Manufacturing of aerosol-generating device housing

Abstract

A method of manufacturing a housing component for an aerosol-generating device is provided. The method includes injection molding the housing component (200) between the first and second mold portions (302, 304). The first mold portion has a concave surface (308) to form a convex surface (214) on the component during molding, the concave surface of the mold having a first texture imparting a corresponding texture on the convex surface of the component during molding, the first texture includes a variable roughness on the concave surface of the first mold portion. A housing component for an aerosol-generating device is also provided, the housing component having a textured convex surface.

Description

Technical Field

[0001] The present disclosure relates to aerosol generating devices, to aspects of housings for such devices, and more particularly to a housing for a tobacco heating product (THP) device. Background Art

[0002] Smoking articles (such as cigarettes, cigars, etc.) burn tobacco during use to produce tobacco smoke. People have tried to provide alternatives to these articles by producing products that release compounds without burning. An example of such a product is a heating device that releases the compound by heating rather than burning the material. The material can be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.

[0003] These heating devices may include a housing that is gripped by a user and that holds internal components. Summary of the invention

[0004] The aerosol generating device may be provided with a housing containing some or all of the components for generating an aerosol from a received consumable. When the device is carried or when it is used to generate an aerosol, parts of the device housing are held by a user. Therefore, the particular form of the housing may affect or improve the usability of the device.

[0005] The housing of the device is used to accommodate the components and functions of generating the aerosol, and to keep some components internally to be isolated from the user. Therefore, the shape and size of the housing may also be affected by the basic function of the device. For example, in a heat-not-burn arrangement, a device that generates an aerosol by heating a tobacco product may be provided with a housing that accommodates a power source, an electrical circuit, and a form of a heating zone. In a device such as a THP device, there may be a large number of components to be accommodated and isolated from the user.

[0006] For example, by providing the housing with a shape that generally conforms to being held by a user's hand, the usability of the device may be improved. The housing may be provided with a surface that is flat or given a certain curvature to be easily held or held in the hand.

[0007] The form of the housing (including the shape and size of the housing) may therefore be influenced by both the usability of the device and the accommodation of the aerosol generating functionality. Thus, a particular housing form and shape may be particularly desirable or advantageous for one or more particular types of aerosol generators. In particular, a combination of planar and convex outer surfaces may be particularly easy to hold during use of the device while providing space for accommodating particular components.

[0008] The housing may be provided with features that provide an improved "user feel" to the device by improving tactile feedback to the user. For example, the use of specific materials in various parts of the housing may give the user a touch sensation or tactile feedback that may be associated with a high quality or sturdy device, or tactile feedback that the user finds pleasant or comfortable.

[0009] Specifically, tactile feedback can be affected by the surface texture of the various parts of the housing. For example, a surface with a texture having a relatively high roughness can give the device a feeling of being easy to hold and can provide reassuring tactile feedback. In another example, a relatively smooth (i.e., having a relatively low roughness) surface can give a solid touch feeling, thereby giving the impression of a high-quality or solid device.

[0010] It may be desirable to provide a housing with different touch sensations at different locations to give the user an overall impression and varying tactile feedback. The housing may be provided with multiple surfaces having different textures (e.g., textures having different roughness from each other). In one example, a surface having a relatively high roughness may be provided at a location of the housing that is intended to be gripped or held by a user, and a surface having a relatively low roughness may be used at a location around a user interface device (such as a button).

[0011] It may therefore be advantageous to provide an aerosol generating device, a housing for an aerosol generating device or components of such a housing which are formed for usability, which components have an aerosol generating function and which provide an improved impression to a user.

[0012] More specifically, providing these advantages may be desirable in the context of tobacco heating product (THP) devices, which may have a relatively large number of internal components to be isolated from a user and therefore include some elements of size, shape and external form specific for this type of device.

[0013] Thus, an aerosol generating device housing may be provided which comprises a portion which is relatively textured compared to other portions of the housing. This portion may comprise a side panel having a generally curved convex shape, the side panel being adapted to be gripped by a user. This portion of the housing may be particularly influential on the overall user impression, as the convex outer surface is the outer surface which is most often held or gripped by a user during use of the device.

[0014] Aerosol generating devices may be produced in high volumes, requiring a large number of device housings to be produced reliably and consistently at a relatively low cost. Injection molding may be used to produce housings or parts of housings for aerosol generating devices. Injection molding may generally include: preparing a material in a liquid, molten form; and introducing the material into a cavity of a mold. The cavity includes a negative shape for the desired shape of the component. The material in the cavity cools and hardens, and the mold is then separated to allow the component to be removed. The mold may be in the form of two or more halves or parts to be separated without damaging the mold so that the mold can be reused.

[0015] The textured convex side panel portion of the aerosol generating device housing may be formed by injection molding in a mold comprising one half having a textured mold surface forming part of the mold cavity. The textured mold surface imparts a corresponding negative texture to the material during cooling, and to the cooled component. The mold halves may be reused, and the method is relatively cheap, effective, and consistent.

[0016] However, due to the specific convex shape of the side panel component, problems may arise in the separation of the mold halves and / or removal of the component from the mold halves. Due to the shape of the component, the molded textured surface may lock into the textured mold surface and into one half of the mold. It may be difficult to remove the component from the mold half without damaging the component or the mold.

[0017] To avoid locking of the mould halves whilst still producing a component that provides an improved impression to a user of the aerosol generating device, the component may be manufactured with specific surface features that aid in removing the component from the mould halves without compromising the textured impression of the surface of the aerosol generating device.

[0018] As used herein, the term "textured" or "rough" for comparison purposes between surfaces may be considered to refer to a relatively higher surface roughness value according to the VDI surface finish scale commonly used in the art.

[0019] According to a first aspect of the present disclosure, there is a method for manufacturing a shell component for an aerosol generating device, the method comprising: injection molding the shell component between a first mold part and a second mold part, the first mold part having a concave surface to form a convex surface on the component during molding, the concave surface of the mold having a first texture, the first texture imparting a corresponding texture on the convex surface of the component during molding, wherein the first texture comprises a variable roughness on the concave surface of the first mold part.

[0020] In another embodiment, the first texture has a variable roughness such that the roughness in a region at the center of the concave surface is greater than the roughness in regions of the concave surface away from the center.

[0021] In a further embodiment of any of the preceding embodiments, the second mold portion includes a surface having a second texture, and the second texture has a roughness that is different from the roughness at any location on the concave surface of the first mold portion.

[0022] According to another aspect of the present disclosure, there is a method for manufacturing a shell component for an aerosol generating device, the method comprising: injection molding a shell component between a first mold part and a second mold part, the first mold part having a concave surface to form a convex surface on the component during molding, the concave surface of the mold having a first texture, and the first texture imparting a corresponding texture on the convex surface of the component during molding, wherein the second mold part includes a surface having a second texture, and the roughness of the second texture is different from the roughness of the first texture.

[0023] In another embodiment, the roughness of the second texture is greater than the roughness of the first texture.

[0024] In a further embodiment of any of the preceding embodiments, the concave surface of the first mold portion includes a coating comprising a friction reducing material.

[0025] In a further embodiment of any of the preceding embodiments, the method further comprises the step of forming one or more protruding features on the concave surface of the housing component during injection molding.

[0026] In a further embodiment of any of the foregoing embodiments, the concave surface of the first mold portion defines a center of curvature, and the concave surface extends at least 160 degrees about the center of curvature.

[0027] In a further embodiment of any of the preceding embodiments, the method further comprises the step of spraying, printing, etching or depositing a material onto the convex surface of the housing component after the step of injection molding.

[0028] According to another aspect of the present disclosure, there is a housing component for an aerosol generating device, the housing component comprising a first convex surface having a first texture having a variable roughness on the convex surface.

[0029] In another embodiment, the first texture comprises a variable roughness such that the roughness in a region at a center of the convex surface is greater than the roughness in regions of the convex surface away from the center.

[0030] In a further embodiment of any of the preceding embodiments, the shell component further comprises a second surface having a second texture, wherein the second texture has a roughness that is different from the roughness at any location on the first convex surface.

[0031] According to another aspect of the present disclosure, there is a housing component for an aerosol generating device, the housing component comprising: a first convex surface having a first texture; and a second surface having a second texture, wherein the first texture and the second texture are different.

[0032] In another embodiment, the roughness of the second texture is greater than the roughness of the first texture.

[0033] In a further embodiment of any of the foregoing embodiments, the first convex surface and the first texture are formed by injection molding.

[0034] Although different examples are described, embodiments of the present disclosure are not limited to these specific combinations. Some of the features or components from one of the examples may be used in combination with features or components from another example. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Some embodiments of the present disclosure will now be described, by way of example only, and with reference to the accompanying drawings, in which:

[0036] Figure 1 An aerosol generating device is shown.

[0037] Figure 2 Shows Figure 1 Device housing and housing components of the device.

[0038] Figure 3 Shows an independent Figure 2 of the housing parts.

[0039] Figure 4 The device housing is shown along Figure 3 Cross-sectional view of section AA.

[0040] Figure 5 The injection molding die is shown in FIG. Figure 3 of the housing parts.

[0041] Figure 6a , Figure 6b and Figure 6c The shell components are shown Figure 5 Injection molding mold.

[0042] Figure 6 shows the orientation Figure 3 A view of the interior of the removable housing component.

[0043] Figure 7Another exemplary housing component is shown.

[0044] Figure 8 Another exemplary housing component is shown.

[0045] Fig. 9 Another exemplary housing component is shown.

[0046] Fig.10 Shown is the method for forming Figure 7 An exemplary mold portion of a housing component.

[0047] Fig.11 Shown is the method for forming Figure 8 An exemplary mold portion of a housing component.

[0048] Fig.12 Shown is the method for forming Fig. 9 An exemplary mold portion of a housing component. DETAILED DESCRIPTION

[0049] Figure 1 An aerosol generating device 100 and a textured moulded housing component 200 coupled to the device 100 are shown.

[0050] The exemplary aerosol generating device 100 is a tobacco heating product (THP) device. The device 100 includes an internal component (not shown) that includes a power source and a heating area. The internal component may include an induction heater to heat the heating area. The internal component is received in a device housing 102, and the device housing 102 substantially surrounds or encloses the internal component so as to contain the internal component within the device 102. The device housing 102 substantially surrounds the internal component in three dimensions, thereby enclosing the internal component.

[0051] The device 100 also includes a receiving portion (not shown) for receiving consumables. In the example shown, the receiving portion is substantially formed within the device housing 102. A receiving portion opening 104 is formed in the device housing 102 and connects the receiving portion to the outside of the device 100.

[0052] In use, a user can insert a consumable into a receiving portion in the device 100 through the receiving portion opening 104. In the example shown, the receiving portion is formed so that the inserted consumable is only partially received in the receiving portion, and a portion of the consumable remains outside the device 100, located on the opposite side of the receiving portion opening 104.

[0053] The heating region is associated with the receiving portion such that the heating region is configured to heat the consumable received in the receiving portion. Upon activation of the device 100, the power source provides heat to the heating region, the heating region heats the consumable received in the receiving portion, and an aerosol is generated from the consumable. In the example shown, the user can inhale the aerosol from a portion of the consumable located outside the device.

[0054] In other examples, an aerosol generating device may include a device configured to generate an aerosol from a liquid precursor material at least partially received within a similar device housing, and an opening is provided in the housing for a user to insert the material and / or inhale the aerosol generated thereby.

[0055] Figure 2 The device housing 102 is shown having a housing component 200 bonded thereto. The housing component 200 is bonded to the base device housing 102 over a portion of the device housing 102. The device housing 102 is a base housing that receives the internal components of the aerosol generating device to be isolated from the user, and receives the housing component 200. The housing component 200 covers a portion of the device housing 102. Thus, the housing component 200 can be formed separately to allow a particular texture to be imparted to the surface of the housing component 200, and then bonded to the device housing 102.

[0056] The device housing 102 defines a device axis X extending through the center of the device 100 in a longitudinal or lengthwise direction. The device housing 102 includes a first end or proximal end 106 and a second end or distal end 108 separated in the longitudinal direction along the axis X. The first end 106 corresponds to the end of the device at which a user of the device can inhale an aerosol generated by the device. The receiving portion opening of the device is formed at the end of the device corresponding to the first end 106 of the device housing 102. The second end 108 corresponds to the opposite end of the device, which is generally the end farthest from the user when the user inhales the aerosol generated by the device.

[0057] The device housing 102 includes a side wall 110 forming a hollow shell that extends longitudinally between two open ends. The hollow interior of the device housing 102 defined by the side wall 110 receives the internal components of the device 100 described above. The side wall 110 extends from the first end 106 of the device 100 to the second end 108. The side wall 110 extends completely around the axis X. The housing 102 is hollow, and the side wall 110 of the housing 102 defines an interior space between the first end 106 and the second end 108, into which the internal components of the device 100 can be received.

[0058] The device housing 102 includes an outer surface 114 that can be formed to be relatively smooth compared to the textured surface of the housing member 200. When used with the textured surface of the side panel housing member 200, the relatively smooth outer surface 114 can provide an improved impression to the user.

[0059] The device housing 102 may also include a first end wall and a second end wall (not shown) corresponding to the first end 106 and the second end 108, respectively. The first end wall and the second end wall are joined to the side wall 110 to cover or close the interior space of the device housing 102 at the first end 106 and the second end 108 of the device 100. The side wall 110 and the first end wall and the second end wall together form a substantially three-dimensional housing for receiving and enclosing the internal components of the device 100. During assembly of the device, the internal components can be placed to be arranged within the side wall 110 before one or both of the end walls are attached to the side wall 110. This arrangement provides ease of manufacturing and assembly.

[0060] The sidewall 110 is joined or connected to both the first end wall and the second end wall of the housing 102 to form the device housing 102 of the assembled device. The sidewall 110 can be connected to the end walls by being integrally formed with either of the end walls. Alternatively, the sidewall 110 can be connected to one or both of the end walls by a non-removable or permanent attachment means (such as by an adhesive or a mechanical interlock).

[0061] As used herein, the term "non-removably connected" or "non-removable" means that the connected elements cannot be separated without damaging the attachment means, such that the elements cannot be reattached by the same attachment means without repair.

[0062] In the example shown, the side wall 110 of the device housing 102 is integrally formed as a single-piece component. In other examples, the side wall 110 includes multiple pieces that are joined by non-removable attachment means.

[0063] The integrally formed and / or non-removable attachment of the first and second end walls and the side wall 110 of the device housing 102 prevents or limits the user from disassembling the device housing 102 or accessing the internal components. This can help prevent the user from being exposed to heating or electrical components within the device 102, or can help prevent the user from accidentally disassembling or disconnecting the device 102.

[0064] Figure 3 A separate textured molded housing component 200 is shown. The housing component 200 is formed separately from the device housing 102 to more easily be formed with a different textured surface. The housing component 200 can then be bonded to the device housing 102.

[0065] The housing member 200 includes a wall 202 having a first end 204 and a second end 206 and extending between the first end and the second end to define a longitudinal axis Y of the housing member 200. When the housing member 200 is received on the device 102, the longitudinal axis Y of the housing member 200 is aligned parallel to the longitudinal axis X of the device 102. The wall 202 also includes a first edge or side 208 and a second edge or side 210, each of which includes a surface extending longitudinally between the first end 204 and the second end 206. The wall 202 includes an inner surface 212 and an opposite outer surface 214. Each of the inner surface 212 and the outer surface 214 extends longitudinally from the first end 204 to the second end 206, and extends laterally from the first side 208 to the second side 210.

[0066] Figure 4 Shows Figure 3 2 is a cross-sectional view of the housing component 200 along line AA. The outer surface 214 of the wall 202 includes a generally curved shape to conform to the grip of the user. The outer surface 214 is a surface that is textured during the injection molding process.

[0067] The outer surface 214 of the wall 202 forms a curved or arcuate surface. The outer surface 214 includes a convex shape, defining a curved portion having an outer curvature. The outer surface 214 is convex in a direction along the axis X so as to form a convex longitudinal profile, or a convex shape when viewed in the direction of the axis X. The outer surface 214 forms a substantially complete arcuate shape and may include a curvature that is generally constant over the substantially complete arcuate shape.

[0068] The curved shape and convexity of the outer surface 214 can be defined according to the center of curvature. The outer surface 214 is away from the center of curvature to define a convex shape. The outer surface 214 can extend about 180 degrees around the center of curvature, or between 160 degrees and 200 degrees to form a substantially complete arc.

[0069] In the depicted embodiment, the inner surface 212 of the wall 202 is also curved or arcuate to conform to the surface of the device housing 102 so that the housing component 200 can be easily received thereon.

[0070] The inner surface 212 includes a concave shape, defining a curved portion having an inner curvature. The inner surface 212 is concave in a direction along the axis Y of the housing component 200 so as to form a convex longitudinal profile, or a convex shape when viewed in the direction of the axis Y. The inner surface 212 forms a substantially complete arc shape, and may include a curvature that is generally constant across the substantially complete arc shape.

[0071] The curved shape and concavity of the inner surface 212 can be defined according to the center of curvature. The inner surface 212 faces the center of curvature, defining a concave shape. The inner surface 212 can extend about 180 degrees around the center of curvature, or between 160 degrees and 200 degrees, so as to form a substantially complete arc.

[0072] The housing component 200 may also include one or more extended features (not shown) extending from the inner surface 212. These extended features may be formed during injection molding of the housing component 200 along with the rest of the housing component 200 and the inner and outer surfaces 212, 214.

[0073] Figure 5 Shows Figure 3 Schematic diagram of a housing component 200 in an injection molding mold 300. The injection molding mold 300 includes two mold parts or halves 302, 304. In other arrangements, the molding mold 300 may include more than two parts. The two parts include a first mold part or cavity side mold part 302 and a second mold part or core side mold part 304.

[0074] Figures 6a to 6c An exemplary injection molding process of a housing component 200 having a textured convex outer surface 214 is schematically illustrated.

[0075] Figure 6a The cavity mold portion 302 and the core mold portion 304 are shown in contact with each other in a closed position. The mold portions 302 and 304 in the closed position form a substantially completely enclosed cavity 306 into which liquid material can be introduced and retained to form the shell component 200. The cavity 306 is an empty space that forms the negative shape of the intended shell component 200.

[0076] The cavity mold portion 302 and the core mold portion 304 include corresponding first and second cavity surfaces 308, 310. The first and second cavity surfaces 308, 310 define the shape of the cavity 306 and thus impart corresponding negative shapes of the respective surfaces 308, 310 to the shell component 200 during molding. In the illustrated embodiment, the first cavity surface 308, which forms part of the cavity mold portion 302, includes a concave shape that corresponds to the negative of the convex outer surface 214 of the shell component 200. In the illustrated embodiment, the second cavity surface 310, which forms part of the core mold portion 304, includes a convex shape that corresponds to the negative of the concave inner surface 212 of the shell component 200.

[0077] The second cavity surface 310 of the core mold portion 304 may include one or more recesses (not shown) into the surface that include a shape corresponding to one or more protruding features to be formed during injection molding on the concave interior surface 212 of the housing component 200. The recesses are configured to be filled with liquid material during molding to form the protruding features.

[0078] The concave shape of the first cavity surface 308 and the convex shape of the second cavity surface 310 can be defined in a manner similar to the outer surface 214 and the inner surface 212 discussed above. For example, one or both of the shapes of the outer surface 214 and the inner surface 212 can define a center of curvature and extend approximately 180 degrees, or between 160 and 200 degrees, about the center of curvature to form a substantially complete arc.

[0079] The first cavity surface 308 includes a textured surface to impart a corresponding negative texture to the outer surface 214 of the shell component 200 during molding.

[0080] like Figure 6b As shown, liquid material 312 may be a heated molten material that is introduced via a gate indicated by arrow 314. Gate 314 comprises a passage through one of mold portions 302 and 304 for injecting material into cavity 306 that is closed except for the gate. Liquid material 312 is prepared outside mold 300 and then forced through gate 314 and held into cavity 306 by forcing liquid material 312. In the embodiment shown, gate 314 is formed through core mold portion 304. Liquid material 312 passes through the gate and substantially completely fills cavity 306.

[0081] like Figure 6c As shown, after the liquid material 312 is introduced, the material is solidified, for example by allowing the molten liquid to cool and harden. The liquid material cools and hardens into the form of the shell component 200. The shape of the shell component 200 when cooled substantially corresponds to the shape of the cavity 306, which in turn is defined by the shapes of the first cavity surface 308 and the second cavity surface 310.

[0082] When removed from the mold portion, in addition to other protruding features of the inner surface 212, the shell component 200 may also include a gate sprue (not shown) that is a portion of the outer material formed of liquid material 312 that remains within the gate 314 during cooling and remains attached to the shell component 200. The gate sprue can be subsequently removed, such as by post-molding processing of the shell component 200.

[0083] After the liquid material cools into the shell component 200, the mold sections 302, 304 are separated from each other to remove the component 200 from the cavity 306 and from between the mold sections 302, 304. The mold sections 302, 304 can be separated from each other by moving one or both mold sections 302, 304 in one or more pull directions. In the illustrated embodiment, the cavity mold section 302 moves in a direction 316 relative to the core mold section 304, and the core mold section 304 moves in a direction 318 relative to the cavity side mold section 302. The pull directions 316, 318 can correspond to directions directly away from the other of the mold sections 302, 304, and can be directions that are both located in a plane of symmetry of the shell component 200.

[0084] After the mold sections 302, 304 are separated, the housing component 200 can then be removed from between the cavity surfaces 308, 310 and optionally sent for further finishing or machining. The mold sections 302, 304 can then be removed from between the cavity surfaces 308, 310 and optionally sent for further finishing or machining. Figure 6a The position shown is returned to contact so that the molding process can be repeated for subsequent parts.

[0085] The material used to form the housing component in injection molding may include thermoplastics. In one example, the material may include a polycarbonate thermoplastic resin. In one example, the material may include a Lexan® copolymer, such as Lexan® copolymer HFD1810.

[0086] The material may be heated to a melt temperature between 260 degrees Celsius and 305 degrees Celsius. The mold may be maintained at a temperature range between 50 degrees Celsius and 80 degrees Celsius.

[0087] A shell component 200 that includes a relatively textured convex or concave surface, such as the outer surface 214, may experience undesirable bonding or locking with the mold portion. This locking may occur particularly at portions of the cavity surface whose surface curvature, together with the pull direction relative to the mold portion, defines a relatively small angle (e.g., less than 20 degrees). This may occur, for example, at the outer surface 214 adjacent to the sides 208, 210 of the shell component 200.

[0088] The combination of the convexly curved surface and the roughened texture can form portions of material on the component surface that include small protrusions relative to one of the pull directions. During the pull of the mold part, this material is prevented from moving relative to the corresponding cavity surface, thereby locking the component in place. This may also require manual removal of the housing component 200 from the mold part 302, which may increase the likelihood of damage.

[0089] The convex surface may be damaged by separation of the mold parts or by manual removal of the part. The surface may be damaged by drag marks which are areas where the texture of the surface is lifted off the mold part surface.

[0090] Additionally, where the component includes protruding features on opposing surfaces (such as inner surface 212), these features may be damaged during the pulling of the die or if the component must be removed manually.

[0091] return Figure 5 In the example of a relatively rough textured component, the convex outer surface 214 of the component may experience bonding to the first cavity surface 308 of the cavity mold portion 302. The bonding may be particularly evident in the area of ​​the outer surface 214 adjacent to the longitudinal sides 208, 210 of the shell component 200. The bonding may damage the outer surface 214 and / or other portions of the shell component 200 when the mold portions 302, 304 are pulled apart, or when the shell component 200 is manually removed from the first cavity surface 308.

[0092] The housing components may be provided with further features which allow the convex surface to be textured which imparts a desired impression to the user and which may be easily formed by injection moulding and which reduces the occurrence of sticking or damage.

[0093] Figure 7 A front view of an exemplary housing component 400 is shown. The housing component 400 may include features of the above-described housing component 200. The housing component 400 includes a convex outer surface 414 extending between the first side 408 and the second side 410, and the convex outer surface 414 is textured by injection molding.

[0094] The convex outer surface 414 may include a relatively textured surface or have a relatively rough texture to improve the impression made on the user, as discussed above. Specifically, the outer surface 414 may include a texture having a roughness at one location that is different from the roughness of the texture of the concave inner surface 412, which may not be imparted with a texture by molding, or may be imparted with a different texture for purposes other than providing an improved impression (as further described below). The roughness of the textured surface of the convex outer surface 414 at one location may be different from the roughness of the texture of the protruding feature formed on the concave inner surface 412, which may form a relatively smooth texture to easily separate from the cavity of the mold used to form the protruding feature.

[0095] The texture imparted to the outer surface 414 by injection molding includes a variable roughness. That is, the roughness of the outer surface 414 at one location is different from the roughness at another location. As further described below, by including an outer surface 414 having a texture with a variable roughness, the housing component 400 can be more easily manufactured by injection molding while retaining a convex shape and texture that is conducive to the use of an aerosol generating device.

[0096] The roughness of the texture of the outer surface 414 is variable around the curvature of the convex shape of the outer surface 414. The longitudinal profile of the outer surface 414 includes side locations (as shown at 416 and 418) directly adjacent to the longitudinal sides 408, 410 of the shell component 400, and a center location (as shown at 420) that is located midway between the two sides 408, 410 on the outer surface 414. The outer surface 414 can include a texture having a roughness at the center 420 that is greater than the roughness at either the first side location 416 or the second side location 418.

[0097] The outer surface 414 may include a texture having a variable roughness formed by providing discrete areas or portions having different roughnesses from one another. The roughness of the texture over the entirety of each of these areas or portions of the outer surface 414 may be substantially the same.

[0098] In the illustrated embodiment, the outer surface 414 includes three such regions or portions. The first surface portion 422 and the second surface portion 424 include regions of the outer surface 414 adjacent to the first side position 418 and the second side position 420, respectively. The outer surface 414 also includes a third surface portion 426, which includes a region of the outer surface 414 between the first surface portion 422 and the second surface portion 424. The first surface portion 422 and the second surface portion 424 include a texture having a roughness different from the roughness of the texture of the third surface portion 426. In one example, the first surface portion 422 and the second surface portion 424 may include a texture having a roughness greater than the roughness of the texture of the third surface portion 426. One or more of the first surface portion 422, the second surface portion 424, and the third surface portion 426 may include a texture having a surface roughness that is substantially the same across the respective surface portions 422, 424, 426.

[0099] Although an example is shown where the outer surface 414 is divided into three regions or portions having different roughnesses, it should be understood that any number of regions or portions may be used to provide an outer surface including a texture having a variable roughness.

[0100] By including portions 422, 424, 426 of the outer surface 414 having textures of varying constant roughness, the outer surface 414 may include an overall variable roughness in a form that is relatively simple to manufacture.

[0101] Figure 8 A front view of another exemplary housing component 500 is shown. Housing component 500 may include features of housing component 200 described above. Housing component 500 includes a convex outer surface 514 extending between first side 508 and second side 510, and convex outer surface 514 is textured by injection molding.

[0102] The convex outer surface 514 may include a relatively textured surface or a texture having a relatively rough surface in order to improve the impression left on the user, as discussed above. Specifically, the outer surface 514 may include a texture having a roughness at one location that is different from the roughness of the texture of the concave inner surface 512, which may not be imparted with a texture by molding, or may be imparted with a different texture for purposes other than providing an improved impression (as further described below). The roughness of the textured surface of the convex outer surface 514 at one location may be different from the roughness of the texture of the protruding feature formed on the concave inner surface 512, which may form a relatively smooth texture to easily separate from the cavity of the mold used to form the protruding feature.

[0103] The housing component 500 is similar to the housing component 400 described previously. The texture imparted to the outer surface 514 by injection molding includes a variable roughness. That is, the roughness of the outer surface 514 at one location is different from the roughness at another location. The roughness of the texture of the outer surface 514 is variable around the curvature of the convex shape of the outer surface 514.

[0104] The housing component 500 differs from the previously described housing component 400 in that the outer surface may not include discrete portions having a texture with varying degrees of roughness, but may instead include a texture having a roughness that varies continuously over a portion of the outer surface 514 .

[0105] like Figure 8 As shown by arrows 528 and 530 , the outer surface 514 may include a texture having a roughness that gradually and substantially continuously changes on the outer surface 514 between the first side 508 and the second side 510 .

[0106] In the example shown, the longitudinal profile of the outer surface 514 includes side locations (as shown at 516 and 518) directly adjacent to the longitudinal sides 508, 510 of the shell component 500, and a center location (as shown at 520) that is located halfway between the two sides 508, 510 on the outer surface 514. The outer surface 514 includes a texture whose roughness gradually and continuously increases between the first side location 516 and the center location 520, as shown by arrow 528. The continuous increase is such that the roughness of the texture at any location of the outer surface 514 closer to the center 520 is the same as or greater than the roughness of the texture at another location closer to the first side location 516.

[0107] The outer surface 514 may also include a texture whose roughness gradually and continuously increases in a similar manner between the second side location 518 and the center 520, as indicated by arrow 530. The roughness of the texture between the second side location 518 and the center 520 may vary to the same degree or profile as between the first side location 516 and the center 520, such that the outer surface 514 includes a substantially symmetrical texture roughness about the center 520.

[0108] In the example shown, the texture may include a substantially constant roughness gradient between two locations, such that the rate of change of the roughness of the texture is consistent between the two locations on the outer surface 514. In other examples, the roughness gradient may vary between the two locations, such that the roughness of the texture may vary continuously, but to different degrees on the outer surface 514 between the two locations.

[0109] By including a texture having a continuously variable roughness, the outer surface 514 may include an overall variable roughness in a form that provides an improved impression to the end user by avoiding step changes in roughness that would otherwise be perceptible by touch when the user grips the outer surface.

[0110] Exemplary shell components are depicted whose outer surface texture has either discrete portions of varying constant roughness or a continuous variable roughness; however, shell components may be provided with a combination of both variable roughness features.

[0111] For example, returns Figure 7With the shell component 400, the first portion 422 and the second portion 424 of the outer surface 414 may include a texture having a roughness that continuously changes over the respective portions, while the third portion 426 may include a roughness that is substantially constant over the portion. In each of the first portion 422 and the second portion 424, the roughness of the texture may gradually increase toward a position in the respective surface portion that is closer to the center 420 of the outer surface 414. The continuous increase makes the roughness of the texture at any position of the respective portion 422, 424 that is closer to the center 420 the same as or greater than the roughness of the texture at the nearest other position of the first side position 416 or the second side position 418.

[0112] By including portions 422, 424, 426 of outer surface 414, some of which have textures with different constant roughnesses and some of which have textures with continuously variable roughnesses, outer surface 414 can balance manufacturing simplicity and providing an improved impression to the end user by avoiding step changes in roughness that are perceptible by touch.

[0113] In any of the above embodiments, the outer surface 414, 514 may include a texture having a roughness that does not vary or is substantially the same along the longitudinal length of the shell component 400 along the axis Y. That is, the outer surface 414, 514 may include a roughness that varies in longitudinal profile but is consistent along the longitudinal length of the respective shell component 400, 500.

[0114] Providing a convex outer surface 414, 514 of the shell component 400, 500 with a variable texture can affect the tendency of the shell component 400, 500 to lock into the injection molding mold part, as described above with respect to Figures 6a to 6c Providing a surface with increased or decreased textural roughness at certain locations compared to other locations can affect the tendency of the surface to adhere to the mold portion at that location. This can be particularly applicable to parts that require a highly convex surface to reduce the tendency of the part to adhere to the mold portion at some ends of the convex shape.

[0115] Thus, providing a convex surface with a texture having a variable roughness can reduce the incidence of damage to the component during pulling of the mould or due to the need to manually remove the component. The texture having a variable roughness can also retain the advantages of providing an aerosol generating device with a convex housing component, as well as the advantage of providing an improved impression to the user by imparting a texture to the gripping component of the device housing.

[0116] In each of the above embodiments, the outer surface 414, 514 may include a texture having a roughness at the center 420, 520 greater than at any of the first side location 416, 516 and the second side location 418, 518 by setting a variable roughness. Where the convex surface texture includes a roughness toward the center of the surface greater than toward the side, the ease of manufacturing the part may be improved because the correlation between increased texture roughness and locking tendency is greater at the side of the convex shape, so the part may be more easily released from the mold portion.

[0117] However, in other embodiments, other variations in roughness on the convex surface can also be used to improve the ease of manufacturing the housing component. For example, the roughness of the texture is the same at the center and at the side locations, but is reduced at other locations on the convex surface, so that the ease of manufacturing can still be improved if the component requires less force to be removed from the mold part.

[0118] Alternatively or additionally to any of the above embodiments, the housing component may be provided with features on surfaces other than the convex exterior surface that also improve the manufacturability of the housing component 500 .

[0119] Fig. 9 A front view of an exemplary housing component 600 is shown. The housing component 600 may include features of the housing component 200 described above. The housing component 600 includes a convex outer surface 614 extending between a first side 608 and a second side 610, and the convex outer surface 614 is imparted with a texture by injection molding. The outer surface 614 may include a texture having a constant roughness over substantially the entire surface from adjacent to the first side 608 to adjacent to the second side 610. Alternatively, the convex outer surface 614 may be provided with a variable roughness according to any of the above embodiments.

[0120] The first side 608 and the second side 610 include longitudinally extending surfaces extending along the axis Y between the first end and the second end of the housing component 600 .

[0121] The component 600 includes a concave inner surface 612 extending between the first side 608 and the second side 610. The concave inner surface 612 may include a first region 616 and a second region 618 of the surface adjacent the first side 608 and the second side 610.

[0122] All or part of the surfaces of the first and second sides 608, 610 and / or the concave inner surface 612 may be provided with a texture having a roughness that is different from the roughness of the texture of the convex outer surface 614 to improve removal of the component 600 from the mold portion.

[0123] All or part of the concave inner surface 612 and / or the first side surface 608 and the second side surface 610 can be textured to increase adhesion to a mold portion different from the mold portion that forms the convex outer surface 614. Thus, during separation of the mold, the convex outer surface 614 and the shell component 600 can be more easily removed from the other side mold portion. The need to manually remove the shell component 600 can also be reduced, which can reduce the occurrence of damage to the component surface or protruding features that may occur during manual removal.

[0124] The concave inner surface 612 can include a texture having a roughness at the first region 616 and the second region 618 that is different from (e.g., greater than) the roughness of the texture of the convex outer surface 614. The roughness at the first region 616 and the second region 618 can be particularly effective in facilitating removal of the component 600 from the mold portion. The concave inner surface 612 away from the first region 616 and the second region 618 can be relatively smooth or non-textured, such that the first region 616 and the second region 618 include a texture having a roughness that is greater than the roughness of the texture of the remaining concave inner surface 612. By including a rough texture on only one portion of the inner surface 612, as discussed, the housing component 600 can be more easily removed from the mold portion without being textured to become difficult to remove from another mold portion.

[0125] Alternatively, the concave interior surface 612 may not include distinct textured areas, and may instead include a texture across the entire surface having a different roughness than the roughness of the texture of the convex exterior surface 614. The degree of roughness across the concave interior surface 612 may alternatively vary to aid in removal from one mold portion without locking to another mold portion.

[0126] Additionally or alternatively to any of the above, a surface of each of the first side 608 and the second side 610 can include a texture having a roughness greater than the roughness of the convex outer surface 614. Both the first side 608 and the second side 610 can include a texture having the same roughness for ease of manufacturing. Alternatively, the first side 608 and the second side 610 can include a texture having different roughnesses on the respective sides 608, 610.

[0127] The first side 608 and the second side 610 may include a relatively textured surface or a texture having a relatively rough surface. The first side 608 and the second side 610 may include a texture having a roughness that is the same as the roughness of the texture of the concave inner surface 612.

[0128] Providing a textured surface at the side of the housing component 600 opposite the convex surface 614 can improve adhesion to the opposite side mold portion. Both the first side surface and the second side surface can face in a direction substantially opposite to the direction of the convex outer surface 614, which can provide particular improvements in facilitating removal of the component 600.

[0129] The position of the concave inner surface 612 and the first and second side surfaces 608, 610 relative to the convex outer surface 614 may be such that the concave inner surface 612 and the side surfaces 608, 610 are hidden from a user when the housing component 600 is coupled to an aerosol generating device, as described above. Therefore, the texture of the concave inner surface 612 and the first and second side surfaces 608, 610 may not be exposed to a user during use by the user and may not affect or detract from the impression given to the user.

[0130] The features of a textured concave inner surface 612 and / or textured first and second side surfaces may be provided in conjunction with a convex outer surface having a texture with variable roughness, as described in any of the above embodiments, to provide a combined effect of features and a shell component with improved ease of manufacturing.

[0131] Fig. 9 , Fig.10 and Fig.11 A mold portion configured to form the features of the housing component described above is shown. The mold portion includes a cavity surface having a negative shape corresponding to the shape of the features described above to form the shape during injection molding. The mold portion can be used in the injection molding mold 300 described above.

[0132] Fig.10 A cavity side mold portion 700 is shown which may include features of the cavity side mold portion 302 of the above-described embodiment. The cavity side mold portion 700 may be used with the core side mold portion 304 of the above-described injection molding mold 300. The cavity side mold portion 700 is configured to form a housing 400 having a convex outer surface 414 having a texture with a variable roughness.

[0133] The cavity-side mold portion includes a concave cavity surface 714 extending between the first mold side 708 and the second mold side 710 , and the concave cavity surface 714 imparts texture during injection molding.

[0134] The concave cavity surface 714 can include a relatively textured surface or a texture having a relatively rough surface to impart a desired texture to the shell component 400, as discussed above. Specifically, the concave cavity surface 714 can include a texture having a roughness at one location that is different from the roughness of the texture of the second cavity surface 310 of the corresponding core-side mold portion 304, which is not imparted with a texture for molding.

[0135] The second cavity surface 310 may be relatively smooth or non-textured such that the concave cavity surface 714 includes a texture having a roughness greater than the roughness of the texture of the second cavity surface 310. The second cavity surface 310 may be relatively smooth to improve ease of manufacturing the protruding features of the housing component, if present.

[0136] The texture of the concave cavity surface 714 includes a variable roughness that corresponds to the variable roughness of the outer surface 414 of the housing component 400. The roughness of the texture of the cavity surface 714 is variable around the curvature of the concave shape of the cavity surface 714. The longitudinal profile of the cavity surface 714 includes side locations (as shown at 716 and 718) directly adjacent to the mold sides 708, 710, and a center location (as shown at 720) that is located midway between the two sides 708, 710 on the cavity surface 714.

[0137] The concave cavity surface 714 includes a first surface portion 722 and a second surface portion 724, which include areas of the cavity surface 714 adjacent to the first side position 718 and the second side position 720, respectively. The cavity surface 714 also includes a third surface portion 726, which includes an area of ​​the outer surface 714 between the first surface portion 722 and the second surface portion 724.

[0138] The features of the concave cavity surface 714 correspond to those features described with respect to the outer surface 414 of the housing component 400, in that the cavity surface 714 includes a negative shape configured to impart a texture on the outer surface 414. The locations 716, 718, 720 and the first, second, and third surface portions 722, 724, and 726 of the cavity surface 714 correspond to the locations 416, 418, 420 and the first, second, and third surface portions 422, 424, and 426 of the outer surface 414, and the features of the variable roughness of the texture of the concave cavity surface 714 correspond accordingly.

[0139] Fig.11A cavity side mold portion 800 is shown that can include features of the cavity side mold portion 302 of the above-described embodiment. The cavity side mold portion 800 can be used with the core side mold portion 304 of the above-described injection molding mold 300. The cavity side mold portion 800 is configured to form a housing 500 having a convex outer surface 514 having a texture having a continuous variable roughness.

[0140] The cavity side mold portion 800 includes similar features as the cavity side mold portion 700, including a concave cavity surface 814 including similar locations 816, 818, 820 formed between the mold sides 808, 810. The cavity side mold portion 800 can be similarly used with a core side mold portion 304 having a relatively smooth or non-textured second cavity surface 310.

[0141] The concave cavity surface 814 includes a texture having a variable roughness corresponding to the variable roughness of the texture of the outer surface 514 of the housing component 500. The roughness of the texture varies continuously in a similar manner between locations 816, 818, and 820, as indicated by arrows 828 and 830. The features of the variable roughness of the texture of the concave cavity surface 814 correspond to those of the convex outer surface 514.

[0142] Fig.12 A core side mold portion 900 is shown, which may include features of the core side mold portion 304 of the above-described embodiment. The core side mold portion 900 may be used with the cavity side mold portion 302 of the above-described injection molding mold 300. The core side mold portion 900 is configured to form a housing 600 having a concave inner surface 612 and a first side surface 608 and a second side surface 610 having a rough texture.

[0143] The core side mold portion includes a convex cavity surface 912 and a first side cavity surface 908 and a second side cavity surface 910. The first side cavity surface 908 and the second side cavity surface 910 can be planar. The first side cavity surface 908 and the second side cavity surface 910 are textured to form corresponding textures 608, 610 on the first side 608 and the second side 610 of the shell component 600.

[0144] The convex cavity surface 912 may include a first region 914 and a second region 916 having a texture different from that of regions distal to the first region 914 and the second region 916 to provide different textures to portions of the concave interior surface of the housing component, as described above.

[0145] The convex cavity surface 912 and the first side cavity surface 908 and the second side cavity surface 910 can include a relatively textured surface or a texture having a relatively rough surface to impart a desired texture to the shell component 600, as discussed above. Specifically, the convex cavity surface 912 and the first side cavity surface 908 and the second side cavity surface 910 can include a texture having a roughness that is different from the roughness of the texture of the first concave cavity surface 308 of the corresponding core side mold portion 302.

[0146] The convex cavity surface 912 and the first and second side surfaces 908 and 910 comprise a negative shape configured to form the concave interior surface 612 and the first and second sides 608 and 610 of the housing component and thus may include any of the features discussed therewith.

[0147] The core mold portion 900 may be used with a cavity mold portion including a substantially untextured or smooth surface as discussed above, or may be used with a cavity side mold portion 700, 800 having any feature of a texture having a variable roughness as discussed above.

[0148] Each of the cavity or core mold portions 700, 800, 900 discussed above may be imparted with a texture including a different degree of roughness through the use of etching (eg, laser etching) on ​​the corresponding cavity surfaces of the mold portions.

[0149] Any or all of the cavity surfaces of any of the above-discussed cavities or core mold portions may be partially or completely covered with a drag-reducing coating comprising a friction-reducing material having a lower coefficient of friction than the cavity surface. In one example, the coating may comprise a Teflon® material. Specifically, such a coating may be applied to a surface comprising a variable roughness so that the housing component may be more easily removed from such a surface.

[0150] Although exemplary embodiments have been described, a worker of ordinary skill in the art would recognize that certain modifications would come within the scope of this disclosure.For that reason, the following claims should be studied to determine the scope and content of this disclosure.

Claims

1. A method of manufacturing a housing component for an aerosol generating device, the method comprising: injection molding a housing component between a first mold part and a second mold part, the first mold part having a concave surface to form a convex surface on the component during molding, the concave surface of the mold having a first texture that imparts a corresponding texture on the convex surface of the component during molding, Wherein the first texture comprises a variable roughness on the concave surface of the first mold portion.

2. The method according to claim 1, wherein: The first texture has a variable roughness such that the roughness in a region at the center of the concave surface is greater than the roughness in a region of the concave surface away from the center.

3. The method according to claim 1 or 2, wherein: The second mold portion includes a surface having a second texture, and the second texture has a roughness that is different from the roughness at any location on the concave surface of the first mold portion.

4. A method of manufacturing a housing component for an aerosol generating device, the method comprising: injection molding a housing component between a first mold part and a second mold part, the first mold part having a concave surface to form a convex surface on the component during molding, the concave surface of the mold having a first texture that imparts a corresponding texture on the convex surface of the component during molding, The second mold portion includes a surface having a second texture, and the second texture has a roughness different from the roughness of the first texture.

5. The method according to claim 4, wherein: The roughness of the second texture is greater than the roughness of the first texture.

6. The method according to any one of claims 1 to 5, wherein: The concave surface of the first mold portion includes a coating comprising a friction reducing material.

7. The method according to any one of claims 1 to 6, further comprising the following steps: One or more projecting features are formed on the concave surface of the housing component during injection molding.

8. The method according to any one of claims 1 to 7, wherein: The concave surface of the first mold portion defines a center of curvature, and the concave surface extends at least 160 degrees about the center of curvature.

9. The method according to any one of claims 1 to 8, further comprising the following steps: After the step of injection molding, material is sprayed, printed, etched or deposited on the convex surface of the housing component.

10. A housing component for an aerosol generating device, the housing component comprising a first convex surface having a first texture, the first texture having a variable roughness on the convex surface.

11. The housing component according to claim 10, wherein: The first texture includes a variable roughness such that the roughness in a region at a center of the convex surface is greater than the roughness in regions of the convex surface away from the center.

12. The housing component according to claim 10 or 11, further comprising a second surface having a second texture, wherein: The second texture has a roughness that is different from the roughness at any location on the first convex surface.

13. A housing component for an aerosol generating device, the housing component comprising: a first convex surface having a first texture; as well as A second surface having a second texture, wherein the first texture and the second texture are different.

14. The housing component according to claim 13, wherein: The roughness of the second texture is greater than the roughness of the first texture.

15. The housing component according to any one of claims 10 to 14, wherein: The first convex surface and the first texture are formed by injection molding.

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