RU2843627C2 - Method of making a sensor for an aerosol-generating device - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: invention relates to the field of aerosol-generating devices, such as electrically driven smoking devices, namely to sensors for such devices and their manufacture. Method comprises providing a layer of a flexible dielectric substrate, printing or mounting a first sensor component in a first location on the flexible dielectric substrate, printing or installing a second sensor component in a second location on the flexible dielectric substrate, printing or installing a third sensor component in a third location on a flexible dielectric substrate, and folding or folding the flexible dielectric substrate such that three layers of the flexible dielectric substrate are formed, wherein the first location, the second location and the third location are stacked on each other to form a sensor.

EFFECT: obtaining a tubular structure comprising a folded flexible dielectric substrate and sensor components to form a three-dimensional sensor which can be placed around the cavity of the aerosol-generating device.

16 cl, 15 dwg

Description

The present invention relates to manufacturing method three-dimensional sensor for an aerosol generating device. The present invention also relates to a three-dimensional sensor used in an aerosol generating device. The present invention also relates to an aerosol generating device comprising a three-dimensional sensor.

It is known to provide an aerosol generating device for generating an inhalable vapor. Such devices can heat an aerosol forming substrate to a temperature at which one or more components of the aerosol forming substrate evaporate without burning the aerosol forming substrate. The aerosol forming substrate can be implemented as a part of an aerosol generating article. The aerosol generating article can have the form of a rod for inserting the aerosol generating article into a cavity, such as a heating chamber, of the aerosol generating device. A heating element can be located in or around the heating chamber for heating the aerosol forming substrate after the aerosol generating article is inserted into the heating chamber of the aerosol generating device. The aerosol generating device contains a plurality of electronic components, such as a controller for controlling the operation of the heating element. One or more sensors, such as a temperature sensor, may also be used, the output of which may be used to control the operation of the heating element. Placing any of these components in the aerosol generating device may be difficult, since the aerosol generating device must be shaped similarly to a traditional cigarette.

It would be desirable to have an improved method for manufacturing a sensor for an aerosol generating device. It would be desirable to have a method for manufacturing a sensor for an aerosol generating device with an improved form factor for the aerosol generating device.

According to one embodiment of the present invention, a method for manufacturing a sensor for an aerosol generating device is provided, wherein the method may include any of the following steps:

providing a flexible dielectric substrate layer,

printing or installing the first sensor component in the first location on the flexible dielectric substrate,

printing or installing a second sensor component at a second location on the flexible dielectric substrate, wherein the second location is different from the first location, and

printing or installing a third sensor component in a third location on the flexible dielectric substrate, wherein the third location is different from the second location and from the first location,

rolling or folding the flexible dielectric substrate in such a way that three layers of the flexible dielectric substrate are formed, wherein the first place, the second place and the third place are superimposed on each other to form a sensor thereby.

According to one embodiment of the present invention, a method for manufacturing a sensor for an aerosol generating device is proposed, comprising:

providing a flexible dielectric substrate layer,

printing or installing the first sensor component in the first location on the flexible dielectric substrate,

printing or installing a second sensor component at a second location on the flexible dielectric substrate, wherein the second location is different from the first location, and

printing or installing a third sensor component in a third location on the flexible dielectric substrate, wherein the third location is different from the second location and from the first location,

rolling or folding the flexible dielectric substrate in such a way that three layers of the flexible dielectric substrate are formed, wherein the first place, the second place and the third place are superimposed on each other to form a sensor thereby.

The sensor may be a three-coordinate sensor.

The manufacture of a three-dimensional sensor in this manner improves the form factor of the sensor. For example, an aerosol-generating device may have a cavity that acts as a heating chamber. The cavity may be a hollow cylindrical cavity. It may be necessary or useful to position the sensor at some point around the periphery of the cavity. The method described in this document allows for the production of a tubular structure containing a rolled flexible dielectric substrate and sensor components to thereby form a three-dimensional sensor that can be positioned in an optimal manner surrounding the cavity of the aerosol-generating device.

The flexible dielectric substrate may be a polyimide sheet. The flexible dielectric substrate may be shaped to fit the perimeter of the cavity of the aerosol generating device.

The flexible dielectric substrate can be rolled at least twice. Preferably, the flexible dielectric substrate can be rolled at least three times. After rolling the flexible dielectric substrate, at least three layers of the flexible dielectric substrate can lie on top of each other. The flexible dielectric substrate can be rolled in such a way that after this, the flexible dielectric substrate has a hollow tubular shape. The flexible dielectric substrate can have a cylindrical shape after the rolling step.

In the process of rolling up the flexible dielectric substrate, each layer of the flexible dielectric substrate can be attached to one or both of the corresponding inner layer and the outer layer. As an example, the second layer of the flexible dielectric substrate can be attached to the first layer of the flexible dielectric substrate. The third layer of the flexible dielectric substrate can be attached to the second layer of the flexible dielectric substrate. The first layer of the flexible dielectric substrate can be the innermost layer. The third layer of the flexible dielectric substrate can be the outermost layer. The second layer of the flexible dielectric substrate can be the middle layer. The second layer of the flexible dielectric substrate can be located between the first layer of the flexible dielectric substrate and the third layer of the flexible dielectric substrate.

The formed three-coordinate sensor can pass between three layers of the flexible dielectric substrate. The three-coordinate sensor can pass in the radial direction between the three layers of the flexible dielectric substrate. The radial direction can be perpendicular to the tangential direction determined by the surface of the outermost layer of the flexible dielectric substrate.

One or more of the following may occur: the first sensor component may be an electrical sensor component, the second sensor component may be an electrical sensor component, and the third sensor component may be an electrical sensor component.

Examples of electrical components include resistor, capacitor, inductor, microprocessor, electronic circuit, interconnect circuit, cavity, stud, and heat sink.

One or more of the first, second and third sensor components may comprise a controller.

The controller may be configured to receive an output signal of the three-coordinate sensor. The controller may be configured to control the operation of the three-coordinate sensor. The controller may comprise or may be a logic unit of the sensor. The controller may be electrically connected to one or more of the first, second and third components of the sensor by electrically conductive paths.

One or more of the first, second and third sensor components may be non-functional before being rolled up or folded. In other words, two or more of the first, second and third sensor components may become functional after being rolled up or folded. Two or more of the first, second and third sensor components may form a functional sensor after being rolled up or folded.

The three-coordinate sensor may contain a pressure sensor.

The three-coordinate sensor can be a pressure sensor.

The three-dimensional sensor can be implemented as a three-dimensional pressure sensor for measuring the air pressure inside the aerosol-generating device, which is drawn through the air flow path of the device by the user during a puff. The three-dimensional sensor can be configured to measure the pressure difference or pressure drop between the ambient air pressure outside the aerosol-generating device and the air that the user draws through the device. The air pressure can be recorded at the air inlet, the mouthpiece of the device, the cavity, the heating chamber or any other passage or chamber in the aerosol-generating device through which air flows. When the user draws on the aerosol-generating device, a negative pressure or vacuum is created inside the device, and the negative pressure can be recorded by the three-dimensional pressure sensor. The term "negative pressure" should be understood as a pressure that is lower than the ambient air pressure. In other words, when the user draws on the device, the air that is drawn through the device has a pressure that is lower than the ambient air pressure outside the device. Initiation of a puff can be registered by a three-dimensional pressure sensor if the pressure difference exceeds a specified threshold value.

One of the first, second and third components of the sensor may comprise a hermetically sealed cavity. Another of the first, second and third components of the sensor may comprise a strain gauge.

The pressure sensor of the three-coordinate sensor can be formed by a hermetically sealed cavity and a strain gauge. The second component of the sensor can contain a hermetically sealed cavity. The hermetically sealed cavity can be located in a second place on the flexible dielectric substrate. The first component of the sensor can contain a cavity support in a first place on the flexible dielectric substrate. The hermetically sealed cavity can rest on the cavity support. The third component of the sensor can contain a strain gauge. The strain gauge can be located on the hermetically sealed cavity.

When ambient air is drawn into the aerosol generating device by the user, a negative pressure is created in the air flow path. The three-dimensional sensor can detect this negative pressure when the hermetically sealed cavity can expand. The hermetically sealed cavity can expand because the air inside the hermetically sealed cavity has a relatively higher pressure than the air drawn through the air flow channel, which has a negative pressure. The expansion of the hermetically sealed cavity can be detected by a strain gauge. Due to the location of the strain gauge on the hermetically sealed cavity, the strain gauge can be affected by the pressure when the hermetically sealed cavity expands. This can lead to a change in the resistance of the strain gauge. This change in resistance can be measured by a controller, as described herein. The change in resistance can indicate a puff performed by the user.

As an alternative to providing the hermetically sealed cavity as part of the second sensor component, the hermetically sealed cavity can be formed between three layers in the process of rolling or folding the flexible dielectric substrate. For example, the first sensor component can comprise a base of the hermetically sealed cavity, the second sensor component can comprise side walls of the hermetically sealed cavity, and the third sensor component can comprise an upper wall of the hermetically sealed cavity. Thus, the entire hermetically sealed cavity can be formed by rolling or folding three layers of the flexible dielectric substrate on top of each other in such a way that the base of the hermetically sealed cavity is formed by the innermost layer containing the first sensor component. The side walls of the hermetically sealed cavity can be formed by the second sensor component, while the middle layer and the upper part of the hermetically sealed cavity can be formed by the third sensor component as the outermost component.

The upper portion of the hermetically sealed cavity may comprise or be formed by a flexible diaphragm. The flexible diaphragm may provide the ability to expand the hermetically sealed cavity. The strain gauge may be located on the flexible diaphragm. The strain gauge may be applied over the flexible diaphragm.

Alternatively, only the first and second sensor components may be used to form the hermetically sealed cavity, or only the second and third sensor components may be used to form the hermetically sealed cavity.

In the process of rolling up, the first place may be on the innermost layer of the flexible dielectric substrate. The second place may be on the middle layer of the flexible dielectric substrate. The third place may be on the outermost layer of the flexible dielectric substrate.

The three-coordinate sensor may contain a spectrometer.

The three-coordinate sensor can be a spectrometer.

One of the first, second and third sensor components may comprise a light source. One of the first, second and third sensor components may comprise a detector.

For example, a first sensor component may comprise a light source and a third sensor component may comprise a detector.

The spectrometer can be designed with the ability to register gas.

One of the first, second and third sensor components may comprise portions of the spectrometer cavity such that the spectrometer cavity is formed after the rolling or folding step.

For example, the first sensor component may comprise the base of the spectrometer cavity, the second sensor component may comprise the side walls of the spectrometer cavity, and the third sensor component may comprise the top wall of the spectrometer cavity. Alternatively, only the first sensor component and the second sensor component may comprise parts of the spectrometer cavity, or only the second sensor component and the third sensor component may comprise parts of the spectrometer cavity.

The base of the spectrometer cavity may comprise a first opening. The upper wall of the spectrometer cavity may comprise a second opening. The base of the spectrometer cavity may comprise a first flap configured to open and close the first opening. The upper wall of the spectrometer cavity may comprise a second flap configured to open and close the second opening. If the first and second flaps are closed, the spectrometer cavity is sealed. If the first and second flaps are open, gas may enter the spectrometer cavity. One or both of the first and second flaps may be configured to open under the influence of negative pressure. In other words, one or both of the first and second flaps may be configured to open during a puff performed by the user.

The light source and the detector may be located in the spectrometer cavity. When the first and second flaps are open, gas may enter the spectrometer cavity. This gas may influence the detector output. The detector output may be influenced, for example, by the scattering of light from the light source by the gas inside the spectrometer cavity.

One or both of the light source and the detector may be electrically connected to the controller as described herein. Since the light source and the detector are located inside the spectrometer cavity, the electrical connection may be implemented by means of electrically conductive paths connecting one or both of the light source and the detector via through-substrate connectors. The through-substrate connectors may pass through one or more of the first, second, and third layers of the flexible dielectric substrate.

The three-coordinate sensor may contain a temperature sensor.

The three-coordinate sensor can be a temperature sensor.

One of the first, second and third sensor components may contain a temperature-sensitive material. Another of the first, second and third sensor components may contain a strain gauge.

As the temperature changes, the temperature-sensitive material may expand or contract. This expansion or contraction may exert pressure on the strain gauge. The resulting change in resistance may be recorded by the controller as described in this document.

For example, the first component of the sensor may contain a temperature-sensitive material and the third component of the sensor may contain a strain gauge or vice versa. The second component of the sensor may contain a through hole. The temperature-sensitive material may pass through the through hole. The strain gauge may be located on or adjacent to the strain gauge.

The temperature-sensitive material may be attached to a flexible dielectric substrate by means of pins. A plate may be located on the opposite side of the layers of the flexible dielectric substrate. The pins may penetrate the flexible dielectric substrate and be connected to the plate to secure the temperature-sensitive material in place.

The temperature sensor may comprise at least two, preferably at least three, separate temperature sensors located in different places of the rolled or folded flexible dielectric substrate. Preferably, in this embodiment, only one controller is provided, and all temperature sensors are connected to one controller. When the three-coordinate sensor is located around the cavity of the aerosol-generating device, the temperature sensors may be located with the ability to measure the temperature in different parts of the cavity.

The three-dimensional sensor may comprise a flow sensor. The flow sensor may be configured to register an air flow through an air flow channel of an aerosol generating device to register a puff performed by the user.

One of the first, second and third sensor components may comprise a freely mounted cantilever structure. One of the first, second and third sensor components may comprise two separate electrodes that are in electrical contact with the freely mounted cantilever structure. As air flows over the freely mounted cantilever structure, the resistance between the two separate electrodes may change. The micro- or nano-electronic architecture of the sensor may be designed such that at least two surfaces are sensitive to changes in environmental conditions, preferably external air flow in this case. The two electrode surfaces may act as poles, wherein the electrical characteristics may change with changes in temperature and/or humidity. For example, electrical humidity sensors may comprise polyaniline nanofibers (PAni), which are characterized by a high response to changes in humidity, rapidly changing their electrical resistance. The same occurs when using a humidity sensor structure based on a PVA nanomesh. Using either of these materials, PAni or PVA nanomesh, sensors can be assembled/designed as described herein, such as those shown in the figures described below (e.g., 2A and 4A).

This change in resistance may be recorded by the controller as described in this document. The change in resistance may indicate a puff being taken by the user.

The three-dimensional sensor may comprise one or more of a humidity sensor, a chemical composition sensor and a biological signal sensor. An example of a humidity sensor may comprise a deposited nanostructured zinc oxide layer as a coating for detecting humidity. The sensor may be assembled as described herein in the form of a free mounted cantilever structure. The sensor may be manufactured using thin-film technology. In this case, the resistance of the films applied as a coating may decrease with increasing relative humidity in a fast and highly reliable manner, since the electrical resistance may change by more than 4-fold when the thin structures of ZnO-based nanomaterials are exposed to conditions from the original standard room conditions with 60% relative humidity to a humidity pulse with 95% relative humidity, which provides a wide range of possibilities for measuring gradients with sufficient accuracy for detecting humidity.

The freely mounted cantilever structure can provide the possibility for the flexible surface of the two electrodes to act as a membrane that is microdeformed under the influence of air flow conditions according to the principles of elementary hydromechanics and due to the characteristics of the material forming the membrane, which, as a result of changing its shape when bent, also changes its electrical characteristics.

The concept of constructing sensors based on overlapping thin film layers as described herein allows for the possibility that different layers can have different characteristics and perform detection in different "directions". As an example, the assemblies presented below, described with reference to Fig. 2A or Fig. 4A, can allow for the possibility that after arranging the layers so that they overlap each other to thereby form a structure of the sensor(s), the sensor can perform detection in the internal direction, detecting the internal region/volume, and in the external direction, detecting the external region/volume.

The present invention also relates to a three-dimensional sensor used in an aerosol generating device, wherein the three-dimensional sensor is manufactured according to any method described herein.

The present invention further relates to an aerosol generating device comprising the three-dimensional sensor described herein.

As used herein, the terms "proximal," "distal," "upstream," and "downstream" are used to describe the relative positions of components or portions of components of an aerosol generating device relative to the direction in which a user draws on the aerosol generating device during use.

The aerosol generating device may comprise a mouth end through which, in use, the aerosol exits the aerosol generating device and is delivered to the user. The mouth end may also be referred to as the proximal end. In use, the user draws on the proximal or mouth end of the aerosol generating device to inhale the aerosol generated by the aerosol generating device. The aerosol generating device comprises a distal end opposite the proximal or mouth end. The proximal or mouth end of the aerosol generating device may also be referred to as the downstream end, and the distal end of the aerosol generating device may also be referred to as the upstream end. Components or portions of components of an aerosol generating device may be described as upstream or downstream relative to one another based on their relative positions between the proximal end, the downstream end, or mouthpiece end, and the distal end or upstream end of the aerosol generating device.

As used herein, the term "aerosol generating device" refers to a device that interacts with an aerosol generating substrate to generate an aerosol. The aerosol generating substrate may be a portion of an aerosol generating article, such as a portion of a smoking article. The aerosol generating device may be a smoking device that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol that is directly inhaled into the lungs of a user through the user's mouth. The aerosol generating device may be a holder. The device may be an electrically heated smoking device. The aerosol generating device may comprise a housing, an electrical circuit, a power source, a heating chamber, and a heating element.

In this document, as applied to the present invention, the term "smoking" as applied to a device, article, system, substrate or anything else does not refer to conventional smoking, in which the aerosol-forming substrate is completely or at least partially combusted. The aerosol-generating device according to the present invention is configured to heat the aerosol-forming substrate to a temperature below the combustion temperature of the aerosol-forming substrate, but to a temperature at which one or more volatile compounds of the aerosol-forming substrate are released to form an inhalable aerosol, or above it.

The aerosol generating device may comprise an electrical circuit. The electrical circuit may comprise a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of a controller. The electrical circuit may comprise additional electronic components. The electrical circuit may be configured to regulate the power supply to the heating element. The power supply may be continuously supplied to the heating element after activation of the aerosol generating device, or may be supplied intermittently, for example from puff to puff. The power supply may be supplied to the heating element in the form of electric current pulses. The electrical circuit may be configured to monitor the electrical resistance of the heating element and, preferably, to control the power supply to the heating element depending on the electrical resistance of the heating element. The electrical circuit may comprise a three-coordinate sensor and a controller electrically connected to the three-coordinate sensor. The controller may control the operation of the aerosol generating device based on the output signal of the three-coordinate sensor.

The aerosol generating device may comprise a power source, typically a battery, within the main body of the aerosol generating device. In one embodiment, the power source is a lithium-ion battery. Alternatively, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, such as a lithium-cobalt, lithium-iron phosphate, lithium-titanium, or lithium-polymer battery. Alternatively, the power source may be another type of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that provides the ability to store energy sufficient for one or more use sessions; for example, the power source may have a capacity sufficient for continuous aerosol generation for a period of approximately six minutes, or for a period of multiples of six minutes. In another example, the power source may have a capacity sufficient to provide a specified number of puffs or individual activations of the heating element.

The cavity of the aerosol generating device may have an open end into which the aerosol generating article is inserted. The open end may be the proximal end. The cavity may have a closed end opposite the open end. The closed end may be the base of the cavity. The closed end may be closed except for the fact that air holes are provided located in the base. The base of the cavity may be flat. The base of the cavity may be round. The base of the cavity may be located upstream of the cavity. The open end may be located downstream of the cavity. The cavity may be elongated. The cavity may have a longitudinal central axis. The longitudinal direction may be a direction passing between the open and closed ends along the longitudinal central axis. The longitudinal central axis of said cavity may be parallel to the longitudinal axis of the aerosol generating device.

The cavity can be made in the form of a heating chamber. The cavity can have a cylindrical shape. The cavity can have a hollow cylindrical shape. The cavity can have a shape corresponding to the shape of the aerosol-generating article to be placed in said cavity. The cavity can have a circular cross-section. The cavity can have an elliptical or rectangular cross-section. The cavity can have an internal diameter corresponding to the external diameter of the aerosol-generating article. A flexible dielectric substrate with sensor components forming a three-coordinate sensor can be located at least partially, preferably completely, around the cavity.

An air flow channel may pass through said cavity. It is possible to draw ambient air into the aerosol generating device into said cavity and towards the user through said air flow channel. Further along the flow relative to the cavity, a mouthpiece may be located, or the user may directly inhale on the aerosol generating product. The air flow channel may pass through the mouthpiece.

In any aspects of the present invention, the heating element may comprise an electrically resistive material. Suitable electrically resistive materials include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made from a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum, platinum, gold, and silver. Examples of suitable metal alloys include stainless steel, nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, gold, and iron-based superalloys, stainless steel, Timetal®, and iron-manganese-aluminum-based alloys. In composite materials, the electrically resistive material may optionally be embedded in, encapsulated in, or coated with the insulating material, or vice versa, depending on the energy transfer kinetics and the desired external physicochemical properties.

As described herein, in any aspect of the invention, the heating element may be part of an aerosol generating device. The aerosol generating device may comprise an internal heating element or an external heating element, or both internal and external heating elements, wherein the words "internal" and "external" are used in relation to the aerosol generating substrate. The internal heating element may have any suitable shape. For example, the internal heating element may have the shape of a heating plate. Alternatively, the internal heater may have the shape of a shell or substrate with different electrically conductive parts or an electrically resistive metal tube. Alternatively, the internal heating element may be one or more heating needles or rods that extend through the center of the aerosol generating substrate. Other alternatives include a heating wire or filament, such as a Ni-Cr (nickel-chromium), platinum, tungsten or alloy wire or heating plate. Optionally, the internal heating element may be applied internally or externally to a rigid carrier material. In one such embodiment, the electrically resistive heating element may be made using a metal characterized by a certain relationship between temperature and specific resistance. In such an example device, the metal may be made in the form of a track on a suitable insulating material, such as a ceramic material, and then placed between layers of another insulating material, such as glass. Heaters made in this way may be used both to heat and to monitor the temperature of the heating elements during operation.

The external heating element may have any suitable shape. For example, the external heating element may have the shape of one or more flexible heating foil sheets on a dielectric substrate, such as polyimide. The flexible heating foil sheets may be shaped to correspond to the perimeter of the cavity for accommodating the substrate. Alternatively, the external heating element may have the shape of a metal grid or grids, a flexible printed circuit board, a molded coupling device (MID), a ceramic heater, a flexible carbon fiber heater, or may be formed using a coating technology such as plasma vapor deposition on a substrate of a suitable shape. The external heating element may also be made using a metal characterized by a certain relationship between temperature and specific resistance. In such an exemplary device, the metal may be present in the form of a track between two layers of suitable insulating materials. An external heating element made in this way can be used both for heating and for monitoring the temperature of the external heating element during operation.

As an alternative to an electrically resistive heating element, the heating element may be an induction heating element. An induction heating element may comprise an inductor and a susceptor. In general, a susceptor is a material that is capable of generating heat when an alternating magnetic field penetrates it when it is placed in an alternating magnetic field. If the susceptor is conductive, the alternating magnetic field usually induces eddy currents. If the susceptor is magnetic, then usually another effect that contributes to heating is called the general term hysteresis loss. Hysteresis loss is caused mainly by movements of groups of magnetic domains in the susceptor due to the fact that their magnetic orientation will align with the magnetic induction field, which is changing. Another effect contributing to hysteresis loss occurs when the magnetic domains in the susceptor expand or contract. All of these changes in the susceptor that occur on a nanoscale or smaller are collectively referred to as "hysteresis losses" because they result in heat generation in the susceptor. Accordingly, if the susceptor is both magnetic and conductive, both the hysteresis losses and the formation of eddy currents will contribute to heating the susceptor. If the susceptor is magnetic but not conductive, the hysteresis losses will be the only mechanism for heating the susceptor when an alternating magnetic field is applied to it. According to the present invention, the susceptor may be conductive or magnetic, or both conductive and magnetic. The alternating magnetic field generated by one or more inductors heats the susceptor, which then transfers heat to the aerosol-forming substrate, resulting in the formation of the aerosol. The heat transfer may occur primarily by conduction. This heat transfer occurs best if the susceptor is in close thermal contact with the aerosol-forming substrate.

As used herein, the term "aerosol-generating article" means an article that contains an aerosol-forming substrate capable of releasing volatile compounds that can form an aerosol. For example, an aerosol-generating article may be a smoking article that generates an aerosol that is directly inhaled and delivered to the user's lungs through his or her mouth. The aerosol-generating article may be disposable.

As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing one or more volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may conveniently be a portion of an aerosol-generating article or a smoking article.

The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may contain both solid and liquid components. The aerosol-forming substrate may contain a tobacco-containing material containing volatile tobacco flavor compounds that are released from the substrate upon heating. The aerosol-forming substrate may contain a non-tobacco material. The aerosol-forming substrate may contain an aerosol forming agent that facilitates the formation of a dense and stable aerosol. Examples of suitable aerosol forming agents include glycerin and propylene glycol.

The aerosol generating substrate preferably comprises a homogenized tobacco material, an aerosol forming agent and water. Providing a homogenized tobacco material can improve the aerosol generation, nicotine content and flavor profile of the aerosol generated by heating the aerosol generating article. In particular, the process of producing homogenized tobacco includes grinding the tobacco leaf, which more effectively ensures the possibility of releasing nicotine and flavor substances when heated.

For brevity, if only the term "rolled" or "rolling" is used for the rolling or folding step, this also covers the "folded" or "folding" variant.

The following is a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

Example 1. Manufacturing method a three-coordinate sensor for an aerosol generating device, comprising:

providing a flexible dielectric substrate layer,

printing or installing the first sensor component in the first location on the flexible dielectric substrate,

printing or installing a second sensor component at a second location on the flexible dielectric substrate, wherein the second location is different from the first location, and

printing or installing a third sensor component in a third location on the flexible dielectric substrate, wherein the third location is different from the second location and from the first location,

rolling or folding the flexible dielectric substrate in such a way that three layers of the flexible dielectric substrate are formed, wherein the first place, the second place and the third place are superimposed on each other to form a three-coordinate sensor due to this.

Example 2. The method according to example 1, wherein one or more of the following occurs: the first sensor component is an electrical sensor component, the second sensor component is an electrical sensor component, and the third sensor component is an electrical sensor component.

Example 3. The method according to any of the previous examples, wherein one or more of the first, second and third sensor components comprises a controller.

Example 4. The method according to any of the previous examples, wherein one or more of the first, second and third sensor components comprise one or more of a resistor, a capacitor, an inductor, a microprocessor, an electronic circuit, a connecting circuit, a cavity, a pin and a heat sink.

Example 5. A method according to any of the previous examples, comprising an additional step after the rolling or folding step, wherein the additional step is attaching an electrical component, preferably electrically conductive tracks, to the three-dimensional sensor.

Example 6. The method according to the previous example, wherein the attachment is carried out by one or more of gluing, friction welding, friction bonding and ultrasonic welding.

Example 7. The method according to any of the previous examples, wherein the attachment is carried out using one or more of glue, epoxy resin, wire and solder.

Example 8. The method according to any of the previous examples, wherein the three-coordinate sensor comprises a pressure sensor.

Example 9. The method according to the previous example, in which one of the first, second and third components of the sensor comprises a hermetically sealed cavity, and wherein another of the first, second and third components of the sensor comprises a strain gauge.

Example 10. The method according to any of the previous examples, wherein the three-coordinate sensor comprises a spectrometer.

Example 11. The method according to the previous example, wherein one of the first, second and third sensor components comprises a light source, and wherein one of the first, second and third sensor components comprises a detector.

Example 12. A method according to any of the previous examples, wherein the three-coordinate sensor comprises a temperature sensor.

Example 13. The method according to the previous example, in which one of the first, second and third components of the sensor comprises a temperature-sensitive material, and wherein another of the first, second and third components of the sensor comprises a strain gauge.

Example 14. The method according to any of the previous examples, wherein the temperature sensor comprises at least two, preferably at least three, separate temperature sensors located in different places of the rolled or folded flexible dielectric substrate.

Example 15. The method according to any of the previous examples, wherein the three-coordinate sensor comprises a flow sensor.

Example 16. The method according to the previous example, in which one of the first, second and third components of the sensor comprises a freely mounted cantilever structure, and wherein one of the first, second and third components of the sensor comprises two separate electrodes electrically contacting the freely mounted cantilever structure.

Example 17. The method according to any of the previous examples, wherein the three-dimensional sensor comprises one or more of a humidity sensor, a chemical composition sensor, and a biological signal sensor.

Example 18. A three-dimensional sensor used in an aerosol generating device, wherein the three-dimensional sensor is manufactured in accordance with any of the previous examples.

Example 19. An aerosol generating device comprising a three-dimensional sensor according to the previous example.

Features described with respect to one embodiment may be equally applied to other embodiments of the present invention.

The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Fig. 1A-1C shows a three-dimensional sensor comprising a pressure sensor;

Fig. 2A-2C shows a three-dimensional sensor containing a spectrometer;

Fig. 3A-3C shows a three-coordinate sensor containing a temperature sensor;

Fig. 4A-4C shows a three-dimensional sensor comprising a plurality of temperature sensors; and

Fig. 5A-5C shows a three-dimensional sensor containing a flow sensor.

Fig. 1A shows a three-coordinate sensor after folding. The three-coordinate sensor comprises a flexible dielectric substrate 10. The flexible dielectric substrate 10 is folded in such a way that three layers A-A', C-C' and E-E' of the flexible dielectric substrate 10 are located on top of each other in the region where the three-coordinate sensor is formed.

The three-dimensional sensor shown in Fig. 1A-1C comprises a pressure sensor 12. The pressure sensor 12 is formed by a first sensor component 14, a second sensor component 16 and a third sensor component 20.

The first component 14 of the sensor is located in the first place 20 on the flexible dielectric substrate. The second component 16 of the sensor is located in the second place 22 on the flexible dielectric substrate. The third component 20 of the sensor is located in the third place 24 on the flexible dielectric substrate.

The first component 14 of the sensor in the embodiment of the pressure sensor 12 shown in Fig. 1 is a base 26 of the hermetically sealed cavity 28. The second component 16 of the sensor contains walls 30, in particular side walls 30, of the hermetically sealed cavity 28. The third component 20 of the sensor contains a flexible diaphragm 32 forming the upper wall of the hermetically sealed cavity 28, a strain gauge 34 lying on top of the flexible diaphragm 32, walls 30 of the hermetically sealed cavity 28, a controller 36 and conductive tracks 38 electrically connecting the strain gauge 34 to the controller 36.

Fig. 1A shows the final three-dimensional sensor. Fig. 1B shows the third component 20 of the sensor or a top view of the folded three-dimensional sensor, and Fig. 1C shows the three-dimensional sensor before the fold step. The arrangement shown in this figure is unchanged for Figs. 1-5. In Fig. 1C shows a separate first sensor component 14, a second sensor component 16 and a third sensor component 20, located on a flexible dielectric substrate 10. The functional pressure sensor 12 is formed only by rolling up the flexible dielectric substrate 10. In this case, a change in pressure, in particular the negative pressure of air drawn through the aerosol generating system, leads to a deformation of the internal volume of the hermetically sealed cavity 28. This deformation leads to a bulging of the flexible diaphragm 32, which leads to a change in resistance in the strain gauge 34. This change in resistance is recorded by the controller 36 and indicates a tightening performed by the user.

Fig. 2A-2C shows a three-dimensional sensor comprising a spectrometer 40. The embodiment shown in Fig. 2A-2C has many components similar to the embodiment shown in Fig. 1A-1C, such as a flexible dielectric substrate 10, a roll-up and layering of the flexible dielectric substrate 10, and a controller 36. For brevity, the description of this and the following embodiments focuses on the differences, and similar elements are not described, and similar elements have the same reference numbers in the drawings.

The spectrometer 40 of Fig. 2A-2C has a spectrometer cavity 42 having walls 30. The first component 14 of the sensor in the first location 20 on the flexible dielectric substrate comprises the walls 30, preferably the base 26, of the spectrometer cavity 42, and the second component 16 of the sensor in the second location 22 on the flexible dielectric substrate comprises the walls 30, preferably the side walls 30, of the spectrometer cavity 42. The first component 14 of the sensor further comprises a light source 44 and a detector 46, both of which are located on the base 26 of the cavity 42 of the spectrometer in such a way that they are located inside the cavity 42 of the spectrometer after rolling up the flexible dielectric substrate 10. The first component 14 of the sensor further comprises a first flap 48, which is located above the opening 50 of the base, located in the base 26 of the flexible dielectric substrate 10. The first component 14 of the sensor further comprises a controller 36 and a first connector 52 passing through the substrate, and a second connector 54 passing through the substrate. The first connector 52 passing through the substrate, and the second connector 54 passing through the substrate, together with the conductive paths 38 are located with the possibility of establishing an electrical connection between the detector 46 and the controller 36.

The third component 18 of the sensor comprises a second flap 56, which is located above the upper opening 58, located in the third place 24 on the flexible dielectric substrate.

After the flexible dielectric substrate 10 is rolled up, as shown in Fig. 2A, the cavity 42 of the spectrometer is completely formed. The first flap 48 and the second flap 56 are arranged so as to allow air to enter the cavity 42 of the spectrometer. The first flap 48 and the second flap 56 are arranged so as to allow air to enter the cavity 42 of the spectrometer when the pressure changes, preferably when the pressure outside the cavity 42 of the spectrometer is negative. The gas entering the cavity 42 of the spectrometer can be detected by the detector 46, since, for example, the scattering of light from the light source 44 affects the light reaching the detector 46.

Fig. 2B shows the first sensor component 14 and the first location 20 on the flexible dielectric substrate. Fig. 2C shows the first sensor component 14, the second sensor component 16 and the third sensor component 20 arranged on the flexible dielectric substrate 10 before the rolling step. Fig. 2C alternatively shows a top view of the rolled three-dimensional sensor.

Fig. 3A-3C shows a three-coordinate sensor comprising a temperature sensor 60. Only the elements that differ from the previous embodiments are described below. The first component 14 of the temperature sensor 60 comprises a strain gauge 62 and a mounting plate 64 at a first location 20 on a flexible dielectric substrate.

The second component 16 of the sensor comprises a through hole 66, and the third component 20 of the sensor comprises a temperature-sensitive material 68. The mounting pins 70 secure the temperature-sensitive material 68 to the mounting plate 64, as shown in Fig. 3A.

After the flexible dielectric substrate 10 is rolled up, the temperature-sensitive material 68 is located adjacent to the strain gauge 62 or is adjacent to it. A change in temperature, in particular an increase in temperature, of the temperature-sensitive material 68 causes the temperature-sensitive material 68 to expand. The expansion of the temperature-sensitive material 68 causes the temperature-sensitive material 68 to apply pressure to the strain gauge 62. This causes a change in the resistance of the strain gauge 62, which can be recorded by the controller 36.

Fig. 4A-4C shows a three-dimensional sensor comprising a plurality of temperature sensors 60. Each of the temperature sensors 60 is constructed similarly to the temperature sensor 60 shown in Fig. 3A-3C. As an example, all three temperature sensors 60 shown in Fig. 4A-4C are connected to a common controller 36 via conductive tracks 38.

In Fig. 5A-5C a three-dimensional sensor is shown, comprising a flow sensor 72 or a flow meter. The flow sensor 72 comprises a freely mounted cantilever structure 74, having a first electrode 76 and a second electrode 78. The freely mounted cantilever structure 74 is located above the cantilever cavity 80. The cantilever cavity 80 is formed by the first sensor component 14 and the second sensor component 16. The first sensor component 14 comprises a freely mounted cantilever structure 74, a first electrode 76 and a second electrode 78. If air flows above the first electrode 76 and the second electrode 78, the resistance on the first electrode 76 and the second electrode 78 changes. This can be registered by the controller 36, connected to the first electrode 76 and the second electrode 78 by conductive paths 38.

Claims (21)

1. A method for manufacturing a sensor for an aerosol generating device, wherein the sensor is formed from at least three sensor components, including: providing a flexible dielectric substrate layer, printing or installing the first sensor component in the first location on the flexible dielectric substrate, printing or installing a second sensor component at a second location on the flexible dielectric substrate, wherein the second location is different from the first location, and printing or installing a third sensor component in a third location on the flexible dielectric substrate, wherein the third location is different from the second location and from the first location, rolling or folding the flexible dielectric substrate in such a way that three layers of the flexible dielectric substrate are formed, wherein the first place, the second place and the third place are superimposed on each other to form a sensor thereby. 2. The method according to claim 1, characterized in that one or more of the following occurs: the first sensor component is an electrical sensor component, the second sensor component is an electrical sensor component, and the third sensor component is an electrical sensor component. 3. The method according to any of the preceding paragraphs, characterized in that one or more of the first, second and third sensor components comprises a controller. 4. A method according to any of the preceding paragraphs, characterized in that the sensor comprises a pressure sensor. 5. The method according to the previous paragraph, characterized in that one of the first, second and third components of the sensor contains a hermetically sealed cavity, and another of the first, second and third components of the sensor contains a strain gauge. 6. A method according to any of the preceding paragraphs, characterized in that the sensor comprises a spectrometer. 7. The method according to the previous paragraph, characterized in that one of the first, second and third components of the sensor contains a light source, and one of the first, second and third components of the sensor contains a detector. 8. A method according to any of the preceding paragraphs, characterized in that the sensor comprises a temperature sensor. 9. The method according to the previous paragraph, characterized in that one of the first, second and third components of the sensor contains a heat-sensitive material, and another of the first, second and third components of the sensor contains a strain gauge. 10. A method according to any of the preceding claims, characterized in that the temperature sensor comprises at least two, preferably at least three separate temperature sensors located in different places of the rolled or folded flexible dielectric substrate. 11. A method according to any of the preceding paragraphs, characterized in that the sensor comprises a flow sensor. 12. The method according to the previous paragraph, characterized in that one of the first, second and third components of the sensor contains a freely installed cantilever structure, and wherein one of the first, second and third components of the sensor contains two separate electrodes electrically contacting the freely installed cantilever structure. 13. The method according to any of the preceding paragraphs, characterized in that the sensor comprises one or more of a humidity sensor, a chemical composition sensor, and a biological signal sensor. 14. A method according to any of the preceding paragraphs, characterized in that the sensor is a three-coordinate sensor. 15. A sensor used in an aerosol generating device, characterized in that the three-dimensional sensor is manufactured in accordance with any of the preceding paragraphs. 16. An aerosol generating device comprising a sensor according to the preceding paragraph.