HEATER SHELL OF HEATER ASSEMBLY FOR AN AEROSOL-GENERATING DEVICE

Abstract

The present invention relates to a heater assembly for an aerosol-generating device. The device comprises a heater shell, a support element and at least one heating element. The heater shell is configured to receive the heating element. The heater shell has an inner wall. The inner wall comprises a plurality of thermally insulating cavities. The heating element is arranged lining the inner wall of the heater shell. The heater shell is arranged within the support element.

Claims

1. Aerosol-generating device comprising a heating chamber and a heater assembly, wherein the heating chamber is configured to receive the heater assembly, wherein the heater assembly comprises a heater shell, a support element and at least one heating element, the heater shell being configured for receiving the heating element, the heater shell having an inner wall comprising a plurality of thermally insulating cavities, wherein the heating element is arranged lining the inner wall of the heater shell, and wherein the heater shell is arranged within the support element.

2. The aerosol-generating device of claim 1, wherein the cavities form a repeating pattern on the inner wall of the heater shell.

3. The aerosol-generating device of claim 1, wherein each cavity has a hexagonal shape, preferably such that the plurality of cavities forms a honeycomb pattern.

4. The aerosol-generating device of claim 1, wherein each cavity has a rectangular shape, preferably such that the plurality of cavities forms a grid pattern.

5. The aerosol-generating device of claim 1, wherein the heater shell has a tubular, cylindrical, conical or frustoconical shape.

6. The aerosol-generating device of claim 1, wherein the heater shell comprises at least one projection on an outer wall of the heater shell, preferably, wherein the at least one projection has a ring shape.

7. The aerosol-generating device of claim 1, wherein the heater shell comprises at least one securing tooth.

8. The aerosol-generating device of claim 1, wherein the support element is configured for receiving the heater shell.

9. The aerosol-generating device of claim 1, wherein the support element has an inner wall, wherein the support element comprises at least one projection on the inner wall of the support element such that at least one thermally insulating cell is formed between the support element and the heater shell, when the heater shell is inserted into the support element, and wherein the at least one projection on the inner wall of the support element preferably has a linear shape.

10. The aerosol-generating device of claim 1, wherein the support element has an outer wall, wherein the support element comprises at least one projection on the outer wall of the support element, wherein the at least one projection preferably has a linear shape.

11. The aerosol-generating device of claim 1, wherein the support element has a tubular, cylindrical, conical or frustoconical shape.

12. The aerosol-generating device of claim 1, wherein the support element has at least one securing tooth.

13. The aerosol-generating device of claim 1, wherein a heat reflective element is provided between the heating element and the heater shell, wherein the heat reflective element is preferably a metal foil.

14. Method for manufacturing a heater assembly for insertion into a heating chamber of an aerosol-generating device, wherein the method comprises the following steps: (a) providing a heater shell, wherein the heater shell is configured for receiving a heating element and having an inner wall comprising a plurality of thermally insulating cavities; (b) inserting into the heater shell at least one heating element lining the inner wall of the heater shell; (c) inserting into a support element the heater shell comprising the heating element, wherein the support element is configured for receiving the heater shell.

Description

[0046] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0047] FIG. 1 shows a heater shell according to this invention;

[0048] FIG. 2 shows a support element according to this invention;

[0049] FIG. 3 shows an exemplary aerosol-generating device according to this invention; and

[0050] FIG. 4 shows an exemplary aerosol-generating device according to this invention provided as a shisha device.

[0051] FIG. 1 shows an embodiment of a tubular heater shell 10. The heater shell defines a cavity 11, defined by an inner wall 12 of the heater shell 10. The inner wall 12 of the heater shell 10 comprises a plurality of hexagonally shaped cavities 14. The hexagonally shaped cavities 14 are arranged in a honeycomb array. The hexagonal shape of the cavities 14 is at least partially defined by the shape of the protrusions 16 on the inner wall 12 of the heater shell 10. In the shown embodiment, the heater shell 10 comprises several ring shaped projections 18 on the outer wall of the heater shell 10. 4 ring shaped projections 18 are shown, in addition to a top rim 22. It will be understood that more of fewer ring shaped projections 18 may be provided. Three securing teeth 20 are provided on the rim 22 of the tubular heater shell 10. The securing teeth 20 may anchor the heater shell 10 inside a support element, such as support element 24 shown in FIG. 2, or may anchor the heater shell 10 inside a heating chamber of an aerosol-generating device.

[0052] At least one heating element (not shown) may be inserted into the cavity 11 of the heater shell 10, such that the heating element follows the inner wall 12. In the illustrated embodiment, the inner wall 12 translates about a circular cross section of varying diameter.

[0053] The heating element in the illustrated embodiment may be inserted into the cavity 11 of the heater shell 10 such that the heating element follows a circumference of the cavity 11 of the tubular heater shell 10. The heating element may be in contact with the inner wall of the heater shell 10. The heating element may be flush with the inner wall of the heater shell 10. The heating element may be adjacent to the heater shell 10, but not be in contact with the inner wall of the heater shell 10. The heating element may follow the surface of the inner wall of the heater shell 10. When the heating element is inserted in the cavity 11 of the heater shell 10, the heating element contributes to the definition of a cavity. An aerosol-generating article comprising an aerosol-forming substrate may be inserted into the cavity at least partially defined by the heating element received in the heater shell 10. The heating element may completely or partially surround the aerosol-generating article. The heating element may be connected to a power supply. The heating element may be a susceptor material. The heating element may be an electrically powered heating element. The heating element may be configured to heat inductively. The heating element may supply energy to the aerosol-generating article when the aerosol-generating article is received in the cavity at least partially defined by the heating element. Preferably, the shape of the heater shell 10 mirrors or complements the shape of the aerosol-generating article in order to provided close contact between the aerosol generating article and the heating element inside the heater shell 10. In this way, the efficiency of energy transfer from the heating element to the aerosol-generating article and aerosol-forming substrate may be maximised.

[0054] FIG. 2 shows an embodiment of a tubular support element 24 comprising an inner wall 26. The inner wall 26 of the support element 24 comprises several linear projections 28. The longitudinal axes of the linear projections 28 are aligned parallel to the inner wall 26 of the tubular support element 24. The support element 24 furthermore comprises linear projections 30 on an outer wall 32 of the support element 24. The projections 30 on the outer wall 32 are arranged such that the longitudinal axes of the linear projections 30 are parallel to the outer wall 32 of the tubular support element 24. The support element also comprises a lower rim 36.

[0055] A heater shell, such as the one shown in FIG. 1, which may comprise a heating element, may be inserted into support element 24. The heater shell 10 may be inserted into the support element 24 such that a layer of air is formed between the inner wall 26 of the support element 24 and the outer wall of the heater shell 10. The ring-shaped projections 18 on the outer wall of the heater shell 10 and the linear projections 28 on the inner wall of the support element 24 are in direct contact. In this way cells, which may be filled with air, are formed between the support element 24 and the heater shell 10. The projections 18 on the outer wall of heater shell 10 and the projections 28 on the inner wall of support element 24 are designed, such that contact area between the projections 18 on the outer wall of heater shell 10 and the projections 28 on the inner wall of support element 24 is minimized, reducing heat loss by heat conduction though the contact area. The dimensions of the projections 28 of the support element and the projections 18 on the outer wall of the heater shell 10 substantially determine the thickness of the layer of air in the cells between the support element 24 and the heater shell 10. The layer of air represents a thermally insulating layer between the support element 24 and the heater shell 10. In this way, convective heat loss from the heater shell to the support element and its external environment is minimised as air circulation in within the cell between the heater shell 10 and the support element 24 is diminished. To reduce heat loss even further, a heat reflective element (not shown) may be inserted between the heater shell 10 and the support element 24. Such a heat reflective element may be a thin metal sheet. The presence of the heat reflective element directs thermal radiation incident on the heat reflective element towards a central space in the cavity 11 of heater shell 10.

[0056] The support element 24 comprises a set of securing teeth 34 on the rim 36 of the tubular support element 24. In some embodiments, the securing teeth 34 may anchor the support element 24 within a heating chamber of an aerosol-generating device into which the support element may be inserted. In some embodiments, the securing teeth 34 may anchor the support element 24 to the heater shell 10. For example, the securing teeth 34 could be bent relative to the heater shell 10, into the cavity 11 by urging the teeth 34 against the inner wall 12 of the heater shell 10 when the heater shell 10 is received within the support element 24. In some embodiments, one or more of the securing teeth 34 may anchor the support element 24 within a heating chamber of an aerosol-generating device into which the support element 24 may be inserted, whilst the other of the securing teeth 34 may anchor the support element 24 relative to the heater shell 10.

[0057] The support element 24 may be integrated into a heating chamber of an aerosol-generating device. The support element may at least partially define the shape and size of the heating chamber. The projections 30 on the outer wall of the support element 24 may be in intimate contact with inner walls of the heating chamber when the support element 24 is received into the heating chamber. Frictional forces between the surface of the projections 30 on the outer wall of the support element 24 and the surface of the inner wall of the heating chamber may firmly hold and retain the support element 24 within the heating chamber. Furthermore, a set of cells, which may comprise air, may form between the inner wall of the heating chamber and the outer wall of the support element 24, thereby forming a thermally insulating layer between the heating chamber and the support element 24 when the support element 24 is placed inside the heating chamber. Such thermally-insulating layer may minimise heat loss from the support element to the walls of the heating chamber.

[0058] FIG. 3 shows a schematic sectional view of an example of an aerosol-generating device 40 according to the invention. The aerosol-generating device comprises a device housing 42. The device housing 42 comprises a power supply 44 and a controller 46. The power supply 44 and the controller 46 are coupled to a user interface 48. The user interface 48 is coupled to a heating element 50. The heating element 50 at least partially surrounds the aerosol-forming substrate 52 of an aerosol-generating article 54. The aerosol-generating article 54 comprising the aerosol-forming substrate 52 is configured to be inserted into the heating element 50. The heating element 50 may be inserted into a heater shell 56. The heater shell 56 may be inserted into a support element 58. The aerosol-generating device may comprise a mouthpiece. The mouthpiece may be arranged downstream of the aerosol-generating article 54. The aerosol-generating article 54 may be at least partially surrounded by the mouthpiece and the other components of the aerosol-generating device. A user may draw on the mouthpiece.

[0059] FIG. 4 shows a schematic sectional view of an example of an aerosol-generating device 60 according to the invention. The aerosol-generating device 60 may be a shisha device. The device 60 includes a vessel 62 defining an interior volume configured to contain liquid 64 and defining a headspace outlet 66 above a fill level for the liquid 62. The liquid 62 preferably comprises water, which may optionally be infused with one or more colorants, one or more flavorants, or one or more colorants and one or more flavorants. For example, the water may be infused with one or both of botanical infusions or herbal infusions.

[0060] The device 60 also includes a heater assembly 68. The heater assembly 68 includes a receptacle 70 configured to receive an aerosol-generating article 72 comprising an aerosol-forming substrate. In some embodiments, for example, as shown in FIG. 4, the aerosol-generating article 72 may be provided in the form of a capsule or a cartridge.

[0061] The heater assembly 68 also includes a heating element 74 which forms at least one surface of the receptacle 70. In the depicted embodiment, the heating element 74 defines the side surfaces of the receptacle 70. The heating element 74 may be inserted into a heater shell 76. The heater shell may be inserted into a support element 78.

[0062] The heater assembly 68 also includes a fresh air inlet channel 80 that draws fresh air into the device 60. The air then enters the aerosol-generating article 72, which is heated by heating element 74, to carry aerosol generated by the aerosol-forming substrate. The air exits an outlet of the heater assembly 68 and enters a conduit 82. The conduit 82 may also be denoted as stem pipe.

[0063] The conduit 82 carries the air and aerosol into the vessel 62 below the level of the liquid 64. The air and aerosol may bubble through the liquid 64 and exit the headspace outlet 66 of the vessel 64 A hose 84 may be attached to the headspace outlet 66 to carry the aerosol to the mouth of a user. A mouthpiece 86 may be attached to, or form a part of, the hose 84.

[0064] An exemplary air flow path of the device, in use, is depicted by thick arrows in FIG. 4. The mouthpiece 86 may include an activation element 88. The activation element 88 may be a switch, button or the like, or may be a puff sensor or the like. The activation element 88 may be placed at any other suitable location of the device 60. The activation element 88 may be in wireless communication with the control electronics 90 to place the device 60 in condition for use or to cause control electronics to activate the heating element 74; for example, by causing power supply 92 to energize the heating element 74.

[0065] The control electronics 90 and power supply 92 may be located in any suitable position of the aerosol generating element 68 other than the bottom portion of the element 68 as depicted in FIG. 4.