Aerosol generating device and manufacturing method

Abstract

A method for manufacturing an aerosol generating device (1). The method comprises: forming an intermediate subassembly (13) by fixing a heater subassembly (21) opposite to a power and control subassembly (22), the heater subassembly comprising a heater (54) and a heating chamber (53), wherein the heater is arranged in the heater subassembly to supply heat to the heating chamber, and the power and control subassembly comprises a power source (221) and a control circuit (222) configured to control the supply of power from the power source to the heater; attaching an inlet subassembly (11) to the intermediate subassembly, the inlet subassembly comprising a device (111) for opening and closing an inlet of the heating chamber; and attaching a housing subassembly (12) to the intermediate subassembly, the housing subassembly comprising a housing for at least a portion of the intermediate subassembly. In addition, a power and control subassembly, a subassembly comprising a heater subassembly fixed opposite to the power and control subassembly, and an aerosol generating device are also provided.

Description

Technical Field

[0001] The present disclosure relates to an aerosol generating device and a method for manufacturing such a device. The present disclosure is particularly applicable to a stand-alone low-temperature portable aerosol generating device. Such a device can be heated by conduction, convection and / or radiation, rather than burning tobacco or other suitable aerosol matrix materials, to produce an aerosol for inhalation. Background Art

[0002] Over the past several years, risk reduction or modification devices, also known as vaporizers, have rapidly gained popularity and widespread use as an aid to help smokers who wish to quit traditional tobacco products such as cigarettes, cigars and roll-ups. There are various devices and systems that heat or increase the temperature of an aerosolizable substance, rather than burning the tobacco in traditional tobacco products.

[0003] A common device for reducing or modifying risk is a heated substrate aerosol generating device or a non-combustion heating device. This device generates aerosol or steam by heating an aerosol substrate that usually contains moist tobacco leaves or other suitable aerosolizable substances to a temperature usually in the range of 150°C to 300°C. Heating the aerosol substrate instead of burning releases an aerosol that contains the ingredients sought by the user but does not contain the toxic and carcinogenic byproducts of combustion. In addition, the aerosol generated by heating tobacco or other aerosolizable substances usually does not contain the burnt or bitter taste that may make the user unhappy due to combustion, so there is no need to add sugar and other additives to the substrate as usual to make smoke and / or steam more palatable to the user.

[0004] Such devices are often mass-produced and it is therefore desirable to provide a device that is as easy to assemble as possible whilst meeting the requirements of a robust structure that is safe and reliable for the user. Summary of the invention

[0005] According to a first aspect of the present disclosure, a method for manufacturing an aerosol generating device is provided, the method comprising: forming an intermediate subassembly by fixing a heater subassembly opposite to a power and control subassembly, the heater subassembly comprising a heater and a heating chamber, wherein the heater is arranged in the heater subassembly to supply heat to the heating chamber or in the heating chamber, and the power and control subassembly comprises a power source and a control circuit configured to control power supply from the power source to the heater; and attaching a housing subassembly to the intermediate subassembly, the housing subassembly comprising a housing for at least a portion of the intermediate subassembly.

[0006] Optionally, the method includes forming a power and control subassembly by aligning a heater subassembly support frame and a power supply support frame with a first PCB therebetween having components of a control circuit mounted thereon; and attaching the heater subassembly support frame to the power supply support frame.

[0007] Optionally, the first PCB is connected to the second PCB via a flexible PCB portion, and forming a power and control subassembly also includes wrapping the flexible PCB portion around a heater subassembly support frame and attaching the second PCB to the heater subassembly support frame so that the heater subassembly support frame is located between the first PCB and the second PCB.

[0008] Optionally, two or more of the heater subassembly support frame, the power supply support frame and the first PCB respectively include first guide members, and aligning the heater subassembly support frame and the power supply support frame with the first PCB therebetween includes aligning the first guide members.

[0009] Optionally, only snap-fit ​​or press-fit mechanical connections are used to form the power and control subassembly.

[0010] Optionally, the heater subassembly and the power and control subassembly each include a second guide member, and securing the heater subassembly opposite the power and control subassembly includes aligning the second guide members.

[0011] Optionally, securing the heater subassembly opposite the power and control subassembly includes attaching a mounting cap to one or both of the heater subassembly and the power and control subassembly, and wherein the heater subassembly, the power and control subassembly and the mounting cap are adapted to interlock with each other such that the heater subassembly is secured opposite the power and control subassembly when the mounting cap is attached to one or both of the heater subassembly and the power and control subassembly.

[0012] Optionally, attaching the housing subassembly to the intermediate subassembly comprises merely attaching a point on the housing to a point on the intermediate subassembly using an attachment means.

[0013] Optionally, the attachment means are fastening means.

[0014] Optionally, the fastening means is a screw.

[0015] Optionally, the method further comprises attaching an inlet subassembly to the intermediate subassembly, the inlet subassembly comprising means for opening and closing the inlet to the heating chamber.

[0016] Optionally, the inlet subassembly and the intermediate subassembly are adapted to form one or more snap-fit ​​or press-fit connections with each other.

[0017] According to a second aspect of the present disclosure, a subassembly for manufacturing an aerosol generating device is provided, the subassembly comprising a heater subassembly fixed opposite a power and control subassembly, wherein the power and control subassembly comprises a power source and a control circuit configured to control power supply from the power source to the heater, the heater subassembly comprises a heater and a heating chamber, and the heater is arranged in the heater subassembly to supply heat to the heating chamber or in the heating chamber.

[0018] Optionally, the power and control subassembly comprises a heater subassembly support frame attached to a power support frame with a first PCB therebetween having components of the control circuit mounted thereon.

[0019] Optionally, the first PCB is connected to the second PCB via a flexible PCB portion, which is wrapped around the heater subassembly support frame, and the second PCB is attached to the heater subassembly support frame so that the heater subassembly support frame is located between the first PCB and the second PCB.

[0020] Optionally, the control circuit comprises a PCB having exposed electrical contacts for testing and / or connection to the heater subassembly.

[0021] Optionally, the subassembly also includes a mounting cap attached to one or both of the heater subassembly and the power and control subassembly, wherein the heater subassembly, the power and control subassembly, and the mounting cap are adapted to interlock with each other so that the heater subassembly is secured opposite the power and control subassembly.

[0022] According to a third aspect of the present disclosure, an aerosol generating device is provided, which includes a subassembly as described above, which serves as an intermediate subassembly, and the aerosol generating device also includes a shell subassembly, which includes a shell for at least a portion of the intermediate subassembly, wherein the shell subassembly is attached to the intermediate subassembly.

[0023] Optionally, the aerosol generating device further comprises an inlet subassembly comprising means for opening and closing the inlet of the heating chamber, wherein the inlet subassembly is attached to the intermediate subassembly.

[0024] Optionally, where the intermediate subassembly comprises a mounting cap, the inlet subassembly is attached only to the mounting cap.

[0025] According to a fourth aspect of the present disclosure, there is provided an aerosol generating device, the aerosol generating device comprising a power source; a heating chamber; a heater arranged to supply heat to the heating chamber; a control circuit configured to control the supply of power from the power source to the heater; a frame; and a housing having an internal cavity containing the power source, the heating chamber, the heater, the control circuit and the frame,

[0026] The control circuit includes at least a first PCB and a second PCB arranged along the frame, the first PCB and the second PCB are connected via a flexible PCB portion, and the first PCB and the second PCB are arranged in two different planes along the frame.

[0027] Optionally, the second PCB is also arranged along the frame.

[0028] Optionally, the second PCB is parallel to or perpendicular to the first PCB.

[0029] Optionally, the control circuit includes a third PCB arranged along the frame and connected to the first PCB through a second flexible PCB portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1A and 1B is a schematic diagram of an aerosol generating device;

[0031] Figure 2 is a schematic diagram of the intermediate sub-assembly;

[0032] Figure 3A and 3B is a schematic diagram of one stage in a method of making an aerosol generating device;

[0033] Figure 4A , 4B and 4C is a schematic diagram of another stage in a method of making an aerosol generating device;

[0034] Figure 5A , 5B and 5C is a schematic diagram of a heater subassembly;

[0035] Fig. 6A and 6B is a schematic diagram of another stage in a method of making an aerosol generating device;

[0036] Fig. 7A and 7B is a schematic diagram of the inlet subassembly.

[0037] Fig. 8A and 8B is a schematic diagram of another stage in a method of making an aerosol generating device;

[0038] Fig. 9A , 9B and 9C is a schematic diagram of another stage in a method of making an aerosol generating device;

[0039] Figures 10A to 10D is a schematic diagram of some other optional components of the aerosol generating device. DETAILED DESCRIPTION

[0040] As a schematic diagram of an aerosol generating device to be manufactured according to one embodiment of the present invention, Figure 1A , Figure 1B and Figure 2 A series of modular sub-assemblies assembled into an aerosol generating device are shown. Figures 3A to 10D Additional details of each subassembly are shown, as well as stages of manufacturing the aerosol generating device. It should be understood that many details of the embodiments are not relevant to explaining the claimed manufacturing method, and therefore, for the purpose of brevity, certain features shown in the drawings are not described in detail, and, for the purpose of simplicity, certain features are completely omitted in some drawings to better illustrate features relevant to understanding and implementing the invention.

[0041] Please refer to Figure 1A According to one embodiment of the present invention, the aerosol generating device 1 includes an inlet subassembly 11 and a housing subassembly 12 .

[0042] The aerosol generating device 1 has an overall elongated pebble-like shape, with a top end provided with an aerosol, a bottom end opposite the top end, and four side surfaces between the bottom end and the top end, the four side surfaces being arranged in a substantially quadrilateral arrangement with two larger opposing side surfaces and two smaller opposing side surfaces.

[0043] The inlet subassembly 11 is located at the top end and includes a device for opening and closing the inlet to the heating chamber inside the aerosol generating device 1, so that the user can supply the aerosol substrate (e.g., tobacco) to be heated in the heating chamber, obtain the generated aerosol, and clean the heating chamber, etc. In this embodiment, the inlet device has a cover 111 attached to the slider mechanism.

[0044] The housing subassembly 12 provides a housing for the internal components of the aerosol generating device 1 and provides at least a portion of the sides and bottom of the aerosol generating device 1. Figure 1A As shown in the central straight area 121 of the housing subassembly 12, in this embodiment, the aerosol generating device 1 includes one or more indicators (such as indicator lights) and one or more input devices (such as buttons) for controlling the aerosol generating device. In embodiments with indicators or input devices, the housing subassembly may include a translucent portion or a touch-sensitive portion, or may simply include a gap that allows access to the internal indicator and input device.

[0045] Please refer to Figure 1B In this schematic diagram, the inlet subassembly 11 and the housing subassembly 12 are shown as "transparent" (shown by dashed edges), and it can be seen that the aerosol generating device 1 also includes an intermediate subassembly 13 accommodated in the inlet subassembly 11 and the housing subassembly 12. Figure 2 Details of the intermediate subassembly 13 are shown in FIG.

[0046] Please refer to Figure 2 The intermediate subassembly 13 includes a heater subassembly 21 fixed opposite to a power and control subassembly 22 .

[0047] The heater subassembly 21 includes a heater and a heating chamber, wherein the heater is arranged in the heater subassembly to supply heat to the heating chamber. The heater subassembly will be described in more detail with reference to FIG.

[0048] The power supply and control subassembly 22 includes a power supply 221, which is a battery in this case. The power supply and control subassembly 22 also includes a control circuit 222, which is configured to control the power supply from the power supply to the heater. In this embodiment, the control circuit 222 is mounted on multiple PCBs, as described below.

[0049] The power supply 221 and the control circuit 222 are supported by the heater subassembly support frame 223 and the power supply support frame 224. The heater subassembly support frame 223 is optionally made of a heat insulating material to isolate the control circuit 222 and the power supply 221 from the heater subassembly 21. The heater subassembly support frame 223 and the power supply support frame 224 may, for example, include polyamide (PA) and / or polyetheretherketone (PEEK). In the aerosol generating device 1, the heater subassembly support frame 223 and the power supply support frame 224 may be collectively regarded as a frame.

[0050] like Figure 2 As also shown, the power and control subassembly 22 may include an indicator array 225 of one or more indicators (e.g., LEDs) for indicating the status of the device and an indicator array 225 associated with the device. Figure 1A The central straight area 121 of the housing subassembly 12 corresponds to one or more input devices 226 (e.g., touch switches). The power supply and control subassembly 22 may also include a vibrator subassembly 227 to provide a further indication of the status of the device. In addition, the power supply and control subassembly 22 may include an external electrical connector 228, which is used to charge the power supply 221 and optionally also to transmit data to or receive data from the control circuit 222.

[0051] A method of manufacturing an aerosol generating device 1 as described above will now be described. The skilled reader will appreciate that many of the steps of the method are independent of each other and may be freely re-sequenced.

[0052] Please refer to Figure 3A and 3B , which shows the stages of assembling the power and control subassembly. Figure 3A In the view of FIG. 2 , the heater subassembly support frame 223 is indicated as “transparent” using dashed lines so that the first PCB 31 can be seen between the two frames. Figure 3B The external view shows that the first PCB 31 is partially enclosed between the heater subassembly support frame 223 and the power supply support frame 224. In this embodiment, the power supply and control subassembly 22 is formed by aligning the heater subassembly support frame 223 and the power supply support frame 224 on both sides of the first PCB 31 and attaching the heater subassembly support frame 223 to the power supply support frame 224.

[0053] The first PCB 31 has at least one component of the control circuit 222 mounted on a substrate thereof. For example, the first PCB 31 may include a processor chip or a memory chip.

[0054] To help align the heater subassembly support frame 223 and the power supply support frame 224, in this embodiment, the heater subassembly support frame 223 and the power supply support frame 224 include respective first guide members 32 and 32' that fit together when the frames are properly aligned. For example, the first guide members 32 and 32' may be protrusions or pins, and corresponding recesses or holes. Alternatively or in addition, in other embodiments, the first PCB 31 may have a first guide member that is used to align the first PCB 31 with the corresponding first guide members of the heater subassembly support frame 223 and / or the power supply support frame.

[0055] To assist in aligning the power and control subassembly 22 with the heater subassembly 21, the heater subassembly support frame also includes second guide members 33, 35, as discussed further below.

[0056] In addition, in this embodiment, the power and control subassembly is formed using only snap-fit ​​or press-fit mechanical connections between the components. That is, the power and control subassembly 22 is mechanically constructed without additional independent components such as screws for fixing. In particular, Figure 3A and 3BIn an embodiment of the heater subassembly support frame 223, the heater subassembly support frame 223 includes a snap-fit ​​connector 34 that is configured to attach to the power supply support frame 224 when the frames have been aligned. Although the mechanical connection is limited to snap-fit ​​and press-fit connections in this embodiment, it should be noted that welding can be used to ensure a good electrical connection between the power supply 221 and the control circuit 222. In addition, in other embodiments, glue can be used to further improve the robustness beyond that achievable using snap-fit ​​or press-fit connections. For example, glue can be used to attach the power supply 221 to the power supply support frame 224.

[0057] Please refer to Figure 4A , 4B and 4C, which shows another stage of assembling the subassembly from different angles around the power and control subassembly. This stage may occur as described above with reference to Figure 3A and 3B As an image of this scheme, in Figure 4C The power supply support frame 224 is shown in FIG. Figure 4A and 4B In order to understand the comparison between these figures, it should be noted that Figure 4B is relative to Figure 4A and 4C Imaged horizontally to more effectively show the flexible PCB portion 41.

[0058] like Figure 4A As shown in FIG. 1-C, the power supply and control subassembly 22 of this embodiment includes a first PCB 31, a second PCB 42 and a flexible PCB portion 41, wherein the first PCB 31 and the second PCB 42 are connected to each other through the flexible PCB portion 41. In this embodiment, the power supply and control subassembly 22 may include another PCB, such as for mounting Figure 2 An indicator array 225 and input device 226 are shown, but these devices are not particularly relevant to the method of the present invention.

[0059] At this stage, forming the power and control subassembly 22 includes wrapping the flexible PCB portion 41 around the heater subassembly support frame 223 and attaching the second PCB 42 to the heater subassembly support frame 223 so that the heater subassembly support frame 223 is located between the first PCB 31 and the second PCB 42, and the first and second PCBs are arranged in two different planes along the heater subassembly support frame 223. Alternatively or additionally, the second PCB may be arranged along the heater subassembly support frame 223. This use of the flexible PCB portion not only means that it is easy to guide the first PCB 31 and the second PCB 42 to the correct position when one of them is fixed, but also means that it is easy to print a large area for the control circuit 222 at one time and divide it between multiple surfaces at the same time, so as to fit the control circuit 222 into an irregular space and reduce the space required for the control circuit 222, and help to reduce the volume of the aerosol generating device 1.

[0060] Figure 4A Also shown is an example of a first guide member 32 ″ in the first PCB 31 as described above, in addition to or instead of the first guide members 32 and 32 ′ in the heater subassembly support frame 223 and the power supply support frame 224 .

[0061] like Figure 4B and 4C As shown, the heater subassembly support frame 223 may include additional snap-fit ​​connectors 43 for attaching the second PCB 42 to the frame. In addition, the second PCB 42 includes electrical contacts 44 for testing and / or connecting with the heater subassembly 21. When the power and control subassembly 22 is installed, these contacts 44 remain exposed, making it easier to test the power and control subassembly and make electrical connections between the heater subassembly 21 and the power and control subassembly 22.

[0062] Go to Figure 5A , 5B 5C, before discussing how to form the intermediate subassembly 13 by fixing the heater subassembly 21 opposite the power and control subassembly 22, some additional details of the heater subassembly 21 are described.

[0063] Figure 5A and 5B The following are the end view and side view of the complete heater subassembly 21. Figure 5A and 5BA heater end frame 51 is provided at each end of the heater subassembly 21 to support, align and attach the heater subassembly. The heater end frame 51 includes respective second guide members 33' and 35', which are used to assist in the alignment between the heater subassembly 21 and the power and control subassembly 22.

[0064] A heat insulating sheath 52 is provided between the heater end frames 51. The heat insulating sheath 52 surrounds Figure 5C 1 and 12 , respectively. The heating chamber 53 and the heater 54 are shown in the figure. The heating chamber is an elongated chamber that is open at one end corresponding to the inlet subassembly 11, and includes a heat conductive material, such as metal, to conduct heat from the heater 54 wrapped outside the heating chamber 53 to the aerosol matrix material in the heating chamber 53. The insulating jacket 52 is used to insulate and contain the heat generated by the heater 54, so that the heat is more efficiently transferred to the heating chamber 53, and other components of the aerosol generating device 1 are less exposed to the heat from the heater 54. In this embodiment, the heater subassembly 21 also includes a temperature sensor that measures the temperature in the heater subassembly.

[0065] The heater 54 and the temperature sensor have electrical contacts or connections to receive power and obtain measurements, respectively.

[0066] Please refer to Fig. 6A and 6B , which shows a series of method steps for fixing the heater subassembly 21 opposite the power and control subassembly 22 to form the intermediate subassembly 13.

[0067] like Fig. 6A As shown, in the first stage, the corresponding second guide members 33, 33', 35 and 35' of the heater subassembly 21 and the power and control subassembly 22 are aligned and fitted together. Like the first guide members, the second guide members can be protrusions or pins, and corresponding recesses or holes. As a result of this alignment and fitting, the heater subassembly 21 and the power and control subassembly 22 are correctly positioned, but not yet attached.

[0068] like Figure 6BAs shown, in the second stage, the mounting cap 23 is arranged to be fitted on the ends of the aligned heater subassembly 21 and the power and control subassembly 22 in the longitudinal direction, at least partially covering the heater subassembly 21 and the power and control subassembly 22. The heater subassembly 21, the power and control subassembly 22 and the mounting cap 23 are adapted to interlock with each other so that the heater subassembly 21 and the power and control subassembly 22 cannot be separated from each other when the mounting cap 23 is arranged on the ends. In particular, in this embodiment, the mounting cap 23 is adapted to surround and partially cover the ends of the aligned heater subassembly 21 and the power and control subassembly 22 in the longitudinal direction, and the second guide members 33, 33', 35, 35' are arranged to prevent relative movement between the heater subassembly 21 and the power and control subassembly 22 in the longitudinal direction, because such movement is transverse to the direction of the second guide members. Therefore, by attaching the mounting cap 23 to one or both of the heater subassembly 21 and the power and control subassembly 22, the heater subassembly 21 and the power and control subassembly 22 can be prevented from relative movement in the longitudinal direction because such movement is transverse to the direction of the second guide member, and the heater subassembly 21 and the power and control subassembly 22 can be prevented from moving around the longitudinal direction because such movement is transverse to the direction of the second guide member or is blocked by the covering and surrounding mounting cap. Therefore, the heater subassembly 21 is fixed directly opposite the power and control subassembly 22.

[0069] In this embodiment, the mounting cap 23 is attached to the power support frame 224 of the power and control subassembly 22 at the mounting cap attachment point 61. The attachment can be made using one or more reversible fastening devices (e.g., screws). By using reversible fastening devices for this attachment, it is easier to extract the heater subassembly 21 for cleaning, although other embodiments use a snap-fit ​​or press-fit connection at the mounting cap attachment point 61.

[0070] It should be noted that the mounting cap 23 is not necessary for fixing the heater subassembly 21 to the power and control subassembly 22, and, in other embodiments, such fixing can be performed by providing an additional snap-fit ​​or press-fit connector as an alternative or supplement to the second guide member 33, 33', 35, 35'. This alternative embodiment can further reduce the number of parts and steps required to manufacture the aerosol generating device. However, even if the mounting cap 23 is not used to fix the heater subassembly 21 to the power and control subassembly 22, including the mounting cap 23 is also beneficial for attaching the inlet subassembly 11 and the housing subassembly 12. In particular, the mounting cap 23 provides a modular attachment interface that is independent of the other components of the intermediate subassembly 13 and can be adapted to be conveniently attached to the housing of the device and is separate from the adaptation of the heater subassembly 21 and the power and control subassembly 22 for any other purpose.

[0071] like Figure 6B As shown, when the heater subassembly 21 is fixed opposite the power and control subassembly 22, it is easy to install an electrical connection, such as a wire, between the heater subassembly 21 and the power and control subassembly 22 using the exposed electrical contacts 44 of the power and control subassembly 22 and the electrical contacts or connections of the heater 54 and the temperature sensor of the heater subassembly 21.

[0072] Go to Fig. 7A and 7B Before discussing how to attach the inlet subassembly 11 to the intermediate subassembly 13 , some additional details of the inlet subassembly 11 are first described.

[0073] Fig. 7A A view of the inlet subassembly 11 is shown in which the inlet housing 71 is made “transparent” (shown in phantom) so that the internal features of the inlet subassembly 11 are more easily seen.

[0074] The cover 111 is attached to the slider carriage 73. The slider carriage is arranged to slide along the slider rail 74 so that the cover 111 can slide between an open position and a closed position. In the closed position, the opening in the inlet housing 71 is blocked by the cover 111. In the open position, the opening in the inlet housing 71 is open. When the aerosol generating device 1 is assembled and the cover 111 is in the open position, the opening in the inlet housing 71 provides an entrance to the heating chamber 53.

[0075] like Fig. 7A As shown, the inlet housing 71 includes a snap-fit ​​connector 75 for attaching the inlet subassembly 11 to the intermediate subassembly 13. In this embodiment, two opposing snap-fit ​​connectors 75 are arranged corresponding to two smaller opposing sides of the aerosol generating device 1, and of course, any effective connector arrangement can also be used. Like the aforementioned snap-fit ​​connector, the snap-fit ​​connector can also be a press-fit connector.

[0076] In addition, the inlet housing 71 includes a stepped edge along its bottom edge (as shown). The inner edge 77 extends downwardly beyond the outer edge 76. As will be described below, the stepped edge helps to secure the inlet subassembly 11 and the housing subassembly 12 together and can distribute impact stresses from the snap-fit ​​connector 75, thereby helping to prevent weak points in the structure at the joint between the inlet subassembly 11 and the intermediate subassembly 13.

[0077] Go to Figure 7B In this figure, the slider rail 74 is hidden so that the slider biasing mechanism 78 can be better seen, and the slider biasing mechanism 78 is used to return the slider cart 73 and the cover 111 to the closed position. This helps to ensure that the heating chamber 53 is covered when not in use.

[0078] Now please refer to Fig. 8A and 8B , wherein a method stage of attaching the inlet subassembly 11 to the intermediate subassembly 13 is shown.

[0079] like Fig. 8A As shown, the mounting cap 23 of the intermediate subassembly 13 has an alignment ridge 81 that is adapted to fit against the outer edge 76 of the inlet subassembly 11 and has a portion 75' that is adapted to connect with the snap-fit ​​connector 75 of the inlet subassembly. The combination of these features means that when the inlet subassembly 11 is pushed onto the top of the intermediate subassembly 13, the inlet subassembly is automatically correctly positioned relative to the intermediate subassembly and attached to the intermediate subassembly. Although the snap-fit ​​connector 75 extends downward to the bottom of the mounting cap 23 in this embodiment, this assembly method may be limited by the presence of the housing subassembly 12. Therefore, in other embodiments, the snap-fit ​​connector 75 and the complementary portion 75' are provided in different configurations so that the inlet subassembly 11 can be attached to the intermediate subassembly 13 before or after the housing subassembly 12 is attached.

[0080] Figure 8B The combined inlet subassembly 11 and intermediate subassembly 13 are shown. Figure 8B As shown, the alignment ridge 81 is adapted to extend along the inner edge 76 of the stepped perimeter shape of the inlet subassembly 11. In addition, the mounting cap 23 includes one or more third guide members 82 to help align the intermediate subassembly 13 with the housing subassembly 12, as described below. In this embodiment, the alignment ridge 81 and the third guide member 82 form an integral protrusion protruding from the mounting cap 23, which strengthens the assembled structure of the mounting cap and makes it easier to manufacture.

[0081] Now please refer to Fig. 9A , 9B 9C, which shows a method stage of attaching the housing subassembly 12 to the intermediate subassembly 13. As described above, in the exemplary design of the snap-fit ​​connector 75, this stage must occur after attaching the access subassembly to the intermediate subassembly. However, in other embodiments, the order of attaching the access subassembly and the housing subassembly can be freely selected. This is Fig. 9A , 9B and 9C are illustrated by omitting the entry subassembly 11 for this stage of the method.

[0082] like Fig. 9AAs shown, the housing subassembly 12 is substantially hollow to accommodate at least a portion of the intermediate subassembly 13. The perimeter around the open end of the housing subassembly 12 is stepped, having an inner edge 91 and an outer edge 92 extending beyond the inner edge. As the alignment ridge 81 of the intermediate subassembly 13 extends, the stepped perimeter is adapted to mate with the stepped perimeter of the inlet subassembly 11, so that when the intermediate subassembly 13 is inserted into the housing subassembly 12, the alignment ridge 81 abuts against the inner edge 91, and when the inlet subassembly 11, the housing subassembly 12 and the intermediate subassembly 13 are all assembled, the outer edges 76 and 92 abut against each other. The inner edge 91 also includes one or more third guide members 82', which are adapted to mate with the third guide members 82 of the intermediate subassembly 13, so that the housing subassembly 12 can be easily and correctly aligned with the intermediate subassembly 13.

[0083] Go to Fig. 9B , which provides a view of the intermediate subassembly 13 attached to the housing subassembly 12. For this figure, the housing subassembly 12 is represented as "transparent" in phantom.

[0084] like Fig. 9B As shown, the heater subassembly support frame 223 and the power supply support frame 224 of this embodiment extend to the bottom end or vicinity of the housing subassembly 12. This enables the intermediate subassembly 13 to be attached to the housing subassembly 12 only by one point on each of the intermediate subassembly 13 and the housing subassembly 12. In this embodiment, the attachment device for attaching the intermediate subassembly 13 to the housing subassembly 12 is a fastening device, which is removable to separate the intermediate subassembly 13 from the housing subassembly 12 for maintenance or cleaning. In particular, in this embodiment, screws are used as fastening devices. It should be noted that in other embodiments, only one of the heater subassembly support frame 223 and the power supply support frame 224 can extend to the bottom end or vicinity of the housing subassembly 12. In addition, in other embodiments, the attachment device can be a permanent connection or a snap-on connection formed using glue, such as when the aerosol generating device is disposable and is not intended to be frequently disassembled and maintained.

[0085] Fig. 9C A view of the combined intermediate subassembly 13 and housing subassembly 12 resulting from this stage of the method is provided.

[0086] Now please refer to Figures 10A to 10D , in which some further optional elements of the aerosol generating device 1 are shown.

[0087] like Fig. 10AAs shown, the first PCB 31, the second PCB 42 and the flexible PCB portion 41 can be formed in a planar arrangement, so that the overall PCB structure including the control circuit 222 on the multiple PCBs can be manufactured as a single unit before assembling the aerosol generating device 1. When this unit is folded using the flexible PCB portion and arranged in the aerosol generating device 1, the control circuit 222 occupies less space and the compactness of the aerosol generating device 1 can be improved.

[0088] like Fig. 10A As further shown, the overall PCB structure may include a third PCB 1001 and / or a fourth PCB 1002, wherein all of the first to fourth PCBs are connected by one or more additional flexible PCB portions 1007. Alternatively, all PCBs may be connected together via a common flexible PCB portion.

[0089] Each PCB in the overall PCB structure may be folded relative to the other PCBs to occupy a different plane from the other PCBs. For example, the second PCB 42 may be parallel or perpendicular to the first PCB 31 when arranged in the aerosol generating device 1 .

[0090] In addition, in this embodiment, when the aerosol generating device 1 is assembled, the third PCB 1001 is arranged along the power supply support frame 224 (as part of the overall frame), such as Fig. 10B As shown, and connected to the first PCB 31 via a flexible PCB portion to provide an indicator array 225 and an input device 226 adjacent to the central linear region 121 of the housing subassembly 12, as shown Figure 1A and Figure 2 shown.

[0091] The fourth PCB 1002 may include control circuitry 1003 for the vibrator element 1005 of the vibrator subassembly 227 .

[0092] The fourth PCB 1002 may additionally or alternatively include a movement sensor arranged to detect movement of the cover 111. The cover 111 or the slider 73 may, for example, include a magnet (e.g. a neodymium magnet), and the movement sensor may be a Hall effect sensor. This eliminates the need to arrange a separate wiring connection for the motion sensor in the aerosol generating device 1, thereby simplifying the assembly process of the aerosol generating device 1 and reducing the length of the wires required in the aerosol generating device 1.

[0093] The fourth PCB 1002 may be Fig. 10C and 10DAs shown, it is arranged along the power supply support frame 224 (as part of the overall frame) and is connected to the first PCB 31 through the flexible PCB portion. In this way, the vibrator element 1005 can be connected to the control circuit 1003 or the fourth PCB 1002 via an electrical connector 1006 (e.g., a wire that can be soldered to the fourth PCB 1002 and / or the vibrator element 1005). In this way, the vibrator element 1005 can be controlled while maintaining the compactness of the control circuits 222 and 1003.

[0094] like Fig. 10A and 10B As further shown, the power supply 221 may be provided with tabs 1004 for making electrical connections to the control circuit 222. When the aerosol generating device 1 is assembled, these tabs may be connected to contacts on the first PCB 31 using solder 1004'.

[0095] In other embodiments, any one of the third PCB and the fourth PCB may be omitted.

[0096] Definitions and Alternative Embodiments

[0097] It should be understood from the above description that many of the features of the described embodiments perform independent functions with independent benefits. Therefore, each of these independent features of the embodiments of the invention defined in the claims may be independently selected for inclusion or omission.

[0098] For example, in the above-described embodiment, a specific design of the power and control subassembly 22 including a plurality of PCBs is used, and the power and control subassembly 22 is connected to the heater subassembly 21 which also has a very specific design. However, any power and control subassembly 22 can be connected to any heater subassembly 21 using the second guide members 33 and 35 as described above, thereby making it easier to fix the heater subassembly 21 to the power and control subassembly 22.

[0099] The term "heater" is understood to refer to any device that is used to output heat energy that is enough to form aerosol from aerosol substrate. The transfer of heat energy from heater 54 to aerosol substrate can be conduction, convection, radiation or any combination of these modes. As a non-limiting example, a conductive heater can directly contact and press the aerosol substrate, or they can contact with independent components, such as a heating chamber, which itself heats the aerosol substrate by conduction, convection and / or radiation.

[0100] Heater can obtain power by electricity, combustion or any other appropriate mode.Electric heater can include resistance heating element (optionally including insulation package), induction heating system (for example including electromagnet and high frequency oscillator) etc.Heater 54 can be arranged around the outside of aerosol matrix, can partially or completely penetrate into aerosol matrix, or adopt any combination of these forms.For example, aerosol generating device can have a blade-type heater extending into the aerosol matrix in the heating chamber, rather than the heater of the above-described embodiment.

[0101] The term "temperature sensor" is used to describe an element capable of determining the absolute or relative temperature of a portion of the aerosol generating device 1. Such elements may include thermocouples, thermopiles, thermistors, etc. The temperature sensor may be part of another component, or may be a separate component. In some examples, more than one temperature sensor may be provided, for example, for monitoring the heating of different parts of the aerosol generating device 1, for example, for determining a thermal profile. Alternatively, in some examples, a temperature sensor is not included; for example, this is possible in the case where a thermal profile has been reliably established and the temperature can be assumed based on the operation of the heater 54.

[0102] The control circuit 222 in the drawings is shown as having a button operable by a single user to trigger the aerosol generating device 1 to start. This maintains the simplicity of the control and reduces the chances of the user misusing the aerosol generating device 1 or failing to properly control the aerosol generating device 1. However, in some cases, the input control device available to the user may be more complex than this, such as for controlling the temperature (e.g., within preset limits), changing the flavor balance of the vapor, or switching between an energy-saving mode or a rapid heating mode.

[0103] Aerosol substrate comprises tobacco, for example tobacco of drying or curing form, and in some cases also contains the additional component for seasoning or producing smoother or more pleasant experience.In some instances, vaporizer can be used to process aerosol substrate, for example tobacco.Vaporizer can improve the steam produced from aerosol substrate.For example, vaporizer can comprise polyol (for example glycerine) or glycol (for example propylene glycol).In some cases, aerosol substrate can contain tobacco, even contain nicotine, but can contain natural or artificial for seasoning, volatilization, improve smoothness and / or provide other pleasant effect composition.Aerosol substrate can be provided in the form of shredded, particle, powder, granulation, strip or sheet solid or pasty material, can be the combination of these forms alternatively.Equally, aerosol substrate can be liquid or gel.In fact, some examples can comprise solid and liquid / gel part.

[0104] Therefore, the aerosol generating device 1 can also be called a "heating tobacco device", a "non-combustion heating tobacco device", a "device for vaporizing tobacco products", etc., which can be interpreted as devices suitable for achieving these effects. The features disclosed herein are also applicable to devices designed to vaporize any aerosol substrate.

[0105] Aerosol generating device 1 can be arranged to aerosol matrix is ​​accommodated in pre-packaged matrix carrier.This matrix carrier can be roughly similar to cigarette, has tubular area, and aerosol matrix is ​​arranged in matrix carrier in a suitable manner.Filter, steam collection area, cooling area and other structure can also be included in some designs.The outer layer of paper or other flexible plane material (for example foil) can also be provided, for example, for aerosol matrix is ​​kept in place, makes it more similar to cigarette etc.This matrix carrier can be fitted in heating chamber 53, or can be longer than heating chamber 53, thus when aerosol generating device 1 is provided with matrix carrier, lid 111 keeps opening.In such embodiment, aerosol can directly provide from matrix carrier, and this matrix carrier serves as the mouthpiece of aerosol generating device.

[0106] As used herein, the term "fluid" should be interpreted as generally describing non-solid materials that are capable of flowing, including but not limited to liquids, pastes, gels, powders, etc. "Fluidized material" should be correspondingly interpreted as a material that is essentially fluid or has been modified to behave like a fluid. Fluidization may include but is not limited to powdering, dissolving in a solvent, gelling, thickening, thinning, etc.

[0107] As used herein, the term "volatile" refers to a substance that can easily change from a solid or liquid state to a gaseous state. As a non-limiting example, a volatile substance can be a substance having a boiling point or sublimation temperature close to room temperature at ambient pressure. Accordingly, "volatilize" is understood to mean to volatilize (a material) and / or to vaporize or disperse it in a vapor.

[0108] As used herein, the term "vapor" means: (i) the form to which a liquid naturally transforms when subjected to sufficient heat; or (ii) liquid / moisture particles suspended in the atmosphere and appearing as clouds of steam / smoke; or (iii) a fluid that fills space like a gas but can be liquefied simply by pressure below its critical temperature.

[0109] Consistent with this definition, the term "vaporize" means: (i) becoming or causing to become vapor; and (ii) a particle changing physical state (ie, from a liquid or solid to a gaseous state).

[0110] As used herein, the term "atomization" means: (i) reducing (a substance, especially a liquid) into very small particles or droplets; and (ii) the particles remain in the same physical state (liquid or solid) as before atomization.

[0111] The term "aerosol" used in this article refers to a particle system dispersed in air or gas, such as mist, dense fog or smoke. Therefore, the term "aerosolization" refers to making an aerosol and / or being dispersed into an aerosol. It should be noted that the meaning of aerosol / aerosolization is consistent with the volatilization, atomization and vaporization defined above. In order to avoid doubt, aerosol is used to uniformly describe the mist or droplet comprising atomized, volatilized or vaporized particles. Aerosol also includes mist or droplet comprising any combination of atomized, volatilized or vaporized particles.

Claims

1. A method for manufacturing an aerosol generating device, the method comprising: forming an intermediate subassembly by securing a heater subassembly opposite a power and control subassembly, the heater subassembly comprising a heater and a heating chamber, wherein the heater is arranged in the heater subassembly to supply heat to or in the heating chamber, and the power and control subassembly comprising a power source and a control circuit configured to control power supplied from the power source to the heater; and attaching a housing subassembly to the intermediate subassembly, the housing subassembly comprising a housing for at least a portion of the intermediate subassembly, The method further comprises forming a power supply and control subassembly by the following steps: aligning the heater subassembly support frame and the power supply support frame with a first PCB therebetween having components of the control circuit mounted thereon; and attaching the heater subassembly support frame to the power supply support frame, in: The first PCB is connected to the second PCB via a flexible PCB portion, and Forming the power and control subassembly also includes wrapping the flexible PCB portion around the heater subassembly support frame and attaching the second PCB to the heater subassembly support frame such that the heater subassembly support frame is located between the first PCB and the second PCB.

2. The method of claim 1, wherein two or more of the heater subassembly support frame, the power supply support frame, and the first PCB respectively include a first guide member, and aligning the heater subassembly support frame and the power supply support frame with the first PCB therebetween includes aligning the first guide member.

3. The method of claim 1 including forming the power and control subassembly using only snap-fit ​​or press-fit mechanical connections.

4. The method of claim 1, wherein the heater subassembly and the power and control subassembly each include a second guide member, and securing the heater subassembly against the power and control subassembly includes aligning the second guide members.

5. A method as claimed in claim 1, wherein securing the heater subassembly against the power supply and control subassembly includes attaching a mounting cap to one or both of the heater subassembly and the power supply and control subassembly, and wherein the heater subassembly, the power supply and control subassembly and the mounting cap are adapted to interlock with each other so that when the mounting cap is attached to one or both of the heater subassembly and the power supply and control subassembly, the heater subassembly is secured against the power supply and control subassembly.

6. The method of claim 1, wherein attaching the housing subassembly to the intermediate subassembly comprises merely attaching a point on the housing to a point on the intermediate subassembly using an attachment device.

7. The method of claim 6, wherein the attachment means is a fastening means.

8. The method of claim 7, wherein the fastening means is a screw.

9. The method of claim 1, further comprising attaching an inlet subassembly to the intermediate subassembly, the inlet subassembly including means for opening and closing an inlet to the heating chamber.

10. The method of claim 9, wherein the inlet subassembly and the intermediate subassembly are adapted to form one or more snap-fit ​​or press-fit connections with each other.

11. A subassembly for manufacturing an aerosol generating device, the subassembly comprising a heater subassembly fixed opposite a power and control subassembly, wherein the power and control subassembly comprises a power source and a control circuit configured to control power supplied from the power source to the heater, the heater subassembly comprising a heater and a heating chamber, and the heater is arranged in the heater subassembly to supply heat to or in the heating chamber, wherein the power and control subassembly comprises a heater subassembly support frame attached to a power supply support frame with a first PCB disposed therebetween having components of a control circuit mounted thereon, wherein the first PCB is connected to the second PCB via a flexible PCB portion, The flexible PCB portion is wrapped around the heater subassembly support frame, and The second PCB is attached to the heater subassembly support frame such that the heater subassembly support frame is located between the first PCB and the second PCB.

12. The subassembly of claim 11, wherein the control circuit comprises a PCB having exposed electrical contacts for testing and / or connecting to the heater subassembly.

13. The subassembly of claim 12, further comprising a mounting cap attached to one or both of the heater subassembly and the power and control subassembly, wherein the heater subassembly, the power and control subassembly, and the mounting cap are adapted to interlock with each other so that the heater subassembly is secured against the power and control subassembly.

14. An aerosol generating device, comprising the subassembly according to any one of claims 11 to 13, the subassembly being an intermediate subassembly, and the aerosol generating device further comprising: A housing subassembly includes a housing for at least a portion of an intermediate subassembly, wherein the housing subassembly is attached to the intermediate subassembly.

15. An aerosol generating device according to claim 14, further comprising an inlet subassembly comprising means for opening and closing the inlet of the heating chamber, wherein the inlet subassembly is attached to the intermediate subassembly.

16. An aerosol generating device as claimed in claim 15, comprising a subassembly as claimed in claim 13 as an intermediate subassembly, wherein the inlet subassembly is attached only to the mounting cap.

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