Method for assembling an aerosol generating device and aerosol generating device.

Abstract

Aerosol generating device with overmolded buttons. The present invention relates to a method for assembling an aerosol generating device. The method comprises a step of providing an outer cover (10) for an aerosol generating device. The outer cover is configured to internally receive a frame assembly (16). The frame assembly comprises a pressure-activated switch. The method comprises a step of providing a through hole in a wall of the outer cover. The method comprises a step of attaching a button (12) to the outer cover to cover the through hole. The method comprises a step of inserting the frame assembly into the outer cover so that the button (12) overlaps the pressure-activated switch. The present invention further relates to an aerosol generating device.

Description

1 / 22 “METHOD FOR ASSEMBLING AN AEROSOL GENERATING DEVICE AND AEROSOL GENERATING DEVICE”

[001] The present invention relates to a method for assembling an aerosol generating device. The present invention further relates to an aerosol generating device.

[002] The provision of an aerosol-generating device for generating an inhalable vapor is known. Such devices may heat an aerosol-forming substrate contained in an aerosol-generating article without burning the aerosol-forming substrate. The aerosol-generating article may have a shape suitable for insertion of the aerosol-generating article into a heating chamber of the aerosol-generating device. For example, the aerosol-generating article may have a column shape. A heating element may be disposed within or around the heating chamber to heat the aerosol-forming substrate after the aerosol-generating article has been inserted into the heating chamber of the aerosol-generating device.

[003] The supply of an aerosol generating device comprising an outer casing that includes internal components housed within the casing is known. The internal components are, for example, components of a heater assembly, a battery and a printed circuit board (PCB) comprising a pressure-activated switch to operate the device.

[004] A button is provided that allows a user to operate the switch located inside the outer cover. For example, the button may be fixed to the switch and may project outward from the outer cover through a hole in the outer cover. Thus, when a user presses the button, the button presses the pressure-activated switch.

[005] In some devices, the device architecture is such Petition 870260051823, dated 05 / 29 / 2026, page 6 / 64 2 / 22 that the internal components are mounted in a frame assembly. The outer cover is arranged to enclose the internal frame assembly.

[006] In aerosol generating devices comprising a frame assembly and an outer cover, it is often desirable for the outer cover walls to be very thin. A thin-walled cover can, for example, reduce material costs or help to provide a lightweight and compact device.

[007] In order to allow for a compact architecture of the aerosol generating device, the design may be such that the internal structure fits very closely into the outer casing. Thus, there may be very little space between the frame assembly and the outer casing when the frame assembly is slid into the outer casing.

[008] The aerosol generating device assembly comprising an inner frame assembly and an outer cover may include a step where the frame assembly is inserted into the outer cover. A button may then be subsequently installed in an additional step. For example, the button may be fixed to the frame assembly and may project through a through hole in the outer cover.

[009] US document 2018 / 0368481 A1 refers to an electronic cigarette or vaporizer that may include a casing and a cartomizer receiveable within a chamber inside a part of the casing.

[0010] Document DE 10341141 A1 refers to an enclosure for a small electrical appliance that has a basic molded plastic body and a decorative and / or specification number layer and a transparent or translucent protective layer externally to the base body, wherein the protective layer is designed Petition 870260051823, dated 05 / 29 / 2026, page 7 / 64 3 / 22 as a molded body that is fixed by means of a bonding material in the two-component spraying process onto the base body.

[0011] It would be desirable to provide an aerosol generating device comprising a button for a user to operate a switch that can be mounted by inserting an internal structure into an external cover. It would be desirable to provide a modular aerosol generating device that is easy to assemble. It would be desirable to provide an aerosol generating device that is reproducibly assembled by machine.

[0012] It would be desirable to provide an aerosol generating device that avoids or reduces gaps between the button and an outer cover wall adjacent to the button. It would be desirable to provide an aerosol generating device comprising a waterproof seal.

[0013] According to one embodiment of the invention, a method is provided for assembling an aerosol generating device. The method may comprise the step of providing an outer cover to an aerosol generating device. The outer cover may be configured to internally receive a frame assembly. The frame assembly may comprise a pressure-activated switch. The method may comprise a step of providing a through hole in a wall of the outer cover. The method may comprise a step of attaching a button to the outer cover to cover the through hole. The method may comprise a step of inserting the frame assembly into the outer cover so that the button overlaps the pressure-activated switch.

[0014] According to one embodiment of the invention, a method is provided for assembling an aerosol generating device. The method comprises a step of providing an outer covering. Petition 870260051823, dated 05 / 29 / 2026, page 8 / 64 4 / 22 for an aerosol generating device. The outer cover is configured to internally receive a frame assembly. The frame assembly comprises a pressure-activated switch. The method comprises a step of providing a through hole in a wall of the outer cover. The method comprises a step of attaching a button to the outer cover to cover the through hole. The method comprises a step of inserting the frame assembly into the outer cover so that the button overlaps the pressure-activated switch.

[0015] The button can be attached directly to the outer cover. The button attachment step on the outer cover can be performed before the frame assembly is inserted into the outer cover. The frame assembly can be slid into the outer cover.

[0016] By attaching the button to the outer cover, the aerosol generating device can be mounted by inserting the inner frame into an outer cover. An additional step of attaching a button to the device after installing a cover and an inner frame assembly is avoided. In this way, a method that can allow for easy mounting of an aerosol generating device can be provided. A method is provided that can allow for reproducibly mounting an aerosol generating device by a machine. By attaching the button to the outer cover, the gaps between the button and a wall of the outer cover adjacent to the button can be reduced or avoided. By reducing the gaps, a waterproof seal can be provided. By reducing the gaps, a more visually appealing device can be provided.

[0017] The button can be fixed to the outer cover to cover the through hole in order to provide an airtight seal between the button and the outer cover. The seal can be waterproof. Petition 870260051823, dated 05 / 29 / 2026, page 9 / 64 5 / 22 in accordance with IPX7.

[0018] The outer cover may comprise a wall. The wall of the outer cover may comprise an outer surface and an opposite inner surface. The outer surface of the outer cover wall faces the exterior of the aerosol generating device and the inner surface of the outer cover wall faces the interior of the aerosol generating device. In the assembled state, the inner surface of the outer cover wall faces the frame assembly.

[0019] The outer roof wall may enclose a hollow interior molded to receive the frame assembly. The inner roof wall may form a generally hollow cylindrical shape. At least one end face of a hollow cylinder formed by the outer roof wall may be at least partially open so that the frame assembly can be slidably inserted into the outer roof along the open end face.

[0020] The outer cover may comprise a hollow cylindrical shape. The frame assembly may comprise a cylindrical shape. The frame assembly may comprise a shape configured to fit tightly within the outer cover.

[0021] The outer cover wall can be thin. The thickness of the outer cover wall can be one millimeter or less than one millimeter, for example, about 0.8 millimeters. A thin-walled cover can be provided, for example, to save material costs or to provide a compact and lightweight device.

[0022] The through hole can be a hole in the outer wall of the covering. The through hole can have a round shape. Petition 870260051823, dated 05 / 29 / 2026, page 10 / 64 6 / 22

[0023] The button may comprise a flexible material. For example, the button may comprise an elastomeric plastic material. The button may be deformable. For example, the button may be deformed when a user presses a finger on the button. The button may deform so as to make contact with and activate the pressure-activated switch.

[0024] The button may comprise an outer surface and an opposing inner surface. When the button is fixed to the outer cover, the outer surface of the button faces the outside of the aerosol generating device and the inner surface of the button faces the inside of the aerosol generating device. The outer surface of the button may comprise a protrusion or bump to allow haptic feedback to a user. A user can thus feel when a user's finger is in a correct position to press the button. More comfortable operation of the device may be possible.

[0025] The button can be permanently fixed to the outer cover. The button can be irreversibly fixed to the outer cover. A button that is permanently or irreversibly fixed cannot be configured to be removed or reattached by a user.

[0026] The button can be attached directly to the outer cover. The button can therefore be permanently anchored directly to the outer casing.

[0027] The button can be attached to the outer cover by a molding process.

[0028] By molding the button into the outer cover, the button can be fixed to a thin wall of the outer cover. By molding the button into the outer cover, additional fastening means that may project in a direction towards the inside of the outer cover can be avoided. In this way, it may be possible to insert the assembly of Petition 870260051823, dated 05 / 29 / 2026, page 11 / 64 7 / 22 frame on the outer cover so that the button overlaps the pressure-activated switch, even if the design of the aerosol generating device is such that the internal structure fits very closely into the outer cover.

[0029] The molding process can be an overmolding process. The molding process can be an injection overmolding process. The molding process can be a plastic injection overmolding process.

[0030] The molding process may comprise a step of positioning an outer mold on top of the through hole on an outer side of the outer cover. The molding process may comprise a step of positioning an inner mold below the through hole on an inner side of the outer cover. The molding process may comprise a step of injecting molten material into a cavity formed between the outer mold and the inner mold to form the button. The molten material may be injected through channels in the inner mold. Alternatively or additionally, the molten material may be injected through channels in the outer mold.

[0031] The method comprises a step of providing a groove in the outer covering. The thickness of the outer covering wall can be reduced at the position of the groove. For example, the thickness of the outer covering wall can be reduced at the position of the groove by about 10 percent to about 90 percent. The thickness of the outer covering wall can be reduced at the position of the groove by about 10 percent to about 30 percent. The thickness of the outer covering wall can be reduced at the position of the groove by about 70 percent to about 90 percent. The thickness of the outer covering wall can be reduced at the position of the groove by about 30 percent to about 70 percent. Petition 870260051823, dated 05 / 29 / 2026, page 12 / 64 8 / 22 percent, preferably between about 40 percent and about 60 percent.

[0032] The thickness of the outer cover wall at the groove position may be between 0.2 millimeters and 0.7 millimeters, preferably between 0.3 millimeters and 0.5 millimeters.

[0033] The groove is provided on the outside of the outer cover. The groove may be provided on the outside of the outer cover wall. The groove is provided around the periphery of the through hole. The button is fixed in the groove of the outer cover.

[0034] The groove can be provided by machining.

[0035] The method may comprise a step of providing a corrugated retaining structure in the groove before securing the button in the groove. The corrugated surface structure may be a rough portion of the outer cover wall surface at the groove position.

[0036] The wavy retaining structure may comprise a slope pattern.

[0037] The slope pattern may comprise a grid form of mitered slopes. A side length of a mitered slope may be between 0.1 millimeter and 0.4 millimeter, preferably about 0.2 millimeter. A grid groove between slopes may be at least 0.03 millimeter deep, for example, between 0.03 millimeter and 0.10 millimeter. The slope pattern may comprise a grid form of mitered slopes of about 0.2 millimeters side length separated by grid grooves of at least 0.03 millimeters deep.

[0038] The wavy retaining structure can be provided by a laser engraving process.

[0039] The method may include an application step of Petition 870260051823, dated 05 / 29 / 2026, page 13 / 64 9 / 22 Apply an adhesive to a surface of the groove before securing the button in the groove. The method may comprise a step of applying an adhesive to the corrugated retaining structure before securing the button in the groove.

[0040] The adhesive can be applied by a spraying process.

[0041] The adhesive may be an adhesive for a coating composed of a mixture of polymers, dressings and pigments dissolved in an organic solvent system.

[0042] The adhesive may comprise about 50% to 55% methyl ethyl ketone, about 20% to 25% of an epoxy resin; about 11% to 20% of ester solvents, about 10% to 15% of xylene, about 1% to 5% of ethylbenzene and about 0.1% to 0.9% of a silane monomer.

[0043] The adhesive may be Chemlok® 213 adhesive, as available from LORD Corporation.

[0044] The outer cover and the button may comprise different materials. The outer cover may be made of a rigid material and the button may be made of a flexible material. The outer cover may comprise a metal, preferably aluminum. The button may comprise a plastic material, preferably a thermoplastic material, more preferably thermoplastic polyurethane. The outer cover may be made of a metal and the button may be made of plastics. The outer cover may be made of aluminum and the button may be made of thermoplastic polyurethane.

[0045] For example, the button can be attached to the outer cover by a molding process, and the outer cover can comprise a metal and the button can comprise plastic material. For example, the button can be attached to the outer cover by a molding process, and the outer cover can be made of a Petition 870260051823, dated 05 / 29 / 2026, page 14 / 64 10 / 22 metal and the button can be made of plastic material.

[0046] Fixing the button in a groove of the outer cover, preferably by molding, as described in this document, can further improve the durability of the connection of a plastic button fixed to a metal outer cover. Providing a corrugated retaining structure in the groove of the outer cover, as described in this document, can further improve the durability of the connection of a plastic button fixed to a metal outer cover. Providing glue in the corrugated retaining structure in the groove of the outer cover, as described in this document, can further improve the durability of the connection of a plastic button fixed to a metal outer cover.

[0047] The button can be positioned flush with an inner surface of an outer roof wall. An inner surface of the button can be positioned flush with an inner surface of an outer roof wall. This can facilitate smooth insertion of the frame assembly into the outer roof.

[0048] The button can be arranged flush with an external surface of an external roof wall. An external surface of the button can be arranged flush with an external surface of an external roof wall.

[0049] As used in this document, the term flush means that the button is flush with the outer roof wall. The button can thus fill the through hole in the outer roof wall without projecting further towards either or both of the outer roof interior and outer roof exterior.

[0050] The button can be positioned flush with the outer cover wall away from a central protrusion of the button in a Petition 870260051823, dated 05 / 29 / 2026, page 15 / 64 11 / 22 outer surface of the outer cover. The protrusion can serve to provide tactile haptic feedback to a user.

[0051] The use of a molding process, as described in this document, can be particularly advantageous for achieving a level arrangement of the button and the outer cover wall.

[0052] The method may comprise, after the step of inserting the frame assembly into the outer cover, a step of securely fixing the frame assembly within the outer cover. The frame assembly may be firmly fixed within the outer cover by screwing a retaining element to one end of the insertion point of the outer cover.

[0053] Preferably, the aerosol generating device comprises electronic control components configured for control operation of the aerosol generating device. The electronic electrical components may be provided on a printed circuit board (PCB). The electronic control components may be connected to the pressure-activated switch. The electronic control components may be configured to change an operating state of the aerosol generating device based on a signal received from the pressure-activated switch.

[0054] The frame assembly may include the electronic control components of the aerosol generating device.

[0055] For example, the pressure-activated switch can be a toggle switch, a pressure switch, or it can use a capacitive sensor.

[0056] Preferably, the aerosol generating device comprises a heating assembly for heating the aerosol-forming substrate. The heating assembly may be an electric heating assembly. The electric heating assembly may comprise a resistance heating element. The heating assembly Petition 870260051823, dated 05 / 29 / 2026, p. 16 / 64 A 12 / 22 electric motor can use inductive heating and may comprise an induction coil and a susceptor.

[0057] The frame assembly may comprise at least a portion of the heating assembly of the aerosol generating device. The frame assembly may comprise a resistance heating element. The frame assembly may comprise an induction coil and a susceptor. The frame assembly may comprise an induction coil and a susceptor may be part of an aerosol forming article to be used with the aerosol generating device.

[0058] Preferably, the aerosol generating device comprises a power supply configured to provide power to the heater of the aerosol generating device. The power supply preferably comprises a power source. Preferably, the power source is a battery, such as a lithium-ion battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging. For example, the power source may have sufficient capacity to permit continuous aerosol generation for a period of about six minutes or for a period that is a multiple of six minutes. In another example, the power source may have sufficient capacity to permit a predetermined number of puffs or discrete activations of the heater assembly.

[0059] The power supply may comprise electronic control components. The electronic control components may comprise a microcontroller. The microcontroller is preferably a programmable microcontroller. The electrical circuit may comprise further electronic components. The electrical circuit may be configured to regulate a power supply to the Petition 870260051823, dated 05 / 29 / 2026, page 17 / 64 13 / 22 heating assembly. Power can be supplied to the heating assembly continuously after system activation or it can be supplied intermittently, such as on a pull-by-pulse basis. Power can be supplied to the heating assembly in the form of electrical current pulses.

[0060] The frame assembly may include the power supply for the aerosol generating device.

[0061] The method for assembling an aerosol generating device may comprise the following steps in the following order. First, provide the outer cover for an aerosol generating device. Second, provide a through hole in a wall of the outer cover. Third, provide a groove on the outside of the outer cover around the periphery of the through hole and, optionally, provide a corrugated retaining structure on a surface of the groove and, optionally, provide glue on the corrugated retaining structure. Fourth, fix a button in the groove of the outer cover to cover the through hole. Preferably, the button is fixed in the groove by a molding process. Fifth, insert the frame assembly into the outer cover so that the button overlaps a pressure-activated switch of the frame assembly.

[0062] According to one embodiment of the invention, an aerosol generating device is provided, obtainable by the method described in this document.

[0063] According to one embodiment of the invention, an aerosol generating device is provided comprising an outer cover and a frame assembly. The outer cover comprises a button extending over a through hole in the outer cover. The button is fixed directly to the outer cover. The frame assembly comprises a pressure-activated switch. Petition 870260051823, dated 05 / 29 / 2026, page 18 / 64 14 / 22 The frame assembly is slid into the outer cover so that the button overlaps the push-activated switch.

[0064] The exterior of the outer cover comprises a groove around the periphery of the through hole. The groove may comprise a laser-engraved pattern. Glue may be applied to the laser-engraved pattern. The button may be molded into the groove.

[0065] As used in this document, the term aerosol-forming substrate refers to a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds can be released by heating or combustion of the aerosol-forming substrate. As an alternative to heating or combustion, in some cases, the volatile compounds can be released by a chemical reaction or by a mechanical stimulus, such as ultrasound. The aerosol-forming substrate can be solid or liquid or can comprise both solid and liquid components. An aerosol-forming substrate can be part of an aerosol-generating article.

[0066] As used in this document, the term aerosol-generating article is used to denote an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. An aerosol-generating article may be disposable. An aerosol-generating article comprising an aerosol-forming substrate comprising tobacco may be referred to in this document as a tobacco stick.

[0067] As used in this document, an aerosol generating device refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. An aerosol generating device may interact with one or both of an aerosol generating article comprising an aerosol-forming substrate and an aerosol-forming substrate. Petition 870260051823, dated 05 / 29 / 2026, page 19 / 64 15 / 22 cartridge comprising an aerosol-forming substrate. In some examples, the aerosol generating device may heat the aerosol-forming substrate to facilitate the release of volatile compounds from the substrate. An electrically operated aerosol generating device may comprise an atomizer, such as an electric heater, to heat the aerosol-forming substrate to form an aerosol.

[0068] As used in this document, the term aerosol generating system refers to the combination of an aerosol generating device with an aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol generating article, the aerosol generating system refers to the combination of the aerosol generating device with the aerosol generating article. In the aerosol generating system, the aerosol-forming substrate and the aerosol generating device cooperate to generate an aerosol.

[0069] Below is a non-exhaustive list of non-limiting examples. Any one or more of the features in these examples may be combined with any one or more features from another example, modality, or aspect described in this document.

[0070] Example A: A method for assembling an aerosol generating device comprising the steps of providing an outer cover for an aerosol generating device, the outer cover being configured to receive internally a frame assembly comprising a pressure-activated switch; provide a through hole in a wall of the outer roof; Provide a groove on the outside of the outer cover around the perimeter of the through hole; Attach a button to the outer cover to cover the hole. Petition 870260051823, dated 05 / 29 / 2026, page 20 / 64 16 / 22 through; and insert the frame assembly into the outer cover so that the button overlaps the push-activated switch, where the button is fixed in the groove of the outer cover.

[0071] Example B: The method of Example A, in which the step of attaching the button to the outer cover precedes the step of inserting the frame assembly into the outer cover.

[0072] Example C: The method of Example A or Example B, in which the button is fixed to the outer cover by a molding process.

[0073] Example D: The method of Example C, wherein the molding process is an injection overmolding process, preferably a plastic injection overmolding process.

[0074] Example E: The method of Example D, in which the molding process comprises steps of positioning an outer mold on top of the through hole from an outer side of the outer cover; Position an inner mold below the through hole on one inner side of the outer cover; and inject molten material through channels in the inner mold into a cavity formed between the outer mold and the inner mold to form the button.

[0075] Example F: The method according to any of the previous examples, where the groove is provided by machining.

[0076] Example G: The method according to any of the previous examples, comprising a step of providing a corrugated retaining structure in the groove before fixing the button in the groove.

[0077] Example H: The method from Example G, where the structure Petition 870260051823, dated 05 / 29 / 2026, page 21 / 64 17 / 22 wavy retention comprises a tilt pattern.

[0078] Example I: The method of Example H, wherein the slope pattern comprises a grid form of square slopes of about 0.2 millimeters of lateral length separated by grooves at least 0.03 millimeters deep.

[0079] Example J: The method of any of Examples G to I, wherein the wavy retention structure is provided by a laser engraving process.

[0080] Example K: The method of any of Examples G to J, comprising a step of applying an adhesive to the corrugated retaining structure before attaching the button to the groove.

[0081] Example L: The method of Example K, in which the adhesive is applied by a spraying process.

[0082] Example M: ​​The method of Example K or Example L, wherein the adhesive is a single-layer adhesive composed of a mixture of polymers, dressings, and pigments dissolved in an organic solvent system.

[0083] Example N: The method of Example M, wherein the adhesive comprises about 50% to 55% methyl ethyl ketone, about 20% to 25% of an epoxy resin; about 11% to 20% of ester solvents, about 10% to 15% of xylene, about 1% to 5% of ethylbenzene and about 0.1% to 0.9% of a silane monomer.

[0084] Example O: The method of any of the above examples, wherein the outer cover and the button comprise different materials, preferably wherein one or both outer covers comprise a metal, preferably aluminum, and the button comprises plastics, preferably thermoplastic polyurethane.

[0085] Example P: The method of any of the examples Petition 870260051823, dated 05 / 29 / 2026, p. 22 / 64 18 / 22 previous, in which the button is positioned flush with an inner surface of an outer wall to facilitate smooth insertion of the frame assembly into the outer cover.

[0086] Example Q: The method of Example P, in which the button is arranged flush with the outer cover wall away from a central protrusion on an outer surface of the outer cover to allow tactile haptic feedback.

[0087] Example R: The method of any of the previous examples, wherein the outer covering comprises a hollow cylindrical form and the frame assembly comprises a cylindrical form.

[0088] Example S: The method of any of the previous examples, where the thickness of the outer covering wall is less than about one millimeter.

[0089] Example T: The method of any of the previous examples, comprising, after the step of inserting the frame assembly into the outer cover, a step of securely fixing the frame assembly inside the outer cover, preferably by screwing a retaining element to one insertion end of the outer cover.

[0090] Example U: The method of any of the previous examples, where the button is fixed to the outer cover to cover the through hole so as to provide a waterproof seal between the button and the outer cover in accordance with IPX7.

[0091] Example V: An aerosol generating device obtainable by the method of any of the previous examples.

[0092] Example W: An aerosol generating device comprising an outer cover including a button extending over a through hole in the outer cover, in which the button is fixed. Petition 870260051823, dated 05 / 29 / 2026, page 23 / 64 19 / 22 directly on the outer cover; and a frame assembly including a pressure-activated switch, wherein the frame assembly is slidably inserted into the outer cover so that the button overlaps the pressure-activated switch, wherein the outer part of the outer cover comprises a groove around the periphery of the through hole, in which the button is fixed in the groove of the outer cover.

[0093] Example X: The aerosol generating device of Example X, wherein the groove comprises a laser-engraved pattern, wherein glue is applied to the laser-engraved pattern, and wherein the button is molded into the groove.

[0094] Features described in relation to one embodiment may also be applied to other embodiments of the invention.

[0095] The invention will be described further, by way of example only, with reference to the accompanying figures, in which: Figure 1 shows a button attached to an outer cover; Figure 2 shows the insertion of a frame assembly into an external covering; Figure 3 shows a through hole in an outer cover; Figure 4 shows a frame assembly inserted into an external covering; Figure 5 shows a frame assembly; Figure 6A and Figure 6B show a molding process; and Figure 7 shows a laser-engraved pattern in a groove.

[0096] Figure 1 shows a portion of an outer covering 10 Petition 870260051823, dated 05 / 29 / 2026, page 24 / 64 20 / 22 of an aerosol generating device. A button 12 is fixed to a wall 14 of the outer cover 10. The button 12 comprises a central protrusion on an outer surface of the outer cover 10. The central protrusion provides tactile haptic feedback to a user.

[0097] Figure 2 schematically shows a frame assembly 16 to be inserted into an outer cover 10. An arrow indicates the sliding insertion of the frame assembly 16 into the outer cover 10. The frame assembly 16 generally has a cylindrical shape. The outer cover 10 has a corresponding shape of a hollow cylinder with one end open to allow the frame assembly 16 to be slid into the outer cover 10. In particular, a battery component 18 may be a component that requires space from the frame assembly 16. In order to allow a compact architecture of the aerosol generating device, the battery component 18 of the frame assembly 16 fits very closely into the outer cover 10. Thus, there is only very little space between the frame assembly 16 and the outer cover 10 when the frame assembly 16 is slid into the outer cover 10.Button 12, fixed to the outer cover 10, is positioned flush with an inner surface of the wall 14 of the outer cover 10. In this way, smooth insertion of the frame assembly 16 into the outer cover 10 is possible.

[0098] Figure 3 shows a through hole 20 of an outer cover 10. A groove 22 is provided on the outside of the outer cover 10. The groove 22 is provided on the outside of the wall 14 of the outer cover 10. The groove 22 is provided around the periphery of the through hole 20. A button (not shown) is fixed in the groove of the outer cover 10.

[0099] Figure 4 shows a portion of a generator device. Petition 870260051823, dated 05 / 29 / 2026, page 25 / 64 21 / 22 aerosol can with a frame assembly being inserted into an outer cover. A groove 22 in the outer wall 14 of the outer cover is provided around the through hole. For illustrative purposes, a button is not shown. A printed circuit board 24 forms part of the inserted frame assembly and is visible through the open through hole. The printed circuit board 24 comprises a pressure-activated switch 26.

[00100] Figure 5 shows a portion of the frame assembly 16 comprising a pressure-activated switch 26 and a movable plunger 28. The plunger 28 comprises a button contact area 30 for contact with the outer cover button (not shown) when the frame assembly 16 is inserted into the outer cover. The plunger 28 further comprises a switch contact area 32 for contact with the pressure-activated switch 26 when the movable plunger 28 is pushed down by a user pressing the button fixed to the outer cover. The plunger 28 comprises two legs 34. The plunger 28 is mounted in the frame assembly 16 with the two legs 34 to create a spring force to automatically return the plunger 28 and therefore the button after it has been pushed down by a user.

[00101] Figure 6A schematically shows a configuration of an injection molding process. The molding process comprises a step of positioning an outer mold 36 on top of the through hole 20 from an outer side of the outer cover 10. The molding process comprises a step of positioning an inner mold 38 below the through hole 20 from an inner side of the outer cover 10. The through hole 20 and the groove 22 of the wall 14 of the outer cover 10 are located between the outer mold 36 and the inner mold 38. The arrows indicate the injection path of the molten material through channels in the mold. Petition 870260051823, dated 05 / 29 / 2026, page 26 / 64 22 / 22 internal 36. Alternatively or additionally, the channels for injecting molten material may be in the external mold 38. The molded button 12 will thus be fixed in the groove 22, as shown in Figure 6B.

[00102] Using the configuration of Figure 6A, the molded button 12 shown in Figure 6B is arranged flush with an inner surface of a wall 14 of the outer cover 10 to facilitate smooth insertion of the frame assembly (not shown) into the outer cover 10. In addition, the groove 22 can further improve a durable connection between the button 12 and the outer cover 10.

[00103] The outer mold 38 of Figure 6A further comprises a recess 40. Thus, a central protrusion 42 of the button 12 on an outer surface of the wall 14 of the outer cover 10 will be provided as shown in Figure 6B. The central protrusion 42 can allow for tactile haptic feedback.

[00104] Figure 7 shows a portion of an outer cover 10 provided with a corrugated retaining structure in the groove 22 before attaching a button in the groove 22.

[00105] The corrugated retaining structure comprises a laser-etched slope pattern. The slope pattern comprises a grid form of square slopes approximately 0.2 millimeters long on each side separated by grooves at least 0.03 millimeters deep.

[00106] The wavy retaining structure can further improve the durability of the connection between the button (not shown) and the outer cover 10 when the button is fixed to the groove 22 by a molding process. Optionally, the durability of the connection between the button and the outer cover 10 can be further improved by spraying an adhesive in the laser-engraved slant pattern before molding the button into the groove 22. Petition 870260051823, dated 05 / 29 / 2026, page 27 / 64

Claims

1 / 3 CLAIMS 1. Method for assembling an aerosol generating device characterized in that it comprises the steps of providing an outer cover (10) for an aerosol generating device, the outer cover (10) being configured to internally receive a frame assembly (16) comprising a pressure-activated switch (26); providing a through hole (20) in a wall of the outer cover (10); providing a groove (22) on the outside of the outer cover (10) around the periphery of the through hole (20); attaching a button (12) to the outer cover (10) to cover the through hole (20); and inserting the frame assembly (16) into the outer cover (10) so that the button (12) overlaps the pressure-activated switch (26), wherein the button (12) is fixed in the groove (22) of the outer cover (10).

2. Method according to claim 1, characterized in that the button (12) is fixed to the outer cover (10) by a molding process, an injection overmolding process, or a plastic injection overmolding process.

3. Method according to claim 1 or 2, characterized in that the button (12) fixing step on the outer cover (10) is performed before the frame assembly (16) insertion step on the outer cover (10).

4. Method according to claim 3, characterized in that the molding process comprises steps of positioning an outer mold (36) on top of the through hole (20) from an outer side of the outer cover (10); positioning an inner mold (38) below the through hole (20) from an inner side of the outer cover (10); and injecting, through channels in the inner mold (38), molten material into a cavity formed between the outer mold (36) and the inner mold (38) to form the button (12).

5. Method, according to any of the preceding claims, characterized in that it comprises a step of providing a wavy retaining structure in the groove (22) before fixing the button (12) in the groove (22).

6. Method according to claim 5, characterized in that the corrugated retaining structure comprises a slope pattern and wherein the slope pattern comprises a square slope grid form of 0.2 millimeter side length separated by grooves of at least 0.03 millimeter depth.

7. Method according to claim 5 or 6, characterized in that the wavy retention structure is provided by a laser engraving process.

8. Method, according to any one of claims 5 to 7, characterized in that it comprises a step of applying an adhesive to the corrugated retaining structure before fixing the button (12) in the groove (22).

9. Method, according to any one of claims 1 to 8, characterized in that the outer cover (10) and the button (12) comprise different materials, wherein one or both of the outer covers (10) comprise aluminum, and the button (12) comprises thermoplastic polyurethane.

10. Method, according to any one of claims 1 to 9, characterized in that the button (12) is arranged flush with an inner surface of a wall (14) of the outer cover (10) to facilitate the smooth insertion of the assembly of the Petition 870260051823, dated 05 / 29 / 2026, page 29 / 64 3 / 3 frame (16) into the outer cover (10).

11. Method according to claim 10, characterized in that the button (12) is disposed flush with the wall (14) of the outer cover (10) away from a central protrusion (42) on an outer surface of the outer cover (10) to allow tactile haptic feedback.

12. Method, according to any one of claims 1 to 11, characterized in that the button (12) is fixed to the outer cover (10) to cover the through hole (20) so as to provide a hermetic seal between the button (12) and the outer cover (10) according to IPX7.

13. Aerosol generating device, characterized in that it comprises an outer cover (10) including a button (12) extending over a through hole (20) in the outer cover (10), wherein the button (12) is fixed directly to the outer cover (10); and a frame assembly (16) including a pressure-activated switch (26), wherein the frame assembly (16) is slidably inserted into the outer cover (10) so that the button (12) overlaps the pressure-activated switch (26), wherein the outer part of the outer cover (10) comprises a groove (22) around the periphery of the through hole (20), wherein the button (12) is fixed in the groove (22) of the outer cover (10).

14. Aerosol generating device, according to claim 13, characterized in that the groove (22) comprises a laser-engraved pattern, wherein the glue is applied to the laser-engraved pattern and wherein the button (12) is molded into the groove (22). Petition 870260051823, dated 05 / 29 / 2026, p. 30 / 64

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