Inductive heating device, aerosol-delivery system comprising an inductive heating device, and method of operating same
11483902 · 2022-10-25
Assignee
Inventors
Cpc classification
H05B2206/023
ELECTRICITY
International classification
H05B1/02
ELECTRICITY
H05B6/10
ELECTRICITY
Abstract
An inductive heating device (1) for heating an aerosol-forming substrate (20) comprising a susceptor (21) comprises: a device housing (10) a DC power source (11) for providing a DC supply voltage (V.sub.DC) and a DC current (I.sub.DC) a power supply electronics (13) comprising a DC/AC converter (132), the DC/AC converter (132) comprising an LC load network (1323) comprising a series connection of a capacitor (C2) and an inductor (L2) having an ohmic resistance (R.sub.Coil), a cavity (14) in the device housing (10) for accommodating a portion of the aerosol-forming substrate (20) to inductively couple the inductor (L2) of the LC load network (1323) to the susceptor (21). The power supply electronics (13) further comprises a microcontroller (131) to determine from the DC supply voltage (V.sub.DC) and the DC current (I.sub.DC) an apparent ohmic resistance (R.sub.a), and from the apparent ohmic resistance (R.sub.a) the temperature (T) of the susceptor (21).
Claims
1. An inductive heating device for heating an aerosol-forming substrate, the inductive heating device comprising: a device housing; a DC power source configured to provide a DC supply voltage and a DC current; power supply electronics configured to operate at a frequency ranging from 1 MHz to 30 MHz, the power supply electronics comprising a DC/AC converter connected to the DC power source, the DC/AC converter comprising an LC load network configured to operate at an ohmic load smaller than 2 Ohms, wherein the LC load network comprises a series connection of a capacitor and an inductor having an ohmic resistance; and a cavity arranged in the device housing, the cavity having an internal surface shaped to accommodate at least a portion of the aerosol-forming substrate, the cavity being arranged such that upon accommodation of the portion of the aerosol-forming substrate in the cavity the inductor of the LC load network is inductively coupled to a susceptor positioned in thermal proximity relative to the aerosol-forming substrate during operation, wherein the power supply electronics further comprises a microcontroller programmed to, in operation, determine from the DC supply voltage of the DC power source and from the DC current drawn from the DC power source an apparent ohmic resistance, and further programmed to, in operation, determine from the apparent ohmic resistance a temperature of the susceptor.
2. The inductive heating device according to claim 1, wherein the device is configured to heat the aerosol-forming substrate of a smoking article.
3. The inductive heating device according to claim 1, wherein the DC power source is a DC battery configured to provide a constant DC supply voltage, and wherein the power supply electronics further comprises a DC current sensor configured to measure a DC current drawn from the DC battery to determine from the constant DC supply voltage and the measured DC current the apparent ohmic resistance.
4. The inductive heating device according to claim 1, wherein the power supply electronics further comprises a DC voltage sensor configured to measure the DC supply voltage of the DC power source.
5. The inductive heating device according to claim 1, wherein the microcontroller is further programmed to interrupt generation of AC power by the DC/AC converter when the determined temperature of the susceptor positioned in thermal proximity relative to the aerosol-forming substrate is equal to or exceeds a preset threshold temperature, and wherein the microcontroller is further programmed to resume generation of AC power when the determined temperature of the susceptor positioned in thermal proximity relative to the aerosol-forming substrate is below the preset threshold temperature again.
6. The inductive heating device according to claim 1, wherein the DC/AC converter comprises a Class-E power amplifier comprising a transistor switch, a transistor switch driver circuit, and the LC load network configured to operate at the ohmic load smaller than 2 Ohms, and wherein the LC load network additionally comprises a shunt capacitor.
7. The inductive heating device according to claim 6, wherein the Class-E power amplifier has an output impedance, and wherein the power supply electronics further comprises a matching network configured to match the output impedance of the Class-E power amplifier to the ohmic load smaller than 2 Ohms.
8. The inductive heating device according to claim 1, wherein a total volume of the power supply electronics is equal to or smaller than 2 cm.sup.3.
9. The inductive heating device according to claim 1, wherein the inductor of the LC load network comprises a helically wound cylindrical inductor coil, which is disposed on or adjacent the internal surface of the cavity.
10. The inductive heating device according to claim 9, wherein the inductor coil has an oblong shape and defines an inner volume in a range of about 0.15 cm.sup.3 to about 1.10 cm.sup.3.
11. An aerosol-delivery system comprising the inductive heating device according to claim 1 and the aerosol-forming substrate, wherein at least a portion of the aerosol-forming substrate being accommodated in the cavity of the inductive heating device with a susceptor positioned in thermal proximity relative to the aerosol-foaming substrate such that the inductor of the LC load network of the DC/AC converter of the inductive heating device is inductively coupled to the susceptor positioned in thermal proximity relative to the aerosol-forming substrate during operation.
12. The aerosol-delivery system according to claim 11, wherein the aerosol-forming substrate is a tobacco-laden solid aerosol-forming substrate.
13. The aerosol-delivery system according to claim 11, wherein the susceptor is made of stainless steel.
14. The aerosol-delivery system according to claim 13, wherein the susceptor comprises a flat strip of stainless steel, the flat strip of stainless steel having a length in a range of about 8 millimeters to about 15 millimeters, having a width in a range of about 3 millimeters to about 6 millimeters, and having a thickness in a range of about 20 micrometers to about 50 micrometers.
15. A method of operating the aerosol-delivery system according to claim 11, the method comprising the steps of: determining from the DC supply voltage of the DC power source and from the DC current drawn from the DC power source the apparent ohmic resistance; and determining from the apparent ohmic resistance the temperature of the susceptor positioned in thermal proximity relative to the aerosol-forming substrate.
16. The method according to claim 15, wherein the DC power source is a DC battery providing a constant DC supply voltage, and wherein the DC current drawn from the DC battery is measured for determining, from the constant DC supply voltage and the measured DC current, the apparent ohmic resistance.
17. The method according to claim 15, further comprising the steps of: interrupting generation of AC power by the DC/AC converter when the determined temperature of the susceptor positioned in thermal proximity relative to the aerosol-forming substrate is equal to or exceeds a preset threshold temperature; and resuming generation of AC power when the determined temperature of the susceptor positioned in thermal proximity relative to the aerosol-forming substrate is below the preset threshold temperature again.
18. The aerosol-delivery system according to claim 11, wherein the susceptor is positioned within the aerosol-forming substrate during operation.
Description
(1) Further advantageous aspects of the invention will become apparent from the following description of embodiments with the aid of the drawings in which:
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(11) In
(12) In addition, in
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(14) Returning to
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(17) Due to the very low number of components the volume of the power supply electronics 13 can be kept extremely small. For example, the volume of the power supply electronics may be equal or smaller than 2 cm.sup.3. This extremely small volume of the power supply electronics is possible due to the inductor L2 of the LC load network 1323 being directly used as the inductor for the inductive coupling to the susceptor 21 of aerosol-forming substrate 20, and this small volume allows for keeping the overall dimensions of the entire inductive heating device 1 small. In case a separate inductor other than the inductor L2 is used for the inductive coupling to the susceptor 21, this would automatically increase the volume of the power supply electronics, this volume being also increased if a matching network 133 is comprised in the power supply electronics.
(18) While the general operating principle of the Class-E power amplifier is known and described in detail in the already mentioned article “Class-E RF Power Amplifiers”, Nathan O. Sokal, published in the bimonthly magazine QEX, edition January/February 2001, pages 9-20, of the American Radio Relay League (ARRL), Newington, Conn., U.S.A., some general principles will be explained in the following.
(19) Let us assume that the transistor switch supply circuit 1322 supplies a switching voltage (gate-source voltage of the FET) having a rectangular profile to FET 1321. As long as FET 1321 is conducting (“on”-state), it does essentially constitute a short circuit (low resistance) and the entire current flows through choke L1 and FET 1321. As FET 1321 is non-conducting (“off”-state), the entire current flows into the LC load network since FET 1321 essentially represents an open circuit (high resistance). Switching the transistor between these two states inverts the supplied DC voltage and DC current into an AC voltage and AC current.
(20) For efficiently heating the susceptor 21, an as large as possible amount of the supplied DC power is to be transferred in the form of AC power to inductor L2 (helically wound cylindrical inductor coil) and subsequently to the susceptor 21 of aerosol-forming substrate 20 which is inductively coupled to inductor 2. The power dissipated in the susceptor 21 (eddy current losses, hysteresis losses) generates heat in the susceptor 21, as described further above. Or to say it in other words, power dissipation in FET 1321 has to be minimized while maximizing power dissipation in susceptor 21.
(21) The power dissipation in FET 1321 during one period of the AC voltage/current is the product of the transistor voltage and current at each point in time during that period of the alternating voltage/current, integrated over that period, and averaged over that period. Since the FET 1321 has to sustain high voltage during a part of that period and conduct high current during a part of that period, it has to be avoided that high voltage and high current exist at the same time, since this would lead to substantial power dissipation in FET 1321. In the “on-” state of FET 1321, the transistor voltage is nearly zero when high current is flowing through the FET 1321. In the “off-” state of FET 1321, the transistor voltage is high but the current through FET 1321 is nearly zero.
(22) The switching transitions unavoidably also extend over some fractions of the period. Nevertheless, a high voltage-current product representing a high power loss in FET 1321 can be avoided by the following additional measures. Firstly, the rise of the transistor voltage is delayed until after the current through the transistor has reduced to zero. Secondly, the transistor voltage returns to zero before the current through the transistor begins to rise. This is achieved by load network 1323 comprising shunt capacitor C1 and the series connection of capacitor C2 and inductor L2, this load network being the network between FET 1321 and the load 1324. Thirdly, the transistor voltage at turn-on time is practically zero (for a bipolar-junction transistor “BJT” it is the saturation offset voltage V.sub.o). The turning-on transistor does not discharge the charged shunt capacitor C1, thus avoiding dissipating the shunt capacitor's stored energy. Fourthly, the slope of the transistor voltage is zero at turn-on time. Then, the current injected into the turning-on transistor by the load network rises smoothly from zero at a controlled moderate rate resulting in low power dissipation while the transistor conductance is building up from zero during the turn-on transition. As a result, the transistor voltage and current are never high simultaneously. The voltage and current switching transitions are time-displaced from each other.
(23) For dimensioning the various components of the DC/AC converter 132 shown in
(24) Let Q.sub.L (quality factor of the LC load circuit) be a value which is in any event greater than 1.7879 but which is a value that can be chosen by the designer (see the afore-mentioned article) let further P be the output power delivered to the resistance R, and let f be the frequency, then the various components are numerically calculated from the following equations (V.sub.o being zero for FETs, and being the saturation offset voltage for BJTs, see above):
L2=Q.sub.L.Math.R/2πf
R=((V.sub.CC−V.sub.o).sup.2/P).Math.0.576801.Math.(1.0000086−0.414395/Q−0.557501/Q.sub.L.sup.2+0.205967/Q.sub.L.sup.3)
C1=(1/(34.2219.Math.f.Math.R)).Math.(0.99866+0.91424/Q.sub.L−1.03175/Q.sub.L.sup.2)+0.6/(2πf).sup.2.Math.(L1)
C2=(½πfR).Math.(1/Q−0.104823).Math.(1.00121+(1.01468/Q.sub.L−1.7879))−(0.2/((2M).sup.2.Math.L1)))
(25) This allows for a rapid heating up of a susceptor having an ohmic resistance of R=0.6Ω to deliver approximately 7 W of power in 5-6 seconds assuming that a current of approximately 3.4 A is available using a DC power source having a maximum output voltage of 2.8 V and a maximum output current of 3.4 A, a frequency of f=5 MHz (duty ratio=50%), an inductivity of inductor L2 of approximately 500 nH and an ohmic resistance of the inductor L2 of R.sub.Coil=0.1Ω, an inductivity L1 of about 1 μH, and capacitances of 7 nF for capacitor C1 and of 2.2 nF for capacitor C2. The effective ohmic resistance of R.sub.Coil and R.sub.Load is approximately 0.6Ω. An efficiency (Power dissipated in the susceptor 21/maximum power of DC power source 11) of about 83.5% may be obtained which is very effective.
(26) For operation, the smoking article 2 is inserted into the cavity 14 (see
(27) The inductive heating device and the smoking articles can generally be distributed separately or as a kit of parts. For example, it is possible to distribute a so-called “starter kit” comprising the inductive heating device as well as a plurality of smoking articles. Once the consumer has purchased such starter kit, in the future the consumer may only purchase smoking articles that can be used with this inductive heating device of the starter kit. The inductive heating device is easy to clean and in case of rechargeable batteries as the DC power source, these rechargeable batteries are easy to be recharged using a suitable charging device that is to be connected to the docking port 12 comprising pin 120 (or the inductive heating device is to be docked to a corresponding docking station of a charging device).
(28) It has already mentioned above, that by determination of the apparent ohmic resistance R.sub.a from the DC supply voltage V.sub.DC of the DC power source 11 and from the DC current I.sub.DC drawn from the DC power source 11 it is possible to determine the temperature T of the susceptor 21. This is possible because surprisingly the relationship of the temperature T of the susceptor 21 and the quotient of the DC supply voltage V.sub.DC and DC current I.sub.DC is strictly monotonic, and may even be practically linear for a Class-E amplifier. Such a strictly monotonic relationship is shown in
(29) As mentioned already, in case of a Class-E amplifier this strictly monotonic relationship between the apparent ohmic resistance R.sub.a and the temperature T of the susceptor is practically linear, at least for the temperature range of interest (for example for the temperature range between 100° C. and 400° C.)
(30) If the relationship between the apparent ohmic resistance R.sub.a and the temperature T of a specific susceptor made of a specific material and having a specific geometry is known (for example, such relationship can be determined through precise measurements in the laboratory for a large number of identical susceptors and subsequent averaging of the individual measurements), this relationship between the apparent ohmic resistance R.sub.a and the temperature T of this specific susceptor can be programmed into the microcontroller 131 (see
(31) It is possible and may be preferred that both the DC supply voltage V.sub.DC and the DC current I.sub.DC drawn from the DC power source 11 can be measured (this can be achieved with a suitable DC voltage sensor and a suitable DC current sensor which can be easily integrated in the small circuit without any relevant space consumption). However, in case of a DC power source of constant supply voltage V.sub.DC a DC voltage sensor can be dispensed with and only a DC current sensor is needed for the measurement of the DC current I.sub.DC drawn from the DC power source 11.
(32) In
(33) As can be seen, once the heating of the susceptor of the aerosol-forming substrate has started, the current I.sub.DC is at a high level and decreases as the temperature T of the susceptor of the aerosol-forming substrate increases (the increase in temperature of the susceptor leads to an increase of R.sub.a which in turn leads to a decrease of I.sub.DC). At different times during this heating process (in particular when the aerosol-forming substrate has reached a certain temperature), the user may take a puff from the smoking article comprising the aerosol-forming substrate with the susceptor arranged therein. At that time, air drawn in leads to a quick decrease of the temperature of the aerosol-forming substrate and of the susceptor. This leads to an decrease in the apparent ohmic resistance R.sub.a, and this in turn leads to a increase in the DC current I.sub.DC drawn from the DC power source 11. These points in time when the user takes a puff are indicated in
(34) As can further be seen in
(35) This can be achieved, for example, by adjusting the duty cycle of the switching transistor. This is described in principle in WO 2014/040988. For example, during heating the DC/AC converter continuously generates alternating current that heats the susceptor, and simultaneously the DC supply voltage V.sub.DC and the DC current I.sub.DC are measured every 10 milliseconds for a period of 1 millisecond. The apparent ohmic resistance R.sub.a is determined (by the quotient of V.sub.DC and I.sub.DC), and as R.sub.a reaches or exceeds a value R.sub.a corresponding to the preset threshold temperature T.sub.th or to a temperature exceeding the preset threshold temperature T.sub.th the switching transistor 1321 (see
(36) For example, the a susceptor 21 may have a length of about 12 millimeters, a width of about 4 millimeters and a thickness of about 50 micrometers, and may be made of stainless steel grad 430 (SS430). As an alternative example, the susceptor may have a length of about 12 millimeters, a width of either about 5 millimeters and a thickness of about 50 micrometers, and may be made of stainless steel grade 420 (SS430). These susceptor may also be made from stainless steel grade 420 (SS420).
(37) Having described embodiments of the invention with the aid of the drawings, it is clear that many changes and modifications are conceivable without departing from the general teaching underlying the instant invention. Therefore, the scope of protection is not intended to be limited to the specific embodiments, but rather is defined by the appended claims.