Aerosol provision device

Abstract

To provide a support for a heater component of an aerosol provision device.SOLUTION: A support 136 for a heater component of an aerosol provision device defines an axis 204 and is configured to engage with an end of the heater component to hold the heater component substantially parallel to the axis at a predetermined distance from a coil. The support defines a channel 210 to receive a wire of a temperature sensor, and the channel defines an opening into a space between the heater component and the coil. An aerosol provision device is also described which comprises: a heater component configured to heat aerosol generating material; a first support that defines an axis and is configured to engage with a first end of the heater component; a second support that is configured to engage with a second end of the heater component; and at least one coil configured to heat the heater component.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to a support for a heater component of an aerosol delivery device, and to an aerosol delivery device including the support.The present invention also relates to an aerosol delivery device, an aerosol delivery system, and an article comprising an aerosol-generating material. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide an alternative to these tobacco-burning articles by creating products that release compounds without combustion. Examples of such products include heating devices that release compounds by heating, rather than burning, a material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of the present disclosure, there is provided a support for a heater component of an aerosol delivery device, the support defining an axis and configured to engage an end of the heater component to hold the heater component substantially parallel to the axis at a predetermined distance from the coil, the support defining a channel for receiving a wire of a temperature sensor, the channel defining an opening to a space between the heater component and the coil.

[0004] According to a second aspect of the present disclosure, A support according to the first aspect, a heater component engaged at one end with a support; a coil extending around the heater component, the coil configured to heat the heater component; a temperature sensor for sensing a temperature of the heater component, the temperature sensor being disposed in a space between the coil and the heater component; a wire disposed in a channel of the support and connected to a temperature sensor; An aerosol delivery device is provided comprising:

[0005] According to a third aspect of the present disclosure, A support defining an axis; A coil and A heater component, The heater component can be heated by a coil, an end of the heater component engages the support to hold the heater component substantially parallel to the axis at a predetermined distance from the coil; a heater component, the support defining a channel defining an opening to a space between the heater component and the coil; a temperature sensor for detecting a temperature of the heater component, the temperature sensor being disposed in a space between the heater component and the coil; a wire disposed in a channel of the support and connected to a temperature sensor; An aerosol delivery device is provided comprising:

[0006] According to a fourth aspect of the present disclosure, a heater component configured to heat the aerosol-generating material; and a first support defining an axis and configured to engage a first end of the heater component; a second support configured to engage a second end of the heater component; and at least one coil configured to heat the heater component; Equipped with An aerosol delivery device is provided in which a first support and a second support hold the heater component substantially parallel to the axis at a predetermined distance from the at least one coil.

[0007] According to a fifth aspect of the present disclosure, a heater component configured to heat the aerosol-generating material; and a support defining an axis, the support configured to engage a first end of the heater component; at least one coil configured to heat the heater component; Equipped with An aerosol delivery device is provided in which a support holds the heater component substantially parallel to the axis at a predetermined distance from at least one coil.

[0008] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments thereof, which description is given by way of example only and is made with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a front view of an example of an aerosol delivery device. [Diagram 2] FIG. 2 is a front view of the aerosol delivery device of FIG. 1 with the outer cover removed. [Diagram 3] 2 is a cross-sectional view of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 3 is an exploded view of the aerosol delivery device of FIG. 2. [Diagram 5] FIG. 5A is a cross-sectional view of a heating assembly in an aerosol delivery device, and FIG. 5B is an enlarged view of a portion of the heating assembly of FIG. 5A. [Figure 6] FIG. 4 is an enlarged view of a support within the aerosol delivery device of FIG. 3. [Figure 7] 7 is an enlarged perspective view of a channel formed in the support of FIG. 6. FIG. [Figure 8] FIG. 8 is a top-down view of the support of FIGS. 6 and 7; [Figure 9] FIG. 2 is a diagram of another exemplary support. [Figure 10] FIG. 2 is a diagram of a further support. [Figure 11] FIG. 2 is a diagram of a susceptor disposed within an aerosol delivery device. [Figure 12] FIG. 2 is a diagram of a susceptor engaged by first and second supports. [Figure 13] FIG. 2 is a diagram of a susceptor surrounded by an insulating member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] As used herein, the term "aerosol-forming material" includes materials that upon heating provide volatile components, typically in the form of an aerosol. Aerosol-forming materials include any tobacco-containing material, and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials may also include other non-tobacco products, which may or may not contain nicotine depending on the particular product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-forming materials may be, for example, a combination or mixture of materials. Aerosol-forming materials may also be referred to as "smoking materials."

[0011] Devices are known that heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, typically to form an inhalable aerosol, without burning or combusting the aerosol-generating material. Such devices are sometimes described as "aerosol generating devices", "aerosol delivery devices", "non-combustion heating devices", "tobacco heating product devices" or "tobacco heating devices". There are also so-called e-cigarette devices, which typically vaporize aerosol-generating material in liquid form, which may or may not contain nicotine. The aerosol-generating material may be in the form of, or provided as part of, a rod, cartridge, cassette, or the like that can be inserted into the device. A heater for heating and volatilizing the aerosol-generating material may be provided as a "permanent" part of the device.

[0012] The aerosol delivery device can receive an article comprising an aerosol-generating material for heating. An "article" in this context is a component that, in use, contains or houses the aerosol-generating material, and optionally other ingredients, where the aerosol-generating material is heated to volatilize it. A user may insert the article into the aerosol delivery device before the article is heated to generate an aerosol that is inhaled by the user. The article may be, for example, of a predetermined or specific size configured to be placed in a heating chamber of a device dimensioned to receive the article.

[0013] A first aspect of the disclosure defines a support for a heater component (e.g., a susceptor) of an aerosol delivery device. As discussed in more detail herein, a susceptor is an electrically conductive object that is heated by electromagnetic induction. An article comprising an aerosol-generating material can be received within the heater component. When the heater component is heated, it transfers heat to the aerosol-generating material, which releases an aerosol. In some examples, the device can monitor the temperature of the heater component at one or more locations as the heater component is being heated. This can be useful because there are cases where the aerosol-generating material needs to be heated to a particular temperature. For example, if the temperature of the heater component is too high, the aerosol-generating material can overheat, which can affect the taste / flavor of the aerosol. If the temperature of the heater component is too low, too little aerosol can be generated. Thus, it can be useful to control and monitor the temperature of the heater component during heating.

[0014] One or more temperature sensors may be in contact with or located near the heater component to monitor the temperature of the heater component. The temperature sensor may be, for example, a thermocouple. One or more wires may connect the temperature sensor to other electronic circuitry within the aerosol delivery device, and therefore must be routed from the heater component to another location within the device.

[0015] As mentioned above, the heater component may be a susceptor, and the heater component may be heated by a coil (such as an inductor coil). The inductor coil is configured to generate a varying magnetic field. The susceptor is heatable by penetration of the varying magnetic field.

[0016] In an exemplary aerosol delivery device, the heater component may be surrounded by one or more components, such as an insulating member that may be coaxially disposed about the heater component. The insulating member may help insulate other components of the device from the heat generated by the heater component. The insulating member may also support one or more coils disposed around and spaced apart from the heater component.

[0017] In some conventional aerosol delivery devices, the wire from the temperature sensor is arranged to penetrate the surface of the insulating member. For example, one or more through holes may be formed through the insulating member, and the wire passes through the through holes. However, it has been found that the through holes may weaken the structural integrity of the insulating member. Thus, the insulating member is more susceptible to damage. In addition, depending on the size and location of the through holes, the holes may also reduce the insulating effect provided by the insulating member. Thus, heat can escape from the space between the heater component and the insulating member.

[0018] The present invention relates to a support that defines a channel through which a wire of a temperature sensor can pass. The support is the element that holds the heater component in place in a device. The channel formed in the support defines an opening to the space between the heater component and the coil / insulation member. This means that there is no need to route the wire through the insulation member and, as a result, does not compromise the structural integrity of the insulation member. One or more wires may be routed through this channel.

[0019] The support, also known as a "cleanout tube," defines an axis and is configured to engage an end of the heater component to hold the heater component substantially parallel to the axis at a predetermined distance from the coil. The support thus holds the heater component in a predetermined position within the device relative to the coil. Thus, a wire can be routed through a channel along (generally axially) the heater component such that the wire can extend out of the space between the heater component and the coil.

[0020] The channel may extend substantially parallel to the axis. In other words, the channel is formed through a portion of the support in a direction substantially parallel to the axis. Thus, when the wire is received in the channel, it extends in a direction substantially parallel to the axis. This structure is easier to manufacture and also defines the shortest path into the space between the heater component and the coil / insulation member, allowing the shortest length of wire to be used. In other examples, the channel may not be parallel to the axis.

[0021] A channel may be open along its length. In other words, a channel may be open along its periphery. In contrast, a channel that is closed along its periphery is a through hole formed through a portion of the support. A channel that is open along its length can be easily manufactured and allows for rapid assembly of the device. For example, instead of requiring the wire to be threaded through a hole, the wire can be placed into the groove of the channel.

[0022] The channel can have a depth measured in a direction perpendicular to the axis. Thus, the channel may define a notch formed in a portion of the support. The channel may have a depth less than about 5 mm, or less than about 3 mm. Preferably, the channel has a depth less than about 2 mm, such as about 1.7 mm. If the channel is too deep, heat can more easily escape from the space between the heater component and the coil. If the channel is too shallow, the wire may need to be angled relative to the axis and heater component, which may bend or break the wire. The above dimensions provide a good balance between these considerations.

[0023] The channel can have a width measured perpendicular to the axis and the depth. The channel may have a width less than about 2 mm, or less than about 1 mm. Preferably, the channel has a width of about 0.9 mm. If the channel is too wide, heat can more easily escape from the space between the heater element and the coil.

[0024] The support may comprise a first portion, and the channel may be formed through the first portion. The first portion may have a first cross-section and may be disposed generally perpendicular to the axis. The first portion may have a substantially circular cross-section, although other cross-sectional shapes are possible. The first portion may have a circumference extending about the axis. The first portion may have a first depth measured in a direction parallel to the axis. Thus, if the channel is formed parallel to the axis, the channel has a length equal to the first depth, or if the channel is not parallel to the axis, the channel has a length greater than the first depth.

[0025] In some examples, the channel is a notch in the outer periphery of the first portion. However, in other examples, the channel is closed around its periphery such that a through hole is formed through the first portion. The inner diameter of the through hole can be substantially the same as the outer diameter of the wire, thereby reducing heat loss from the heater component.

[0026] The insulating member may surround the heater component and abut at least a portion of the first portion of the support, such that the insulating member is disposed at a predetermined radial distance outside / away from the heater component. The first portion may thus be disposed inside the insulating member. The first portion may thus act as a "plug" to at least partially seal / close the space between the insulating member and the heater component. The first portion may thus reduce heat loss.

[0027] The support may include a second portion spaced apart from the first portion in a direction parallel to the axis, and a second channel may be formed through the second portion to receive the wire. Thus, the "channel" formed in the first portion may be known as the "first channel." The second portion may have substantially the same shape and / or dimensions as the first portion. Thus, the wire passes through the first channel formed in the first portion and through the second channel formed in the second portion. The second portion provides a second "barrier" to help close / seal / insulate the space between the heater component and the induction coil / insulation member.

[0028] In some examples, the second portion may not include a channel, and instead, a wire may be disposed around the second portion.

[0029] The support (or aerosol delivery device) may further comprise an elastic member disposed between the first and second parts. The elastic member may thus be held in place along the axis by the first and second parts. In other words, the elastic member cannot move past the first and second parts along the axis. The elastic member may be, for example, an O-ring. The elastic member thus surrounds the support and helps to close / seal / insulate the space between the heater component and the induction coil / insulating member. In examples where an insulating member is present, the elastic member may abut an inner surface of the insulating member.

[0030] In some examples, the resilient member surrounds / encircles the wire. In other words, the resilient member extends around the wire. Thus, in examples where the resilient member is an O-ring, the wire passes inside the "O." This configuration can help keep the wire in a taught state to reduce the chance of the wire being damaged and / or to keep the wire in the channel. Keeping the wire in the channel can help stop the temperature sensor from being pulled away from the surface of the heater component.

[0031] In another example, the wire passes through an opening / hole formed in the elastic member. This configuration means that the elastic member (such as an O-ring) can function better to create a seal. For example, the inner surface of the O-ring can better conform to the support without the wire passing between the O-ring and the support. The elastic member can be an O-ring, and the wire extends through an opening formed in the O-ring such that the (full) circumference of the wire abuts the O-ring.

[0032] In some examples, the second portion may be omitted. In such examples, the resilient member is longitudinally spaced from the channel. In other words, the second portion is not necessarily required to hold the resilient member in place. The O-ring may be held in place by friction, e.g., the O-ring may tighten the support as it encircles the support.

[0033] The support may include ends configured to abut ends of an insulating member surrounding the heater component, and thus may hold the insulating member in place and help close / seal the space between the heater component and the induction coil / insulating member.

[0034] The support may include at least two channels, each formed in the first portion. Each channel may receive a single wire. In other examples, more than one wire may be introduced into one or each channel. In a particular example, there are four channels, each configured to receive a single wire. In one example, the device includes two temperature sensors, each temperature sensor including two wires, each wire received in a separate channel.

[0035] Having a separate channel for each wire helps to electrically isolate each wire from adjacent wires. A separate channel for each wire can also reduce heat loss from the heater component.

[0036] As mentioned above, a second aspect of the present disclosure defines an aerosol delivery device comprising a support as described above. The device further comprises a heater component engaged at one end with the support and a coil extending around the heater component, the coil configured to heat the heater component (e.g., by a magnetic field). The device further comprises a temperature sensor for sensing a temperature of the heater component, the temperature sensor being disposed in a space between the coil and the heater component. The device further comprises a wire disposed in a channel of the support and connected to the temperature sensor.

[0037] The device may define a longitudinal axis substantially parallel to the axis of the support. The device may define a proximal end and a distal end. In use, the proximal end of the device may be held closer to a user's mouth than the distal end. In use, an aerosol may be drawn towards the proximal end of the device. In one example, the support engages the distal end of the heater component.

[0038] The device may further comprise an insulating member. The support may comprise a first portion, the channel being formed through the first portion. The insulating member may surround the heater component and abut at least a portion of the first portion of the support, thereby positioning the insulating member outwardly from the heater component at a predetermined radial distance. Thus, the insulating member surrounds the first portion of the support. In other words, the insulating member is disposed between the heater component and the coil and is spaced a first distance from the axis. The periphery of the first portion is spaced a second distance from the axis. The first distance may be substantially equal to the second distance. Thus, the first distance may be slightly greater than the second distance, such that the first portion can fit inside the hollow insulating member. The periphery of the first portion may abut an inner surface of the insulating member. In examples where a resilient member is present, an outer edge of the resilient member may be spaced a third distance from the axis, the third distance being substantially equal to the first distance. Thus, the resilient member may abut an inner surface of the insulating member.

[0039] In some examples, the device includes a first coil and a second coil. The first coil can be used to heat a first portion of the heater component and the second coil can be used to heat a second portion of the heater component. In one example, the device includes a first temperature sensor positioned to sense a temperature of the first portion of the heater component and a second temperature sensor positioned to sense a temperature of the second portion of the heater component. Each temperature sensor can be accompanied by two wires, and the support can define four channels, each channel receiving a wire.

[0040] Thus, the device may include a second temperature sensor to detect the temperature of the heater component, the second temperature sensor being disposed in the space between the coil and the heater component, a second wire being connected to the second temperature sensor, and the support defining a second channel to receive the second wire.

[0041] In some instances, the temperature sensor is in contact with the heater component, which allows for a more accurate indication of the temperature of the heater component.

[0042] A fourth aspect of the disclosure relates to the placement of a heater component relative to first and second supports. The first and second supports engage opposite ends of the heater component to hold the heater component in place within the aerosol delivery device. One or more coils are positioned a predetermined distance away from the heater component. In some configurations, the one or more coils extend around the heater component. The heater component may be known as a susceptor in some examples.

[0043] The first and second supports (also known as heater component pedestals or susceptor pedestals) ensure that the heater component is properly positioned relative to the one or more coils. By keeping the distance between the heater component and the coils constant at all times, the heater component can be effectively heated whenever the device is in use. Furthermore, because the first and second supports are not integral with the heater component, heat is conducted to the first and second supports more slowly. This can help insulate other components of the device from the heated heater component. However, in other examples, the first and second supports are integral with the heater component. For example, they may be molded together. This may increase the flow rate of heat conducted from the heater component, but may hold the heater component in place more strongly.

[0044] The first and second supports may be thermally insulating. As mentioned above, this reduces the flow of heat through the first and second supports to other components of the device. In one particular example, the first and second supports have a thermal conductivity of less than about 0.5 W / mK. It has been found that a suitable insulating effect can be achieved when the first and second supports have a thermal conductivity less than this value. The first and second supports may have the same thermal conductivity or may have different thermal conductivities. In a further example, the first and second supports have a thermal conductivity of less than about 0.35 W / mK, such as about 0.32 W / mK.

[0045] The first and second supports may include a plastic material. For example, they may be made, completely or partially, from one or more plastic materials. The portions of the supports that engage the heater components preferably include a plastic material. Plastic is a good insulator, is relatively inexpensive and lightweight, and can be easily molded into the shape required to engage the heater components. In one example, the plastic material includes polyether ether ketone (PEEK). PEEK is a particularly suitable material for the first and second supports because it has a thermal conductivity of about 0.32 W / mK, a melting point of about 343° C., is not electrically conductive, and therefore does not generate heat by the coil. In one example, the PEEK is Victrex® PEEK 450G.

[0046] In some examples, the first and second supports have a melting point greater than about 300° C. Preferably, the first and second supports have a melting point greater than about 340° C. In some examples, during use, the one or more coils are configured to heat the heater component to a temperature of between about 240° C. and about 280° C. Thus, by having the first and second supports having a melting point temperature greater than the temperature of the heated heater component, the first and second supports are less likely to soften and lose structural integrity by melting.

[0047] In use, the at least one coil may be configured to heat the heater component to a first temperature, the first and second supports having a melting point at a second temperature, the second temperature being at least about 60° C. higher than the first temperature. This ensures that the first and second supports remain structurally stable and do not begin to weaken as the temperature of the heater component increases. For example, in some configurations, the first temperature is 250° C. and the second temperature is 343° C. In another example, the first temperature is 280° C. and the second temperature is 343° C. In some devices, the coil may operate in two modes. In the first mode, the heater is heated to a lower temperature than in the second mode.

[0048] In some examples, the aerosol delivery device further comprises an insulating member extending around the heater component, the insulating member being spaced from the heater component to provide an air gap around the heater component. The insulating member may be disposed between the at least one coil and the heater component such that the at least one coil extends around the insulating member. In certain configurations, the coil may be in contact with the insulating member. However, in other examples, an additional air gap may be provided between the insulating member and the coil. Such a configuration provides an improved insulating device. The specific arrangement of the air gap and insulating member improves insulation from the heated heater component. The air gap helps to insulate the insulating member from heat. Additionally, the first and second supports, the air gap, and the insulating member help to insulate other components of the device from heat. For example, the supports, the air gap, and the insulating member reduce any heating of the coil, electronics, and / or battery by the heater component.

[0049] As mentioned above, the insulating member is spaced away from the receiver / heater component to provide an air gap. For example, the inner surface of the insulating member is spaced from the outer surface of the heater component. This means that the air gap surrounds the outer surface of the heater component and the heater component is not in contact with the insulating member in this area. Any contact may provide a thermal bridge through which heat can flow.

[0050] In certain configurations, the heater component is elongated and defines an axis, such as a longitudinal axis. The insulating member extends azimuthally around the heater component and the axis. Thus, the insulating member is disposed radially outward from the heater component, e.g., the insulating member may be coaxial with the heater component. This radial direction is defined as being perpendicular to the axis of the heater component. Similarly, the coil extends around the insulating member and is disposed radially outward from both the heater component and the insulating member. The coil may be coaxial with the insulating member and the heater component.

[0051] The insulating member is thermally insulating. For example, the insulating member may comprise a plastic material and may have a low thermal conductivity, such as a thermal conductivity of less than about 0.5 W / mK. In one example, the plastic material is PEEK and may therefore be made from the same material as the first and second supports.

[0052] The insulating member may abut at least one of the first support and the second support such that the insulating member is held substantially parallel to the axis. For example, the insulating member may extend between the first support and the second support such that a first end of the insulating member abuts the first support and a second end of the insulating member abuts the second support. Thus, the first and second supports also support the insulating member and the heater component, thereby reducing the number of components of the device.

[0053] The first support may include a first resilient member, which may abut an inner surface of the insulating member. Thus, the insulating member may extend around a portion of the first support that includes the first resilient member. The resilient member may be, for example, an O-ring. The resilient member may extend around an outer surface of the first support. When the resilient member abuts an inner surface of the insulating member, the resilient member may help seal a space between the heater component and the insulating member to better insulate the heater component from other components of the device. In some examples, the resilient member may not abut an inner surface of the insulating member, but may still provide improved insulation compared to a configuration without the resilient member.

[0054] The first support may comprise a first portion and a second portion spaced apart from the first portion in a direction parallel to the axis, and the elastic member is disposed between the first portion and the second portion. Thus, the elastic member may be held in position along the axis by the first and second portions. In other words, the elastic member cannot move past the first and second portions along the axis.

[0055] The second support may include a second elastic member, which may abut the inner surface of the insulating member, such that the first and second elastic members seal the gap. Thus, the insulating member may extend around a portion of the second support that includes the second elastic member. The second elastic member may be, for example, an O-ring. The second elastic member may extend around an outer surface of the second support. When the second elastic member abuts the inner surface of the insulating member, the second elastic member may help seal the space between the heater component and the insulating member to better insulate the heater component from other components of the device. In some examples, the second elastic member may not abut the inner surface of the insulating member, but may still provide improved insulation compared to a configuration without the second elastic member.

[0056] In some examples, the second support includes a recess in which the second elastic member is received / placed. By having a recess rather than a first and second portion as in the first support, the body of the second support can be made wider, thereby allowing the second support to function as an expansion chamber. The wider expansion chamber allows the hot aerosol to expand in volume, thereby cooling to a more comfortable temperature. In some examples, at least for the same purpose, the second elastic member may have a narrower width than the width of the first elastic member.

[0057] Alternatively, the second support may include a third portion and a fourth portion spaced apart from the third portion in a direction parallel to the axis, and the second elastic member is disposed between the third portion and the fourth portion.

[0058] The elastic member may include a silicone, such as silicone rubber. Silicone rubber is heat resistant and has good mechanical properties that do not change over a wide temperature range. Silicone rubber is also safe for use in aerosol delivery devices. In one example, the silicone rubber is Elastosil™ from Wacker Chemie AG.

[0059] The elastic member may be thermally insulating, for example having a thermal conductivity of less than about 0.5 W / mK, which slows down the transfer of heat between the support and other components of the device.

[0060] The first and second elastic members may have a first thermal conductivity, and the first and second supports may have a second thermal conductivity, the first thermal conductivity being less than the second thermal conductivity. Thus, each of the first and second elastic members may have a thermal conductivity less than the thermal conductivity of the first and second supports. This particular configuration reduces the rate at which heat flows from the heater component through the first and second supports, through the first and second elastic members, and to the insulating member. This helps insulate the insulating member. In a particular example, the first thermal conductivity is less than about 0.3 W / mK and the second thermal conductivity is less than about 0.5 W / mK. For example, silicone rubber may have a thermal conductivity of about 0.2 W / mK to about 0.25 W / mK, and PEEK may have a thermal conductivity of about 0.32 W / mK. The first and second elastic members may have a thermal conductivity less than that of the first and second supports, but they may each have a different thermal conductivity. Similarly, the first and second supports may each have a different thermal conductivity.

[0061] It is desirable to reduce the surface area of ​​the insulating member in contact with the first and second resilient members to reduce / slow the flow of heat. Similarly, it is desirable to reduce the surface area of ​​the heater component in contact with the first and second supports to reduce / slow the flow of heat. In one example, less than 5% of the heater component's surface area is in contact with each support. It is preferred that less than 3% of the heater component's surface area is in contact with each support. It is more preferred that less than 2% of the heater component's surface area is in contact with each support. In some examples, more than 1% of the heater component's surface area is in contact with each support. This can provide sufficient engagement to hold the heater component in place.

[0062] In some examples, instead of having either or both resilient members to help seal the space between the heater component and the insulating member, the insulating member can be molded to the first and / or second supports, which may increase heat flow but may provide a better seal.

[0063] The first support may include an engagement region that includes two or more protrusions that extend along the heater component in a direction parallel to the axis. Each of the protrusions may be spaced about an outer surface of the heater component and separated by a gap. When the heater component is inserted into and engages the engagement region, the protrusions allow the first support to flex outward. This makes the device easier to assemble and less likely to damage the heater component.

[0064] The second support may also include a second engagement region comprising two or more protrusions extending along the heater component in a direction parallel to the axis.

[0065] For better support, the engagement region(s) preferably comprises three or four protrusions.

[0066] In some examples, the heater component comprises an inductively heatable portion and a non-inductively heatable portion. The inductively heatable portion heats an item. The non-inductively heatable portion or portions may connect the heater component to a device and are therefore preferably good insulators. The non-inductively heatable portion or portions may also provide rigidity for receiving an item. The non-inductively heatable portion or portions may be located at the ends of the heater component.

[0067] In a particular example, the heater component comprises an inductively heatable portion, a first non-inductively heatable portion disposed at a first end of the heater component, and a second non-inductively heatable portion disposed at a second end of the heater component. The first support can be engaged with the first non-inductively heatable portion and the second support can be engaged with the second non-inductively heatable portion. Engaging the non-inductively heatable portion can provide better support for the heater component and can provide better insulation for the first and second supports from the inductively heatable portions.

[0068] In another aspect, a first support is provided for supporting a heater component of an aerosol delivery device, the first support defining an axis and configured to engage a first end of the heater component to hold the heater component substantially parallel to the axis at a predetermined distance from the at least one coil. The first support may have any or all of the features described above in relation to the aerosol delivery device.

[0069] In another aspect, a second support is provided for supporting a heater component of an aerosol delivery device, the second support configured to engage a second end of the heater component to hold the heater component substantially parallel to the axis at a predetermined distance from the at least one coil. The second support may have any or all of the features described above in relation to the aerosol delivery device.

[0070] In some examples, the device may include only one of the first and second supports. For example, in one aspect, an aerosol delivery device is provided that includes a heater component configured to heat an aerosol generating material, a support defining an axis and configured to engage a first end of the heater component, and at least one coil configured to heat the heater component. The support holds the heater component substantially parallel to the axis at a predetermined distance from the at least one coil. In such examples, less than 5% of the surface area of ​​the heater component may be in contact with the support. Preferably, less than 3% of the surface area of ​​the heater component is in contact with the support. More preferably, less than 2% of the surface area of ​​the heater component is in contact with the support. In some examples, more than 1% of the surface area of ​​the heater component is in contact with the support. This can provide sufficient engagement to hold the heater component in place.

[0071] The heater component may be hollow and / or substantially tubular and capable of receiving the aerosol-forming material within the heater component such that the heater component surrounds the aerosol-forming material. The insulating member may be hollow and / or substantially tubular such that the heater component may be disposed within the insulating member.

[0072] The coil may be substantially helical. For example, the coil may be formed from a wire, such as a Litz wire, and is helically wound around the insulating member. In another example, the coil may not extend around the heater component, but may instead be in a different configuration to heat the heater component.

[0073] The coil may be spaced from the outer surface of the heater component by a distance of about 3 mm to about 4 mm. Thus, the inner surface of the coil and the outer surface of the heater component may be spaced apart by this distance. This distance may be a radial distance. A distance within this range has been found to provide a good balance between having the heater component radially close to the coil so that it can be efficiently heated, and radially far enough away to improve insulation of the coil (and insulating members, if any).

[0074] In another example, the coil may be positioned a distance greater than about 2.5 mm from the outer surface of the heater component.

[0075] In another example, the coil may be positioned about 3 mm to about 3.5 mm away from the outer surface of the heater component. In a further example, the coil may be positioned about 3 mm to about 3.25 mm away from the outer surface of the heater component, preferably about 3.25 mm away, for example. In another example, the coil may be positioned more than about 3.2 mm away from the outer surface of the heater component. In a further example, the coil may be positioned less than about 3.5 mm away from the outer surface of the heater component, or less than about 3.3 mm away from the outer surface of the heater component. It has been found that a distance within this range provides a balance between having the heater component radially close to the coil so that the heater component can be efficiently heated, and radially spaced apart to improve insulation of the coil and insulating member.

[0076] Reference to an "outer surface" of an entity means the surface disposed furthest from the axis of the heater component in a direction perpendicular to the axis. Reference to an "inner surface" of an entity means the surface disposed closest to the axis of the heater component in a direction perpendicular to the axis.

[0077] The insulating member may have a thickness of about 0.25 mm to about 1 mm. For example, the insulating member may have a thickness less than about 0.7 mm, or less than about 0.6 mm, or may have a thickness of about 0.25 mm to about 0.75 mm, or preferably has a thickness of about 0.4 mm to about 0.6 mm, such as about 0.5 mm. These thicknesses have been found to provide a good balance between reducing heating of the insulating member and coil (by making the insulating member thinner and increasing the size of the air gap) and increasing the robustness of the insulating member (by making the insulating member thicker).

[0078] The heater component may have a thickness of about 0.025 mm to about 0.5 mm, or about 0.025 mm to about 0.25 mm, or about 0.03 mm to about 0.1 mm, or about 0.04 mm to about 0.06 mm. For example, the heater component may have a thickness greater than about 0.025 mm, or greater than about 0.03 mm, or greater than about 0.04 mm, or less than about 0.5 mm, or less than about 0.25 mm, or less than about 0.1 mm, or less than about 0.06 mm. These thicknesses have been found to provide a good balance between allowing the heater component to heat up quickly (if made thin) and ensuring that the heater component is robust (if made thick).

[0079] In one example, the heater component has a thickness of about 0.05 mm. This provides a balance between rapid and effective heating and robustness. Such a heater component may be easier to manufacture and assemble as part of an aerosol delivery device than other heater components with thinner dimensions.

[0080] References to the "thickness" of an entity mean the average distance between an inner surface of the entity and an outer surface of the entity. The thickness may be measured in a direction perpendicular to the axis of the heater component.

[0081] In a particular configuration of the aerosol delivery device, the coil is positioned from an outer surface of the heater component a distance of about 3 mm to about 4 mm, the insulating member has a thickness of about 0.25 mm to about 1 mm, and the heater component has a thickness of about 0.025 mm to about 0.5 mm. Such an aerosol delivery device allows for rapid heating and effective insulating properties of the heater component.

[0082] In another particular configuration, the coil may be positioned from an outer surface of the heater component a distance of about 3 mm to about 3.5 mm, the insulating member has a thickness of about 0.25 mm to about 0.75 mm, and the heater component has a thickness of about 0.04 mm to about 0.06 mm. Such an aerosol delivery device allows for improved heating and improved insulating properties of the heater component.

[0083] In a further particular configuration, the coil is positioned about 3.25 mm from an outer surface of the heater component, the insulating member has a thickness of about 0.5 mm, and the heater component has a thickness of about 0.05 mm. Such an aerosol delivery device allows for efficient heating and good insulating properties of the heater component.

[0084] The coil, heater element, and insulating member may be coaxial. This configuration ensures that the heater element is heated efficiently, and that the air gap and insulating member provide effective insulation.

[0085] The inner surface of the coil may be in contact with the outer surface of the insulating member. Thus, the insulating member may support the coil without the need for other components. However, in other examples, there may be an additional gap between the inner surface of the coil and the outer surface of the insulating member. The distance between the inner surface of the coil and the outer surface of the insulating member may be less than about 0.1 mm, for example, about 0.05 mm.

[0086] The insulating member may have a melting point greater than about 280° C., such as greater than about 300° C., or greater than about 340° C. PEEK has a melting point of 343° C. An insulating member with such a melting point ensures that the insulating member remains rigid / stiff when the heater component is heated.

[0087] Preferably the device is a tobacco heating device, also known as a non-combustion heating device.

[0088] As briefly mentioned above, in some examples, the coil(s) are configured, when in use, to cause heating of at least one electrically conductive heating component / element (also referred to as a heater component / element), such that thermal energy can be conducted from the at least one electrically conductive heating component to the aerosol-generating material, thereby causing heating of the aerosol-generating material.

[0089] In some examples, the coil(s) are configured to generate a varying magnetic field for penetrating at least one heating component / element in use, thereby inductively heating and / or magnetic hysteresis heating the at least one heating component. In such configurations, each heating component may be referred to as a "susceptor." A coil configured to generate a varying magnetic field for penetrating at least one electrically conductive heating component in use, thereby inductively heating the at least one electrically conductive heating component may be referred to as an "induction coil" or "inductor coil."

[0090] The device may include a heating component(s), e.g., conductive heating component(s), which may be suitably positioned or positionable relative to the coil(s) to enable such heating of the heating component(s). The heating component(s) may be in a fixed position relative to the coil(s). Alternatively, both the device and the article / consumable may comprise at least one respective heating component, e.g., at least one conductive heating component, and the coil(s) may be such that the respective heating component(s) of the device and article are heated when the article is in the heating zone.

[0091] In some examples, the coil(s) are helical. In some examples, the coil(s) surround at least a portion of a heating zone of the device configured to receive the aerosol generating material. In some examples, the coil(s) are helical coil(s) surrounding at least a portion of the heating zone of the device configured to receive the aerosol generating material. The heating zone can be a receptacle configured to receive the aerosol generating material.

[0092] In some examples, the device includes an electrically conductive heating element at least partially surrounding the heating zone, and the coil(s) is a helical coil(s) surrounding at least a portion of the electrically conductive heating element. In some examples, the electrically conductive heating element is tubular. In some examples, the coil is an inductor coil.

[0093] 1 shows an example of an aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. In general, device 100 can be used to heat a replaceable article 110 that contains an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0094] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it is heated by one or more components of the heater assembly.

[0095] The device 100 of this example includes a first end member 106 with a lid 108 movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. In Figure 1, the lid 108 is shown in an open configuration, but the cap 108 may be moved to a closed configuration. For example, a user may slide the lid 108 in the direction of arrow "A."

[0096] The device 100 may include a user-operable control element 112, such as a button or switch, that when pressed activates the device 100. For example, a user may turn on the device 100 by operating the switch 112.

[0097] The device 100 may include an electrical component, such as a socket / port 114, that can receive a cable for charging a battery in the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

[0098] 2 depicts the device 100 of FIG. 1 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134.

[0099] 2, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first end member 106 and the second end member 116 together at least partially define an end surface of the device 100. For example, a bottom surface of the second end member 116 at least partially defines a bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of a top surface of the device 100.

[0100] The end of the device closest to the opening 104 is sometimes referred to as the proximal end (or mouth end) of the device 100, as it is closest to the user's mouth during use. In use, a user inserts an article 110 into the opening 104, operates a user control 112 to initiate heating of the aerosol-generating material, and inhales the aerosol generated by the device, which causes the aerosol to flow through the device 100 along a flow path toward the proximal end of the device 100.

[0101] The other end of the device, furthest from opening 104, is sometimes referred to as the distal end of device 100, as it is the end furthest from a user's mouth in use. As a user inhales the aerosol generated by the device, the aerosol flows out of the distal end of device 100.

[0102] The device 100 further comprises a power source 118. The power source 118 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power to heat the aerosol-generating material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

[0103] The device further comprises at least one electronic module 122. The electronic module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may comprise one or more electrical traces for electrically connecting various electronic components of the device 100. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via electrical traces.

[0104] In the exemplary device 100, the heating assembly is an induction heating assembly, which includes various components for heating the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element, for example one or more induction coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. This varying magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore the susceptor is heated by Joule heating due to the eddy currents flowing against this resistance. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., the orientation of the magnetic dipoles of the magnetic material changes as a result of alignment with the varying magnetic field. Compared to heating by thermal conduction, for example, induction heating allows for rapid heating since heat is generated inside the susceptor, and furthermore, no physical contact is required between the induction heater and the susceptor, allowing greater flexibility in manufacturing and application.

[0105] The induction heating assembly of the exemplary device 100 includes a susceptor device 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are made from a conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made from a Litz wire / cable that is wound in a helical shape to form the helical inductor coils 124, 126. The Litz wire is composed of multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect losses of the conductor. In the exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are made from copper Litz wire with a rectangular cross-section. In other examples, the Litz wire may have other shaped cross-sections, such as circular.

[0106] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first portion of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second portion of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along a longitudinal axis 134 of the device 100 (i.e., the first inductor coil 124 and the second inductor coil 126 do not overlap). The susceptor device 132 may include a single susceptor or may include two or more separate susceptors. Each end 130 of the first inductor coil 124 and the second inductor coil 126 may be connected to the PCB 122.

[0107] It should be understood that the first inductor coil 124 and the second inductor coil 126 may have at least one different characteristic in some examples. For example, the first inductor coil 124 may have at least one different characteristic than the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different value of inductance than the second inductor coil 126. In FIG. 2, the first inductor coil 124 and the second inductor coil 126 are of different lengths such that the first inductor coil 124 is wound over a smaller portion of the susceptor 132 compared to the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0108] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when each inductor coil is energized at a different time. For example, the first inductor coil 124 may be operated to heat a first portion of the article 110 first, and the second inductor coil 126 may be operated to heat a second portion of the article 110 at a later time. Winding each coil in opposite directions helps reduce the current induced in the non-energized coil when used in combination with certain types of control circuits. In FIG. 2, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124, 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0109] The susceptor 132 in this example is hollow and thus defines a receptacle in which the aerosol-generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 132 is tubular with a circular cross-section.

[0110] 2 further includes an insulating member 128, which may be generally tubular and may at least partially surround the susceptor 132. The insulating member 128 may be made from any insulating material, such as, for example, plastic. In this particular example, the insulating member is made from polyetheretherketone (PEEK). The insulating member 128 may help insulate various components of the device 100 from heat generated by the susceptor 132.

[0111] The insulating member 128 may also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 2, the first inductor coil 124 and the second inductor coil 126 are disposed around the insulating member 128 and contact a radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, a small gap may exist between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

[0112] In a particular example, the susceptor 132 , the insulating member 128 , and the first and second inductor coils 124 and 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0113] 3 is a partial cross-sectional side view of device 100. In this example, outer cover 102 is present. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 can be seen more clearly.

[0114] The device 100 further comprises a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0115] The device may also include a second printed circuit board 138 that resides within the control element 112 .

[0116] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward a distal end of the device 100. The spring 142 allows the second lid 140 to be opened to access the susceptor 132. A user may open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0117] The device 100 further includes an expansion chamber 144 that extends away from the proximal end of the susceptor 132 toward the opening 104 of the device. A retaining clip 146 is positioned at least partially within the expansion chamber 144 to abut and retain the article 110 when the article 110 is received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0118] FIG. 4 is an exploded view of the device 100 of FIG. 1 without the outer cover 102.

[0119] FIG 5A illustrates a cross-section of a portion of the device 100 of FIG 1. FIG 5B illustrates a close-up of a region of FIG 5A. FIGs 5A and 5B show the article 110 received within the susceptor 132, with the article 110 sized so that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures that heating is most efficient. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also include other components, such as a filter, packaging material, and / or cooling structure.

[0120] FIG. 5B illustrates a longitudinal axis 158 of a hollow, tubular susceptor 132. The inner and outer surfaces of the susceptor 132 extend azimuthally about the axis 158. Surrounding the susceptor 132 may be a hollow, tubular insulating member 128. The inner surface of the insulating member 128 is spaced from the outer surface of the susceptor 132 to provide a gap between the insulating member 128 and the susceptor 132. This gap provides insulation from heat generated in the susceptor 132. Surrounding the insulating member 128 are inductor coils 124, 126. It will be appreciated that in some instances, only one inductor coil may surround the insulating member 128. The inductor coils 124, 126 are spirally wound around the insulating member and extend along the axis 158.

[0121] 5B shows that the outer surface of the susceptor 132 is separated from the inner surfaces of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In particular examples, the distance 150 is about 3 mm to 4 mm, about 3 to 3.5 mm, or about 3.25 mm. The outer surface of the susceptor 132 is the surface furthest from the axis 158. The inner surface of the susceptor 132 is the surface closest to the axis 158. The inner surfaces of the inductor coils 124, 126 are the surfaces closest to the axis 158. The outer surface of the insulating member 128 is the surface furthest from the axis 158.

[0122] The susceptor 132 may be held in place by one or more components of the device 100 to provide a relative spacing 150 between the susceptor 132 and the inductor coils 124, 126. In the example of Figure 5A, the susceptor 132 is held in place at one end by a first support 136 and at the other end by a second support 144 (which may also function as an expansion chamber). The insulating member 128 may also be held in place by the first and second supports 136, 144.

[0123] 5B further illustrates that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm such that the inductor coils 124, 126 abut and contact the insulating member 128.

[0124] In one example, the susceptor 132 has a wall thickness 154 of about 0.025 mm to 1 mm. In this example, the susceptor 132 has a thickness 154 of about 0.05 mm. The thickness of the susceptor 132 is the average distance between the inner surface of the susceptor 132 and the outer surface of the susceptor 132, measured in a direction perpendicular to the axis 158.

[0125] In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 50 mm, about 40 mm to 45 mm, or about 44.5 mm. In this particular example, the susceptor 132 has a length of about 44.5 mm and is capable of receiving an article 110 comprising an aerosol-generating material 110a having a length of about 42 mm. The lengths of the aerosol-generating material and the susceptor 132 are measured in a direction parallel to the axis 158.

[0126] In one example, the insulating member 128 has a thickness 156 of about 0.25 mm to about 2 mm, or about 0.25 mm to about 1 mm. In this particular example, the insulating member has a thickness 156 of about 0.5 mm. The thickness 156 of the insulating member 128 is the average distance between the inner surface of the insulating member 128 and the outer surface of the insulating member 128, measured in a direction perpendicular to the axis 158.

[0127] Figure 6 is an enlarged view of the support 136, briefly described above in relation to Figure 3. The support 136 defines an axis 204 that is disposed parallel to the longitudinal axis 134 of the device 100. The axis 204 may be, for example, the longitudinal axis of the support 136.

[0128] The support 136 includes an engagement region 202 at one end that receives and engages the distal end of the susceptor 132. The distal end of the susceptor 132 is the end of the susceptor 132 that is disposed furthest from a user's mouth when the device 100 is in use. In other examples, the support 136 may be positioned to engage the other end of the susceptor 132. In this example, the susceptor 132 and the engagement region 202 form an interference fit, although other attachment means may be used. The support 136 holds the susceptor parallel to an axis 204 at a predetermined distance from one or more inductor coils 124, 126 that surround the susceptor (as seen most clearly in FIG. 2).

[0129] As described above, the device 100 includes a hollow insulating member 128 that surrounds the susceptor 132 and at least a portion of the support 136. The inner surface of the insulating member 128 is disposed a predetermined distance from the axis 204. A space 206 (e.g., a gap) is provided between the outer surface of the susceptor 132 and the inner surface of the insulating member 128. The gap 206 and the insulating member 128 act to insulate the components of the device 100 from heat generated in the susceptor 132.

[0130] The device 100 may include one or more temperature sensors that can be used to measure the temperature of the susceptor 132. The temperature sensors may be attached to an outer surface of the susceptor 132 or may be located proximate to the susceptor 132. Each sensor may include one or more wires connected to the temperature sensor. FIG. 6 shows a first wire 208 connected to a first temperature sensor (not visible in FIG. 6). The wire 208 connects the temperature sensor to other components in the device, such as the PCB 122. For example, a controller located on the PCB 122 can determine the temperature of the susceptor 132 based on a signal received from the temperature sensor(s). The device 100 may be configured to control one or more inductive coils 124, 126 based on the detected temperature. For example, the inductor coils may be switched off when the temperature of the susceptor 132 reaches a predetermined threshold.

[0131] 6, the wires 208 are disposed parallel to the axis 204. However, in some examples, the wires 208 may not be parallel to the axis 204. For example, the wires may undulate or bend as they pass through the space 206.

[0132] To connect the temperature sensor to other components within the device 100, the support 136 defines a channel 210 through which the wire 208 is routed. The presence of the channel 210 means that the wire 208 does not need to penetrate the surface of the insulating member 128.

[0133] In this example, the channel 210 is formed in a first portion 212 of the support 136. The channel 210 thus extends through the first portion 212. In this example, the first portion is generally disc-shaped and thus has a generally circular cross-sectional shape (as seen most clearly in FIG. 8). The first portion 212 is disposed substantially perpendicular to the axis 204. The first portion 212 has a thickness / depth 221 measured in a direction parallel to the axis 204. The channel 210 extends through the first portion 212 in a direction substantially parallel to the axis 204, and thus the channel 210 has a length equal to the depth 221 of the first portion 212.

[0134] The first portion 212 has an outer periphery that may abut an inner surface of the insulating member 128 to help seal the space 206 between the susceptor 132 and the insulating member 128. In some examples, a gap may exist between the outer periphery of the first portion 212 and the inner surface of the insulating member 128. The insulating member 128 surrounds the first portion 212, with the inner surface of the insulating member 128 being positioned a predetermined radial distance 222 from the outer surface of the susceptor 132.

[0135] In this example, the support 136 further comprises a second portion 216, the second portion 216 being spaced apart from the first portion 212 along the axis 204. In other examples, the second portion may be omitted. The second portion 216 may be similar to the first portion 212. For example, the first portion 212 and the second portion 216 may have a similar cross-sectional shape and / or size and / or a similar depth. In this example, the second portion 216 comprises a second channel 218 through which the wire 208 is routed.

[0136] The support 136 further comprises a resilient member 214, such as an O-ring, spaced from the channel 210 along the axis 204. In this example, the support 136 comprises a second portion 216, with the resilient member 214 disposed between the first portion 212 and the second portion 216. The resilient member 214 is thus held in place by the first and second portions 212, 216. The wire 208 passes behind the resilient member 214 and is held against a surface of the support 136. The resilient member 214 thus helps to hold the wire 208 within the channels 210, 218 and maintain the wire 208 in a taught state. The resilient member 214 may abut against an inner surface of the insulating member 128 to help seal the space 206 between the susceptor 132 and the insulating member 128.

[0137] In some examples, the second portion may not include a channel, and may have a smaller cross-sectional area than the cross-sectional area of ​​the first portion. Thus, the wire may be routed around the second portion, rather than through a channel formed in the second portion. The second portion in such examples may function to hold the elastic member in place.

[0138] In some examples, the support 136 further comprises an end 220 that abuts the distal end of the insulating member 128. The end 220 supports and holds the insulating member 128 in place while also helping to further seal the space 206 between the susceptor 132 and the insulating member 128. In other examples, the insulating member 128 may be supported by other means.

[0139] End 220 is disposed adjacent to an end of insulating member 128 and is wider than insulating member 128. This means that end 220 has a larger cross-sectional area than the cross-sectional area of ​​insulating member 128, so that insulating member 128 does not surround end 220.

[0140] In some examples, the support 136 is hollow. Debris and / or liquid from the heated aerosol-generating material may flow from the susceptor 132 into the hollow cavity of the support 136. As discussed in connection with FIGURE 3, the device 100 may include a second lid 140 that is openable to allow a user to clean the susceptor 132 and / or the support 136.

[0141] 7 is a perspective view of the support 136 near a channel 210. As shown, the channel 210 is formed through the first portion 212 with the wire 208 passing through the channel 210. The channel 210 has a depth 302a measured in a direction perpendicular to the axis 204. The channel also has a width 302b measured in a direction perpendicular to the depth 302a. In this example, the depth 302a is about 1.3 mm and the width 302b is about 0.9 mm. The wire 208 is also surrounded by the elastic member 214 and passes through a second channel 218 formed in the second portion 216.

[0142] 6 and 7, the first portion 212 and the second portion 216 each include four channels through which four wires 208, 308a, 308b, 308c are routed. For example, the first wire 208 and the second wire 308a may be connected to a first temperature sensor, and the third wire 308b and the fourth wire 308c may be connected to a second temperature sensor.

[0143] Figure 8 is a top down view of the support 136 of Figures 6 and 7. A hollow cylindrical susceptor 132 is shown engaged with the engagement region 202 of the support 136. In this example, the outer periphery of the resilient member 214 is further away from the axis 204 than the outer periphery of the first portion 212, as measured in the radial direction 304. Thus, the resilient member 214 can abut against the inner surface of the insulating member, if one is present.

[0144] As shown in Figure 8, the channel 210 is open along its length (where the length is measured from the page into the page along the axis 204). The channel 210 thus forms a notch in the periphery of the first portion 212. Each of the other three channels has the same configuration. In contrast, Figure 9 shows another support 336 in which the channel 310 is closed along its length, thus forming a through hole in the first portion 312. The support 336 of Figure 9 may be used in the device 100, and the support 336 may have any or all of the features of the support 136.

[0145] Figure 10 illustrates an example of another support 436 that may be used with device 100. This example support 436 differs from the support of Figures 6 and 7 in that it does not include a second portion or a resilient member. Although channel 410 is provided by a through hole, channel 410 may instead be an open channel along its length.

[0146] 10 includes an engagement region 402 that receives and engages the distal end of the susceptor 132. The support 436 defines an axis 404 that may be disposed parallel to the longitudinal axis 134 of the device 100. For example, the axis 404 may be the longitudinal axis of the support 436. The support 436 holds the susceptor parallel to the axis 404.

[0147] The device 100 includes a hollow insulating member 128 that surrounds a susceptor 132. A space 406 (eg, an air gap) is provided between an outer surface of the susceptor 132 and an inner surface of the insulating member 128.

[0148] The device 100 includes a temperature sensor 424 attached to an outer surface of the susceptor 132. The wire 408 is connected to the temperature sensor 424. One or more other wires (not shown) may also be connected to the temperature sensor 424. There may also be a second temperature sensor within the device 100.

[0149] The support 436 defines a channel 410 in the form of a through hole through which the wire 408 is disposed. In this example, the channel 410 is formed through a first portion 412 of the support 436. The first portion 412 has a depth measured in a direction parallel to the axis 404, and the channel 410 extends through the first portion 412 in a direction substantially parallel to the axis 404. The through hole thus has a length equal to the depth of the first portion 412. As shown, the first portion 412 has an outer periphery that abuts the inner surface of the insulating member 128.

[0150] The support 436 further comprises an end 420 that abuts the distal end of the insulating member 128. The end 420 supports and holds the insulating member 128 in place while also helping to further seal the space 406 between the susceptor 132 and the insulating member 128. In this example, the end 420 also defines a channel 426 in the form of a through hole through which the wire 408 is routed so that the wire 408 can be connected to other components of the device 100.

[0151] 6-10, the first portion, second portion, susceptor, and insulating member each have a substantially circular cross-section, although in other examples the cross-section of any or all of these components may take any other shape, such as square, rectangular, or oval.

[0152] 11 shows a portion of device 100. Inductor coils 124, 126 and insulating member 128 have been omitted for clarity of illustration. In this example, first support 136 defines an axis 204 disposed parallel to longitudinal axis 158 of susceptor 132, which may also be disposed parallel to longitudinal axis 134 of device 100. For example, axis 204 may be the longitudinal axis of support 136.

[0153] 12 is an enlarged view of the first support 136, the second support 144, and the susceptor 132. The first support 136 includes a first engagement region 202 at one end that receives and engages the distal end of the susceptor 132. The distal end of the susceptor 132 is the end of the susceptor 132 that is disposed furthest from a user's mouth when the device 100 is in use. In this example, the susceptor 132 and the first engagement region 202 form an interference or friction fit, although other attachment means may be used.

[0154] The first engagement region 202 may include two or more protrusions 224 or projections that extend from an end of the first support 136 along the susceptor 132 in the direction of the axis 204. Each of the protrusions 224 is spaced about the outer surface of the susceptor 132 and separated by gaps. The protrusions 224 flex outward when the susceptor 132 is inserted into the first engagement region 202.

[0155] Similarly, the second support 144 includes a second engagement region 506 at one end that receives and engages the proximal end of the susceptor 132. The proximal end of the susceptor 132 is the end of the susceptor 132 that is positioned closest to a user's mouth when the device 100 is in use. In this example, the susceptor 132 and the second engagement region 506 form an interference or friction fit, although other attachment means may be used.

[0156] The second engagement region 506 may also include two or more protrusions 226 or projections extending from an end of the second support 144 along the susceptor 132 in the direction of the axis 204. Each of the protrusions 226 is spaced about the outer surface of the susceptor 132 and separated by gaps. The protrusions 226 allow the second support 144 to flex when the susceptor 132 is inserted into the engagement region 506.

[0157] The first and second supports 136, 144 together hold the susceptor 132 parallel to an axis 204 at a predetermined distance 150 from one or more inductor coils 124, 126 that surround the susceptor (as seen most clearly in Figures 5A and 5B).

[0158] The first support 134 and the second support 144 may be made of the same material or different materials. In this example, the first and second supports 134, 144 are both made of a plastic material such as PEEK, which has a thermal conductivity of about 0.32 W / mK and a melting point of about 343° C. With a low thermal conductivity, the flow rate of heat from the susceptor 132 through the first and second supports 134, 144 is low. Alternatively, other materials with low thermal conductivity may be used. It is preferred that the first and second supports 134, 144 are made of a plastic material, as this can be made lightweight.

[0159] In some examples, the susceptor 132 is heated by the first and second inductor coils 124, 126 to a temperature of about 240° C. to about 280° C. If the first and second supports 134, 144 have a melting point that is at least 60° C. higher than the temperature of the heated susceptor 132, the first and second supports 134, 144 are unlikely to soften or weaken due to heating.

[0160] Figure 13 shows the configuration of Figure 12 with insulating member 128 surrounding susceptor 132. Insulating member 128 is shown as being transparent so that susceptor 132 can be seen within hollow insulating member 128. Insulating member 128 may or may not be transparent.

[0161] The insulating member 128 is spaced from the susceptor 132 such that a gap 206 is provided between the outer surface of the susceptor 132 and the inner surface of the insulating member 128. The gap 206 provides insulation.

[0162] The insulating member 128 may be held in place by one or more components of the device 100. However, in this example, the insulating member 128 abuts the first support 136 near an end of the insulating member. For example, the first support 136 may include an end 220 having a cross-section larger than the cross-section of the insulating member 128. Thus, the first end of the insulating member 128 abuts the end 220 of the first support 136. By abutting at least one of the first support 136 and the second support 144, the insulating member 128 may be held substantially parallel to the axis 204.

[0163] In some examples, the insulating member 128 also abuts the second support 144 near an end of the insulating member 128. For example, the second support 144 may also include an end 512 having a cross-section larger than the cross-section of the insulating member 128. Thus, the second end of the insulating member 128 may abut the end 512 of the second support 144. FIG. 13 illustrates a small gap between the end 512 of the second support 144 and the second end of the insulating member 128. This small gap can allow for manufacturing tolerances, but in certain examples, this small gap may not be present.

[0164] 12 and 13 show the first support 136 having a first resilient member 214 extending around a portion of the support 136. In this example, the first resilient member 214 is an O-ring. FIG. 13 shows that the first resilient member 214 has dimensions such that the first resilient member 214 abuts the inner surface of the insulating member 128 when the insulating member 128 is in place. Thus, the first resilient member 214 can help seal the space 208 between the susceptor 132 and the insulating member 128 to better insulate the device 100. When the insulating member 128 surrounds the susceptor 132, the first resilient member 214 may be compressed.

[0165] In some examples, the first support 132 comprises a first portion 212 and a second portion 216, and the first elastic member 214 is disposed between the first portion 212 and the second portion 216. The first and second portions 212, 216 prevent the first elastic member 214 from sliding along the first support 136, which may reduce the sealing effect.

[0166] 12 and 13 show the second support 144 having a second resilient member 520 extending around a portion of the support 144. In this example, the second resilient member 520 is an O-ring. In some examples, the second resilient member 520 is dimensioned such that the second resilient member 520 abuts an inner surface of the insulating member 128 when the insulating member 128 is in place. When both the first and second resilient members 214, 520 abut the insulating member 128, the device 100 may be better insulated than a configuration in which either one of the resilient members 214, 520 abuts the insulating member 128 or neither of them abuts the insulating member 128.

[0167] In some examples, the second support 144 includes a recess 522 in which the second resilient member is disposed. In some examples, the second resilient member 520 has a width that is narrower than the width of the first resilient member 214. The width of the resilient member is measured in a direction perpendicular to the axis 204.

[0168] In this example, the first and second elastic members 214, 520 are made from a material having a thermal conductivity of less than about 0.5 W / mK, such as less than about 0.25 W / mK. The first and second elastic members 214, 520 may be made from, for example, silicone rubber.

[0169] The above embodiments should be understood as illustrative of the invention. Further embodiments of the invention are envisioned. It should be understood that any feature described with respect to any one embodiment may be used alone or together with other features described, and may also be used together with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Moreover, equivalents and modifications not described above may also be used without departing from the scope of the invention, which is defined in the appended claims.

Claims

1. 1. A support for a heater component of an aerosol delivery device, the support defining an axis, the support configured to engage an end of the heater component to hold the heater component substantially parallel to the axis at a predetermined distance from a coil, the support defining a channel for receiving a wire of a temperature sensor, the channel defining an opening to a space between the heater component and the coil.

2. The support of claim 1 , wherein the channel extends substantially parallel to the axis.

3. A support according to claim 1 or 2, wherein the channel is open along its length.

4. 4. A support according to any one of claims 1 to 3, wherein the support comprises a first portion, the channel being formed through the first portion, the channel being a notch in a periphery of the first portion.

5. the support includes a second portion spaced apart from the first portion in a direction parallel to the axis; The support of claim 4 , wherein a second channel is formed through the second portion for receiving the wire.

6. The support of claim 5 further comprising a resilient member disposed between the first portion and the second portion.

7. A support according to any preceding claim, further comprising a resilient member spaced longitudinally from the channel.

8. A support according to claim 6 or 7, wherein the wire passes through an opening / hole formed in the elastic member.

9. A support according to any preceding claim, further comprising an edge configured to abut an edge of an insulating member surrounding the heater component.

10. A support according to any one of claims 1 to 9, which defines at least two channels.

11. A support according to any one of claims 1 to 10; a heater component engaged at one end with the support; a coil extending around the heater component, the coil configured to heat the heater component; a temperature sensor for detecting a temperature of the heater component, the temperature sensor being disposed in a space between the coil and the heater component; a wire disposed in the channel of the support and connected to the temperature sensor; 1. An aerosol delivery device comprising:

12. Further comprising an insulating member; the support comprises a first portion, the channel being formed through the first portion; The aerosol delivery device of claim 11 , wherein the insulating member surrounds the heater component and abuts at least a portion of the first portion of the support, thereby positioning the insulating member a predetermined radial distance outward from the heater component.

13. a second temperature sensor for sensing a temperature of the heater component, the second temperature sensor being disposed in a space between the coil and the heater component; a second wire connected to the second temperature sensor; Further equipped with The aerosol delivery device of claim 11 or 12, wherein the support defines a second channel for receiving the second wire.

14. The aerosol delivery device of any one of claims 11 to 13, wherein the temperature sensor is in contact with the heater component.

15. A support defining an axis; A coil and A heater component, the heater element is heatable by the coil; an end of the heater component engages the support to hold the heater component substantially parallel to the axis at a predetermined distance from the coil; a heater component, the support defining a channel defining an opening to a space between the heater component and the coil; a temperature sensor for detecting a temperature of the heater component, the temperature sensor being disposed in the space between the heater component and the coil; a wire disposed in the channel of the support and connected to the temperature sensor; 1. An aerosol delivery device comprising:

16. An aerosol delivery device according to any one of claims 11 to 15; an article comprising an aerosol-forming material; An aerosol delivery system comprising:

17. a heater component configured to heat the aerosol-generating material; and a first support defining an axis and configured to engage a first end of the heater component; a second support configured to engage a second end of the heater component; and at least one coil configured to heat the heater element; Equipped with The aerosol delivery device, wherein the first support and the second support hold the heater component substantially parallel to the axis at a predetermined distance from the at least one coil.

18. an insulating member extending around the heater component; the insulating member is spaced from the heater component to provide an air gap around the heater component; 20. The aerosol delivery device of claim 17, wherein the insulating member is disposed between the at least one coil and the heater component such that the at least one coil extends around the insulating member.

19. 20. The aerosol delivery device of claim 18, wherein the insulating member abuts at least one of the first support and the second support such that the insulating member is held substantially parallel to the axis.

20. 20. The aerosol delivery device of claim 19, wherein the first support comprises a first resilient member, the first resilient member abutting an inner surface of the insulating member.

21. 21. The aerosol delivery device of claim 20, wherein the second support comprises a second elastic member, the second elastic member abutting an inner surface of the insulating member, and the first elastic member and the second elastic member sealing the gap.

22. 22. The aerosol delivery device of claim 21, wherein the first elastic member and the second elastic member have a first thermal conductivity, the first support and the second support have a second thermal conductivity, the first thermal conductivity being less than the second thermal conductivity.

23. The aerosol delivery device of any one of claims 17 to 22, wherein the first support and the second support are thermally insulating.

24. The aerosol delivery device of any one of claims 17 to 22, wherein the first support and the second support have a thermal conductivity of less than about 0.5 W / mK.

25. The aerosol delivery device of any one of claims 17 to 24, wherein the first support and the second support comprise a plastic material.

26. 26. The aerosol delivery device of claim 25, wherein the plastic material comprises polyetheretherketone (PEEK).

27. The aerosol delivery device of any one of claims 17 to 26, wherein the first substrate and the second substrate have a melting point greater than about 300°C.

28. 28. The aerosol delivery device of claim 27, wherein the first substrate and the second substrate have a melting point greater than about 340°C.

29. 29. The aerosol delivery device of any one of claims 17 to 28, wherein, in use, the at least one coil is configured to heat the heater component to a first temperature, the first support and the second support have melting points at a second temperature, and the second temperature is at least about 60°C higher than the first temperature.

30. 30. The aerosol delivery device of any one of claims 17 to 29, wherein the first support comprises an engagement region comprising two or more protrusions extending along the heater component in a direction parallel to the axis.

31. An aerosol delivery device according to any one of claims 17 to 30; an article comprising an aerosol-forming material; An aerosol delivery system comprising:

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