Aerosol Generation Device with Heat Dissipation Housing

Abstract

An aerosol generation device includes a cover element with a heat dissipation material. Further, an aerosol generation device includes: a heating unit for heating an aerosol generation substrate for generating an aerosol; and a device housing which forms at least a part of the exterior surface of the aerosol generation device; wherein the device housing includes an aerogel material configured to insulate the heating unit and/or dissipate heat generated by the heating unit.

Claims

1. An aerosol generation device comprising: a heating unit for heating an aerosol generation substrate for generating an aerosol; and a device housing which forms at least a part of an exterior surface of the aerosol generation device, wherein the device housing comprises an aerogel material configured to insulate the heating unit and/or dissipate heat generated by the heating unit.

2. The aerosol generation device according to claim 1, wherein the device housing comprises an aerogel layer comprising the aerogel material.

3. The aerosol generation device according to claim 1, wherein the aerogel material has a density of 0.10-0.15 g/cm.sup.3, preferably 0.11-0.12 g/cm.sup.3.

4. The aerosol generation device according to claim 2, wherein the aerogel layer is in a solid state.

5. The aerosol generation device according to claim 2, wherein the aerogel layer has the shape of a sheet or a film.

6. The aerosol generation device according to claim 2, wherein the device housing further comprises a layer of plastic, at least one of the aerogel layer or the layer of plastic is arranged as the outermost layer of the device housing, and a side of the aerogel layer is arranged to be directly attached on the layer of plastic.

7. The aerosol generation device according to claim 6, wherein the device housing comprises another layer of plastic arranged to be directly attached on another side of the aerogel layer in way that the aerogel layer is sandwiched between the layer of plastic and the another layer of plastic.

8. The aerosol generation device according to claim 7, wherein the layer of plastic is a transparent plastic and the other layer of plastic is a non-transparent plastic.

9. The aerosol generation device according to claim 6, wherein one surface of the aerogel layer is completely attached to a surface of the layer of plastic.

10. The aerosol generation device according to claim 2, wherein the aerogel layer is thicker in at least one portion of the housing that is adjacent to the heating unit than in other portions of the housing that are not adjacent to the heating unit.

11. The aerosol generation device according to claim 2, wherein the aerogel layer has an average thickness (A) of at least 0.2 mm.

12. The aerosol generation device according to claim 2, wherein the aerogel layer has a bending strength of at least 0.025 MPa, and at most 0.45 MPa.

13. The aerosol generation device according to claim 1, wherein the aerogel material has a thermal conductivity of at least 0.010 W/m.Math.K and at most 0.017 W/m.Math.K.

14. The aerosol generation device according to claim 1, wherein the aerogel material has a visible light transmission of at least at 92% at 800 nm and at most 99% at 800 nm.

15. The aerosol generation device according to claim 1, wherein the aerogel material has a water contact angle with super water repellency of at least at 125° and at most 160°.

16. The aerosol generation device according to claim 1, wherein the device housing comprises a main body, and a cover element which is detachably attached or connected to the main body, and the cover element comprises the aerogel material.

17. The aerosol generation device according to claim 16, wherein the cover element has a curvature so that when the device is in use, the heat from the heating unit can be dissipated into multiple directions.

18. A manufacturing method of a device housing for an aerosol generation device according to claim 2, the method comprising steps of: attaching the aerogel layer to a plastic layer by gluing, in-mold decorating, or out-mold decorating; or fixing the aerogel layer between two plastic layers with male-female fit.

19. The manufacturing method according to claim 18, wherein the aerogel layer is in solid state.

20. The manufacturing method according to preceding claim 18, wherein one surface of the aerogel layer is completely attached to a surface of the layer of plastic.

21. The manufacturing method according to claim 18, further comprising a step of: obtaining the aerogel layer, which comprises the aerogel material with a density of 0.10-0.15 g/cm.sup.3, preferably 0.11-0.12 g/cm.sup.3.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0066] FIGS. 1A and 1B respectively show schematic illustrations of a side-view and a top-view of an aerosol generation device, according to embodiments of the invention;

[0067] FIGS. 2A and 2B respectively show schematic illustrations of cross sections of a part of the cover element of the aerosol generation device, according to embodiments of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0068] In the description of the present invention, it should be understood that the terms “one end”, “the other end”, “outer side”, “upper”, “above”, “inner side”, “under”, “below”, “horizontal”, “coaxial”, “central”, “end” “part”, “length”, “outer end” etc., which indicate the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings. The terms such as “upper”, “above”, “below”, “under” and the like used in the present invention to indicate a relative position in space are used for the purpose of facilitating explanation to describe a unit or feature shown in the drawings relative to the relationship of another unit or feature. The term of the relative position in space may be intended to include different orientations of the device in use or operation other than those shown in the figures. For example, if the device in the figure is turned over, the unit described as being “below” or “under” other units or features will be “above” the other units or features. Therefore, the exemplary term “below” can encompass both the above and below orientations. The device can be oriented in other ways (rotated by 90 degrees or other orientations), and the space-related descriptors used herein are explained accordingly. More specifically, the word “above” means that one unit, layer or element is arranged or configured relatively in an exterior direction of the device towards the (an)other unit(s), layer(s) or element(s); the word “below” means that one unit, layer or element is arranged or configured relatively in an interior direction of the device towards the other units, layers or elements.

[0069] As shown in FIGS. 1A and 1B, the aerosol generation device wo comprises a device housing comprising a main housing 200 and an optional cover element 300. The main housing 200 is configured to accommodate an aerosol generation unit for generating an aerosol for consumption by a user. The aerosol generation unit comprises a heating unit 110 that is configured for heating a consumable 120 comprising an aerosol generation substrate. The aerosol generation device 100 also comprises a power supply that may be a replaceable and/or rechargeable power supply, and may additionally be provided with a USB port functioning as a charging port for charging the rechargeable power supply or a data transmission line, and an operator/CPU. The power supply may be a battery that may be provided with a battery vent and a battery vent cover. The cover element 300 may be detachably attached to the main housing 200. The cover element being detachable means that the cover element 300 is detachable from the main housing by a user of the aerosol generation device 100 without requiring any additional tools or aids, such that it can be detached by the user utilizing one or both hands. As an alternative, the cover element may not be detachable and may be integrally formed with the main housing.

[0070] The aerosol generation device 100 may have an elongated shape to improve the comfort of a user when holding the aerosol generation device 100. The longitudinal direction of the aerosol generation device 100 is the direction in which the aerosol generation device 100 is elongated.

[0071] As shown in FIG. 1A, in case a cover element 300 is provided, an operation interface portion (not shown) may be provided at a portion of the main housing 200 that is covered by the cover element 300. The operation interface portion is protected from outside influences by the cover element 300, and like the user operation portion 320, can be actuated by a user for providing an operation input to the aerosol generation device 100. The operation interface portion comprises one or more operation input elements 230 such as a mechanical or capacitive touch button or switch, an optical sensor, or a magnetic sensor. In a preferred configuration shown in FIG. 1B, the user operation portion 320 and the operation interface portion may be configured such that actuating the user operation portion 320 actuates the operation interface portion for providing an operation input to the aerosol generation device 100. In this case, actuating the user operation portion 320 alone may not provide any operation input to the aerosol generation device boo. Rather, the resulting actuation of the operation interface portion caused by the actuation of the user operation portion 320 results in an operation input. For example, the user operation portion 320 may comprise a mechanical button or switch that can be pressed or moved by a user. The mechanical button or switch 320 actuates an operation input element 230 of the operation interface portion by having a protrusion or similar arrangement protruding towards the operation input element of the operation interface portion such as a button or switch 230. When the button or switch of the user operation area 320 is pressed, the protrusion causes the button or switch of the operation interface portion to be pressed. Additionally, or alternatively, the user operation portion 320 may be provided with a magnetic detection object such as a magnet or ferromagnetic object, or an optical detection object such as reflective surface, that can respectively actuate a magnetic sensor or an optical sensor provided as an operation input element 230 of the operation interface portion when the button or switch 330 is actuated. Alternatively, instead of a mechanical button or switch, the user operation portion 320 may comprise a flexible area that can be flexibly deformed towards the operation interface portion when pressed by a user to actuate an operation input element 230 of the operation interface portion. Such configurations allow a user to actuate the operation interface portion for providing an operation input to aerosol generation device wo from outside the aerosol generation device by actuating the user operation area 320 without directly accessing or exposing the operation interface portion covered by the cover element 300.

[0072] The aerosol generation device wo may be an electronic cigarette and may be configured to generate an aerosol from an e-vapor or t-vapor aerosol generation substrate. For example, the heating unit no may comprise a receptacle configured for receiving a tobacco stick or similar consumable 120, and a heating element may be configured for heating the receptable and the tobacco stick received in the receptacle. Alternatively, the receptable may be configured for receiving a cartridge containing an aerosol generation substrate such as a liquid, and the heating unit no may comprise a wicking element and a heating element configured for heating the wicking element. Depending on the aerosol generation substrate, the heating unit may heat the aerosol generation substrate to temperatures up to 350° C. for generating an aerosol. The aerosol generation device comprises an airflow path the extends from an air inlet via the aerosol generation unit to an air outlet. When a user consumes a consumable by inhaling a generated aerosol, air enters the air inlet, passes to the aerosol generation unit where an aerosol is generated by the heating unit by heating the aerosol generation substrate, and transports the generated aerosol the air outlet such as a mouthpiece. While the airflow path is in communication with the aerosol generation unit, the airflow path is typically not in communication with the remaining interior space of the aerosol generation. A portion of the heat generated by the heating unit 110 is transferred to the aerosol generation substrate for generating an aerosol and to the flow of air that transports the generated aerosol to a user for inhalation. However, a remaining and substantial portion of the generated heat is transferred to the interior space of the aerosol generation device that is not in communication with the airflow path and the aerosol generation unit. This substantial portion of the generated heat is subsequently dissipated over time through heat conduction and heat radiation to the outer surface of the aerosol generation device and subsequently to the ambient air. Since this heat does not serve to heat the aerosol generation substrate, this heat corresponds to lost heat that is lost to the interior space of the aerosol generation device in surrounding of the heating unit 110 that is not in communication with the heating unit 110. The heat, hence, may increase the temperature of the outer main housing 200 in case of consecutive vaping, and the device 100 may not be usable until the temperature back to normal. There is a need to prevent consumers and the device body from hotness caused by heat coming from heater.

[0073] To address this problem, the device housing comprises an aerogel material. Instead of arranging further insulation units inside the aerosol generation device 100, providing an aerogel material in the device housing makes the aerosol generation device 100 compact and have a better thermal insulation performance.

[0074] In some embodiments, the aerogel material is aerogel powder filled in the cover element 300, together with other thermal insulation material such as diatomaceous earth powder, zirconia powder etc.

[0075] In some of the preferred embodiments of the present invention, an aerogel sheet and/or aerogel film are used. Preferably the monolith type (sheet-like aerogel and film-like aerogel), which has a block shape, e.g. Super Functional Air (SUFA) developed by Tiem factory Inc., is used. In other preferred embodiments of the present invention, an aerogel granule is used(granule-like aerogel) Super Functional Air (SUFA) developed by Tiem factory Inc. The manufacturing method, the properties and statistics of SUFA from Tiem factory Inc. is disclosed in WO2020166302A1 (TIEM FACTORY INC [JP]; AIZAWA MAMORU; UEGAKI AI).

[0076] In some embodiments, the aerogel material is obtainable by a sol generation step for generating a sol by adding a silicon compound to an aqueous solution containing an acid catalyst, and performing hydrolysis, namely hydrolyzing it, to generate a sol, wherein the silicon compound comprises a quadri-functional silane compound and a tri-functional silane compound, and preferably further comprises a bi-functional silane compound, and more preferably, the silicon compound is a mixture of a quadri-functional silane compound, a tri-functional silane compound, and a bi-functional silane compound having portions satisfying o<Qx<50, 50 Tx≤100, 0≤Dx<30, and Qx+Tx+Dx=100, where Qx, Tx, and Dx represent the mass percentages of the quadri-functional silane compound, the tri-functional silane compound, and the bi-functional silane compound, respectively.

[0077] With this composition, the aerogel material may have an improved heat insulating property, and in addition, may be used to produce a plate-shape or film-shape having a large area of 400 cm2 or more, which makes it possible to be mass produced.

[0078] In some embodiments, when the structure of the aerogel of the present invention is observed microscopically, it mainly comprises a bulk portion (skeleton portion) filled with solid matter, and pore portions, which penetrates into the bulk portion in a three-dimensional network shape.

[0079] The bulk portion is composed of a continuum in which solids form a three-dimensional network by siloxane bonds. In the three-dimensional network, when the lattice, which is the minimum unit of the network, is approximated by a cube, the average length of one side thereof is 2 nm or more and 25 nm or less. The average length of one side is preferably 2 nm or more, 5 nm or more, 7 nm or more, 10 nm or more, and 25 nm or less, 20 nm or less, and 15 nm or less.

[0080] Further, the pore portion has a tubular shape penetrating the inside of the bulk portion, and the pore is approximated by a tube, and the average inner diameter when the inner diameter of the tube is approximated by a circle is 5 nm or more and 100 nm or less. The average inner diameter of the pores is preferably 5 nm or more, 7 nm or more, 10 nm or more, 20 nm or more, 30 nm or more, 50 nm or more, and wo nm or less, 90 nm or less, 80 nm or less, 70 nm or less. Here, the inner diameter of the tube is smaller than the mean free path (MFP) of the element molecules constituting the air at atmospheric pressure.

[0081] Further, the porosity of the aerogel, that is, the ratio of the volume of the pores to the total volume of the aerogel is 70% or more. As an example of the porosity, it may be 75% or more, 80% or more, 85% or more, 90% or more.

[0082] In other embodiments, as long as the other physical properties of the aerogel are met, the aerogel of the present invention may also include a structure other than the bulk part and the pore portions. As an example, voids different from the above-mentioned pores may be included. In addition, as yet another example, it may comprise, except water, organic solvent, surfactant, catalyst, and decomposition products thereof.

[0083] In the embodiment of FIGS. 1A and 1B., the cover element 300 comprises an aerogel layer, preferably in a solid state, more preferably an aerogel sheet and/or aerogel film, which is solidified from the aerogel material during manufactory. With the aerogel layer, the cover element 300 is able to reduce heat up of the exterior surface of the aerosol generation device 100 by the lost heat from the heating unit 110 to prevent a user from being injured by the heat while touching the cover element 300 for using the user operation portion 320.

[0084] The cover element 300 may have a central portion that is substantially planar, and one or more peripheral or circumferential portions that are curved or bent to allow the cover element 300 to be adjoined to the main housing 200 with a space arranged or enclosed between the main housing 200 and the cover element 300 within which one or more operation input elements 230 may be arranged. Alternatively, the cover element 300 may have a continuously curved shape with a central portion having a curvature that is smaller than the curvature of one or more peripheral or circumferential portions. The aerogel layer of this invention is flexible and easy to form the above shape, thanks to the certain level of bending strength the aerogel film and sheet has. The bending strength of the aerogel film and sheet of this invention is at least 0.025 MPa, preferably at least 0.05 MPa, more preferably at least 0.1 MPa, most preferably at least 0.15 MPa, and at most 0.45 MPa, more preferably at most 0.4 MPa, even more preferably at most 0.3 MPa, and most preferably at most 0.25 MPa. The density of the aerogel layer is 0.10-0.15 g/cm.sup.3, preferably 0.11-0.12 g/cm.sup.3. With this arrangement, especially the density, as shown, the aerogel material can be in a stable and solid state, and can be mass produced. As the density of aerogel decreases, the thermal conductivity decreases, and the heat insulating property improves accordingly.

[0085] With a density of 0.15 g/cm.sup.3 or less, the thermal conductivity thereof can be as small as 0.01 W/m.Math.K or less. The aerogel material with this density is obtained by the mercury porosimetry method, also known as mercury intrusion method, during manufactory. The aerogel layer has a compressive strength of 8-10 MPa, preferably 8.5-9.5 MPa, more preferably 9.1-9.5 MPa, most preferably 9.2-9.25 MPa, and a compression modulus of 0.5-1 MPa, preferably 0.6-0.9 MPa, more preferably 0.7-0.75 MPa. With the combination of the aerogel layer and the curved shape of the cover element 300, the thermal insulation and dissipation performance is substantially increased, because the heat is dissipated in multiple directions. With this structure, the aerogel layer 311 dissipates heat from the heating unit more effectively, and the surface temperature of at least the cover element is maintained to be consistent. In one embodiment of the present invention, the aerogel layer is thicker in at least one portion of the housing that is adjacent to the heating unit than in other portions of the housing that are not adjacent to the heating unit. More specifically, the central portion has a thicker aerogel layer than the peripheral or circumferential portions. This arrangement can make the device housing have a constant tactile or surface temperature through its cover element and use less aerogel material.

[0086] The aerogel layer also reduces the thickness of the insulator applied to the heating unit 110, so as to reduce the general size and increase the inner space of the aerosol generation device 100. The aerogel sheet or film 311 can bring out almost the same performance, while only having half or even just one-third of the thickness of most of the traditional thermal insulation material, such as PEEK and copper. More specifically, the aerogel layer used in the present invention has an average thickness of at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.3 mm, most preferably at least 0.5 mm, and at most 1.2 mm, more preferably at most 1.0 mm, even more preferably at most 0.8 mm, and most preferably at most 0.6 mm. The thermal conductivity thereof is at least 0.010 W/m.Math.K, preferably at least 0.011 W/m.Math.K, more preferably at least 0.012 W/m.Math.K, most preferably at least 0.013 W/m.Math.K, and at most 0.017 W/m.Math.K, more preferably at most 0.016 W/m.Math.K, even more preferably at most 0.015 W/m.Math.K, and most preferably at most 0.014 W/m.Math.K. The average pore diameter of the aerogel layer is 20-100 nm, preferably 30-90 nm, more preferably 40-80 nm, most preferably 50-70 nm. The dielectric constant thereof is 1.05 to 1.15, preferably 1.08 to 1.12, more preferably 1.09 to 1.11. The heat resistant temperature is up to 550° C., preferably 600° C., more preferably up to 615° C., most preferably up to 630° C. in Nitrogen atmosphere, and up to 350° C., preferably 400° C., more preferably up to 450° C., most preferably up to 467° C. in air atmosphere. The coefficient of thermal expansion is 62×10-6 to 66×10-6/K, preferably 63×10-6 to 65×10-6/K, more preferably 63.5×10-6 to 64.5×10-6/K.

[0087] Another benefit of the aerogel layer is that it may be super water repellent. While consuming the aerosol generation substrate such as a liquid, the vaporized liquid may stream into the aerosol generation device 100. In case of other thermal insulation material, the performance on thermal insulation goes down once it absorbs water property. However, with the aerogel layer of this invention, the performance on thermal insulation is maintained thanks to its super water repellency property. More specifically, the aerogel layer of this invention has a water contact angle with super water repellency of at least at 125°, preferably at least 130°, more preferably at least 135°, most preferably at least 140°, and at most 160°, more preferably at most 155°, even more preferably at most 150°, and most preferably at most 145°.

[0088] As shown in FIG. 2A, a decorative layer (color layer or ink layer) 310 having a printed pattern showing for example the position and/or the function of the user operation portion 320 and/or other information about the aerosol generation device 100 is provided and configured underneath the aerogel layer 311. In other words, the decorative layer 310 is provided and configured in a more interior position in the device 100 than the aerogel layer 311. The decorative layer is a layer of non-transparent plastic. Thanks to the transparency of the aerogel sheet and film 311, unlike the aerogel powder, the aerogel sheet and film do not cut out the visibility of patterns and color from the decorative layer and the LED indication, which may be configured underneath the cover element 300. So that the aerogel layer 311 is the outermost layer. The visible light transmission of the aerogel layer 311 of the present invention is at least at 92% at 800 nm, preferably at least 93% at 800 nm, more preferably at least 94% at 800 nm, most preferably at least 95% at 800 nm, and at most 99% at 800 nm, more preferably at most 98% at 800 nm, even more preferably at most 97% at 800 nm, and most preferably at most 96% at 800 nm. The refractive index thereof is 1.02 to 1.08, preferably 1.03 to 1.07, more preferably 1.04 to 1.06.

[0089] As shown in FIG. 2B, in order to prevent the aerogel layer 311 and the decorative layer 310 from any damage such as scratch and color fading of the decorative layer 310 caused by UV light, a transparent plastic layer 312, preferably a plastic plate, is configured thereon. The transparent plastic layer 312 is configured as the outermost layer of the device housing, and the aerogel layer 311 is configured between the transparent plastic layer 312 and the decorative layer 310. Although not shown in the figures, some other layers may be arranged below the transparent plastic layer 312, and those layers are introduced below.

[0090] As shown in both FIGS. 2A and 2B, the aerogel layer 311 is arranged in a way that it is closely attached, namely clings to or sticks on at least one, preferably two plastic layers. With this arrangement, no condensation would happen inside the device. In other words, one surface of the aerogel layer 311 is completely attached to at least one surface of the layer of plastic 310, 312, and preferably completely attached to one surface of each of the layers of plastic 310, 312.

[0091] In order to manufacture the cover element 300, the aerogel material of this invention is applied into the cover element 200 in a way such that the aerogel sheet or film 311 of this invention is closely attached to at least one of the plastic layers. Preferably, the aerogel film or sheet 311 is applied into the cover element 200. Since the aerogel film and sheet is already in shape, unlike the aerogel powder, and due to its flexibility, the manufacture of the cover element 200 is easier and does not demand harsh and complicated manufacturing conditions and environments.

[0092] More specifically, the aerogel sheet or film 311 of this invention can be stuck onto the decorative layer 310 by applying a layer of glue onto the decorative layer 310 and then attaching the aerosol sheet or film 311 onto the layer of glue on the decorative layer 310. In other words, the aerogel layer 310 is configured as the outer layer, and the decorative layer is set underneath the aerogel layer 310.

[0093] The glue layer has the effect of combining the decorative layer 310, preferably comprising molding plastic, with the aerogel layer 311. The molding plastic can be an IDF (in-decoration film) colored plastic, an OMR (out-side transfer) colored plastic, or an NCVM (non-conductive vacuum metallization) colored plastic etc. The glue layer is preferably made from one selected from the group consisting of acrylic, nitrification fiber, polyamine format, chlorination rubber, vinyl chloride-co-vinyl-acetic ester copolymer, polyamide, polyester, epoxy, polycarbonate, olefin, and acrylonitrile-butylene-styrene monomer resin, for example. The glue layer is generally provided via concave, screen, and offset printing, or spraying, a dip-coating method, or a coating in reverse order method, for example. The decorative layer 310 may comprise a plastic base layer and a print layer. As mentioned above, the decorative layer 310 is used to display patterns and colors, and the decorative layer 310 is formed by coating the plastic base layer with printing ink, which is the print layer.

[0094] The thickness of the cover element T is at least 0.75 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 2.8 mm, preferably at most 2.4 mm, most preferably at most 2.1 mm. The thickness of the plastic base layer is at least 0.6 mm, more preferably at least 0.7 mm, even more preferably at least 0.8 mm, most preferably at least 0.9 mm, and at most 1.2 mm, preferably at most 1.1 mm, most preferably at most 1.0 mm. The thickness of the print layer is at least 0.1 mm, more preferably at least 0.15 mm, even more preferably at least 0.2 mm, most preferably at least 0.25 mm, and at most 0.4 mm, preferably at most 0.35 mm, most preferably at most 0.3 mm.

[0095] In other embodiment, the aerogel sheet or film 311 can be closely attached to the plastic layer 310 by in-mold-decorating or out-mold decorating. The methods of in-mold-decoration and out-mold-decoration, namely OMR (Out-mold-release), IMR(In-mold-release), OMF (Out-mold-film) and IMF (In-mold-film), are known to the skilled person. The methods are known, for example, from JP 316025, JP 322046, JP 345288, TW 1230002, U.S. Pat. No. 7,070,849, EP 1327510. In general, a film (decorative film or labeling film) is adhered to a plastic object when it is molded. If the base of the film is removed when it is molded, it is an OMR or IMR because it is “released”. If the base remains in the mold, it is an OMF or IMF.

[0096] To produce the cover element by in-mold-decorating or out-mold decorating, firstly a film is produced, and the film may comprise multiple layers in the order of a base, a first glue layer (or a binder), an aluminum sheet (silver) layer (as an anti-reflection layer or a metal film layer), a second glue layer (or a binder), an aerogel layer of this invention, a second glue layer (or a binder), a print layer or color sheet (red), a third glue layer, and a top coating layer. Secondly, the film is be placed in a cavity of a mold, with the base surface in contact with a surface of the cavity. Thirdly, the resin is injected into the mold to obtain an integrated body of the film and a substrate composed of the resin (the plastic layer). The skilled person would take any one of the above layers as appropriate, such as the aluminum sheet layer, out of the film in order to achieve a thinner product.

[0097] In this case, the thickness of the cover element T is at least 0.75 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 2.8 mm, preferably at most 2.4 mm, most preferably at most 2.1 mm. The thickness of the plastic base layer is at least 0.6 mm, more preferably at least 0.7 mm, even more preferably at least 0.8 mm, most preferably at least 0.9 mm, and at most 1.2 mm, preferably at most 1.1 mm, most preferably at most 1.0 mm. The thickness of the print layer or the rest of the film excluding the aerogel layer is at least 0.1 mm, more preferably at least 0.15 mm, even more preferably at least 0.2 mm, most preferably at least 0.25 mm, and at most 0.4 mm, preferably at most 0.35 mm, most preferably at most 0.3 mm.

[0098] If there is any concern of the pressure from outside, another transparent substrate composed of the resin (another plastic layer) can be further attached, or in-mold decorated or out-mold decorated on the integrated body, so that a transparent substrate or plastic as the outermost layer or surface of the cover element can protect the aerogel and the colored plastic.

[0099] In this case, the thickness of the cover element T is at least 1.35 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 4.0 mm, preferably at most 3.0 mm, most preferably at most 2.1 mm. The thickness of the print layer or the rest of the film excluding the aerogel layer is at least 0.1 mm, more preferably at least 0.15 mm, even more preferably at least 0.2 nm, most preferably at least 0.25 mm, and at most 0.4 mm, preferably at most 0.35 mm, most preferably at most 0.3 mm.

[0100] In yet another embodiment, the aerogel layer 311 can be fixed inside or sandwiched or placed between a decorative plastic layer 310 and a transparent plastic layer 312 by a male-female fit with connectors or fasteners such as screws etc. in a way that the aerogel layer 311 can be closely attached to one plastic layer, preferably two plastic layers on different sides of the aerogel layer 311 as shown in FIGS. 2A and 2B.

[0101] In this case, the thickness of the cover element T is at least 0.75 mm, more preferably 1.0 mm, even more preferably 1.3 mm, most preferably 1.7 mm, and at most 2.8 mm, preferably at most 2.4 mm, most preferably at most 2.1 mm.

[0102] In an alternative embodiment, the aerogel layer 311 may be configured underneath or rare of the decorative layer 310.

[0103] Although in the preceding embodiments, only the cover element 200 is configured with the aerogel material or the aerogel layer 310 arranged throughout its surface area, the aerogel material or the aerogel layer 310 can also be configured in the entire outer housing of the device wo or any other exterior portions of the device wo, namely arranged throughout the complete surface area of the housing of the device 100.