HEATER WITH AT LEAST TWO ADJACENT METAL MESHES

Abstract

The invention relates to a heater for generating an inhalable aerosol in an aerosol-generating device. The heater comprises at least two meshes. The meshes are arranged to be distanced from each other so that the meshes are configured for enabling wicking of aerosol-forming substrate between the meshes.

Claims

1. Heater for generating an inhalable aerosol in an aerosol-generating device, wherein the heater comprises at least two meshes, wherein the meshes are arranged to be distanced from each other so that the meshes are configured for enabling wicking of aerosol-forming substrate between the meshes.

2. Heater according to claim 1, wherein the at least two meshes are configured as concentrically arranged tubular meshes, wherein a first mesh is provided with a first diameter, wherein a second meshes is provided with a second diameter, wherein the first diameter is smaller than the second diameter, and wherein the first mesh is arranged inserted into the second mesh.

3. Heater according to claim 1, wherein the at least two meshes are configured to have at least a substantially flat plane.

4. Heater according to claim 1, wherein the at least two meshes are configured as a single crimped mesh.

5. Heater according to claim 1, wherein at least one of the meshes is configured as an electrically resistive metal heater.

6. Heater according to claim 5, wherein both, preferably all, meshes are configured as electrically resistive metal heater.

7. Heater according to claim 6, wherein the at least two metal meshes are connected to a power supply in series or in parallel.

8. Heater according to claim 6, wherein electrical connections are provided bridging both, preferably all, metal meshes.

9. Heater according to claim 1, wherein the heater comprises an induction coil arranged to surround the at least two meshes and configured for heating the at least two meshes, and wherein the at least two meshes are formed from susceptor material.

10. Heater according to claim 1, wherein the heater further comprises a tubular heater, which is arranged to be distanced from and surround the at least two meshes.

11. Heater according to claim 10, wherein at least two tubular heaters are provided, which are arranged to be distanced from and surround the at least two meshes, and wherein the at least two tubular heaters are provided near opposite ends of the heater.

12. Heater according to claim 10, wherein the tubular heater at least partially covers the outer surface of the at least two meshes.

13. Heater according to claim 1, wherein the at least two meshes are arranged to be distanced from each other by 5 to 200 μm.

14. Aerosol-generating device for generating an inhalable aerosol, wherein the device comprises: a storage portion for storing aerosol-forming substrate, a heater according to any one of the preceding claims, and a power supply for supplying power to the heater, wherein the at least two meshes contact the storage portion for enabling wicking of aerosol-forming substance from the storage portion towards a heating chamber of the aerosol-generating device.

15. Method for manufacturing a heater for generating an inhalable aerosol in an aerosol-generating device, wherein the method comprises the following step: i) providing at least two meshes, wherein the meshes are arranged to be distanced from each other so that the meshes are configured for enabling wicking of aerosol-forming substrate between the meshes.

Description

[0054] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0055] FIG. 1 shows a heater 10 having a tubular shape. The heater 10 comprises a first mesh 12 and a second mesh 14. The meshes 12, 14 are preferably formed from metal and configured as electrical heaters. The meshes 12, 14 may, however, also be formed from a susceptor material, in which case an induction coil surrounding the meshes 12, 14 is provided for heating the meshes 12, 14.

[0056] Both meshes 12, 14 have a tubular shape. The first mesh 12 has a diameter which is smaller than the diameter of the second mesh 14 so that the first mesh 12 can be arranged inside of the second mesh 14. The meshes 12, 14 are distanced from each other. The distance between the two meshes 12, 14 is chosen such that liquid aerosol-forming substrate can be wicked between the two meshes 12, 14 by capillary action.

[0057] The meshes 12, 14 are arranged contacting a liquid storage 16. The liquid storage 16 contains the liquid aerosol-forming substrate. The substrate is configured for generating an inhalable aerosol after being heated. The meshes 12, 14 are arranged to span a space and be in contact with the liquid storage 16 at both ends of the meshes 12, 14. The spanned space is an airflow channel 18 of an aerosol-generating device, in which the heater 10 is arranged. The air flowing through the airflow channel 18 is indicated by arrows next to the meshes 12, 14. The air flows around the meshes 12, 14 for entraining vaporized substrate. Liquid aerosol-forming substrate is wicked from the liquid storage 16 towards the center of the airflow channel 18 for aerosol generation. The meshes 12, 14 are configured to heat the substrate, preferably by being configured as resistive heaters, and thus have a double functionality. The first functionality of the meshes 12, 14 is to wick the substrate from the liquid storage 16 towards the center of the airflow channel 18. The second functionality of the meshes 12, 14 is to heat the substrate, thereby vaporizing the substrate.

[0058] The liquid storage 16 preferably contains capillary material for enabling storage of the liquid aerosol-forming substrate. The meshes 12, 14 preferably penetrate the liquid storage 16 so that the meshes 12, 14 extend into the liquid storage 16. In this way, the contact surface between the liquid aerosol-forming substrate and the meshes 12, 14 is increased and wicking of the substrate from the liquid storage 16 towards the airflow channel 18 is optimized. More than two meshes 12, 14 may be provided, if the amount of substrate to be wicked should be increased. Each individual mesh 12, 14 is, independently of the number of meshes, arranged to be distanced to the next mesh so that capillary action taking place in the space between the meshes 12, 14 is enabled.

[0059] FIG. 1 further shows contacts 20 for contacting the meshes 12, 14. The contacts 20 are configured to supply electrical energy from a power source such as a battery towards the meshes 12, 14. The aerosol-generating device preferably comprises a controller for controlling energy supply to the meshes 12, 14. The device may comprise a puff sensor such as a pressure sensor for detecting a puff of a user. The controller may control supply of electrical energy towards the meshes 12, 14 in response to a detected puff. In FIG. 1, two contacts 20 are shown. In this case, the meshes 12, 14 may be electrically connected with each other such that current can flow from a first contact 20 though both of the two meshes 12, 14 towards a second contact 20. Also, only the outer mesh 14, i.e. the second mesh 14, may be used for heating, while the inner mesh 12, i.e. the first mesh 12, may only be used to facilitate the desired degree of wicking. Alternatively, pairs of contacts 20 could be provided for individually contacting corresponding meshes 12, 14. If multiple meshes 12, 14 are used for heating, these meshes 12, 14 may be contacted parallel or serially. Also shown in the right part of FIG. 1 is a blow-up of the mesh construction of the meshes 12, 14. The meshes 12, 14 preferably are configured as woven wires.

[0060] FIG. 2 shows different embodiments of mesh types. The first embodiment shown in FIG. 2A is the embodiment shown in FIGS. 1 and 3, in which the meshes 12, 14 are configured as tubular meshes 12, 14, wherein the first mesh 12 is arranged inside of the second mesh 14. In comparison with the embodiments shown in FIGS. 1 and 3, however, FIG. 2A shows a third mesh 22 surrounding the first and second meshes 12, 14. In total, three meshes 12, 14, 22 are thus provided for increased surface area and for optimized wicking. Any desired number of meshes may be employed, and any number of those meshes may be used for heating, while all meshes contribute to wicking of substrate.

[0061] FIG. 2B shows a further embodiment, in which the individual meshes 12, 14, 22 are provided as flat meshes 12, 14, 22. Again, the meshes 12, 14, 22 are arranged distanced from each other such that liquid aerosol-forming substrate can be wicked between the individual mesh layers 12, 14, 22. Instead of the tubular meshes 12, 14 shown in FIGS. 1 and 3, the flat meshes 12, 14, 22 shown in FIG. 2B may be utilizing to contact the liquid storage 16 and span the airflow channel 18 for aerosol generation. As described with reference to FIG. 1, the contacts 20 contacting the mesh 12, 14, 22 may be arranged to only contact one mesh 12. In this case only this mesh 12 will be configured as a heating mesh. The meshes 12, 14, 22 may alternatively be connected with each other or contacted separately by corresponding contacts 20.

[0062] FIG. 2C shows a further embodiment of a mesh 12. In this embodiment, the mesh 12 is configured as a single mesh 12. However, the mesh 12 is crimped so that layers of the mesh 12 are disposed next to each other. Again, capillary action is enabled between the layers of the mesh 12 due to the distance between the layers of the mesh 12 been chosen accordingly. In FIG. 2C, multiple layers of the mesh 12 are provided. The number of layers may be chosen according to the desired amount of liquid aerosol-forming substrate to be wicked and vaporized per time. In all described embodiments, the distance between mesh layers is around 5 to 200 μm, preferably 10 to 150 μm, more preferably 20 to 100 μm. The contacts 20 for contacting the crimped layered mesh 12 as shown in FIG. 2C are arranged to facilitate uniform current flow through the mesh 12. If desired, the contacts 20 may be provided as multiple parallel contacts 20 contacting the mesh 12 at different portions for optimizing uniform current flow.

[0063] FIG. 3 shows a further embodiment, in which a tubular heater 24 is provided surrounding the meshes 12, 14 as shown in FIG. 1. In this embodiment, preferably the heating functionality and the wicking functionality are separated. The meshes 12, 14 are provided for wicking the liquid aerosol-forming substrate from the liquid supply 16 towards the airflow channel 18. The tubular heater 24 is provided for heating and vaporizing the liquid aerosol-forming substrate so that air flowing through the airflow channel 18 may entrain the vaporized substrate and carry the generated aerosol towards a user. Alternatively, the tubular heater 24 may be provided in addition to the meshes 12, 14 for heating purposes. In this case, at least one of the meshes 12, 14 as well as the tubular heater 24 are configured for heating the substrate.

[0064] The tubular heater 24 may also be arranged distanced from the meshes 12, 14 so that the tubular heater 24 contributes to the wicking of liquid aerosol-forming substrate. In other words, the tubular heater 24 may contribute to the wicking of substrate while also being configured for heating of the substrate.

[0065] The tubular heater 24 may also be used in an inductive heater system. In this case, preferably the tubular heater 24 as well as the meshes 12, 14 are formed from susceptor material and an induction coil is arranged to surround these meshes 12, 14, 24 for inductively heating all of these meshes 12, 14, 24.

[0066] The contacts 20 depicted in FIG. 3 contact the tubular heater 24. In FIG. 3, two tubular heaters 24 are depicted. However, only one tubular heater 24 may be provided being contacted by both contacts 20. If two tubular heaters 24 are provided as shown in FIG. 3, the two tubular heaters 24 may be electrically connected with each other to enable current flow between the two tubular heaters 24. The electrical connection may be provided independent from the two meshes 12, 14 so that the meshes 12, 14 do not contribute to the heating of the liquid aerosol-forming substrate. However, the tubular heaters 24 may also be electrically connected at least to the outer second mesh 14 so that this mesh 14 contributes to the heating and constitutes the electrical connection between the tubular heaters 24. The first mesh 12 may be electrically connected to the second mesh 14 so that all of the meshes 12, 14 as well as the tubular heaters 24 are used for heating of the liquid aerosol-forming substrate.