heating chamber may be configured for receiving an aerosol-generating article.
  • the heating chamber is configured for receiving an aerosol-generating article comprising an aerosol-forming substrate.
  • the heating chamber may comprise a cavity into which the aerosol-generating article is inserted.
  • the cavity may be tubular.
  • the cavity may include a thermally conductive material.
  • the cavity may comprise a tube made of metal, preferably stainless-steel or the tube may comprise a ceramic.
  • the heating chamber may comprise an opening at the downstream end of the heating chamber for receiving the aerosolgenerating article. The opening may also serve as an air outlet.
  • the heating chamber may comprise a heating element configured for heating the aerosol-generating article.
  • the heating element may comprise a substrate layer of flexible material.
  • the substrate layer may comprise a thermally stable polymer, preferably polyimide.
  • the heating element may be arranged on the substrate layer.
  • the heating element may be a resistive heating element.
  • the heating element may contain wire connections configured for being connected with the control element.
  • the heating element may comprise heating tracks arranged on the substrate layer.
  • the heating tracks may comprise a thermally conductive material, preferably metals, such as stainless steel.
  • the heating tracks may be electrically connected to said wire connections.
  • the heating chamber may comprise a tube made of metal wrapped into said substrate layer of flexible material, wherein the heating elements are arranged on the substrate layer.
  • the portion of the heating element, which is in contact with the aerosol-forming substrate is heated as a result of the electrical current passing through the heating element.
  • the current is supplied by a power source.
  • this portion of the heating element is configured to reach a temperature of between about 140 degree Celsius and about 270 degree Celsius in use.
  • the heating element is configured to reach a temperature of between about 180 degree Celsius and about 240 degree Celsius.
  • the heating chamber configured for receiving the aerosol-forming article may be housed in the heater casing and may be spaced apart from the inner walls of the heater casing. This may provide thermal insulation between the inner walls of the heater casing and the heating chamber in which heat is generated.
  • the space between the inner walls of the heater casing and the heating chamber may be airtight.
  • the space may be filled with air.
  • the space may also be filled with a gaseous mixture, preferably an inert gas such as nitrogen. This may provide a particularly good insulation between the inner walls of the heater casing and the heating chamber.
  • the heater casing may comprise a downstream heater opening for inserting the aerosol-generating article into the heating chamber.
  • the downstream heater opening may be located at the downstream end of the airflow path through the aerosol-generating device.
  • the heater casing upstream part may comprise an air-flow tube.
  • the air-flow tube may be configured for providing air to the heater module.
  • the air-flow tube may be configured to provide air to the heater casing.
  • the year-flow tube may be configured to provide air to the heater module located within the heater casing.
  • the air-flow tube may comprise heat stable polymers.
  • the air-flow tube may comprise the same heat stable polymers as the heater casing.
  • the one-piece element comprising the heater casing upstream part and the air-flow tube on the one hand and the heater casing downstream part on the other hand may comprise the same heat stable polymers.
  • the air-flow tube or the one-piece element, respectively, may comprise one or both of polyphenylene sulfone (PPSU) and polyether ether ketone (PEEK).
  • PPSU polyphenylene sulfone
  • PEEK polyether ether ketone
  • the heater casing upstream part and the air-flow tube may be formed as a one-piece element.
  • the heater casing upstream part and the air-flow tube may be formed as a monolithic element.
  • This may provide the heater casing upstream part and the air-flow tube in one-piece. This may provide an easy method to assemble an internal component of the aerosolgenerating device including a heater casing with a heater module and an upstream air-flow tube.
  • This one-piece element may be formed for example via moulding, for example injection moulding. This may enable an easy one-piece connection between the heater casing upstream part and the air-flow tube without the necessity of forming connections configured for mounting the heater casing upstream part to the air-flow tube.
  • the one-piece element or the monolithic element of the heater casing upstream part and the air-flow tube may be formed from polymers or from metal.
  • the heater casing may comprise inner walls.
  • the inner walls of the heater casing may comprise one or both of a thermally reflective coating, and a polymer.
  • the thermally stable polymer may be selected from a group of polymers consisting of polyphenylene sulfone (PPSU) and polyether ether ketone (PEEK).
  • PPSU polyphenylene sulfone
  • PEEK polyether ether ketone
  • the thermally stable polymer may comprise a polyphenylene sulfone (PPSU).
  • the thermally reflective coating may comprise a metal. Such a metal coating may reflect the heat emitted from the heating chamber of the heater casing.
  • the metal coating may comprise metals such as gold or aluminium, preferably gold.
  • the inner walls of the heater casing also may comprise a heat insulation material.
  • the aerosol-generating device may furthermore comprise a control element.
  • the control element may be configured for controlling the operation of the aerosol-generating device.
  • the control element may comprise a substrate, for example a printed circuit board.
  • Control circuitry may be mounted on the substrate.
  • the control circuitry may be configured for controlling operation of the aerosol-generating device.
  • the heating element of the heater module may comprise electrical connections for connection to the control element.
  • the heater casing upstream part may comprise through holes for directing the electrical connections through the heater casing upstream part.
  • control element may be located adjacent to the heater casing upstream part in the aerosol-generating device.
  • the heater casing, the air-flow tube and the control element may be mounted to one another to form a self-supporting component of the aerosol-generating device.
  • the self-supporting component may simplify the assembly of the aerosol-generating device.
  • the self-supporting component may support itself and its own weight without the necessity for an external frame for arranging the heater casing, the air-flow tube and the control element relative to each other.
  • the heater casing, the air-flow tube and the control element may hold each other in position.
  • the self-supporting component may form a separate unit of the aerosol-generating device.
  • the self-supporting component may form an internal component of the aerosol-forming device.
  • the internal component of the aerosol-forming device may be partly located within an outer casing of the aerosol-generating device.
  • the self-supporting component may preferably be completely housed within the outer casing of the aerosol-generating device.
  • the method may comprise the method step of providing a heater module and a heater module holder.
  • the method may furthermore comprise providing a heater casing downstream part, and a heater casing upstream part for assembly of a heater casing.
  • the heater casing may house the heater module.
  • the method may comprise the step of mounting the heater module holder on the heater casing upstream part. Positioning the heater module holder relative to the heater casing upstream part may also position the heater module relative to the heater casing upstream part.
  • the method may furthermore comprise the method step of connecting the heater casing downstream part to the heater casing upstream part with the mounted heater module to form the heater casing.
  • Another embodiment of the invention provides a method for assembling an aerosolgenerating device.
  • the method comprises the method step of providing a heater module and a heater module holder.
  • the method furthermore provides the step of providing a heater casing downstream part, a heater casing upstream part for assembly of the heater casing, wherein the heater casing houses the heater module.
  • the method comprises the method step of mounting the heater module on the heater module holder.
  • the method also comprises mounting the heater module holder on the heater casing upstream part, wherein the positioning of the heater module relative to the heater casing upstream part is done by positioning the heater module holder relative to the heater casing upstream part.
  • the method comprises the method step of connecting the heater casing downstream part to the heater casing upstream part with the mounted heater module to form the heater casing.
  • the heater module holder may comprise a protruding upstream connection section.
  • the upstream connection section may be configured for connection to the heater casing upstream part.
  • the heater casing upstream part may comprise a mounting recess.
  • the mounting recess may be configured for receiving the protruding upstream connection section of the heater module holder.
  • the protruding upstream connection section of the heater module holder may be positioned within the mounting recess when mounting the heater module holder on the heater casing upstream part.
  • the heater module may first be mounted on the heater module holder. Subsequently, the arrangement of the heater module on the heater module holder may be positioned within the mounting recess of the heater casing upstream part. The relative positioning of the heater module holder in relation to the heater casing upstream part may then also lead to a positioning of the heater module which is already mounted on the heater module holder relative to the heater casing upstream part.
  • the heater module holder may be positioned within the mounting recess of the heater casing upstream part and the relative position of the heater module holder may be locked in relation to the heater casing upstream part. Subsequently the heater module may then be mounted on the heater module holder which is connected to the heater casing upstream part.
  • the heater module is first mounted on the heater module holder and then subsequently this arrangement is positioned within the mounting recess of the heater casing upstream part.
  • An inner surface of the mounting recess may be spaced apart from an opposing outer surface of the protruding upstream connection section. This may create a mounting gap when the protruding upstream connection section of the heater module holder is received in the mounting recess of the heater casing upstream part.
  • the heater module holder and the heater casing upstream part may be moved relative to each other within the mounting gap in the mounting recess in order to position the heater module holder relative to the heater casing upstream part.
  • the aerosol-generating device may comprise a longitudinal axis.
  • the heater module holder arranged in the mounting recess of the heater casing upstream part may be moved relative to each other perpendicular to the longitudinal axis of the aerosol-generating device when mounting the heater module holder on the heater casing upstream part.
  • a flexible sealing element may be arranged between the protruding upstream connection section and the mounting recess.
  • the heater module holder and the heater casing upstream part may be moved relative to each other on the flexible sealing element in the mounting recess in order to position the heater module holder relative to the heater casing upstream part.
  • the heater module holder and the heater casing upstream part may be rotated relative to each other on the flexible sealing element.
  • the heater module holder and the heater casing upstream part may also be tilted relative to each other on the flexible sealing element with regard to the longitudinal axis of the aerosol-generating device.
  • Aerosol-generating device comprising: a heater casing with having a heater casing downstream part and a heater casing upstream part, the heater casing housing a heater module, wherein the heater module is mounted in the heater casing on a heater module holder, wherein the heater module holder is connected to the heater casing upstream part.
  • Example Ex2 The aerosol-generating device according to example Ex1 , wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream part and wherein the heater casing upstream part comprises a mounting recess configured for receiving the protruding upstream connection section.
  • Example Ex3 The aerosol-generating device according to the preceding example, wherein an inner surface of the mounting recess is spaced apart from an opposing outer surface of the protruding upstream connection section for creating a mounting gap.
  • Example Ex4 The aerosol-generating device according to the preceding example, wherein the mounting gap is configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part, preferably wherein the aerosol-generating device comprises a longitudinal axis and wherein the mounting gap is configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part perpendicular to the longitudinal axis of the device.
  • Example Ex5 The aerosol-generating device according to the preceding examples Ex3 or Ex4, wherein a flexible sealing element is arranged between the protruding upstream connection section and the mounting recess, the flexible sealing element configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part, preferably wherein the sealing element is configured to allow a rotational movement of the heater module holder in relation to the heater casing upstream part.
  • Example Ex6 The aerosol-generating device according to any of the preceding examples, wherein the heater casing downstream part, the heater casing upstream part and the heater module holder are tubular, preferably further dependent on any of the examples Ex3 to Ex5, wherein the mounting gap is a radial mounting gap.
  • Example Ex7 The aerosol-generating device according to the preceding example further dependent on example Ex5, wherein the flexible sealing element comprises an O-ring.
  • Example Ex8 The aerosol-generating device according to any of the preceding examples, wherein one or both of the heater casing upstream part and the heater casing downstream part comprises connections configured for mounting the heater casing downstream part to the heater casing upstream part and for locking a position of the heater module holder relative to the heater casing upstream part.
  • Example Ex9 The aerosol-generating device according to any of the preceding examples, wherein the heater module is mounted on the heater module holder by protruding elements and corresponding grooves configured for receiving the protruding elements.
  • Example Ex10 The aerosol-generating device according to any of the preceding examples, wherein the heater module comprises a heating element, the heating element at least partially circumscribing a heating chamber.
  • Example Ex11 The aerosol-generating device according to any of the preceding examples, wherein the heater casing upstream part comprises an air-flow tube configured for providing air to the heater module, preferably wherein the heater casing upstream part and the air-flow tube are formed as a one-piece element, more preferably wherein the heater casing upstream part and the air-flow tube are formed as a monolithic element.
  • Example Ex12 The aerosol-generating device according to any of the preceding examples, further comprising a control element configured for controlling operation of the aerosol-generating device.
  • Example Ex13 The aerosol-generating device according to the preceding example, further being dependent on example Ex10, wherein the heating element further comprises electrical connections for connection to the control element, preferably wherein the heater casing upstream part comprises through holes for directing the electrical connection through the heater casing upstream part.
  • Example Ex14 The aerosol-generating device according to example Ex11 and
  • Example Ex15 The aerosol-generating device according to the preceding example, further comprising an outer casing, wherein the self-supporting component is at least partly housed within the outer casing.
  • Example Ex16 Method for assembling an aerosol-generating device, comprising the method steps of:
  • Example Ex17 Method according to the preceding example, wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream part and wherein the heater casing upstream part comprises a mounting recess configured for receiving the protruding upstream connection section and wherein the protruding upstream connection section is positioned within the mounting recess when mounting the heater module holder on the heater casing upstream part.
  • Example Ex18 Method according to the preceding example, wherein an inner surface of the mounting recess is spaced apart from an opposing outer surface of the protruding upstream connection section for creating a mounting gap and wherein the heater module holder and the heater casing upstream part are moved relative to each other within the mounting gap in the mounting recess in order to position the heater module holder relative to the heater casing upstream part, preferably wherein the aerosol-generating device comprises a longitudinal axis and wherein the heater module holder and the heater casing upstream part are moved relative to each other perpendicular to the longitudinal axis.
  • Example Ex19 Method according to any of the preceding examples Ex17 or
  • a flexible sealing element is arranged between the protruding upstream connection section and the mounting recess, and wherein the heater module holder and the heater casing upstream part are moved relative to each other on the flexible sealing element in the mounting recess in order to position the heater module holder relative to the heater casing upstream part, preferably wherein the heater module holder and the heater casing upstream part are rotated relative to each other on the flexible sealing element.
  • Fig. 1 shows a schematic exploded view of parts of an aerosol-generating device including the heater casing upstream part, the heater casing downstream part, the heater module and the heater module holder;
  • Fig. 2 depicts a schematic cross-sectional view of a relative spatial arrangement of a heater module holder and the heater module in relation to parts of the heater casing upstream part;
  • Fig. 3 depicts another schematic cross-sectional view of a heater module holder with a flexible sealing element indicating the mounting gap to a heater casing upstream part;
  • Fig. 4 depicts a schematic exploded view of the mounting of the heater module on the heater module holder and of the mounting of the heater module holder to the heater casing upstream part;
  • Fig. 5 shows a schematic view of an aerosol-generating device including a self- supporting internal element including the heater casing with the air-flow tube mounted to a control element.
  • Fig. 1 shows a schematic exploded view of a heater assembly for an aerosol-generating device 10.
  • the heater assembly comprises a heater casing upstream part 12 which forms a one-piece member, preferably a monolithic element with an upstream air-flow tube 12A. Furthermore, a heater module holder 14 is present onto which a heater module 16 with electrical connections 22 for connection to a control element can be mounted.
  • the heater casing downstream part 18 can be connected to the heater casing upstream part 12 in order to form the heater casing surrounding the heater module.
  • Connection elements 20, for example screws can connect the heater casing downstream part 18 to the heater casing upstream part 12.
  • the heater module 16 mounted on the heater module holder 14 is also reliably locked within the heater casing.
  • the heater module holder 14 serves as a mounting element for the heater module 16 and allows a reliable alignment between the heater casing upstream part 12 and the heater module 16 despite larger manufacturing tolerances of both elements.
  • Fig. 2 depicts a schematic cross-sectional view of the heater module 16 relative to the heater module holder 14 and an upper part of heater casing upstream part 12.
  • the heater module holder 14 comprises a protruding upstream connection section 14A.
  • This protruding upstream connection section 14A can be received in the mounting recess 12B of the heater casing upstream part 12 as indicated by the dashed lines.
  • a relative movement of the protruding upstream connection section 14A in the mounting recess 12B of the heater casing upstream part 12 allows a more reliable alignment of the heater module holder 14 and therefore the heater module 16 relative to the heater casing upstream part.
  • the heater module holder 14 comprises a heater module holder recess 14B which is configured to receive heater module protruding connection elements 16A of the heater module 16 as indicated by the dashed lines.
  • the heater module holder 14 allows a reliable alignment of the heater module 16 relative to the heater casing upstream part 12 along a longitudinal axis 11 of the aerosol-generating device.
  • Fig. 3 depicts the interaction between the heater module holder 14 and the upper part of the heater casing upstream part 12 in greater detail.
  • An inner surface 12C of the mounting recess of the heater casing upstream part 12 is spaced away from an outer surface 14B of the protruding upstream connection section 14A. This can be achieved when a width of the protruding upstream connection section 14A is smaller than a width of the mounting recess 12B.
  • This creates a mounting gap 13.
  • This mounting gap 13 allows relative movement of the heater casing upstream part 12 in relation to the heater module holder 14.
  • the mounting gap 13 allows a relative movement of the heater casing upstream part 12 in relation to the heater module holder 14 perpendicular to the longitudinal axis 1 1 of the aerosolgenerating device.
  • a flexible sealing element 24, for example an O-ring is present.
  • This flexible sealing element 24 also allows rotational movement of the heater module holder 14 relative to the heater casing upstream part 12.
  • the flexible sealing element 24 also may allow a tilt of the heater module holder 14 relative to the heater casing upstream part 12 with regard to the longitudinal axis 1 1 of the aerosol-generating device.
  • Fig. 4 depicts in greater detail the mounting of the heater module 16 on the heater module holder 14, as indicated by the arrow. Additionally, the heater module holder 14 can be mounted in the recess of the heater casing upstream part 12 as indicated by an arrow.
  • Fig. 5 depicts an aerosol-generating device 10 with an outer casing 32.
  • This aerosolgenerating device includes a self-supporting internal element made up of the heater casing downstream part 18 mounted to the heater casing upstream part 12 and the control element 26.
  • the air-flow tube is formed as a monolithic member with the heater casing upstream part.
  • the air-flow tube is mounted to the control element to form the self-supporting component of the aerosol-generating device.
  • the self-supporting element comprising the heater casing downstream part, the heater casing upstream part, the airflow tube and the control element also includes the heater module 16 mounted on the heater module holder 14 which are housed in the heater casing.
  • the control element 26 preferably comprises a substrate, such as a printed circuit board also including control circuitry 30 for controlling an operation of the aerosol-generating device.
  • a connection element 22, such as a screw is present, which connects the heater casing downstream part 18 to the heater casing upstream part 12 and which furthermore locks the heater module holder 14 in a fixed position within the heater casing.
  • the electrical connections 22 are directed through through holes of the heater casing upstream part 12 towards the control element in order to provide an electrical connection to the control element.
  • a power source 28, such as a battery is located inside the outer casing 32 for providing energy for operating the aerosol-generating device.

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Abstract

The invention relates to an aerosol-generating device comprising (10): • a heater casing having a heater casing downstream part (18) and a heater casing upstream part (12), the heater casing housing a heater module (16), • wherein the heater module is mounted in the heater casing on a heater module holder (14), wherein the heater module holder is connected to the heater casing upstream part. • This device allows for an easier mounting of the heater module relative to heater casing upstream part owing to the heater module holder.

Description

AEROSOL-GENERATING DEVICE WITH A HEATER MODULE HOLDER
The present disclosure relates to an aerosol-generating device with a heater module holder. The present disclosure further relates to a method of assembling an aerosol-generating device using a heater module holder.
It is known to provide an aerosol-generating device for generating an inhalable vapor. Such devices may heat an aerosol-forming substrate contained in an aerosol-generating article without burning the aerosol-forming substrate. The aerosol-generating device may comprise a heating module comprising a heating element and including a heating chamber for receiving the aerosol-generating article. The heating module may be housed in a heater casing.
Upon heating to a target temperature, the aerosol-forming substrate vaporises to form an aerosol.
It would be desirable to provide an aerosol-generating device which can easily be assembled and which is compact. It would be desirable to provide an aerosol-generating device with a high manufacturing tolerance. It would be desirable to provide an aerosolgenerating device wherein the heating module can easily be positioned within the heater casing.
According to an embodiment of the invention there is provided an aerosol-generating device which may comprise a heater casing having a heater casing downstream part and a heater casing upstream part. The heater casing may house a heater module. The heater module may be mounted in the heater casing on a heater module holder. The heater module holder may be connected to the heater casing upstream part.
Another embodiment of the invention provides an aerosol-generating device comprising a heater casing having a heater casing downstream part and a heater casing upstream part. The heater casing houses a heater module. The heater module is mounted in the heater casing on a heater module holder. The heater module holder is connected to the heater casing upstream part.
The heater module may easily be mounted within the heater casing owing to the heater module holder. The heater module holder may provide a reliable connection between the heater module and the heater casing upstream part. The heater module holder may reliably position the heater module within the heater casing. The heater module holder may allow an easy positioning of the heater module in relation to the heater casing upstream part.
As used herein, the terms “upstream”, and “downstream”, are used to describe the relative positions of components, or portions of components, of the aerosol-generating device in relation to the direction in which air flows through the aerosol generating device during use thereof along the air flow path. Aerosol generating devices according to the invention comprise a proximal end through which, in use, an aerosol exits the device. The proximal end of the aerosol generating device may also be referred to as the mouth end or the downstream end. The mouth end is downstream of the distal end. The distal end of the aerosol generating article may also be referred to as the upstream end. Components, or portions of components, of the aerosol generating device may be described as being upstream or downstream of one another based on their relative positions with respect to the airflow path of the aerosol generating device.
The heater module holder may comprise a protruding upstream connection section. The protruding upstream connection section may be configured for connection to the heater casing upstream part. The heater casing upstream part may comprise a mounting recess. The mounting recess may be configured for receiving the protruding upstream connection section.
Such a connection system may allow a reliable connection between the heater module holder and the heater casing upstream part. This may allow an easy connection between the heater module holder and the heater casing upstream part. Owing to the protruding upstream connection section, the heater module holder may simply be placed in the mounting recess of the heater casing upstream part in order to provide a reliable connection.
An inner surface of the mounting recess of the heater casing upstream part may be spaced apart from an opposing outer surface of the protruding upstream connection section. This may create a mounting gap.
In particular, the inner surface of the mounting recess of the heater casing upstream part may be spaced apart from the opposing outer surface of the protruding upstream connection section when the protruding upstream connection section is received in the mounting recess. The mounting gap may be formed when the heater module holder is received in the mounting recess of the heater casing upstream part. The mounting gap may provide a tolerance when connecting the heater module holder to the heater casing upstream part. This may allow to produce the heater module holder and the heater casing upstream part with greater manufacturing tolerances. This may allow the heater module holder being correctly aligned to the heater casing upstream part despite large manufacturing tolerances.
The mounting gap may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part. The relative movement of the heater module holder in relation to the heater casing upstream part may advantageously allow more tolerance when positioning the heater module holder in the heater casing upstream part.
The mounting gap may allow a relative movement of the heater module holder in relation to the heater casing upstream part during the assembly of the aerosol-generating device. After correct positioning of the heater module holder in relation to the heater casing upstream part, the correct position may be fixed by employing connection elements. This may reliably position the heater module holder in the correct position with regard to the heater casing upstream part. This may also allow an easy and correct positioning of the heater module in relation to the heater casing upstream part. This may be due to the heater module being mounted on the heater module holder during the assembly of the aerosol-generating device.
A width of the protruding upstream connection section of the heater module holder may be between 6 percent to 15 percent smaller than a width of the mounting recess of the heater casing upstream part. Preferably, the width of the protruding upstream connection section may be between 8 percent to 12 percent more preferably 10 percent smaller than the width of the mounting recess of the heater casing upstream part.
This may provide a mounting gap large enough to reliably position the heater module holder relative to the heater casing upstream part despite large manufacturing tolerances.
The aerosol-generating device may comprise a longitudinal axis. The mounting gap may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part perpendicular to the longitudinal axis of the aerosol-generating device.
This may allow an easy alignment of the heater module holder and therefore of the heater module relative to the heater casing upstream part along the longitudinal axis of the aerosol-generating device.
This may allow an easy formation of a continuous airflow path leading through the heater module and the heater casing upstream part.
A flexible sealing element may be arranged between the protruding upstream connection section and the mounting recess. The flexible sealing element may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part.
The flexible sealing element may be located at a downstream end of the protruding upstream connection section of the heater module holder. The heater module holder may comprise the flexible sealing element.
This may allow an easy arrangement of the flexible sealing element relative to the mounting recess when mounting the protruding upstream connection section of the heater module holder within the mounting recess of the heater casing upstream part.
The flexible sealing element may also be configured to provide an additional movement of the protruding upstream connection section of the heater module holder in the recess of the heater casing upstream part owing to the flexibility of the flexible sealing element.
The flexible sealing element may also be compressible. This may allow an additional movement of the heater module holder relative to the heater casing upstream part. This may allow a tilt of the heater module holder in relation to the heater casing upstream part. In particular, the tilt of the heater module holder may be a relative to the longitudinal axis of the aerosol-generating device. This may provide an additional way of movement of the heater module holder relative to the heater casing upstream part.
The flexible sealing element may be configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part.
This may provide an additional freedom of movement of the heater casing upstream part relative to the heater module holder.
The flexible sealing element may also be configured to seal the mounting gap at the downstream part of the mounting gap. This may provide the possibility to render the heater casing airtight despite the mounting gap.
The flexible sealing element may be formed of one of rubber or an elastomer, in particular silicone rubber.
The heater casing upstream part may comprise an air-flow path for providing air into the heater casing. The heater casing downstream part may comprise an air-flow path for providing air to the heater casing. Similarly, the heater module holder may comprise a through hole for providing an air-flow path through the heater module holder into the heater module mounted on the heater module holder.
The heater casing downstream part, the heater casing upstream part and the heater module holder may be tubular.
This may provide a tubular heater casing with a heater module which may be configured to receive an aerosol-generating article which is also tubular or which is formed as a rod. The aerosol-generating article may have the overall shape of a cigarette.
As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. For example, an aerosol-generating article may be a smoking article that generates an aerosol that is directly inhalable into a user’s lungs through the user's mouth. An aerosolgenerating article may be disposable.
As used herein, an ‘aerosol-generating device’ relates to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate may be part of an aerosol-generating article, for example part of a smoking article. An aerosol-generating device may be a smoking device that interacts with an aerosol-forming substrate of an aerosolgenerating article to generate an aerosol that is directly inhalable into a user’s lungs thorough the user's mouth. An aerosol-generating device may be a holder. The device is preferably a portable or handheld device that is comfortable to hold between the fingers of a single hand.
As used herein, the term “aerosol-forming substrate” refers to a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds may be released by heating or combusting the aerosol-forming substrate. The aerosol-forming substrate may be solid or liquid or may comprise both solid and liquid components. An aerosolforming substrate may be part of an aerosol-generating article.
The mounting gap may be a radial mounting gap. This may allow an easy way to rotate the heater module holder relative to the heater casing upstream part. This may allow an easy way to allow a relative movement of the heater module holder in relation to the heater casing upstream part perpendicular to the longitudinal axis of the aerosol-generating device.
The flexible sealing element may comprise an O-ring. The flexible sealing element may be formed as an O-ring. This may allow an easy alignment between the flexible sealing element and a radial mounting gap. This may allow the flexible sealing element to reliably seal a downstream end of the radial mounting gap.
In the case of a radial mounting gap, a diameter of the protruding upstream connection section of the heater module holder may be between 6 percent to 15 percent smaller than a diameter of the mounting recess of the heater casing upstream part. Preferably, the diameter of the protruding upstream connection section may be between 8 percent to 12 percent, more preferably 10 percent smaller than the diameter of the mounting recess of the heater casing upstream part.
This may provide a radial mounting gap with sufficient dimensions to reliably position the heater module holder relative to the heater casing upstream part.
One or both of the heater casing upstream part and the heater casing downstream part may comprise connections. The connections may be configured for mounting the heater casing downstream part to the heater casing upstream part. This may block a position of the heater module holder relative to the heater casing upstream part. The connections may comprise holes in both of the heater casing upstream part and the heater casing downstream part. A connection element may be positioned in both the holes of the heater casing upstream part and the heater casing downstream part for locking both parts together. This also may block a further movement of the heater module holder inside of the heater casing relative to the heater casing downstream part. The connection elements may for example comprise screws which may be configured for screwing the heater casing downstream part to the heater casing upstream part. One or both of the holes in the heater casing upstream part and the heater casing downstream part may comprise threads for accommodating the connection elements, in particular the screws.
The heater module may be mounted on the heater module holder by protruding elements and corresponding grooves configured for receiving the protruding elements.
This may provide an easy method for mounting the heater module on the heater module holder. This may also provide an easy way to align the heater module on the heater module holder relative to heater casing upstream part. The heater module may comprise a heating element. The heating element may at least partially circumscribe a heating chamber. The heating chamber may be located within the heater casing. The heating chamber may be configured for receiving an aerosol-generating article.
The heating chamber is configured for receiving an aerosol-generating article comprising an aerosol-forming substrate. The heating chamber may comprise a cavity into which the aerosol-generating article is inserted. The cavity may be tubular. The cavity may include a thermally conductive material. The cavity may comprise a tube made of metal, preferably stainless-steel or the tube may comprise a ceramic. The heating chamber may comprise an opening at the downstream end of the heating chamber for receiving the aerosolgenerating article. The opening may also serve as an air outlet.
The heating chamber may comprise a heating element configured for heating the aerosol-generating article. The heating element may comprise a substrate layer of flexible material. The substrate layer may comprise a thermally stable polymer, preferably polyimide.
The heating element may be arranged on the substrate layer. The heating element may be a resistive heating element. The heating element may contain wire connections configured for being connected with the control element. The heating element may comprise heating tracks arranged on the substrate layer. The heating tracks may comprise a thermally conductive material, preferably metals, such as stainless steel. The heating tracks may be electrically connected to said wire connections.
In particular, the heating chamber may comprise a tube made of metal wrapped into said substrate layer of flexible material, wherein the heating elements are arranged on the substrate layer.
The portion of the heating element, which is in contact with the aerosol-forming substrate is heated as a result of the electrical current passing through the heating element. The current is supplied by a power source. In one embodiment, this portion of the heating element is configured to reach a temperature of between about 140 degree Celsius and about 270 degree Celsius in use. Preferably, the heating element is configured to reach a temperature of between about 180 degree Celsius and about 240 degree Celsius.
The heating chamber configured for receiving the aerosol-forming article may be housed in the heater casing and may be spaced apart from the inner walls of the heater casing. This may provide thermal insulation between the inner walls of the heater casing and the heating chamber in which heat is generated. The space between the inner walls of the heater casing and the heating chamber may be airtight. The space may be filled with air. The space may also be filled with a gaseous mixture, preferably an inert gas such as nitrogen. This may provide a particularly good insulation between the inner walls of the heater casing and the heating chamber. The heater casing may comprise a downstream heater opening for inserting the aerosol-generating article into the heating chamber. The downstream heater opening may be located at the downstream end of the airflow path through the aerosol-generating device.
The heater casing upstream part may comprise an air-flow tube. The air-flow tube may be configured for providing air to the heater module. The air-flow tube may be configured to provide air to the heater casing. The year-flow tube may be configured to provide air to the heater module located within the heater casing.
The air-flow tube may comprise heat stable polymers. The air-flow tube may comprise the same heat stable polymers as the heater casing. In particular, the one-piece element comprising the heater casing upstream part and the air-flow tube on the one hand and the heater casing downstream part on the other hand may comprise the same heat stable polymers. The air-flow tube or the one-piece element, respectively, may comprise one or both of polyphenylene sulfone (PPSU) and polyether ether ketone (PEEK).
The heater casing upstream part and the air-flow tube may be formed as a one-piece element. Preferably, the heater casing upstream part and the air-flow tube may be formed as a monolithic element.
This may provide the heater casing upstream part and the air-flow tube in one-piece. This may provide an easy method to assemble an internal component of the aerosolgenerating device including a heater casing with a heater module and an upstream air-flow tube.
This one-piece element may be formed for example via moulding, for example injection moulding. This may enable an easy one-piece connection between the heater casing upstream part and the air-flow tube without the necessity of forming connections configured for mounting the heater casing upstream part to the air-flow tube.
The one-piece element or the monolithic element of the heater casing upstream part and the air-flow tube may be formed from polymers or from metal.
The heater casing may comprise inner walls. The inner walls of the heater casing may comprise one or both of a thermally reflective coating, and a polymer. The thermally stable polymer may be selected from a group of polymers consisting of polyphenylene sulfone (PPSU) and polyether ether ketone (PEEK). Preferably, the thermally stable polymer may comprise a polyphenylene sulfone (PPSU). The thermally reflective coating may comprise a metal. Such a metal coating may reflect the heat emitted from the heating chamber of the heater casing. The metal coating may comprise metals such as gold or aluminium, preferably gold. The inner walls of the heater casing also may comprise a heat insulation material.
The aerosol-generating device may furthermore comprise a control element. The control element may be configured for controlling the operation of the aerosol-generating device. The control element may comprise a substrate, for example a printed circuit board. Control circuitry may be mounted on the substrate. The control circuitry may be configured for controlling operation of the aerosol-generating device.
The heating element of the heater module may comprise electrical connections for connection to the control element. In particular, the heater casing upstream part may comprise through holes for directing the electrical connections through the heater casing upstream part.
This may provide an easy way of directing the electrical connections through the heater casing upstream part to the control element. The control element may be located adjacent to the heater casing upstream part in the aerosol-generating device.
The heater casing, the air-flow tube and the control element may be mounted to one another to form a self-supporting component of the aerosol-generating device.
The self-supporting component may simplify the assembly of the aerosol-generating device. The self-supporting component may support itself and its own weight without the necessity for an external frame for arranging the heater casing, the air-flow tube and the control element relative to each other. The heater casing, the air-flow tube and the control element may hold each other in position. The self-supporting component may form a separate unit of the aerosol-generating device. The self-supporting component may form an internal component of the aerosol-forming device. The internal component of the aerosol-forming device may be partly located within an outer casing of the aerosol-generating device.
The self-supporting component may preferably be completely housed within the outer casing of the aerosol-generating device.
Another embodiment of the invention provides a method for assembling an aerosolgenerating device. The method may comprise the method step of providing a heater module and a heater module holder. The method may furthermore comprise providing a heater casing downstream part, and a heater casing upstream part for assembly of a heater casing. The heater casing may house the heater module. The method may comprise the step of mounting the heater module holder on the heater casing upstream part. Positioning the heater module holder relative to the heater casing upstream part may also position the heater module relative to the heater casing upstream part. The method may furthermore comprise the method step of connecting the heater casing downstream part to the heater casing upstream part with the mounted heater module to form the heater casing.
Another embodiment of the invention provides a method for assembling an aerosolgenerating device. The method comprises the method step of providing a heater module and a heater module holder. The method furthermore provides the step of providing a heater casing downstream part, a heater casing upstream part for assembly of the heater casing, wherein the heater casing houses the heater module. The method comprises the method step of mounting the heater module on the heater module holder. The method also comprises mounting the heater module holder on the heater casing upstream part, wherein the positioning of the heater module relative to the heater casing upstream part is done by positioning the heater module holder relative to the heater casing upstream part. Finally, the method comprises the method step of connecting the heater casing downstream part to the heater casing upstream part with the mounted heater module to form the heater casing.
The heater module holder may comprise a protruding upstream connection section. The upstream connection section may be configured for connection to the heater casing upstream part. The heater casing upstream part may comprise a mounting recess. The mounting recess may be configured for receiving the protruding upstream connection section of the heater module holder. The protruding upstream connection section of the heater module holder may be positioned within the mounting recess when mounting the heater module holder on the heater casing upstream part.
This may provide an easy method to mount the heater module holder on the heater casing upstream part.
The heater module may first be mounted on the heater module holder. Subsequently, the arrangement of the heater module on the heater module holder may be positioned within the mounting recess of the heater casing upstream part. The relative positioning of the heater module holder in relation to the heater casing upstream part may then also lead to a positioning of the heater module which is already mounted on the heater module holder relative to the heater casing upstream part.
Alternatively, first the heater module holder may be positioned within the mounting recess of the heater casing upstream part and the relative position of the heater module holder may be locked in relation to the heater casing upstream part. Subsequently the heater module may then be mounted on the heater module holder which is connected to the heater casing upstream part.
Preferably, the heater module is first mounted on the heater module holder and then subsequently this arrangement is positioned within the mounting recess of the heater casing upstream part.
An inner surface of the mounting recess may be spaced apart from an opposing outer surface of the protruding upstream connection section. This may create a mounting gap when the protruding upstream connection section of the heater module holder is received in the mounting recess of the heater casing upstream part. During mounting of the heater module holder to the heater casing upstream part, the heater module holder and the heater casing upstream part may be moved relative to each other within the mounting gap in the mounting recess in order to position the heater module holder relative to the heater casing upstream part.
The aerosol-generating device may comprise a longitudinal axis. The heater module holder arranged in the mounting recess of the heater casing upstream part may be moved relative to each other perpendicular to the longitudinal axis of the aerosol-generating device when mounting the heater module holder on the heater casing upstream part.
A flexible sealing element may be arranged between the protruding upstream connection section and the mounting recess. The heater module holder and the heater casing upstream part may be moved relative to each other on the flexible sealing element in the mounting recess in order to position the heater module holder relative to the heater casing upstream part.
In particular, the heater module holder and the heater casing upstream part may be rotated relative to each other on the flexible sealing element. The heater module holder and the heater casing upstream part may also be tilted relative to each other on the flexible sealing element with regard to the longitudinal axis of the aerosol-generating device.
This may provide additional ways of movement of the heater module holder relative to the heater casing upstream part.
Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.
Example Ex1 : Aerosol-generating device comprising: a heater casing with having a heater casing downstream part and a heater casing upstream part, the heater casing housing a heater module, wherein the heater module is mounted in the heater casing on a heater module holder, wherein the heater module holder is connected to the heater casing upstream part.
Example Ex2: The aerosol-generating device according to example Ex1 , wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream part and wherein the heater casing upstream part comprises a mounting recess configured for receiving the protruding upstream connection section.
Example Ex3: The aerosol-generating device according to the preceding example, wherein an inner surface of the mounting recess is spaced apart from an opposing outer surface of the protruding upstream connection section for creating a mounting gap.
Example Ex4: The aerosol-generating device according to the preceding example, wherein the mounting gap is configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part, preferably wherein the aerosol-generating device comprises a longitudinal axis and wherein the mounting gap is configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part perpendicular to the longitudinal axis of the device.
Example Ex5: The aerosol-generating device according to the preceding examples Ex3 or Ex4, wherein a flexible sealing element is arranged between the protruding upstream connection section and the mounting recess, the flexible sealing element configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part, preferably wherein the sealing element is configured to allow a rotational movement of the heater module holder in relation to the heater casing upstream part.
Example Ex6: The aerosol-generating device according to any of the preceding examples, wherein the heater casing downstream part, the heater casing upstream part and the heater module holder are tubular, preferably further dependent on any of the examples Ex3 to Ex5, wherein the mounting gap is a radial mounting gap.
Example Ex7: The aerosol-generating device according to the preceding example further dependent on example Ex5, wherein the flexible sealing element comprises an O-ring.
Example Ex8: The aerosol-generating device according to any of the preceding examples, wherein one or both of the heater casing upstream part and the heater casing downstream part comprises connections configured for mounting the heater casing downstream part to the heater casing upstream part and for locking a position of the heater module holder relative to the heater casing upstream part.
Example Ex9: The aerosol-generating device according to any of the preceding examples, wherein the heater module is mounted on the heater module holder by protruding elements and corresponding grooves configured for receiving the protruding elements.
Example Ex10: The aerosol-generating device according to any of the preceding examples, wherein the heater module comprises a heating element, the heating element at least partially circumscribing a heating chamber.
Example Ex11 : The aerosol-generating device according to any of the preceding examples, wherein the heater casing upstream part comprises an air-flow tube configured for providing air to the heater module, preferably wherein the heater casing upstream part and the air-flow tube are formed as a one-piece element, more preferably wherein the heater casing upstream part and the air-flow tube are formed as a monolithic element.
Example Ex12: The aerosol-generating device according to any of the preceding examples, further comprising a control element configured for controlling operation of the aerosol-generating device.
Example Ex13: The aerosol-generating device according to the preceding example, further being dependent on example Ex10, wherein the heating element further comprises electrical connections for connection to the control element, preferably wherein the heater casing upstream part comprises through holes for directing the electrical connection through the heater casing upstream part.
Example Ex14: The aerosol-generating device according to example Ex11 and
EX12, wherein the heater casing, the air-flow tube and the control element are mounted to one another to form a self-supporting component of the aerosol-generating device. Example Ex15: The aerosol-generating device according to the preceding example, further comprising an outer casing, wherein the self-supporting component is at least partly housed within the outer casing.
Example Ex16: Method for assembling an aerosol-generating device, comprising the method steps of:
- providing a heater module and a heater module holder,
- providing a heater casing downstream part, and a heater casing upstream part for assembly of a heater casing, the heater casing housing the heater module,
- mounting the heater module on the heater module holder,
- mounting the heater module holder on the heater casing upstream part, wherein the positioning of the heater module relative to the heater casing upstream part is done by positioning the heater module holder relative to the heater casing upstream part
- connecting the heater casing downstream part to the heater casing upstream part with the mounted heater module to form the heater casing.
Example Ex17: Method according to the preceding example, wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream part and wherein the heater casing upstream part comprises a mounting recess configured for receiving the protruding upstream connection section and wherein the protruding upstream connection section is positioned within the mounting recess when mounting the heater module holder on the heater casing upstream part.
Example Ex18: Method according to the preceding example, wherein an inner surface of the mounting recess is spaced apart from an opposing outer surface of the protruding upstream connection section for creating a mounting gap and wherein the heater module holder and the heater casing upstream part are moved relative to each other within the mounting gap in the mounting recess in order to position the heater module holder relative to the heater casing upstream part, preferably wherein the aerosol-generating device comprises a longitudinal axis and wherein the heater module holder and the heater casing upstream part are moved relative to each other perpendicular to the longitudinal axis.
Example Ex19: Method according to any of the preceding examples Ex17 or
Ex18, wherein a flexible sealing element is arranged between the protruding upstream connection section and the mounting recess, and wherein the heater module holder and the heater casing upstream part are moved relative to each other on the flexible sealing element in the mounting recess in order to position the heater module holder relative to the heater casing upstream part, preferably wherein the heater module holder and the heater casing upstream part are rotated relative to each other on the flexible sealing element.
Features described in relation to one embodiment may equally be applied to other embodiments of the invention. The invention will be further described, by way of example only, with reference to the accompanying drawings in which:
Fig. 1 shows a schematic exploded view of parts of an aerosol-generating device including the heater casing upstream part, the heater casing downstream part, the heater module and the heater module holder;
Fig. 2 depicts a schematic cross-sectional view of a relative spatial arrangement of a heater module holder and the heater module in relation to parts of the heater casing upstream part;
Fig. 3 depicts another schematic cross-sectional view of a heater module holder with a flexible sealing element indicating the mounting gap to a heater casing upstream part;
Fig. 4 depicts a schematic exploded view of the mounting of the heater module on the heater module holder and of the mounting of the heater module holder to the heater casing upstream part;
Fig. 5 shows a schematic view of an aerosol-generating device including a self- supporting internal element including the heater casing with the air-flow tube mounted to a control element.
In the following elements with the same functionality are marked with the same reference numerals throughout all the figures.
Fig. 1 shows a schematic exploded view of a heater assembly for an aerosol-generating device 10. The heater assembly comprises a heater casing upstream part 12 which forms a one-piece member, preferably a monolithic element with an upstream air-flow tube 12A. Furthermore, a heater module holder 14 is present onto which a heater module 16 with electrical connections 22 for connection to a control element can be mounted. The heater casing downstream part 18 can be connected to the heater casing upstream part 12 in order to form the heater casing surrounding the heater module. Connection elements 20, for example screws can connect the heater casing downstream part 18 to the heater casing upstream part 12. When the heater casing downstream part 18 is connected to the heater casing upstream part 12 via the connection elements, then the heater module 16 mounted on the heater module holder 14 is also reliably locked within the heater casing. The heater module holder 14 serves as a mounting element for the heater module 16 and allows a reliable alignment between the heater casing upstream part 12 and the heater module 16 despite larger manufacturing tolerances of both elements.
Fig. 2 depicts a schematic cross-sectional view of the heater module 16 relative to the heater module holder 14 and an upper part of heater casing upstream part 12. The heater module holder 14 comprises a protruding upstream connection section 14A. This protruding upstream connection section 14A can be received in the mounting recess 12B of the heater casing upstream part 12 as indicated by the dashed lines. A relative movement of the protruding upstream connection section 14A in the mounting recess 12B of the heater casing upstream part 12 allows a more reliable alignment of the heater module holder 14 and therefore the heater module 16 relative to the heater casing upstream part. The heater module holder 14 comprises a heater module holder recess 14B which is configured to receive heater module protruding connection elements 16A of the heater module 16 as indicated by the dashed lines. The heater module holder 14 allows a reliable alignment of the heater module 16 relative to the heater casing upstream part 12 along a longitudinal axis 11 of the aerosol-generating device.
Fig. 3 depicts the interaction between the heater module holder 14 and the upper part of the heater casing upstream part 12 in greater detail. An inner surface 12C of the mounting recess of the heater casing upstream part 12 is spaced away from an outer surface 14B of the protruding upstream connection section 14A. This can be achieved when a width of the protruding upstream connection section 14A is smaller than a width of the mounting recess 12B. This creates a mounting gap 13. This mounting gap 13 allows relative movement of the heater casing upstream part 12 in relation to the heater module holder 14. In particular, the mounting gap 13 allows a relative movement of the heater casing upstream part 12 in relation to the heater module holder 14 perpendicular to the longitudinal axis 1 1 of the aerosolgenerating device. Additionally, a flexible sealing element 24, for example an O-ring is present. This flexible sealing element 24 also allows rotational movement of the heater module holder 14 relative to the heater casing upstream part 12. The flexible sealing element 24 also may allow a tilt of the heater module holder 14 relative to the heater casing upstream part 12 with regard to the longitudinal axis 1 1 of the aerosol-generating device.
Fig. 4 depicts in greater detail the mounting of the heater module 16 on the heater module holder 14, as indicated by the arrow. Additionally, the heater module holder 14 can be mounted in the recess of the heater casing upstream part 12 as indicated by an arrow.
Fig. 5 depicts an aerosol-generating device 10 with an outer casing 32. This aerosolgenerating device includes a self-supporting internal element made up of the heater casing downstream part 18 mounted to the heater casing upstream part 12 and the control element 26. The air-flow tube is formed as a monolithic member with the heater casing upstream part. The air-flow tube is mounted to the control element to form the self-supporting component of the aerosol-generating device. The self-supporting element comprising the heater casing downstream part, the heater casing upstream part, the airflow tube and the control element also includes the heater module 16 mounted on the heater module holder 14 which are housed in the heater casing. The control element 26 preferably comprises a substrate, such as a printed circuit board also including control circuitry 30 for controlling an operation of the aerosol-generating device. A connection element 22, such as a screw is present, which connects the heater casing downstream part 18 to the heater casing upstream part 12 and which furthermore locks the heater module holder 14 in a fixed position within the heater casing. The electrical connections 22 are directed through through holes of the heater casing upstream part 12 towards the control element in order to provide an electrical connection to the control element. Additionally, a power source 28, such as a battery is located inside the outer casing 32 for providing energy for operating the aerosol-generating device.

Claims

1 . Aerosol-generating device comprising: a heater casing having a heater casing downstream part and a heater casing upstream part, the heater casing housing a heater module, wherein the heater module is mounted in the heater casing on a heater module holder, wherein the heater module holder is connected to the heater casing upstream part, wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream part and wherein the heater casing upstream part comprises a mounting recess configured for receiving the protruding upstream connection section, and wherein an inner surface of the mounting recess is spaced apart from an opposing outer surface of the protruding upstream connection section for creating a mounting gap.
2. The aerosol-generating device according to the preceding claim, wherein the mounting gap is configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part, preferably wherein the aerosol-generating device comprises a longitudinal axis and wherein the mounting gap is configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part perpendicular to the longitudinal axis of the device.
3. The aerosol-generating device according to any of the preceding claims, wherein a flexible sealing element is arranged between the protruding upstream connection section and the mounting recess, the flexible sealing element configured to allow a relative movement of the heater module holder in relation to the heater casing upstream part, preferably wherein the sealing element is configured to allow a rotational movement of the heater module holder in relation to the heater casing upstream part.
4. The aerosol-generating device according to any of the preceding claims, wherein the heater casing downstream part, the heater casing upstream part and the heater module holder are tubular, preferably wherein the mounting gap is a radial mounting gap.
5. The aerosol-generating device according to the preceding claim further dependent on claim 3, wherein the flexible sealing element comprises an O-ring.
6. The aerosol-generating device according to any of the preceding claims, wherein one or both of the heater casing upstream part and the heater casing downstream part comprises connections configured for mounting the heater casing downstream part to the heater casing upstream part and for locking a position of the heater module holder relative to the heater casing upstream part.
7. The aerosol-generating device according to the preceding claim, wherein the heater module comprises a heating element and wherein the heating element further comprises electrical connections for connection to the control element, preferably wherein the heater casing upstream part comprises through holes for directing the electrical connection through the heater casing upstream part.
8. The aerosol-generating device according to any of the preceding claims, wherein the heater casing upstream part comprises an air-flow tube configured for providing air to the heater module, and wherein the aerosol-generating device further comprises a control element configured for controlling operation of the aerosol-generating device and wherein the heater casing, the air-flow tube and the control element are mounted to one another to form a self-supporting component of the aerosol-generating device.
9. The aerosol-generating device according to the preceding claim, further comprising an outer casing, wherein the self-supporting component is at least partly housed within the outer casing.
10. Method for assembling an aerosol-generating device, comprising the method steps of:
- providing a heater module and a heater module holder,
- providing a heater casing downstream part, and a heater casing upstream part for assembly of a heater casing, the heater casing housing the heater module,
- mounting the heater module on the heater module holder,
- mounting the heater module holder on the heater casing upstream part, wherein the positioning of the heater module relative to the heater casing upstream part is done by positioning the heater module holder relative to the heater casing upstream part
- connecting the heater casing downstream part to the heater casing upstream part with the mounted heater module to form the heater casing,
- wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream part and wherein the heater casing upstream part comprises a mounting recess configured for receiving the protruding upstream connection section and wherein the protruding upstream connection section is positioned within the mounting recess when mounting the heater module holder on the heater casing upstream part, and
- wherein an inner surface of the mounting recess is spaced apart from an opposing outer surface of the protruding upstream connection section for creating a mounting gap and wherein the heater module holder and the heater casing upstream part are moved relative to each other within the mounting gap in the mounting recess in order to position the heater module holder relative to the heater casing upstream part.
11. Method according to the preceding claim, wherein the aerosol-generating device comprises a longitudinal axis and wherein the heater module holder and the heater casing upstream part are moved relative to each other perpendicular to the longitudinal axis.
12. Method according to any of the preceding claims 10 or 11 , wherein a flexible sealing element is arranged between the protruding upstream connection section and the mounting recess, and wherein the heater module holder and the heater casing upstream part are moved relative to each other on the flexible sealing element in the mounting recess in order to position the heater module holder relative to the heater casing upstream part, preferably wherein the heater module holder and the heater casing upstream part are rotated relative to each other on the flexible sealing element.
PCT/EP2023/076384 2022-09-29 2023-09-25 Aerosol-generating device with a heater module holder WO2024068538A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP22198822 2022-09-29
EP22198822.3 2022-09-29

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017075759A1 (en) * 2015-11-03 2017-05-11 惠州市吉瑞科技有限公司深圳分公司 Electrically heated cigarette
KR102033035B1 (en) * 2017-05-26 2019-10-16 주식회사 케이티앤지 Heater assembly and aerosol generating apparatus having the same
US20200178605A1 (en) * 2017-07-28 2020-06-11 Philip Morris Products S.A. Heater assembly with cavity
WO2020187911A1 (en) * 2019-03-21 2020-09-24 Nerudia Limited Aerosol delivery device
WO2021123817A1 (en) * 2019-12-20 2021-06-24 Nicoventures Trading Limited Article for use in an aerosol provision system
CN114766724A (en) * 2017-09-06 2022-07-22 韩国烟草人参公社 Aerosol generating device

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017075759A1 (en) * 2015-11-03 2017-05-11 惠州市吉瑞科技有限公司深圳分公司 Electrically heated cigarette
KR102033035B1 (en) * 2017-05-26 2019-10-16 주식회사 케이티앤지 Heater assembly and aerosol generating apparatus having the same
US20200178605A1 (en) * 2017-07-28 2020-06-11 Philip Morris Products S.A. Heater assembly with cavity
CN114766724A (en) * 2017-09-06 2022-07-22 韩国烟草人参公社 Aerosol generating device
WO2020187911A1 (en) * 2019-03-21 2020-09-24 Nerudia Limited Aerosol delivery device
WO2021123817A1 (en) * 2019-12-20 2021-06-24 Nicoventures Trading Limited Article for use in an aerosol provision system

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