Aerosol-generating device with heater module holder

Abstract

The present invention relates to an aerosol-generating device (10) comprising: a heater housing having a heater housing downstream portion (18) and a heater housing upstream portion (12), the heater housing containing a heater module (16) wherein the heater module is mounted on a heater module holder (14) in the heater housing, wherein the heater module holder is connected to the upstream portion of the heater housing. The device allows for easier installation of the heater module relative to the upstream portion of the heater housing due to the heater module holder.

Description

Technical Field

[0001] The present disclosure relates to an aerosol generating device having a heater module holder. The present disclosure also relates to a method of assembling an aerosol generating device using a heater module holder. Background Art

[0002] It is known to provide an aerosol generating device for generating an inhalable vapour. Such a device can heat an aerosol-forming substrate contained in an aerosol-generating article without burning the aerosol-forming substrate. The aerosol generating device can include a heating module, the heating module including a heating element and including a heating chamber for receiving the aerosol-generating article. The heating module can be housed in a heater housing.

[0003] Upon heating to a target temperature, the aerosol-forming substrate vaporizes to form an aerosol.

[0004] It is desirable to provide an aerosol generating device that is easy to assemble and compact. It is desirable to provide an aerosol generating device that has high manufacturing tolerances. It is desirable to provide an aerosol generating device in which a heating module can be easily positioned within a heater housing. Summary of the invention

[0005] According to an embodiment of the present invention, an aerosol generating device is provided, which may include a heater housing having a heater housing downstream portion and a heater housing upstream portion. The heater housing may accommodate a heater module. The heater module may be mounted on a heater module holder in the heater housing. The heater module holder may be connected to the heater housing upstream portion.

[0006] Another embodiment of the present invention provides an aerosol generating device, which includes a heater housing having a heater housing downstream portion and a heater housing upstream portion. The heater housing accommodates a heater module. The heater module is mounted on a heater module holder in the heater housing. The heater module holder is connected to the heater housing upstream portion.

[0007] Due to the heater module holder, the heater module can be easily installed in the heater housing. The heater module holder can provide a reliable connection between the heater module and the upstream part of the heater housing. The heater module holder can reliably position the heater module in the heater housing. The heater module holder can allow easy positioning of the heater module relative to the upstream part of the heater housing.

[0008] As used herein, the terms "upstream" and "downstream" are used to describe the relative position of components or parts of components of an aerosol generating device to the direction in which air flows through the aerosol generating device along an airflow path during use. An aerosol generating device according to the present invention comprises a proximal end, through which the aerosol leaves the device in use. The proximal end of the aerosol generating device may also be referred to as the mouth end or the downstream end. The mouth end is downstream of the distal end. The distal end of the aerosol generating article may also be referred to as the upstream end. Components or parts of components of an aerosol generating device may be described as being upstream or downstream of each other based on their relative position relative to the airflow path of the aerosol generating device.

[0009] The heater module holder may include a protruding upstream connection section. The protruding upstream connection section may be configured to be connected to the heater housing upstream portion. The heater housing upstream portion may include a mounting recess. The mounting recess may be configured to receive the protruding upstream connection section.

[0010] Such a connection system may allow a reliable connection between the heater module holder and the upstream part of the heater housing. This may allow an easy connection between the heater module holder and the upstream part of the heater housing. Due to the protruding upstream connection section, the heater module holder may simply be placed in a mounting recess of the upstream part of the heater housing so as to provide a reliable connection.

[0011] The inner surface of the mounting recess of the upstream portion of the heater housing may be spaced apart from the opposing outer surface of the protruding upstream connecting section. This may create a mounting gap.

[0012] In particular, when the protruding upstream connection section is received in the mounting recess, the inner surface of the mounting recess of the upstream portion of the heater housing can be spaced apart from the opposite outer surface of the protruding upstream connection section. When the heater module holder is received in the mounting recess of the upstream portion of the heater housing, a mounting gap can be formed. When the heater module holder is connected to the upstream portion of the heater housing, the mounting gap can provide a tolerance. This can allow the heater module holder and the upstream portion of the heater housing to be produced with a larger manufacturing tolerance. Despite the large manufacturing tolerance, this can allow the heater module holder to be correctly aligned with the upstream portion of the heater housing.

[0013] The mounting clearance may be configured to allow relative movement of the heater module holder relative to the heater housing upstream portion. The relative movement of the heater module holder relative to the heater housing upstream portion may advantageously allow for greater tolerance when positioning the heater module holder in the heater housing upstream portion.

[0014] The mounting clearance may allow for relative movement of the heater module holder relative to the upstream portion of the heater housing during assembly of the aerosol generating device. After the heater module holder is correctly positioned relative to the upstream portion of the heater housing, the correct position may be fixed by employing a connecting element. This may reliably position the heater module holder in the correct position relative to the upstream portion of the heater housing.

[0015] This may also allow easy and correct positioning of the heater module relative to the upstream part of the heater housing.This may be due to the heater module being mounted on the heater module holder during assembly of the aerosol generating device.

[0016] The width of the protruding upstream connection section of the heater module holder may be 6% to 15% smaller than the width of the mounting recess of the upstream portion of the heater housing. Preferably, the width of the protruding upstream connection section may be 8% to 12% smaller than the width of the mounting recess of the upstream portion of the heater housing, more preferably 10% smaller.

[0017] This may provide a sufficiently large mounting clearance to reliably position the heater module retainer relative to the upstream portion of the heater housing despite larger manufacturing tolerances.

[0018] The aerosol generating device may comprise a longitudinal axis.The mounting gap may be configured to allow relative movement of the heater module holder relative to the upstream portion of the heater housing perpendicular to the longitudinal axis of the aerosol generating device.

[0019] This may allow easy alignment of the heater module holder, and hence the heater module, relative to the upstream portion of the heater housing along the longitudinal axis of the aerosol generating device.

[0020] This may allow easy formation of a continuous air flow path through the heater module and the upstream portion of the heater housing.

[0021] A flexible sealing element may be arranged between the protruding upstream connection section and the mounting recess.The flexible sealing element may be configured to allow relative movement of the heater module holder with respect to the upstream portion of the heater housing.

[0022] A flexible sealing element may be located at a downstream end of the protruding upstream connection section of the heater module holder.The heater module holder may include a flexible sealing element.

[0023] This may allow for easy arrangement of the flexible sealing element relative to the mounting recess when mounting the protruding upstream connecting section of the heater module holder within the mounting recess of the upstream portion of the heater housing.

[0024] Due to the flexibility of the flexible sealing element, the flexible sealing element may also be configured to provide additional movement of the protruding upstream connection section of the heater module holder in the recess of the upstream portion of the heater housing.

[0025] The flexible sealing element may also be compressible. This may allow additional movement of the heater module holder relative to the upstream part of the heater housing. This may allow tilting of the heater module holder relative to the upstream part of the heater housing. In particular, the tilting of the heater module holder may be relative to the longitudinal axis of the aerosol generating device. This may provide additional movement of the heater module holder relative to the upstream part of the heater housing.

[0026] The flexible sealing element may be configured to permit relative movement of the heater module retainer relative to the upstream portion of the heater housing.

[0027] This may provide additional freedom of movement of the upstream portion of the heater housing relative to the heater module holder.

[0028] The flexible sealing element may also be configured to seal the mounting gap at a downstream portion of the mounting gap. This may provide the possibility of making the heater housing gas-tight despite the presence of the mounting gap.

[0029] The flexible sealing element may be formed from one of rubber or elastomer, in particular silicone rubber.

[0030] The heater housing upstream portion may include an airflow path for providing air into the heater housing. The heater housing downstream portion may include an airflow path for providing air into the heater housing. Similarly, the heater module holder may include a through hole for providing an airflow path through the heater module holder into a heater module mounted on the heater module holder.

[0031] The heater housing downstream portion, the heater housing upstream portion, and the heater module retainer may be tubular.

[0032] This may provide a tubular heater housing having a heater module which may be configured to receive an aerosol-generating article which is also tubular or formed as a rod.The aerosol-generating article may have the general shape of a cigarette.

[0033] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of releasing volatile compounds that can form an aerosol. For example, the aerosol-generating article may be a smoking article that generates an aerosol that can be inhaled directly into the user's lungs through the user's mouth. The aerosol-generating article may be disposable.

[0034] As used herein, the term "aerosol generating device" relates to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate may be part of an aerosol-generating article, such as part of a smoking article. The aerosol generating device may be a smoking device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol that can be inhaled directly into the user's lungs through the user's mouth. The aerosol generating device may be a holder. Preferably, the device is a portable or handheld device that is suitable for holding between the fingers of a single hand.

[0035] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds may be released by heating or burning the aerosol-forming substrate. The aerosol-forming substrate may be solid or liquid, or may include both solid and liquid components. The aerosol-forming substrate may be part of an aerosol-generating article.

[0036] The mounting gap may be a radial mounting gap. This may allow an easy way to rotate the heater module holder relative to the upstream part of the heater housing. This may allow an easy way to allow relative movement of the heater module holder relative to the upstream part of the heater housing perpendicular to the longitudinal axis of the aerosol generating device.

[0037] The flexible sealing element may include an O-ring. The flexible sealing element may be formed as an O-ring. This may allow easy alignment between the flexible sealing element and the radial mounting gap. This may allow the flexible sealing element to reliably seal the downstream end of the radial mounting gap.

[0038] In the case of radial mounting clearance, the diameter of the protruding upstream connection section of the heater module holder may be 6% to 15% smaller than the diameter of the mounting recess of the upstream portion of the heater housing. Preferably, the diameter of the protruding upstream connection section may be 8% to 12% smaller than the diameter of the mounting recess of the upstream portion of the heater housing, more preferably 10% smaller.

[0039] This may provide a radial mounting clearance of sufficient size to securely position the heater module retainer relative to the upstream portion of the heater housing.

[0040] One or both of the upstream part of the heater housing and the downstream part of the heater housing may include a connection portion. The connection portion may be configured to mount the downstream part of the heater housing to the upstream part of the heater housing. This can limit the position of the heater module holder relative to the upstream part of the heater housing. The connection portion may include holes in both the upstream part of the heater housing and the downstream part of the heater housing. The connecting element may be positioned in the holes of both the upstream part of the heater housing and the downstream part of the heater housing for locking the two parts together. This can also prevent the heater module holder from moving further relative to the downstream part of the heater housing inside the heater housing. The connecting element may, for example, include a screw, which may be configured to screw the downstream part of the heater housing to the upstream part of the heater housing. One or both of the holes in the upstream part of the heater housing and the downstream part of the heater housing may include threads for accommodating the connecting element, in particular the screw.

[0041] The heater module may be mounted on the heater module holder via a protruding element and a corresponding slot configured to receive the protruding element.

[0042] This may provide an easy method for mounting the heater module on the heater module holder. This may also provide an easy way to align the heater module on the heater module holder relative to the upstream portion of the heater housing.

[0043] The heater module may include a heating element. The heating element may at least partially define a heating chamber. The heating chamber may be located within the heater housing. The heating chamber may be configured to receive an aerosol-generating article.

[0044] The heating chamber is configured to receive an aerosol generating article comprising an aerosol-forming substrate. The heating chamber may include a cavity into which the aerosol generating article is inserted. The cavity may be tubular. The cavity may include a thermally conductive material. The cavity may include a tube made of metal, preferably stainless steel, or the tube may include ceramic. The heating chamber may include an opening at the downstream end of the heating chamber for receiving the aerosol generating article. The opening may also serve as an air outlet.

[0045] The heating chamber may comprise a heating element configured for heating the aerosol-generating article. The heating element may comprise a substrate layer of a flexible material. The substrate layer may comprise a thermally stable polymer, preferably a polyimide.

[0046] The heating element may be arranged on the substrate layer. The heating element may be a resistive heating element. The heating element may include a wire connection configured to be connected to the control element. The heating element may include a heating trace arranged on the substrate layer. The heating trace may include a thermally conductive material, preferably a metal, such as stainless steel. The heating trace may be electrically connected to the wire connection.

[0047] In particular, the heating chamber may comprise a tube made of metal wrapped into a substrate layer of said flexible material, wherein the heating element is arranged on the substrate layer.

[0048] As a result of the current passing through the heating element, the portion of the heating element in contact with the aerosol-forming substrate is heated. The current is provided by a power supply. In one embodiment, this portion of the heating element is configured to reach a temperature of between about 140° C. and about 270° C. in use. Preferably, the heating element is configured to reach a temperature of between about 180° C. and about 240° C.

[0049] A heating chamber configured to receive an aerosol-forming article may be housed in a heater housing and may be spaced apart from the inner wall of the heater housing. This may provide thermal insulation between the inner wall of the heater housing and the heating chamber in which heat is generated. The space between the inner wall of the heater housing and the heating chamber may be airtight. The space may be filled with air. The space may also be filled with a gas mixture, preferably an inert gas, such as nitrogen. This may provide particularly good isolation between the inner wall of the heater housing and the heating chamber.

[0050] The heater housing may comprise a downstream heater opening for inserting an aerosol-generating article into the heating chamber.The downstream heater opening may be located at the downstream end of an airflow path through the aerosol-generating device.

[0051] The upstream portion of the heater housing may include an airflow duct. The airflow duct may be configured to provide air to the heater module. The airflow duct may be configured to provide air to the heater housing. The airflow duct may be configured to provide air to the heater module located within the heater housing.

[0052] The airflow duct may comprise a thermally stable polymer. The airflow duct may comprise the same thermally stable polymer as the heater housing. In particular, the one-piece element comprising the heater housing upstream portion and the airflow duct on the one hand and the heater housing downstream portion on the other hand may comprise the same thermally stable polymer. The airflow duct or the one-piece element may comprise one or both of polyphenylsulfone (PPSU) and polyetheretherketone (PEEK), respectively.

[0053] The heater housing upstream portion and the airflow duct may be formed as a one-piece element. Preferably, the heater housing upstream portion and the airflow duct may be formed as a one-piece element.

[0054] This may provide the heater housing upstream part and the gas flow duct in one piece.This may provide an easy method to assemble the internal components of the aerosol generating device, comprising the heater housing with the heater module and the upstream gas flow duct.

[0055] The one-piece element may be formed, for example, via molding, such as injection molding. This may enable an easy one-piece connection between the heater housing upstream portion and the airflow tube without the need to form a connection configured for mounting the heater housing upstream portion to the airflow tube.

[0056] The one-piece or integral element of the upstream portion of the heater housing and the gas flow duct may be formed from a polymer or from a metal.

[0057] The heater housing may include an inner wall. The inner wall of the heater housing may include one or both of a heat reflective coating and a polymer. The thermally stable polymer may be selected from a polymer group including polyphenylsulfone (PPSU) and polyetheretherketone (PEEK). Preferably, the thermally stable polymer may include polyphenylsulfone (PPSU). The heat reflective coating may include a metal. Such a metal coating may reflect heat emitted from the heating chamber of the heater housing. The metal coating may include a metal, such as gold or aluminum, preferably gold. The inner wall of the heater housing may also include a thermally insulating material.

[0058] The aerosol generating device may further comprise a control element. The control element may be configured to control the operation of the aerosol generating device. The control element may comprise a substrate, such as a printed circuit board. The control circuit may be mounted on the substrate. The control circuit may be configured to control the operation of the aerosol generating device.

[0059] The heating element of the heater module may comprise an electrical connection for connecting to the control element. In particular, the heater housing upstream part may comprise a through hole for guiding the electrical connection through the heater housing upstream part.

[0060] This may provide an easy way of leading electrical connections through the upstream part of the heater housing to the control element.The control element may be located adjacent to the upstream part of the heater housing in the aerosol generating device.

[0061] The heater housing, the airflow tube and the control element may be mounted to each other to form a self-supporting component of the aerosol generating device.

[0062] The self-supporting component may simplify the assembly of the aerosol generating device. The self-supporting component may support itself and its own weight without the need for an external frame for arranging the heater housing, the airflow tube and the control element relative to each other. The heater housing, the airflow tube and the control element may be held in place with each other. The self-supporting component may form an independent unit of the aerosol generating device. The self-supporting component may form an internal component of the aerosol forming device. The internal component of the aerosol forming device may be partially located within the external housing of the aerosol generating device.

[0063] Preferably, the self-supporting member may be entirely contained within the outer housing of the aerosol generating device.

[0064] Another embodiment of the present invention provides a method for assembling an aerosol generating device. The method may include a method step of providing a heater module and a heater module holder. The method may also include providing a heater housing downstream portion and a heater housing upstream portion for assembling the heater housing. The heater housing may accommodate the heater module. The method may include the step of installing the heater module holder on the upstream portion of the heater housing. Positioning the heater module holder relative to the upstream portion of the heater housing may also position the heater module relative to the upstream portion of the heater housing. The method may also include a method step of connecting the downstream portion of the heater housing to the upstream portion of the heater housing having the installed heater module to form the heater housing.

[0065] Another embodiment of the present invention provides a method for assembling an aerosol generating device. The method includes the method steps of providing a heater module and a heater module holder. The method also provides the steps of providing a downstream portion of a heater housing, an upstream portion of a heater housing for assembling the heater housing, wherein the heater housing accommodates the heater module. The method includes the method steps of mounting the heater module on the heater module holder. The method also includes mounting the heater module holder on the upstream portion of the heater housing, wherein the positioning of the heater module relative to the upstream portion of the heater housing is accomplished by positioning the heater module holder relative to the upstream portion of the heater housing. Finally, the method includes the method steps of connecting the downstream portion of the heater housing to the upstream portion of the heater housing having the installed heater module to form the heater housing.

[0066] The heater module holder may include a protruding upstream connection section. The upstream connection section may be configured to be connected to the upstream portion of the heater housing. The upstream portion of the heater housing may include a mounting recess. The mounting recess may be configured to receive the protruding upstream connection section of the heater module holder. When the heater module holder is mounted on the upstream portion of the heater housing, the protruding upstream connection section of the heater module holder may be positioned in the mounting recess.

[0067] This may provide an easy method of mounting the heater module holder to the upstream portion of the heater housing.

[0068] The heater module may first be mounted on the heater module holder. Subsequently, the arrangement of the heater module on the heater module holder may be positioned in the mounting recess of the upstream portion of the heater housing. The relative positioning of the heater module holder with respect to the upstream portion of the heater housing may therefore also result in the positioning of the heater module already mounted on the heater module holder with respect to the upstream portion of the heater housing.

[0069] Alternatively, first, the heater module holder can be positioned in the mounting recess of the upstream portion of the heater housing, and the relative position of the heater module holder can be locked relative to the upstream portion of the heater housing. Subsequently, the heater module can then be mounted on the heater module holder connected to the upstream portion of the heater housing.

[0070] Preferably, the heater module is first mounted on the heater module holder and the arrangement is then subsequently positioned within the mounting recess of the upstream portion of the heater housing.

[0071] The inner surface of the mounting recess may be spaced apart from the opposing outer surface of the protruding upstream connection section. When the protruding upstream connection section of the heater module holder is received in the mounting recess of the heater housing upstream portion, this may create a mounting gap. During installation of the heater module holder to the heater housing upstream portion, the heater module holder and the heater housing upstream portion may move relative to each other in the mounting recess within the mounting gap to position the heater module holder relative to the heater housing upstream portion.

[0072] The aerosol generating device may comprise a longitudinal axis.The heater module holders arranged in the mounting recess of the heater housing upstream portion may move relative to each other perpendicularly to the longitudinal axis of the aerosol generating device when the heater module holder is mounted on the heater housing upstream portion.

[0073] A flexible sealing element may be arranged between the protruding upstream connection section and the mounting recess.The heater module holder and the heater housing upstream portion may be moved relative to each other on the flexible sealing element in the mounting recess to position the heater module holder relative to the heater housing upstream portion.

[0074] In particular, the heater module holder and the heater housing upstream portion may be rotatable relative to each other on the flexible sealing element.The heater module holder and the heater housing upstream portion may also be tiltable relative to each other on the flexible sealing element relative to the longitudinal axis of the aerosol generating device.

[0075] This may provide additional means of movement of the heater module holder relative to the upstream portion of the heater housing.

[0076] A non-exhaustive list of non-limiting examples is provided below.Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0077] Example Ex1: an aerosol generating device, comprising:

[0078] a heater housing having a heater housing downstream portion and a heater housing upstream portion, the heater housing housing housing a heater module,

[0079] The heater module is mounted on a heater module holder in the heater housing, wherein the heater module holder is connected to an upstream portion of the heater housing.

[0080] Example Ex2: An aerosol generating device according to Example Ex1, wherein the heater module holder includes a protruding upstream connection section configured to be connected to an upstream portion of the heater housing, and wherein the upstream portion of the heater housing includes a mounting recess configured to receive the protruding upstream connection section.

[0081] Example Ex3: An aerosol generating device according to the preceding example, wherein an inner surface of the mounting recess is spaced apart from an opposite outer surface of the protruding upstream connecting section for creating a mounting gap.

[0082] Example Ex4: An aerosol generating device according to the previous example, wherein the mounting gap is configured to allow relative movement of the heater module holder relative to the upstream part of the heater housing, preferably wherein the aerosol generating device comprises a longitudinal axis, and wherein the mounting gap is configured to allow relative movement of the heater module holder relative to the upstream part of the heater housing perpendicular to the longitudinal axis of the device.

[0083] Example Ex5: An aerosol generating device according to the aforementioned Example Ex3 or Ex4, wherein a flexible sealing element is arranged between the protruding upstream connecting section and the mounting recess, and the flexible sealing element is configured to allow relative movement of the heater module holder relative to the upstream part of the heater housing, preferably wherein the sealing element is configured to allow rotational movement of the heater module holder relative to the upstream part of the heater housing.

[0084] Example Ex6: An aerosol generating device according to any one of the preceding examples, wherein the downstream portion of the heater housing, the upstream portion of the heater housing and the heater module retainer are tubular, preferably further belonging to any one of Examples Ex3 to Ex5, wherein the mounting gap is a radial mounting gap.

[0085] Example Ex7: An aerosol generating device according to the preceding example further dependent on example Ex5, wherein the flexible sealing element comprises an O-ring.

[0086] Example Ex8: An aerosol generating device according to any of the preceding examples, wherein one or both of the upstream part of the heater housing and the downstream part of the heater housing include a connecting portion, which is configured to mount the downstream part of the heater housing to the upstream part of the heater housing and to lock the position of the heater module retainer relative to the upstream part of the heater housing.

[0087] Example Ex9: An aerosol generating device according to any of the preceding examples, wherein the heater module is mounted on the heater module holder by a protruding element and a corresponding slot configured to receive the protruding element.

[0088] Example Ex10: An aerosol generating device according to any of the preceding examples, wherein the heater module comprises a heating element that at least partially defines a heating chamber.

[0089] Example Ex11: An aerosol generating device according to any of the preceding examples, wherein the upstream portion of the heater housing comprises an airflow tube configured to provide air to the heater module, preferably wherein the upstream portion of the heater housing and the airflow tube are formed as a one-piece element, more preferably wherein the upstream portion of the heater housing and the airflow tube are formed as an integral element.

[0090] Example Ex12: An aerosol generating device according to any of the preceding examples, further comprising a control element configured to control the operation of the aerosol generating device.

[0091] Example Ex13: An aerosol generating device according to the previous example further subordinate to Example Ex10, wherein the heating element also includes an electrical connection portion for connecting to the control element, preferably wherein the upstream portion of the heater housing includes a through hole for guiding the electrical connection portion through the upstream portion of the heater housing.

[0092] Example Ex14: An aerosol generating device according to Examples Ex11 and Ex12, wherein the heater housing, the airflow tube and the control element are mounted to each other to form a self-supporting component of the aerosol generating device.

[0093] Example Ex15: The aerosol generating device according to the preceding example, further comprising an outer shell, wherein the self-supporting member is at least partially contained within the outer shell.

[0094] Example Ex16: A method for assembling an aerosol generating device, comprising the following method steps:

[0095] - providing a heater module and a heater module holder,

[0096] - providing a heater housing downstream part and a heater housing upstream part for assembling a heater housing, said heater housing accommodating said heater module,

[0097] - mounting the heater module on the heater module holder,

[0098] - mounting the heater module holder on the heater housing upstream part, wherein positioning of the heater module relative to the heater housing upstream part is accomplished by positioning the heater module holder relative to the heater housing upstream part,

[0099] - connecting the heater housing downstream portion to the heater housing upstream portion with the mounted heater module to form the heater housing.

[0100] Example Ex17: A method according to the previous example, wherein the heater module retainer includes a protruding upstream connection section configured to be connected to the upstream portion of the heater housing, and wherein the upstream portion of the heater housing includes a mounting recess configured to receive the protruding upstream connection section, and wherein when the heater module retainer is mounted on the upstream portion of the heater housing, the protruding upstream connection section is positioned in the mounting recess.

[0101] Example Ex18: A method according to the previous example, wherein the inner surface of the mounting recess is spaced apart from the relative outer surface of the protruding upstream connecting section for producing a mounting gap, and wherein the heater module holder and the upstream portion of the heater housing move relative to each other in the mounting gap in the mounting recess so as to position the heater module holder relative to the upstream portion of the heater housing, preferably wherein the aerosol generating device includes a longitudinal axis, and wherein the heater module holder and the upstream portion of the heater housing move relative to each other perpendicular to the longitudinal axis.

[0102] Example Ex19: A method according to any one of the aforementioned examples Ex17 or Ex18, wherein a flexible sealing element is arranged between the protruding upstream connecting section and the mounting recess, and wherein the heater module holder and the upstream part of the heater housing move relative to each other on the flexible sealing element in the mounting recess so as to position the heater module holder relative to the upstream part of the heater housing, preferably wherein the heater module holder and the upstream part of the heater housing rotate relative to each other on the flexible sealing element.

[0103] Features described with respect to one embodiment may be equally applicable to other embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0104] The present invention will be further described, by way of example only, with reference to the accompanying drawings, in which:

[0105] Figure 1 showing a schematic exploded view of parts of an aerosol generating device including a heater housing upstream portion, a heater housing downstream portion, a heater module and a heater module holder;

[0106] Figure 2 a schematic cross-sectional view depicting the relative spatial arrangement of portions of a heater module holder and a heater module relative to an upstream portion of a heater housing;

[0107] Figure 3 depicts another schematic cross-sectional view of a heater module retainer having a flexible sealing element indicating a mounting clearance with an upstream portion of a heater housing;

[0108] Figure 4 a schematic exploded view depicting the mounting of a heater module on a heater module holder and the mounting of the heater module holder to an upstream portion of a heater housing;

[0109] Figure 5 A schematic view of an aerosol generating device is shown, the aerosol generating device comprising a self-supporting internal element including a heater housing and an airflow tube mounted to a control element. DETAILED DESCRIPTION

[0110] In the following, elements having the same function are marked with the same reference numerals in all figures.

[0111] Figure 1A schematic exploded view of a heater assembly for an aerosol generating device 10 is shown. The heater assembly comprises an upstream portion 12 of a heater housing, which forms a one-piece component, preferably a monolithic element, with an upstream gas flow tube 12A. In addition, there is a heater module holder 14, to which a heater module 16 having an electrical connection 22 for connecting to a control element can be mounted. A heater housing downstream portion 18 can be connected to the heater housing upstream portion 12 so as to form a heater housing surrounding the heater module. A connecting element 20, such as a screw, can connect the heater housing downstream portion 18 to the heater housing upstream portion 12. When the heater housing downstream portion 18 is connected to the heater housing upstream portion 12 via the connecting element, the heater module 16 mounted on the heater module holder 14 is therefore also reliably locked in the heater housing. The heater module holder 14 serves as a mounting element for the heater module 16 and allows reliable alignment between the heater housing upstream portion 12 and the heater module 16, despite the large manufacturing tolerances of the two elements.

[0112] Figure 2 A schematic cross-sectional view of the heater module 16 is depicted relative to the heater module holder 14 and the upper portion of the heater housing upstream portion 12. The heater module holder 14 includes a protruding upstream connection section 14A. The protruding upstream connection section 14A can be received in a mounting recess 12B of the heater housing upstream portion 12, as indicated by the dashed line. The relative movement of the protruding upstream connection section 14A in the mounting recess 12B of the heater housing upstream portion 12 allows for a more reliable alignment of the heater module holder 14 and therefore the heater module 16 relative to the heater housing upstream portion. The heater module holder 14 includes a heater module holder recess 14B, which is configured to receive a heater module protruding connection element 16A of the heater module 16, as indicated by the dashed line. The heater module holder 14 allows for reliable alignment of the heater module 16 relative to the heater housing upstream portion 12 along the longitudinal axis 11 of the aerosol generating device.

[0113] Figure 3The interaction between the heater module holder 14 and the upper part of the upstream part 12 of the heater housing is depicted in more detail. The inner surface 12C of the mounting recess of the upstream part 12 of the heater housing is spaced apart from the outer surface 14B of the protruding upstream connection section 14A. This can be achieved when the width of the protruding upstream connection section 14A is less than the width of the mounting recess 12B. This creates a mounting gap 13. The mounting gap 13 allows relative movement of the upstream part 12 of the heater housing with respect to the heater module holder 14. In particular, the mounting gap 13 allows relative movement of the upstream part 12 of the heater housing perpendicular to the longitudinal axis 11 of the aerosol generating device with respect to the heater module holder 14. In addition, there is a flexible sealing element 24, such as an O-ring. The flexible sealing element 24 also allows rotational movement of the heater module holder 14 with respect to the upstream part 12 of the heater housing. The flexible sealing element 24 can also allow the heater module holder 14 to tilt with respect to the upstream part 12 of the heater housing with respect to the longitudinal axis 11 of the aerosol generating device.

[0114] Figure 4 The mounting of the heater module 16 on the heater module holder 14 is depicted in more detail, as indicated by the arrows. Additionally, the heater module holder 14 may be mounted in a recess of the heater housing upstream portion 12, as indicated by the arrows.

[0115] Figure 5 An aerosol generating device 10 having an outer housing 32 is depicted. The aerosol generating device comprises a self-supporting internal element consisting of a heater housing downstream portion 18 mounted to a heater housing upstream portion 12 and a control element 26. The airflow tube is formed as an integral component with the heater housing upstream portion. The airflow tube is mounted to the control element to form a self-supporting component of the aerosol generating device. The self-supporting element comprising the heater housing downstream portion, the heater housing upstream portion, the airflow tube and the control element further comprises a heater module 16 mounted on a heater module holder 14, which is accommodated in the heater housing. The control element 26 preferably comprises a substrate, such as a printed circuit board, which further comprises a control circuit 30 for controlling the operation of the aerosol generating device. There is a connecting element 22, such as a screw, which connects the heater housing downstream portion 18 to the heater housing upstream portion 12 and also locks the heater module holder 14 in a fixed position within the heater housing. The electrical connection 22 is guided through a through hole of the heater housing upstream portion 12 towards the control element so as to provide an electrical connection to the control element. Additionally, a power source 28 , such as a battery, is located within the outer housing 32 for providing energy for operating the aerosol generating device.

Claims

1. An aerosol generating device comprising: a heater housing having a heater housing downstream portion and a heater housing upstream portion, the heater housing housing housing a heater module, wherein the heater module is mounted on a heater module holder in the heater housing, wherein the heater module holder is connected to the heater housing upstream portion, wherein the heater module holder includes a protruding upstream connection section configured to be connected to the heater housing upstream portion, and wherein the heater housing upstream portion includes a mounting recess configured to receive the protruding upstream connection section, and The inner surface of the mounting recess is spaced apart from the opposite outer surface of the protruding upstream connecting section to generate a mounting gap.

2. An aerosol generating device according to the preceding claim, wherein the mounting gap is configured to allow relative movement of the heater module holder relative to the upstream part of the heater housing, preferably wherein the aerosol generating device comprises a longitudinal axis, and wherein the mounting gap is configured to allow relative movement of the heater module holder relative to the upstream part of the heater housing perpendicular to the longitudinal axis of the device.

3. An aerosol generating device according to any one of the preceding claims, wherein a flexible sealing element is arranged between the protruding upstream connecting section and the mounting recess, and the flexible sealing element is configured to allow relative movement of the heater module holder relative to the upstream part of the heater housing, preferably wherein the sealing element is configured to allow rotational movement of the heater module holder relative to the upstream part of the heater housing.

4. An aerosol generating device according to any one of the preceding claims, wherein the heater housing downstream portion, the heater housing upstream portion and the heater module holder are tubular, preferably wherein the mounting gap is a radial mounting gap.

5. An aerosol generating device according to the preceding claim, further dependent on claim 3, wherein the flexible sealing element comprises an O-ring.

6. An aerosol generating device according to any of the preceding claims, wherein one or both of the upstream part of the heater housing and the downstream part of the heater housing include a connecting portion, which is configured to mount the downstream part of the heater housing to the upstream part of the heater housing and to lock the position of the heater module retainer relative to the upstream part of the heater housing.

7. An aerosol generating device according to the preceding claim, wherein the heater module comprises a heating element, and wherein the heating element further comprises an electrical connection for connecting to a control element, preferably wherein the upstream part of the heater housing comprises a through hole for guiding the electrical connection through the upstream part of the heater housing.

8. An aerosol generating device according to any of the preceding claims, wherein the upstream portion of the heater housing includes an airflow tube configured to provide air to the heater module, and wherein the aerosol generating device also includes a control element configured to control the operation of the aerosol generating device, and wherein the heater housing, the airflow tube and the control element are mounted to each other to form a self-supporting component of the aerosol generating device.

9. An aerosol generating device according to the preceding claim, further comprising an outer housing, wherein the self-supporting member is at least partially housed within the outer housing.

10. A method for assembling an aerosol generating device comprising the following method steps: - providing a heater module and a heater module holder, - providing a heater housing downstream part and a heater housing upstream part for assembling a heater housing, said heater housing accommodating said heater module, - mounting the heater module on the heater module holder, - mounting the heater module holder on the heater housing upstream part, wherein positioning of the heater module relative to the heater housing upstream part is accomplished by positioning the heater module holder relative to the heater housing upstream part, - connecting the heater housing downstream portion to the heater housing upstream portion with the mounted heater module to form the heater housing, - wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater housing upstream part, and wherein the heater housing upstream part comprises a mounting recess configured for receiving the protruding upstream connection section, and wherein when the heater module holder is mounted on the heater housing upstream part, the protruding upstream connection section is positioned in the mounting recess, and - wherein an inner surface of the mounting recess is spaced apart from an opposing outer surface of the protruding upstream connecting section for creating a mounting gap, and wherein the heater module retainer and the upstream portion of the heater housing move relative to each other in the mounting recess within the mounting gap so as to position the heater module retainer relative to the upstream portion of the heater housing.

11. A method according to the preceding claim, wherein the aerosol generating device comprises a longitudinal axis, and wherein the heater module holder and the heater housing upstream portion are moved relative to each other perpendicularly to the longitudinal axis.

12. The method according to any one of the preceding claims 10 or 11, wherein a flexible sealing element is arranged between the protruding upstream connecting section and the mounting recess, and wherein the heater module holder and the upstream part of the heater housing move relative to each other on the flexible sealing element in the mounting recess so as to position the heater module holder relative to the upstream part of the heater housing, preferably wherein the heater module holder and the upstream part of the heater housing rotate relative to each other on the flexible sealing element.

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