Patent Description:
The present invention also concerns an assembly method of such an aerosol generation device.

Different types of aerosol generation devices are already known in the art. Generally, such a device comprises a housing defining an internal space. The internal space comprises a storage portion for storing a vaporizable material that can be for example a liquid or a solid. Usually, the internal space also comprises a heat source. For example, this heat source is a heating system that is made up of one or more electrically activated resistive heating elements arranged to heat said vaporizable material to generate aerosol. The aerosol is released into a flow path extending between an inlet and outlet of the device. The outlet may be arranged as a mouthpiece, through which a user inhales for delivery of the aerosol.

<CIT> discloses an electronic cigarette atomizer comprising a housing, said housing comprising multiple thermal insulation layers.

In case of extensive vaping, the heat source can generate a significant amount of heat. This can lead to the heating of the housing in such a way that it may become uncomfortable for a user to hold the device. The user may then be obliged to stop vaping in order to allow the device to cool down.

One of the aims of the invention is to provide an aerosol generation device in which overheating is reduced.

For this purpose, the invention relates to an aerosol generation device comprising a housing, the housing defining an internal space, the device comprising at least a heat source within the internal space;.

The interlaced structure of the mesh sublayer forms perforations on the thermo-protected portion of the outer surface. These perforations ease the flow of heat from within the internal space towards the outside of the device.

According to some embodiments, the mesh sublayer is made up of wood or fabric.

Wood and fabric are materials that are relatively good thermal insulators. Therefore, the mesh sublayer allows heat to flow through its mesh openings but conducts only little heat.

According to some embodiments, the thermal insulation layer further comprises a backer sublayer fixed to said thermo-protected portion and an adhesive sublayer fixed to the backer sublayer, the mesh sublayer being fixed to the adhesive sublayer.

Thanks to these features, the mesh sublayer is firmly attached to the insulation wall.

According to some embodiments, the aerosol generation device further comprises a heat-diffusion layer arranged between at least a thermo-diffusion portion of the inner surface of the insulation wall and the internal space of the device.

According to some embodiments, the heat-diffusion layer extends substantially parallel to a plane of extension of the insulation wall.

According to some embodiments, the heat-diffusion layer is a heat-conducting plate.

According to some embodiments, the heat-conducting plate is made up of copper.

Thanks to these features, the heat generated by the heat source is diffused throughout the housing. This makes it possible to avoid the accumulation of heat in a narrow space surrounding the heat source. This also widens the surface of heat exchange with the thermo-protected portion. The flow of heat through the mesh sublayer is increased.

According to some embodiments, the aerosol generation device further comprises a support attached to the housing and extending within the internal space and at least a magnet arranged on the support to fix the heat-diffusion layer to the support.

Thanks to these features, the heat-diffusion layer is easily fixed to the device.

According to some embodiments, the aerosol generation device further comprises a light source within the internal space of the device.

According to some embodiments, the heat-diffusion layer comprises a light orifice arranged facing the light source.

Thanks to these features, despite the presence of the heat-diffusion layer, a user can acknowledge whether the device is powered on or not thanks to the light coming from the light source and passing through the light orifice.

According to some embodiments, the insulation wall is a removable wall of the housing.

Thanks to these features, the insulation wall is customizable. A user of the device can choose a specific insulation wall depending on its insulation features or depending on other features such as its appearance or its texture.

According to some embodiments, the heat source is a heating system configured to generate aerosol from a vaporizable material.

The heating system of an aerosol generation device may generate a significant amount of heat. Thanks to these features, the device can evacuate important amounts of heat coming from its heating system.

The invention also relates to an assembly method of an aerosol generation device as disclosed above, comprising a step of fixing of the thermal insulation layer on the thermo-protected portion of the outer surface of the insulation wall.

According to some embodiments, the thermal insulation layer further comprises a backer sublayer fixed to the thermo-protected portion and an adhesive sublayer fixed to the backer sublayer, the mesh sublayer being fixed to the adhesive sublayer, the fixing step comprising:.

As used herein, the term "aerosol generation device" or "device" may include a vaping device to deliver an aerosol to a user, including an aerosol for vaping, by means of aerosol generating unit (e.g. an aerosol generating element which generates vapor which condenses into an aerosol before delivery to an outlet of the device at, for example, a mouthpiece, for inhalation by a user). The device may be portable. "Portable" may refer to the device being for use when held by a user. The device may be adapted to generate a variable amount of aerosol, e.g. by activating a heating system for a variable amount of time (as opposed to a metered dose of aerosol), which can be controlled by a trigger. The trigger may be user activated, such as a vaping button and/or inhalation sensor. The inhalation sensor may be sensitive to the strength of inhalation as well as the duration of inhalation to enable a variable amount of vapor to be provided (so as to mimic the effect of smoking a conventional combustible smoking article such as a cigarette, cigar or pipe, etc.).

As used herein, the term "aerosol" may include a suspension of precursor as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. Aerosol herein may generally refer to/include a vapor. Aerosol may include one or more components of the precursor.

As used herein, the term "vaporizable material" or "aerosol-forming precursor" or "precursor" or "aerosol-forming substance" or "substance" may refer to one or more of a: liquid; solid; gel; mousse; foam or other substances. The precursor may be processable by the heating system of the device to form an aerosol as defined herein. The precursor may comprise one or more of: nicotine; caffeine or other active components. The active component may be carried with a carrier, which may be a liquid. The carrier may include propylene glycol or glycerine. A flavoring may also be present. The flavoring may include Ethylvanillin (vanilla), menthol, Isoamyl acetate (banana oil) or similar. A solid aerosol forming substance may be in the form of a rod, which contains processed tobacco material, a crimped sheet or oriented strips of reconstituted tobacco (RTB).

Referring to <FIG> and <FIG>, an aerosol generation device <NUM> according to the invention comprises a housing <NUM>. For example, as shown on <FIG>, the housing <NUM> has a substantially parallelepiped shape with slightly rounded edges. The housing <NUM> comprises walls <NUM> defining an internal space <NUM> of the device <NUM>. For example, the housing <NUM> comprises a front wall <NUM>, an opposite rear wall <NUM>, two lateral side walls <NUM> and two upper and lower side walls <NUM>.

The device <NUM> further comprises a support <NUM> attached to the housing <NUM>, extending within the internal space <NUM> and configured to support functional components of the device <NUM>. The support <NUM> may be formed by a chassis adapted to receive and fix such functional components within the housing <NUM>. For example, such functional components comprise electronic components, a battery or a power supply designed to power said electronic components. In some embodiments, the functional components may further comprise a storage portion (non-illustrated) for storing vaporizable material. In these embodiments, the storage portion is thus arranged inside the housing <NUM>. It can be refilled in this case directly with vaporizable material or using a removable cartridge designed to be inserted in such a portion. In some other embodiments, a storage portion may be formed outside the housing <NUM>, for example by a removable cartridge. In this case, the housing <NUM> defines fixing means configured to receive and fix the removable cartridge.

The device <NUM> further comprises at least a heat source <NUM> arranged within the internal space <NUM>. For example, the heat source <NUM> is attached to the support <NUM> and is comprised in a heating system of the device <NUM>, configured to generate aerosol by heating vaporizable material. In this case, the heat source <NUM> may correspond to a heating element used to heat the vaporizable material comprised in the storing portion, like for example a heating plate, electrical resistance or susceptor. According to other examples, the heat source <NUM> is formed by the battery and/or power supply of the device or any other electrical component of the device. In some examples, the heat source <NUM> is formed by several components among the components cited above.

In case of extensive use of the device <NUM>, the heat source <NUM> can generate a significant amount of heat. This can lead to an overheating of the device <NUM>, in particular to an overheating of the housing's walls <NUM>. A user of the device <NUM> may then feel this unpleasant heat on its hands. In case of severe overheating, the user may suffer from it and the bearing of the device <NUM> may become impossible. It may then become necessary to shut down the heat source <NUM> in order to avoid damage to the device <NUM>.

For example, as illustrated on <FIG> and <FIG>, the device <NUM> further comprises a light source <NUM> arranged within the internal space <NUM>. For example, the light source <NUM> is attached to the support <NUM> and faces the front wall <NUM> of the housing. For example, it is configured to emit light when the device <NUM> is on, in particular when the battery or the power supply supplies power to the electronic components of the device or to the heating system to generate aerosol.

In view of <FIG> and <FIG>, the housing <NUM> comprises at least an insulation wall <NUM>. For example, the insulation wall <NUM> is one of the walls <NUM> of the housing <NUM>, for example the front wall <NUM>. For example, the insulation wall <NUM> extends substantially along a plane of extension P. It comprises an inner surface <NUM> facing the internal space <NUM> and an outer surface <NUM> opposite the inner surface <NUM>. The insulation wall <NUM> is for example a removable wall of the housing <NUM> movable between a mounted position (<FIG>) in which the insulation wall <NUM> is mounted on the housing <NUM> and a spaced away position (<FIG>, <FIG> and <FIG>) in which it is spaced away from the housing <NUM>. In the mounted position, the insulation wall <NUM> protects the internal space <NUM> from external elements, for example dust or water. As it will be explained below, in the mounted position, the insulation wall <NUM> also regulates the flow of heat coming from the heat source <NUM>. In the spaced away position, the user can access the internal space <NUM> for example for repairing or maintenance of the functional elements of the device <NUM>. In some embodiments, the user can access the internal space <NUM> to refill the storage portion directly with vaporizable material or with a removable cartridge.

The insulation wall <NUM> can also be removed and replaced by another insulation wall <NUM> presenting different features such as another aspect or another texture of the outer surface <NUM>. For example, the insulation wall <NUM> is fixed to the other walls of the housing <NUM> or the support <NUM> by snap fitting. For example, the lateral side walls <NUM> and the upper and lower side walls <NUM> comprise a peripheral snap fitting box (non-illustrated) on their forward edge. The insulation wall <NUM> may comprise a peripheral snap fitting pin on its edges designed to cooperate with the peripheral snap fitting box in order to attach the insulation wall <NUM> to the walls <NUM>, <NUM> in the mounted position.

In some embodiments, as for example in the embodiment shown on <FIG>, the insulation wall <NUM> comprises a light orifice <NUM> designed to let the light emitted by the light source <NUM> pass through and reach the outside of the device <NUM>. For example, the light orifice <NUM> of the insulation wall <NUM> is filled with a translucent material in order to allow the emitted light to pass through but to prevent external elements from entering the internal space <NUM>.

The outer surface <NUM> of the insulation wall <NUM> comprises at least a thermo-protected portion. The device <NUM> comprises a thermal insulation layer <NUM> arranged on the thermo-protected portion, for example, fixed to the thermo-protected portion. As illustrated on the example of <FIG>, the thermo-protected portion corresponds to the entire outer surface <NUM>. According to other embodiments of the invention, the thermo-protected portion corresponds to a part of the outer surface <NUM>, for example to a part of the outer surface <NUM> facing the heat source <NUM>.

As shown on <FIG>, the thermal insulation layer <NUM> comprises a mesh sublayer <NUM>. For example, the thermal insulation layer <NUM> further comprises an adhesive sublayer <NUM> and a backer sublayer <NUM>. For example, the backer sublayer <NUM> is fixed on the outer surface <NUM> of the insulation wall <NUM>, the adhesive sublayer <NUM> is placed on top of the backer sublayer <NUM> and the mesh sublayer <NUM> is placed on top of the adhesive sublayer <NUM>.

The mesh sublayer <NUM> comprises an interlaced structure of a material such as, for example, wood or fabric. The mesh sublayer <NUM> is thus made up of interlaced fibers. For example, the mesh sublayer <NUM> is made up of wood fibers or fabric fibers. Wood fibers are for example made up of cellulose. For example, fabric fibers are made up of cotton, polyester, nylon, acrylic and/or polyurethane. The interlaced structure may be a woven or non-woven structure of wood fibers or fabric fibers. Such interlaced structure comprises through-holes through which the heat generated by the heat source <NUM> flows from the internal space <NUM> to the outside of the device <NUM>. For example, the mesh sublayer <NUM> extends facing the entire outer surface <NUM> of the insulation wall <NUM>. For example, the mesh sublayer <NUM> is fixed on the adhesive sublayer <NUM>. The through-holes of the mesh sublayer <NUM> also let the light emitted by the light source <NUM> pass through and reach the outside of the device <NUM>. For example, the through-holes have a size between <NUM> and <NUM>, preferably between <NUM> and <NUM>, more preferably between <NUM> and <NUM>, even more preferably between <NUM> and <NUM>, notably substantially equal to <NUM>. Of course, other value ranges are possible for the size of the through-holes.

The backer sublayer <NUM> is fixed to the thermo-protected portion. For example, the backer sublayer <NUM> is made up of non-woven fibers. For example, said non-woven fibers are made up of polyester.

The adhesive sublayer <NUM> is fixed to the backer sublayer. For example, the adhesive sublayer <NUM> is made up of glues of thermoplastic resin which flexibly change its shape. For example, the adhesive sublayer <NUM> is made up of hot melt glues like acrylic resin adhesive. For example, the mesh sublayer <NUM> is fixed to the adhesive sublayer <NUM> and is therefore fixed to the insulation wall <NUM> via the adhesive sublayer <NUM> and the backer sublayer <NUM>. For example, the backer sublayer <NUM> and the adhesive sublayer <NUM> extend facing only parts of the thermo-protected portion and only parts of the mesh sublayer <NUM>. This way, the backer sublayer <NUM> and the adhesive sublayer <NUM> do not disrupt the flow of heat from the heat source <NUM> to the outside of the device <NUM> but still firmly attach the mesh sublayer <NUM> to the insulation wall <NUM>.

Referring to <FIG>, the inner surface <NUM> of the insulation wall <NUM> comprises at least a thermo-diffusion portion. For example, the device <NUM> further comprises a heat-diffusion layer <NUM> arranged between the thermo-diffusion portion of the inner surface <NUM> of the insulation wall <NUM> and the internal space <NUM> of the device <NUM>. The heat-diffusion layer <NUM> extends substantially parallel to the plane of extension P of the insulation wall <NUM>. For example, it is fixed to the inner surface <NUM> of the insulation wall <NUM>. The heat-diffusion layer <NUM> is for example a heat-conducting plate, for example made up of copper or any other heat-diffusion material. The heat-diffusion layer <NUM> is configured to diffuse the heat generated by the heat source <NUM> throughout its entirety, for example throughout the plane of extension P. The heat-diffusion layer <NUM> spreads the generated heat on an increased surface facing the thermos-protected portion. The heat exchange surface between the internal space <NUM> and the outside of the device <NUM> is therefore increased. For example, as shown on <FIG>, the heat-diffusion layer <NUM> comprises a light orifice <NUM> arranged facing the light source <NUM> when the insulation wall <NUM> is in its mounted position. In the mounted position of the insulation wall <NUM>, the light emitted by the light source <NUM> exits the housing <NUM> through the light orifice <NUM> of the heat-diffusion layer <NUM>, the light orifice <NUM> of the insulation wall <NUM> and through the through-holes of the mesh sublayer <NUM>.

For example, as shown on <FIG> and <FIG>, the device <NUM> further comprises at least a magnet <NUM> arranged on the support <NUM> to fix the heat-conducting plate to the support <NUM> when the heat-conducting plate is made up of a ferromagnetic material like copper. For example, as shown on <FIG> and <FIG>, the device <NUM> comprises two magnets <NUM>. The magnets <NUM> account for an additional fixation means between the insulation wall <NUM> and the walls <NUM>, <NUM>.

It would apparent for one skilled in the art, that the thermal insulation layer <NUM> and the heat-diffusion layer <NUM> as described above can be arranged on any other wall <NUM> of the housing <NUM>, depending notably on the arrangement of the heat source <NUM> inside the housing. In some embodiments, these layers <NUM>, <NUM> can be arranged on several walls <NUM> or on a unique lateral wall <NUM> when for example the housing <NUM> has a cylindrical shape.

An operation method of the aerosol generation device <NUM> will now be explained. A user of the device <NUM> activates a vaping button or an inhalation sensor in order to generate aerosol. By doing so, the heat source <NUM> is powered on and generates heat. For example, when the heat source <NUM> generates heat, the light source <NUM> emit light. The user of the device <NUM> can then acknowledge that the heat source <NUM> is powered on by seeing the light emitted through the light orifices <NUM> and <NUM> and through mesh sublayer <NUM>. The heat-diffusion layer <NUM> diffuses the heat generated by the heat source <NUM> throughout its entirety. The heat is for example diffused over an extended surface parallel to the plane of extension P. The diffused heat then flows through the insulation wall <NUM> and through the through-holes of the mesh sublayer <NUM> from within the internal space <NUM> to the outside of the device <NUM>. This lead to an efficient cooling of the internal space <NUM> and of the housing <NUM>. Even in case of extensive vaping, overheating of the walls <NUM> is prevented.

If needed, the user can remove the insulation wall <NUM> together with the thermal insulation layer <NUM> and the heat-diffusion layer <NUM> and replace it with a different insulation wall comprising, for example, different layers <NUM>, <NUM> or a different aspect or texture.

Claim 1:
An aerosol generation device (<NUM>) comprising a housing (<NUM>), the housing (<NUM>) defining an internal space (<NUM>), the device (<NUM>) comprising at least a heat source (<NUM>) within the internal space (<NUM>);
the housing (<NUM>) comprising at least an insulation wall (<NUM>) comprising an inner surface (<NUM>) facing the internal space (<NUM>) and an outer surface (<NUM>) opposite to the inner surface (<NUM>);
the device (<NUM>) further comprising a thermal insulation layer (<NUM>) arranged on at least a thermo-protected portion of the outer surface (<NUM>) of the insulation wall (<NUM>), the thermal insulation layer (<NUM>) comprising a mesh sublayer (<NUM>), the mesh sublayer (<NUM>) comprising an interlaced structure,
characterized in that the interlaced structure comprises through-holes through which the heat generated by the heat source (<NUM>) flows from the internal space (<NUM>) to the outside of the device (<NUM>), the through-holes having a size between <NUM> and <NUM>.