Device assembly method and device manufactured according to this method

Abstract

An aerosol generating system comprising an aerosol generating device for heating an aerosol-forming substrate, and an outer sleeve; the aerosol generating device comprising: a device housing, and a plurality of internal components contained within an internal space enclosed by the device housing; wherein the device housing comprises an outer surface and at least one bendable portion that bends or is bendable into or toward the internal space to interact with one of the internal components; and wherein the outer sleeve is configured to cover at least one bendable portion. The bendable portion may include a tab defined by a cutout in the outer surface. At least one tab may interact with at least one of the internal components so as to retain the internal component. Alternatively or in addition, at least one tab may interact with the internal component as part of a user interface of the device, thereby allowing a user to operate the device.

Description

Technical Field

[0001] The present disclosure relates to aerosol generating devices and methods of manufacturing aerosol generating devices. In particular, the present disclosure relates to aerosol generating devices that are simple and cheap to manufacture and that allow user customization. Background Art

[0002] Handheld aerosol generating devices for heating an aerosol-forming substrate are now common and used as an alternative to smoking. Handheld aerosol generating devices, such as personal vaporizers or "heat-not-burn" devices that heat tobacco, typically include a plurality of internal components arranged within a device housing. For example, WO2015 / 177255 discloses an induction heating device for heating an aerosol-forming substrate. The device includes a power supply, power electronics, and a series connection of a capacitor and an inductor, all of which are positioned within the device housing. The device housing also defines a cavity having an inner surface shaped to accommodate at least a portion of an aerosol-forming substrate to be heated by the device.

[0003] In such handheld aerosol-forming devices, the device housing is a functional component of the device, but must also have a pleasing look and feel to the user of the device. The housing must secure and protect the internal components from damage, and support and house user interface elements, such as buttons, that allow the user to operate the device. At the same time, the housing is ideally pleasing to look at and to hold. The look and feel of the device is largely determined by the device housing, and is often an important factor in how the user perceives the overall quality of the device. It can be complex and expensive to manufacture an aerosol generating device with a device housing that is both functionally and aesthetically acceptable. Furthermore, once an aerosol generating device has been manufactured, the device housing cannot usually be easily replaced.

[0004] It is desirable to reduce the cost of manufacturing an aerosol generating device.It is also desirable to allow a user to customise the appearance of an aerosol generating device, and to allow a user to replace a device housing if the device housing becomes scratched or damaged during use of the aerosol generating device. Summary of the invention

[0005] In a first aspect, there is provided an aerosol generating system comprising an aerosol generating device for heating an aerosol-forming substrate, and an outer sleeve;

[0006] The aerosol generating device comprises:

[0007] a device housing, and

[0008] a plurality of internal components contained within an interior space enclosed by the device housing;

[0009] wherein the device housing comprises an outer surface and at least one curved or bendable portion that curves or is bendable into or toward the interior space to interact with one of the interior components; and

[0010] Wherein the outer sleeve is configured to removably cover at least one curved or bendable portion.

[0011] At least the curved or bendable portion may include a tab defined by a cutout in the outer surface. Preferably, the cutout extends completely through the device housing. If there is more than one curved or bendable portion, there may be more than one tab. At least one tab may interact with at least one of the internal components to retain the internal component. Alternatively or in addition, at least one tab may interact with an internal component that is part of a user interface of the device, thereby allowing a user to operate the device.

[0012] Inexpensive and simple manufacturing methods can be used to manufacture the at least one tab. Advantageously, the outer sleeve covers the at least one tab so that the at least one tab is not visible to a user of the device. Without covering the at least one tab, the outer surface of the device housing may have an unacceptable appearance or surface finish. By covering the at least one tab with the outer sleeve, an acceptable look and feel may be provided.

[0013] The outer sleeve may cover all or at least most of the device housing. The appearance of the aerosol generating device covered by the outer sleeve may depend on the appearance of the outer sleeve. By providing replaceable outer sleeves with different appearances, the aerosol generating device can be customized. The outer sleeve may include visual information, text or other brand information. For example, the outer sleeve may be a specific color or combination of colors. The outer sleeve may include a logo. The outer sleeve may be opaque. When the device housing has an unacceptable appearance or surface finish, an opaque outer sleeve advantageously improves the appearance of the device.

[0014] The outer sleeve may advantageously be removed from the aerosol generating device and replaced. The outer sleeve may be replaced when damaged or scratched. Furthermore, the outer sleeve may be replaced with a different outer sleeve having a different appearance, as desired by the user. This advantageously allows a user of the aerosol generating system to customize their aerosol generating device after manufacture or purchase. Replacement of the outer sleeve may be performed by the user of the aerosol generating system. Alternatively, the user may take the device to an outer sleeve supplier to perform replacement of the outer sleeve.

[0015] The device housing may comprise a ductile material. For example, the device housing may comprise a metal or a thermoplastic. The device housing may comprise stainless steel. Ductile materials advantageously allow the tabs to be formed simply by bending or pressing.

[0016] The aerosol generating system may comprise a plurality of tabs formed in the outer surface of the device housing, wherein at least one tab comprises a fixing element that deflects into the interior space and engages the internal component. A fixing element formed in this manner advantageously provides a reliable engagement with the internal component while being cheap and easy to manufacture. The fixing element engaging the internal component advantageously holds the internal component in position relative to the device housing. The engagement may be irreversible.

[0017] The fixing element can be formed by deflecting the tab into the inner space of the device housing to engage the internal components. The tab defined by the cutout can advantageously isolate the tab, thereby reducing the undesirable deflection of other areas of the outer surface when the tab is deflected into the inner space. The cutout defining the tab can advantageously reduce the force required to deflect the tab to its fixed position for engaging the internal components. The tab for forming the fixing element can be defined by the cutout on at least two sides. The tab can be defined by a curved cutout in the outer surface. Alternatively or in addition, the tab can be defined by a straight cutout in the outer surface. The tab can have two uncut ends or fixed ends on opposite sides. In such cases, the tab for forming the fixing element can preferably be defined by a cutout behind the convex outer surface of the device housing. This can advantageously allow the tab to be pressed into the inner space without the need to stretch the tab.

[0018] At least one tab of the outer surface of the device housing may comprise a user interface element deflectable by a user towards the interior space of the device housing.A user interface element formed in this way is advantageously inexpensive and simple to manufacture.

[0019] The user interface element may be formed by bending the tab. The user interface element may be a lever. The lever may be deflected by the user toward the interior space of the device housing. The lever may be bent away from the interior space of the device housing to provide a protruding user interface element in an intermediate position. Alternatively, the lever may be flush with the surrounding portion of the device housing and may be deflected inwardly by the user during operation. Alternatively, the lever may be bent toward the interior space of the device housing to provide a recessed user interface element in an intermediate position.

[0020] The shape and position of the cutouts defining the tabs forming the user interface element may be selected so that the lever has a desired shape and size. The tab may be defined by cutouts on at least two sides. The tab may be defined by a curved cutout in the outer surface. Alternatively or in addition, the tab may be defined by a straight cutout in the outer surface. Preferably, the cutouts are connected to form a continuous cutout defining three sides of the tab.

[0021] When the outer sleeve covers the device housing, the interface portion of the outer sleeve may cover the user interface element. A user of the device pressing on the interface portion may deflect the user interface element toward the interior space of the device housing.

[0022] The portion of the outer sleeve that covers the user interface element may include markings. These markings may be visible markings. For example, the markings may be printed on the surface of the outer sleeve. Alternatively or in addition, the markings may be formed by raised features on the surface of the outer sleeve. Alternatively or in addition, the markings may be formed by depressions in the outer sleeve.

[0023] The interface portion of the outer sleeve may comprise a region of increased thickness relative to the rest of the outer sleeve. This may ensure that there is contact between the outer sleeve and the lever. This may have the advantage that less force is required by the user when pressing on the interface portion.

[0024] Alternatively or in addition, the interface portion of the outer sleeve may be a region of increased flexibility relative to the rest of the outer sleeve. The region of increased flexibility may be the result of a recess in the outer sleeve. Advantageously, the recess is configured to allow the portion of the outer sleeve covering the user interface element to move relative to the rest of the sleeve.

[0025] A plurality of internal components may include a control circuit system configured to sense the deflection of a user interface element. When the deflection of the user interface element is detected, the deflection of the user interface element may cause the control circuit system to turn on or activate the aerosol generating device. For example, the control circuit system may include a switch or button in contact with the user interface element. The switch or button may be actuated by moving the user interface element by deflection. The control circuit system may also include a microprocessor, a microcontroller or an application specific integrated chip (ASIC), which may be a programmable microprocessor, or other electronic circuit systems capable of providing control. The circuit system may include additional electronic components.

[0026] The plurality of internal components contained within the device housing may include at least one of a power source, control circuitry, a heater assembly, or a receiving portion configured to receive an aerosol-generating article comprising an aerosol-forming substrate.

[0027] The power source may be a battery, such as a lithium iron phosphate battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may need to be charged and may have a capacity that allows storage of energy sufficient for one or more smoking experiences. The power source may have sufficient capacity to allow continuous generation of aerosol for a period of about six minutes, corresponding to the typical time spent smoking a conventional cigarette.

[0028] The heater assembly may be an induction heating assembly. Examples of induction heating assemblies are described in WO2015 / 177255. The induction heating assembly may include an inductor. The inductor may be in the form of a coil or a plurality of coils. A plurality of coils may form a spiral. The inductor may be electrically connected to a power source. The power supply from the power source to the inductor may be controlled by a control circuit system. The control circuit system may use the sensed deflection of the user interface element to start a heating cycle (i.e., start supplying power to the inductor). The control circuit system may control the supply of power according to a predetermined heating curve stored in the control circuit system. The power source may be a DC power source, and the control circuit system may include a DC / AC inverter connected to the DC power source. The DC / AC inverter may include a class D or class E power amplifier. The power source may include a power supply electronic device configured to operate at a high frequency. For the purposes of this application, the term "high frequency" is understood to mean a frequency of 1 MHz to 30 MHz, preferably a frequency of 1 MHz to 10 MHz, and even more preferably a frequency of 5 MHz to 7 MHz.

[0029] The inductor may be configured to heat an electrically conductive susceptor element in the vicinity of the inductor. The susceptor element may be an electrically conductive element that heats up when subjected to a changing magnetic field. Such a changing magnetic field may be generated in the inductor as a result of a high frequency power source connected to the inductor. The heating of the susceptor may be a result of at least one of eddy currents and hysteresis losses induced in the susceptor element. Possible materials for the susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and virtually any other electrically conductive element. In use, the changing electromagnetic field generated by the inductor heats the susceptor element, which then transfers heat to an aerosol-forming substrate of the aerosol-forming article primarily by conduction. The susceptor element may be configured to heat the aerosol-forming substrate by at least one of conductive heat transfer, convective heat transfer, radiative heat transfer, and combinations thereof. To this end, the susceptor is thermally adjacent to the material of the aerosol-forming substrate.

[0030] Preferably, the susceptor element does not form part of an aerosol-generating device. Rather, the susceptor is contained within an aerosol-generating article for use with an aerosol-generating device. The susceptor may be thermally adjacent to an aerosol-forming substrate of the aerosol-generating article.

[0031] Advantageously, the susceptor element has a relative permeability between 1 and 40,000. When it is desired that most of the heating be dependent on eddy currents, a lower permeability material may be used, whereas when a hysteresis effect is desired, a higher permeability material may be used. Preferably, the material has a relative permeability between 500 and 40,000. This provides efficient heating.

[0032] The material of the susceptor element may be selected based on its Curie temperature. Above its Curie temperature the material is no longer ferromagnetic and therefore heating due to hysteresis effects no longer occurs. The Curie temperature may correspond to the maximum temperature that the susceptor element should have (that is, the Curie temperature is the same as the maximum temperature to which the susceptor element should be heated, or deviates from this maximum temperature by about 1%-3%). This reduces the likelihood of rapid overheating.

[0033] The plurality of internal components may further comprise a receiving portion configured to receive an aerosol-generating article comprising an aerosol-forming substrate. The heating assembly may be positioned to heat the aerosol-generating article when the aerosol-generating article is received in the receiving portion. The inductor coil of the heating assembly may be positioned in the receiving portion. This has the advantage that the inductor surrounds the aerosol-generating article received in the receiving portion. This is particularly advantageous when the susceptor element is contained within the aerosol-generating article, as it ensures close proximity between the inductor coil of the aerosol-generating device and the susceptor element of the aerosol-generating article.

[0034] The device housing may comprise metal. The device housing may be formed from a single piece of material. This simplifies manufacturing because no joints or connections are required between multiple pieces of housing. Any fixing elements or user interface elements, such as buttons, may be formed in a single piece of material of the device housing. This again simplifies manufacturing because no joints or connections are required between multiple pieces of housing. The device housing may be substantially tubular. The device housing may be substantially cylindrical.

[0035] The outer sleeve may be particularly suitable for devices having a single-piece device housing. In particular, the outer sleeve may be suitable for devices that do not include any element that penetrates the aerosol-forming substrate. In devices that include a penetrating element (such as a heater) that penetrates the aerosol-forming substrate, a slidable portion of the device housing is typically provided to assist in extracting the aerosol-forming substrate from the penetrating element after use. Devices using inductive heating typically do not include any penetrating element. The outer sleeve may be particularly suitable for devices using inductive heating.

[0036] The internal component may also include a flux concentrator. The flux concentrator may distort the fluctuating magnetic field generated by the inductor coil towards the center of the receiving portion (i.e., towards the aerosol-forming article received in the receiving portion). This advantageously concentrates the magnetic field within the receiving portion and thereby increases the level of heat generation in the susceptor for a given power level through the inductor coil. The flux concentrator may also include an electromagnetic shield that may be positioned to prevent the magnetic field from escaping the inductor. If the inductor is in the shape of a coil, the flux concentrator may have a ring shape. The flux concentrator may then be positioned to surround the inductor coil.

[0037] The outer sleeve may comprise silicone. Silicone advantageously combines durability and flexibility. Silicone also has elastic properties. An outer sleeve comprising silicone may advantageously be inexpensive to manufacture while being easy to mold into a desired shape with a desired appearance. Features may be molded into an outer sleeve comprising silicone.

[0038] The outer sleeve may comprise a plurality of separate parts connected together. An outer sleeve comprising a plurality of parts may advantageously be more easily fitted to or removed from an aerosol generating device. If the outer sleeve has a portion covering a user interface element, this may be formed in only one of the plurality of separate parts. The parts may have a very similar appearance (i.e., for example, each part may comprise the same visual information, text or brand). Alternatively, one part may have a different appearance from another part. The plurality of parts of the outer sleeve may be connected by a snap-fit ​​connection.

[0039] As used herein, the term "snap-fit ​​connection" means a connection comprising a male part and a female part. The male part may be formed in a first part of the outer sleeve, and the female part may be formed in a second part of the outer sleeve. In an unstressed state, the male part and the female part may not fit together. However, the outer sleeve may have elastic properties, and thus when a force is applied, one or both of the male part and the female part may bend, thereby allowing the first part and the second part to fit together. After the engagement operation, the male part and the female part may return to an unstressed state. The snap-fit ​​connection advantageously allows a removable but elastic connection between the first part and the second part of the outer sleeve. The female part may be a groove formed in the first part of the outer sleeve. The male part may be a lip or rib formed in the second part of the outer sleeve.

[0040] As used herein, the term "aerosol-generating substrate" relates to a substrate capable of releasing 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 part of an aerosol-forming article.

[0041] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of releasing volatile compounds that can form an aerosol. For example, an aerosol-generating article can be an article that generates an aerosol that can be directly inhaled by a user drawing or sucking on a mouthpiece at the proximal or user end of the system. The aerosol-generating article can be disposable. Articles that include an aerosol-forming substrate that includes tobacco are referred to as tobacco rods.

[0042] As used herein, the term "aerosol-generating device" refers to a device that interacts with an aerosol-generating article to generate an aerosol. The aerosol-generating device may be reusable.

[0043] As used herein, the term "outer sleeve" refers to a sleeve configured to fit over an aerosol generating device.

[0044] As used herein, the term "aerosol generating system" refers to the combination of an aerosol generating article, an aerosol generating device and an outer sleeve.

[0045] Preferably, the aerosol-forming substrate comprises a tobacco-containing material that is included in the volatile tobacco flavor compounds that are released from the aerosol-forming substrate when heated. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise an aerosol-forming agent that contributes to the formation of a dense and stable aerosol. As used herein, the term "aerosol-forming agent" is used to describe any suitable known compound or mixture of compounds that contribute to the formation of an aerosol in use. Suitable aerosol-forming agents are substantially resistant to thermal degradation at the operating temperature of aerosol-generating articles. The example of suitable aerosol-forming agents is glycerol and propylene glycol.

[0046] Aerosol-forming substrate can be a solid aerosol-forming substrate. Alternatively, aerosol-forming substrate can include solid and liquid components. In a particularly preferred embodiment, aerosol-forming substrate includes a curled sheet of the gathering of homogenized tobacco material. As used herein, term "curled sheet" means a sheet with a plurality of substantially parallel ridges or corrugations.

[0047] In a second aspect of the invention, there is provided a kit comprising an aerosol generating device for heating an aerosol-forming substrate and at least one outer sleeve;

[0048] The aerosol generating device comprises:

[0049] a device housing, and

[0050] a plurality of internal components contained within an interior space enclosed by the device housing;

[0051] wherein the device housing is formed from a single piece of material and includes an outer surface and at least a curved or bendable portion that curves or is bendable into or toward the interior space to interact with one of the interior components; and

[0052] At least one outer sleeve is configured to removably cover at least one curved or bendable portion.

[0053] At least one of the curved or bendable portions may comprise a tab defined by a cut-out in the outer surface.

[0054] The kit may include a first outer sleeve and a second outer sleeve, wherein the first outer sleeve includes an outer surface that includes visual information, text or other brand information, and the second outer sleeve includes an outer surface that includes visual information, text or other brand information that is different from the visual information, text or other brand information of the outer surface of the first outer sleeve. This advantageously allows a user to customize the aerosol generating device. For example, a user may have a preference about the appearance of the first outer sleeve or the second outer sleeve, and may fit either appearance they prefer to the aerosol generating device. This may be done at home, or with the help of a professional performing the fitting on behalf of the user.

[0055] In a third aspect of the invention there is provided a method of manufacturing an aerosol generating system, the method comprising the steps of:

[0056] providing a device housing for containing a plurality of internal components within an interior space, and wherein the device housing includes an exterior surface;

[0057] providing at least one curved or bendable portion in the device housing, the curved or bendable portion being curved or bendable toward the interior space to interact with one of the interior components; and

[0058] An outer sleeve is provided and is configured to removably cover at least one curved or bendable portion.

[0059] The method of manufacturing an aerosol generating system may further comprise the steps of deflecting at least one curved or bendable portion into the interior space to interact with one of the components and mating the outer sleeve to the device housing.

[0060] The method of manufacturing an aerosol generating system may further comprise the step of cutting the outer surface of the device housing to define at least one tab as at least one curved or bendable portion, wherein the tab is deflectable towards the interior space to interact with one of the internal components. Features described with respect to one aspect may be applied to other aspects of the disclosure. In particular, advantageous or optional features described with respect to the first aspect of the disclosure may be applied to the second and third aspects of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Embodiments of an aerosol generating system and a method of making an aerosol generating system will now be described in detail, by way of example only, and with reference to the accompanying drawings, in which:

[0062] Figure 1 is a perspective view of an aerosol generating system comprising an aerosol generating device and an outer sleeve.

[0063] Figure 2 Yes Figure 1A perspective view of a kit of an aerosol generating device and a first outer sleeve and a second outer sleeve, the first sleeve comprising different visual information, text or branding than the second sleeve.

[0064] Figure 3 yes Figure 1 Schematic diagram of a cross-section of an aerosol-generating device in which an aerosol-generating article is received.

[0065] Figure 4 yes Figure 1 An exploded perspective view of an aerosol generating device showing the internal components contained by the device housing.

[0066] Figure 5 Shows Figure 1 Four embodiments of a cut-out in a device housing of an aerosol generating device, wherein each embodiment is shown as a schematic plan view of the device housing viewed from above.

[0067] Figure 6 Is shown covered Figure 1 Aerosol generating device Figure 1 Schematic cross-sections of three different embodiments of the outer sleeve of FIG. Each embodiment is shown as a close-up schematic cross-section.

[0068] Figure 7 yes Figure 1 A perspective view of an embodiment of an outer sleeve comprising two connecting parts.

[0069] Figure 8 yes Figure 8 A close-up illustration of the connection between the two connecting parts of the outer sleeve is shown.

[0070] Fig. 9 It means manufacturing Figure 1 A flow chart of a method of an aerosol generating system is shown. DETAILED DESCRIPTION

[0071] Figure 1 A perspective view of an aerosol generating system 10 comprising an aerosol generating device 100 and an outer sleeve 120 is shown. The aerosol generating device 100 is configured for heating an aerosol-forming article comprising an aerosol-forming substrate. The aerosol generating device 100 comprises a device housing 102 and Figure 1The device housing 102 has an outer surface 103 and encloses an interior space 104. A plurality of internal components are contained within the interior space 104. The device housing 102 is tubular and formed from a single piece of metal. A plurality of bendable portions are formed in the outer surface 103 of the device housing 102, which bend or bendable into or toward the interior space 104 to interact with one of the internal components. Each bendable portion includes tabs 106, 107, and 108 defined by cutouts in the outer surface 103 of the device housing 102. Each tab 106, 107, and 108 interacts with one of the internal components.

[0072] Tabs 106 and 107 are fixing elements. Each fixing element is formed by cutting through the outer surface 103 to define a tab, and then deflecting the tab toward the interior space 104. The fixing elements 106, 107 interact with the internal components by engaging the internal components. This engagement holds the corresponding internal components in place relative to the device housing 102.

[0073] Tab 108 is a user interface element in the form of a lever. Lever 108 is formed by cutting into device housing 102 to form a tab and bending the tab toward the interior space of the device housing so that it enters the interior space of the device housing. When operated by a user, lever 108 can be further deflected into the interior space of the device housing. The lever interacts with the internal components when deflected.

[0074] The device housing 102 securely houses the internal components, protecting them from damage as well as supporting any additional user interface elements, such as LEDs. It is cheap and simple to form the tabs in the outer surface 103 by cutting and then deflecting or bending the tabs. The device housing 102 is functionally operable without any external sleeve. However, the device housing 102 with the cutout tabs is not pleasant to look at or hold.

[0075] By providing an outer sleeve 120 on the aerosol generating device 100, the aerosol generating device can be made aesthetically acceptable. Figure 1 In the illustrated embodiment, the outer sleeve 120 is configured to removably cover the entire outer surface 103 of the device housing. However, this may not be required. The aerosol generating device 100 may be aesthetically acceptable if the outer sleeve 120 covers enough of the outer surface 103 so that any tabs are covered. Some portions of the device housing 102 may have an acceptable look and feel.

[0076] The outer sleeve 120 is made of silicone, which is both durable and flexible, and is molded to match the shape of the aerosol generating device 100, so that when the outer sleeve is assembled, there is a tight fit between the sleeve and the device, and the outer sleeve does not easily move relative to the device housing. The outer sleeve is held in place by friction between the outer sleeve and the device housing.

[0077] The outer sleeve 120 comprises an interface portion 122. When the outer sleeve 120 covers the aerosol generating device 100, the interface portion 122 covers the lever 108. A user of the device pressing on the interface portion 122 deflects the lever 108 towards the interior space 104 of the device housing 102. The interface portion 122 is defined by a raised ring 124 formed in the surface of the outer sleeve 120. The raised ring 124 is an indicator to the user of the device as to the position of the lever 108 covered by the outer sleeve 120.

[0078] As described above, the use of the outer sleeve 120 to cover the aerosol generating device 100 results in the aerosol generating device 100 having an acceptable look and feel. The appearance of the aerosol generating device 100 depends on the appearance of the outer sleeve 120. A customized outer sleeve 120 having a specific appearance can be provided. By removing a first outer sleeve and replacing it with a second outer sleeve, the appearance of the aerosol generating device 100 can be changed, thereby allowing continued customization of the aerosol generating device. This is in Figure 2 Example in.

[0079] Figure 2 It includes such as Figure 1 A perspective view of a kit of the aerosol generating device 100 and the first outer sleeve 202 and the second outer sleeve 212. The first outer sleeve 202 and the second outer sleeve 212 are identical to each other and to the outer sleeve 120 described above, except for having different appearances. The outer sleeve 202 includes the first logo 204 and is a single color. The outer sleeve 212 includes the second logo 214 and has a striped pattern consisting of two different alternating colors. Thus, the outer sleeve 202 has a different appearance than the outer sleeve 212. Covering the aerosol generating device 100 with the outer sleeve 212 instead of the outer sleeve 202 (or vice versa) will change the appearance of the aerosol generating device 100. This allows the aerosol generating device 100 to be customized.

[0080] It should be understood that Figure 2 The outer sleeves 202 and 212 shown in the figure are exemplary. The outer sleeve may include any visual information, text or other branding to give the aerosol generating device a desired appearance. In addition, it should be clear that the first logo 204 and the second logo 214 are merely placeholders to indicate that different sleeves may include different brands, and do not represent the actual brand to be included on the outer sleeve.

[0081] Figure 3 is a schematic cross-sectional view of an aerosol-generating device 100 in which an aerosol-generating article 302 is received. Figure 3 Various internal components contained within device housing 102 are shown.

[0082] The aerosol generating device 100 comprises a receiving portion 304. The receiving portion 304 comprises an opening 310 through which the aerosol generating article 302 can be inserted and removed. The receiving portion further comprises a heating assembly comprising an inductor coil 312. The inductor coil 312 is a spiral inductor coil having a magnetic axis corresponding to the longitudinal axis of the receiving portion 304, see Figure 3 The aerosol generating device 100 also includes a power source 306, such as a rechargeable battery, and a control circuit system 308, such as a printed circuit board having circuit systems. The control circuit system 308 and the inductor coil 312 both receive power from the power source 306.

[0083] The aerosol-forming article 302 comprises an aerosol-generating substrate and a conductive susceptor element 303, which is arranged in the aerosol-generating article 302 so that when the aerosol-forming article 302 is received in the receiving portion 304, the conductive susceptor element can be inductively heated by the inductor coil 312. The aerosol-forming substrate is a tobacco-containing material that includes volatile tobacco flavor compounds that are released from the aerosol-forming substrate when heated. The aerosol-forming substrate also contains an aerosol-forming agent, such as glycerol or propylene glycol, that promotes the formation of a dense and stable aerosol.

[0084] The operation of the aerosol generating device 100 is controlled by the control circuitry 308. This includes initiating a heating cycle whereby the control circuitry 308 controls the supply of power to the inductor coil 312 according to a predetermined heating profile stored in the control circuitry 308.

[0085] The control circuit system 308 includes a DC / AC inverter connected to the power supply 306, which is a DC power supply. The DC / AC inverter includes a class E power amplifier with a transistor switch, a transistor switch drive circuit, and an LC load network. Class E power amplifiers are generally known and described in detail, for example, in the article "Class E RF Power Amplifier" (Nathan O. Sokal, published in the bimonthly QEX, January / February 2001 edition, pages 9-20, American Radio Relay League (ARRL), Newington, Connecticut, USA). Therefore, a high-frequency current can be supplied to the inductor coil 312. A changing magnetic field is generated by the inductor as a result of the high-frequency current. This induces a changing current in the conductive susceptor element 303, resulting in heating of the susceptor element 303. The heated susceptor element 303 heats the aerosol-forming substrate of the aerosol-generating article 302 to a sufficient temperature to form an aerosol. The aerosol may then be drawn downstream through the aerosol-generating article 302 for inhalation by a user of the device.

[0086] The receiving portion 304 also includes a flux concentrator including an electromagnetic shield ( Figure 3 304). The flux concentrator distorts the fluctuating magnetic field generated by the inductor coil 312 toward the center of the receiving portion 304 (i.e., toward the aerosol-forming article 302 received in the receiving portion 304). This concentrates the magnetic field within the receiving portion 304 and, therefore, increases the level of heat generated in the susceptor element 303 for a given power level through the inductor coil 312. The flux concentrator is tubular and surrounds the inductor coil, extending along its longitudinal axis. The flux concentrator is made of ferrite. The electromagnetic shield reduces undesirable heating of adjacent conductive parts of the device (e.g., a metal device housing), or undesirable heating of adjacent conductive items external to the aerosol generating device 100. Concentrating the magnetic field of the inductor coil 312 and reducing undesirable heating and losses increases the efficiency of the aerosol generating device 100.

[0087] Figure 41 is an exploded perspective view of the aerosol generating device 100, showing a plurality of internal components and a device housing 102 having an outer surface 103. The main frame 402 carries a power source 306 and a control circuit system 308. The receiving portion 304 is an assembly of a coil former 404, a flux concentrator 406 (as described above), and an encapsulating sleeve 408, each of which is sequentially assembled into the other. The encapsulating sleeve is a protective outer layer for holding the flux concentrator in place. The coil former 404 includes an inductor coil 312. The coil former 404 defines an opening 310 in which the aerosol generating article 302 is received. When the aerosol generating device 100 is assembled, the main frame 402 is inserted into the interior space 104 of the device housing 102, followed by the assembled receiving portion 304 adjacent to the main frame 402. The end pieces 410 are pushed into the device housing 102 at either end.

[0088] When the main frame 402 is inserted into the device housing 102, the lever 108 formed in the device housing 102 contacts the control circuit system 308. The control circuit system 308 detects the deflection of the lever 108. The control circuit system then initiates the heating cycle described previously.

[0089] The fixture 106 is in contact with the power source 306, and the fixture 107 is in contact with the receiving portion 304. This prevents movement of the internal components relative to the device housing.

[0090] Figure 5 5 is a schematic plan view of a portion of a device housing 102 showing embodiments of cutouts in the device housing 102 defining areas where tabs may be formed. The cutouts are shown by dashed lines 502. In each embodiment, the areas defined by the cutouts 502 have different shapes. A skilled person will clearly understand that the tabs formed by these areas will have different shapes.

[0091] Figure 5 (a) shows an embodiment in which a cutout 502 defines an area 504 on three sides in the device housing. The fourth side of the area 504 is not cut. One end of the area 504 is surrounded by the cutout and will be referred to as the free end in this article. The other end is not cut and will be referred to as the fixed end in this article.

[0092] When the region 504 is deflected toward the interior space of the device housing, a fixed element is formed so that the free end will be lower than the fixed end and the free end interacts with the internal component to hold it in place.

[0093] The user interface element is formed because the area 504 can be deflected into the interior space 104 of the device housing 102. In some embodiments, the user interface element bends into or away from the interior space of the device housing at an intermediate position. However, this is not required. The user interface element is a lever, and therefore the closer the user presses to the free end, the lower the force required to deflect the lever.

[0094] Figure 5 (b) and Figure 5 (c) shows a similar embodiment, where regions 506 and 508 have free ends and fixed ends, the free ends being defined by cutouts on all sides. The cutouts in different embodiments have different shapes, and thus the regions defined by the cutouts have different shapes.

[0095] Figure 5 The embodiment shown in (d) is Figure 5 The embodiment of (a) to (c) differs in that it is formed by two parallel cuts adjacent to each other and of substantially equal length. The area 510 defined between the two cuts does not have a free end, but has two fixed ends.

[0096] Figure 5 The tab of (d) has an axis defined from the first fixed end to the second fixed end. The tab axis preferably follows the convex outer surface of the device housing. This allows the tab to be pressed into the interior space without the need to stretch the tab.

[0097] A securing element is formed when the region 510 is deflected toward the interior space 104 of the device housing 102. A central portion of the region 510 interacts with the interior component.

[0098] Return to see Figure 3 The aerosol generating device comprises a plurality of fixing elements 106, 107, 336, 337 formed by cut-outs in the housing of the device and interacting with the internal components. The aerosol generating device also comprises a lever 108 interacting with the control circuit system 308.

[0099] The fixing elements 106, 107, 336, 337 are formed by cutouts in the device housing 102, such as Figure 5 (d) is shown. Fixing elements 106 and 336 are deflected to interact with power source 306. Fixing elements 107 and 337 are deflected to interact with receiving portion 304. The interaction with power source 306 and receiving portion 304 is that the fixing elements are deflected into frictional contact and thus hold the power source and receiving portion in place relative to the device housing. Figure 3In the embodiment shown, the fixing element is deflected into a recess in the corresponding component. This improves the reliability of the fixing element to hold the component in place, but is not a necessary feature. Frictional contact between the fixing element and the internal component is sufficient. In addition, in Figure 3 In the embodiment shown, the power source 306 and the receiving portion 304 are each held in place by two fixtures on opposite sides of each component. Again, this is not a required feature. Depending on the specific design of the aerosol generating device, there may be any number of fixtures in contact with any number of internal components.

[0100] according to Figure 5 In the embodiment shown in (a), the lever 108 is formed by a cutout in the device housing 102. The lever 108 has been bent towards the interior space of the device housing 102 so that it is very close to the switch 340, which forms part of the control circuit system 308. The lever 108 is deflectable. The deflection of the lever 108 can be sensed by the switch 340. When the deflection is sensed, the control circuit system 308 is configured to initiate the operation of the aerosol generating device. For example, by initiating a heating cycle, whereby the control circuit system 308 controls the power supply to the sensor 312 according to a predetermined heating curve stored in the control circuit system 308.

[0101] Figure 3 The illustrated embodiment includes both a fixing element and a user interface element. However, the aerosol generating device may include only a fixing element or a user interface element. For example, the aerosol generating device may include a puff sensor in the form of a microphone. In such an embodiment, a user interface element may not be required because the operation of the device may be initiated when the microphone detects the flow of air through the device due to the user's puff on the aerosol generating article 302 received in the aerosol generating device 100. In such an embodiment, there may be at least one fixing element without a user interface element. In another embodiment, multiple internal components only need to be held in place at either end of the device housing 102 by an end piece 410 inserted into the aerosol generating device 100. Therefore, a fixing element formed by a tab may not be required.

[0102] The contact between the outer sleeve 120 and the lever 108, in particular the contact between the interface portion 122 and the lever 108, is Figure 6 Shown in. Figure 6 Three different embodiments of a portion of the outer sleeve 120 covering the lever 108 are shown as close-up cross-sections.

[0103] Figure 6(a) shows a first embodiment of the interface portion 122. In this embodiment, the interface portion 122 is defined by a mark in the form of a raised feature in the surface of the outer sleeve. The raised feature is a raised ring 124 in the surface of the outer sleeve 120. The raised ring 124 acts as an indicator to the user of the device as to the position of the lever 108. When the user pushes down on the interface portion 122, the outer sleeve made of flexible silicone will bend towards the lever 108. Once in contact with the lever 108, the lever 108 will deflect towards the interior space 104 of the aerosol generating device 100.

[0104] Figure 6 (b) shows a second embodiment of the interface portion 122. In this embodiment, the interface portion of the outer sleeve 120 includes a region having an increased thickness 602 relative to the remainder of the outer sleeve 120. Figure 6 As shown in (b), the increased thickness 602 is on the side of the outer sleeve 120 that contacts the lever 108. This reduces the distance the interface portion 122 needs to move before deflecting the lever 108, so the user needs less force when pressing on the interface portion 122 to deflect the lever 108.

[0105] Figure 6 (c) shows a third embodiment of the interface portion 122. In this embodiment, the interface portion 122 is defined by a notch 604 in the outer sleeve. The notch 604 has a ring shape. The notch 604 is an area of ​​reduced thickness relative to the rest of the outer sleeve 120, and therefore has increased flexibility relative to the rest of the outer sleeve 120. This reduces the amount of force required to bend the outer sleeve 120 so that the interface portion 122 deflects the lever 108. Figure 6 In the embodiment shown in (c), the notches 604 are on both sides of the outer sleeve. However, it should be understood that the notches 604 may be on only one side.

[0106] Figure 6 Features from (a) to (c) may be combined. For example, Figure 6 The embodiment shown in (b) may also include Figure 6 (a) shown in the raised ring 124 or Figure 6 The notch 604 is shown in (c).

[0107] Figure 7 1 is a perspective view of an embodiment of an outer sleeve 120 including a first part 702 and a second part 704 connected together at a connection 706. The interface portion 122 forms a portion of the first part 702. The connection 706 is formed at Figure 8806 is shown as a close-up cross-section in FIG. Connection 706 is a snap-fit ​​connection. First part 702 is a female part including groove 802. Second part 704 is a male part including lip or rib 804. In an unstressed state, lip 804 and groove 802 do not fit together. However, outer sleeve 120 has elastic properties, and therefore when force is applied, one or both of lip 804 and groove 802 bends, thereby allowing the first part and the second part to fit together. After the engagement operation, lip 804 and groove 802 return to an unstressed state, thereby forming a removable but resilient connection.

[0108] Fig. 9 It means manufacturing Figure 1 A flow chart of a method of an aerosol generating system is shown.

[0109] First, in step 900, a device housing 102 is provided. As described previously, the device housing 102 is tubular and encloses an internal space. The device housing 102 is made of metal.

[0110] In step 902, a plurality of internal components are positioned in the interior space 104 of the device housing 102. Prior to this step, the internal components need to be assembled. The power supply 306 and the control circuit system 308 are both carried on the main frame 402. The receiving portion 312 is assembled from the coil former 404, which is inserted into the flux concentrator 406, which is then inserted into the packaging tube 408. The assembled receiving portion 312 abuts the main frame 402 and is mechanically engaged to the main frame 402. This mechanical engagement includes an electrical connection so that the power supply 306 and the control circuit system 308 of the main frame 402 are in electrical communication with the receiving portion 412.

[0111] In step 904, a cut is formed in the outer surface 103 of the device housing by pressing a cutting tool into the outer surface 103 with sufficient force to cut through the outer surface 103 of the device housing 102. The cut in the device housing defines a tab, which is a curved or bendable portion of the outer housing. Any number of tabs may be defined by cutting into the outer surface 103. Depending on the cutting tool used, the tabs may be defined simultaneously or sequentially.

[0112] In some embodiments of the manufacturing method, after forming the cutouts in the outer surface 103 of the device housing 102, the plurality of internal components may be positioned in the interior space of the device housing 102. In such embodiments, step 902 will occur after step 904.

[0113] In step 906, use a pressing tool to bend or deflect tabs into or away from the inside of the device housing. If more than one tab is defined in step 904, any number of tabs in these tabs can be bent or deflected, so. When using a press to deflect tabs toward the interior space of the device housing until it engages the internal components positioned in the device housing 102, a fixed element is formed. When using a die tool to bend tabs toward the interior space 104 of the device housing until it is in close proximity with the internal components positioned in the device housing, when a user interface element is to be formed, a user interface element is formed. Lever 108 is an example of such a user interface element formed in this way. Alternatively or in addition, a user interface element can be formed by bending tabs away from the inside of the device housing.

[0114] Step 906 of the manufacturing process is optional. For some user interface elements, there is no need to bend or deflect the tab defined in step 904. The user interface element can be a tab that is deflectable toward the interior space. The tab can be deflected once it is cut. There is no need to bend the tab in order to form the user interface element. For such a user interface element, step 906 is not performed, and the manufacturing process jumps directly from step 904 to 908. This is done by Fig. 9 The dashed arrow shows.

[0115] In step 908, an outer sleeve 120 is provided. The outer sleeve 120 is molded from silicone. In embodiments where the aerosol generating device 100 includes a user interface element, the molded outer sleeve includes an interface region 122. The interface region 122 is molded into the outer sleeve. The outer sleeve 120 is assembled to the device housing to cover the tabs cut into the device housing 100. In some embodiments, either or both of steps 908 and 910 form part of a process separate from the process outlined in steps 900 to 906. For example, after purchasing the device and outer sleeve 120 separately, the assembly of the outer sleeve 120 to the device housing can be performed by the user of the device. The assembly may require special tools. In these cases, the user of the device can take the outer sleeve 120 and the device to a supplier who will use special tools to assemble or remove the outer sleeve.

[0116] The outer sleeve 120 includes visual information, text or branding. Some of these are included when the outer sleeve 120 is molded. For example, silicone with a specific color is used to mold the outer sleeve. However, features such as text and branding must usually be included in the post-processing of the outer sleeve. Such post-processing methods are well known in the art and include, for example, printing.

[0117] In some embodiments, the outer sleeve 120 is molded as a single piece. However, in other embodiments, the outer sleeve 120 includes two pieces, and these pieces can be connected using a snap-fit ​​connection. In such cases, these pieces include reciprocal grooves formed when the outer sleeve 120 is molded.

Claims

1. An aerosol generating system comprising an outer sleeve and an aerosol generating device for heating an aerosol-forming substrate; The aerosol generating device comprises: a device housing, and a plurality of internal components contained within an interior space enclosed by the device housing; wherein the device housing comprises an outer surface and at least one curved portion, the curved portion being curved to interact with an internal component of the plurality of internal components; wherein the at least one curved portion comprises a tab defined by a cutout in the outer surface, and wherein the tab forms a securing element that is deflected into the interior space and engages the interior component to hold the interior component in position relative to the device housing, and Wherein the outer sleeve covers the at least one curved portion.

2. An aerosol generating system according to claim 1, comprising a plurality of tabs formed in the outer surface of the device housing.

3. An aerosol generating system according to claim 2, wherein at least one tab of the outer surface of the device housing comprises a user interface element that is deflectable towards the interior space of the device housing.

4. An aerosol generating system according to claim 3, wherein the outer sleeve is configured such that: when the outer sleeve covers the device shell, the portion of the outer sleeve covering the user interface element is configured such that tactile input from a user of the aerosol generating device on the portion will cause the user interface element to deflect toward the internal space of the device shell.

5. An aerosol generating system according to claim 3, wherein the plurality of internal components comprises control circuitry configured to sense movement of the user interface element.

6. An aerosol generating system according to claim 1, wherein the plurality of internal components contained within the device housing include at least one of a power source, a control circuit system, a heater assembly, or a receiving portion configured to receive an aerosol generating article comprising an aerosol-forming substrate.

7. An aerosol generating system according to claim 6, wherein the plurality of internal components comprises a heater assembly, and wherein the heater assembly is an induction heating assembly.

8. An aerosol generating system according to claim 6 or 7, wherein the plurality of internal components comprises a heating assembly and a receiving portion, and wherein the heating assembly is positioned to heat the aerosol generating article when the aerosol generating article is received in the receiving portion.

9. An aerosol generating system according to claim 1, wherein the device housing is formed from a single piece of material.

10. An aerosol generating system according to claim 1, wherein the outer sleeve comprises a plurality of separate parts connected together.

11. A kit comprising at least one outer sleeve and an aerosol generating device for heating an aerosol-forming substrate, wherein: The aerosol generating device comprises: a device housing, and a plurality of internal components contained within an interior space enclosed by the device housing; wherein the device housing is formed from a single piece of material and includes an outer surface and at least one curved portion, the curved portion being curved to interact with an internal component of the plurality of internal components; wherein the at least one curved portion comprises a tab defined by a cutout in the outer surface, and wherein the tab forms a securing element that is deflected into the interior space and engages an internal component to retain the internal component in position relative to the device housing; and Wherein the at least one outer sleeve is configured to removably cover the at least one curved portion.

12. A kit according to claim 11, comprising a first outer sleeve and a second outer sleeve, wherein the first outer sleeve comprises an outer surface, the outer surface of the first outer sleeve comprises visual information, text or other brand information, and the second outer sleeve comprises an outer surface, the outer surface of the second outer sleeve comprises visual information, text or other brand information that is different from the visual information, text or other brand information of the outer surface of the first outer sleeve.

13. A method of manufacturing an aerosol generating system, the method comprising the steps of: providing a device housing for containing a plurality of internal components within an interior space, and wherein the device housing includes an exterior surface; providing at least one curved portion in the device housing, the curved portion being curved to interact with one of the plurality of internal components; as well as providing an outer sleeve to removably cover the at least one curved portion, The step of providing at least one curved portion comprises: cutting the outer surface of the device housing to define a tab; and deflecting the tab into the interior space to engage an interior component to hold the interior component in position relative to the device housing, thereby forming a securing element.

14. A method of manufacturing an aerosol generating system according to claim 13, further comprising the steps of: The outer sleeve is assembled onto the device housing.

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