Aerosol provision device

Abstract

To provide an aerosol provision device and a chassis for the aerosol provision device.SOLUTION: An aerosol provision device is described. The device comprises an aerosol generating assembly, an electrical component, which may be a printed circuit board (PCB), and a chassis holding the aerosol generating assembly and the electrical component. The aerosol generating assembly has a heater assembly to receive aerosol generating material. The heater assembly has: a susceptor which is heatable by penetration with a varying magnetic field; and an inductor coil extending around the heater assembly. The inductor coil generates the varying magnetic field. The inductor coil has a coil wire end engaged with the electrical component. The chassis has a coil wire end positioning arrangement to hold and align the coil wire end with the electrical component.SELECTED DRAWING: Figure 14

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device and a chassis for an aerosol delivery device. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion. An example of such a product is a heating device that releases compounds by heating a material without burning it. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Summary of the Invention

[0003] According to one aspect of the disclosure, there is provided an aerosol delivery device comprising an aerosol generation assembly, an electrical component, and a housing for holding the aerosol generation assembly and the electrical component, the aerosol generation assembly having a heater assembly configured to receive an aerosol-generating material, the heater assembly including a susceptor heatable by penetration of a varying magnetic field, and an inductor coil extending around the heater assembly, the inductor coil configured to generate the varying magnetic field, the inductor coil comprising a coil wire end that engages the electrical component, the housing comprising a coil wire end positioning arrangement configured to hold and align the coil wire end with respect to the electrical component.

[0004] In some embodiments, the electrical component is a printed circuit board (PCB).

[0005] The coil wire end may be a first end of an inductor coil, and the inductor coil may have a second end.

[0006] In some examples, the coil wire end positioning arrangement may have a first positioning means configured to provide a first end of the inductor coil at a first location and a second positioning means configured to provide a second end of the inductor coil at a second location.

[0007] In some examples, the device includes only one inductor coil, while in other examples, the device may include two or more inductor coils, and thus the inductor coil mentioned above may be referred to as the first inductor coil.

[0008] The aerosol delivery device may further comprise a second inductor coil extending around the coil support. The second inductor coil may comprise a second coil wire, the first and second coil wire ends of which are engaged to the electrical component. The positioning arrangement may be configured to provide (and / or hold and align) the first and second coil wire ends of the second inductor coil to the electrical component.

[0009] The coil wire end positioning arrangement may have third positioning means configured to position the first end of the second inductor coil at a third location and fourth positioning means configured to position the second end of the second inductor coil at a fourth location.

[0010] In instances where more than one coil wire is provided, the positioning arrangement may comprise a plurality of positioning means.

[0011] In some examples, the positioning arrangement is further configured to hold the coil wire ends in a first, second, third and fourth position (or any other multiple), in some embodiments, the first and second positions may not be axially aligned with one another.

[0012] In other embodiments, the first and second locations may be axially aligned with one another.

[0013] In some embodiments, the third and fourth positions may not be axially aligned with one another.

[0014] In other embodiments, the third and fourth locations may be axially aligned with one another.

[0015] In some embodiments, the first and third locations may be aligned on a first axis and the second and fourth locations may be aligned on a second axis. The first and second axes are different from one another. They may also extend in a direction parallel to the longitudinal axis of the device.

[0016] In some embodiments, the first, second, third and fourth positions are axially aligned with one another.

[0017] The aerosol delivery device may further include a battery and a battery connector, the battery connector configured to receive a cable for charging the device's battery, and the battery connector may be positioned on an electrical component, e.g., a PCB, so as to be axially aligned with the first, second, third and fourth positions.

[0018] In some embodiments, each of the positioning means may comprise an alignment tab projecting from the housing with a through hole therethrough sized and shaped to receive an end of the coil wire.

[0019] The alignment tabs may extend inwardly from the housing and in a direction parallel to the electrical component (which may be a PCB). The through holes may extend in a direction perpendicular to the electrical component.

[0020] According to a second aspect of the present disclosure, a housing for an aerosol delivery device is provided, the housing comprising an electrical component mounting portion, an aerosol generation assembly mounting portion, and an inductor coil wire end positioning arrangement configured to hold and align first and second wire ends of an inductor coil of an aerosol generation assembly mountable to the housing relative to an electrical component mountable to the housing.

[0021] In some embodiments, the electrical component is a printed circuit board "PCB."

[0022] The inductor coil wire end positioning arrangement may have a first positioning means configured to provide a first inductor coil wire end at a first location and a second positioning means configured to hold a second inductor coil wire end at a second location. This may be achieved by providing the first positioning means at a first location on the housing and the second positioning means at a second location on the housing. This may also be achieved in other ways.

[0023] The coil wire end positioning arrangement may further comprise a third positioning means configured to provide and / or retain a third inductor coil wire end of the inductor coil wire at a third location and a fourth inductor coil wire end of the inductor coil wire at a fourth location. This may be achieved by providing the third positioning means at a third location on the housing and providing a fourth retaining means at a fourth location on the housing. This may also be achieved in other ways.

[0024] In some embodiments, the first and second locations may not be axially aligned with one another, while in other embodiments, the first and second locations may be axially aligned with one another.

[0025] In some embodiments, the third and fourth locations may not be axially aligned with one another, while in other embodiments, the third and fourth locations may be axially aligned with one another.

[0026] In some embodiments, the first and third locations may be aligned on a first axis, and the second and fourth locations may be aligned on a second axis. The first and second axes are different from one another. They may also extend in a direction parallel to the longitudinal axis of the device.

[0027] In some embodiments, the first, second, third and fourth locations may be axially aligned with one another. The housing may further comprise a battery and a battery connector, the battery connector configured to receive a cable for charging a battery of the device, the battery connector disposed on an electronic component, e.g., a PCB, such that the battery connector is axially aligned with the first, second, third and fourth locations.

[0028] In some embodiments, each of the positioning means may comprise an alignment tab protruding from the housing with a through hole sized and shaped to receive the coil wire end therethrough. The alignment tab may extend inwardly from the housing and in a direction parallel to the front components or PCB. The through hole may extend in a direction perpendicular to the electrical components. Although protrusions having alignment tabs with through holes are illustrated in the examples described herein, the devices and housings described herein are not limited thereto and other means for holding the coil wire ends in place relative to each other and / or relative to the electrical components may be envisioned.

[0029] The coil support may be a tubular member.

[0030] The coil support may be a thermal insulating member.

[0031] The aerosol delivery device may include a thermal insulation layer extending around the susceptor between the susceptor and the coil support.

[0032] The coil support can act as a barrier.

[0033] The aerosol delivery device may include an electromagnetic shield extending around the coil support. The electromagnetic shield may be a ferrite shield. The electromagnetic shield may abut the coil support.

[0034] The coil support may support an electromagnetic shield.

[0035] The electromagnetic shield may be glued to the coil support.

[0036] The inductor coil may be surrounded by a coil support and an electromagnetic shield.

[0037] The inductor coil or coils may be surrounded by a coil support and an electromagnetic shield.

[0038] The coil support may be of one piece construction.

[0039] The aerosol delivery device may include a first end support member at one end of the susceptor and a second end support member at an opposite end of the susceptor, where the coil support extends between the first end support member and the second end support member.

[0040] The aerosol delivery device may include a thermocouple mounting portion adjacent the locating feature. The thermocouple mounting portion may include at least one of a flat locating surface, a recess, and a clip.

[0041] In use, the inductor coil may be configured to heat the susceptor to a temperature of about 200° C. to about 300° C. In use, the inductor coil may be configured to heat the susceptor to a temperature of about 350° C.

[0042] The inductor coil may be substantially helical. The inductor coil may follow a helical path or a non-helical path. The inductor coil may follow a spiral path. For example, the inductor coil may comprise a wire, such as a Litz wire, wound helically on a coil support. Other wires are contemplated. For example, the wire may be a solid wire.

[0043] By axial position it is meant position relative to the longitudinal axis of the device.

[0044] By "thickness" of a real object is meant the average distance between the inner surface of the object and the outer surface of the object. The thickness may be measured in a direction perpendicular to the axis of the inductor coil or coils.

[0045] The inductor coil(s), susceptor, and thermal insulation member may be coaxial.

[0046] In some examples, during use, the inductor coil is configured to heat the susceptor to a temperature of about 200° C. to about 350° C. (such as about 240° C. to about 300° C. or about 250° C. to about 280° C.) When the outer cover is spaced at least this distance from the susceptor, the temperature of the outer cover is maintained at a safe level, such as less than about 60° C., less than about 50° C., less than about 48° C., or less than about 43° C.

[0047] One or more of the housing, the coil support, the barrier member, the first end support, and the second end support may be made from an insulating material such as plastic. In one particular example, the coil support is constructed from polyetheretherketone (PEEK). PEEK has excellent insulating properties and is well suited for use in aerosol delivery devices.

[0048] In another example, the coil support, the barrier member, the first end support and the second end support may comprise mica or a mica-glass ceramic.

[0049] The aerosol delivery device may be a tobacco heating device, also known as a non-combustion heating device.

[0050] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only and with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0051] [Figure 1] FIG. 1 is a front view of an example of an aerosol delivery device. [Diagram 2] 2 is a partially exploded side view of the aerosol delivery device of FIG. 1 showing the housing, PCB, end piece, power supply, aerosol generation assembly, replaceable items, and outer cover. [Diagram 3] 2 is an enlarged cross-sectional side view of a portion of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 3 is an enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. [Diagram 5] FIG. 3 is another enlarged cross-sectional view showing the proximal portion of the aerosol generation assembly of FIG. 2. [Figure 6] FIG. 3 is another enlarged cross-sectional view showing the distal portion of the aerosol generation assembly of FIG. 2. [Figure 7] FIG. 3 is another enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. [Figure 8] FIG. 3 is another enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. [Figure 9] FIG. 3 is a side view of the aerosol generation assembly of FIG. 2 including an inductor coil and a coil support. [Figure 10] FIG. 10 is a side view of the coil support of FIG. [Figure 11]FIG. 3 is a side view of the housing and aerosol generation assembly of FIG. 2. [Figure 12] FIG. 5 is an enlarged side view of a portion of the coil support of FIG. 4 showing a thermocouple mounting portion. [Figure 13] FIG. 2 is a perspective view showing the housing of a device described herein. [Figure 14] FIG. 14 is a perspective view of the housing of FIG. 13 with first and second inductor coils disposed therein and with respective coil ends positioned in positioning structures. [Figure 15a] FIG. 2 illustrates a PCB when positioned within an enclosure with first and second inductor coils connected to the PCB in a first configuration. [Figure 15b] FIG. 15b is a side view showing the first and second inductor coils connected to the PCB as shown in FIG. 15a. [Figure 16a] FIG. 13 illustrates a PCB positioned within an enclosure with first and second inductor coils connected to the PCB in a second configuration. [Figure 16b] FIG. 16b is a side view showing the first and second inductor coils connected to the PCB as shown in FIG. 16a. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0052] As used herein, the term "aerosol generating material" includes materials that provide volatilization upon heating, usually in the form of an aerosol. Aerosol generating materials include any tobacco-containing material, such as one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol generating materials also include other non-tobacco products, which may or may not contain nicotine. Aerosol generating materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol generating materials may also be a combination or mixture of materials. Aerosol generating materials may also be known as "smoking materials."

[0053] Devices are known that heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, thereby forming an inhalable aerosol, usually without burning or combusting the aerosol-generating material. Such devices may be described as "aerosol-generating devices", "aerosol delivery devices", "non-combustion heating devices", "tobacco heating product devices", "tobacco heating devices", etc. Similarly, there are so-called e-cigarette devices that vaporize an aerosol-generating material, usually in liquid form, which may or may not contain nicotine. The aerosol-generating material may be in the form of, or may be provided as, a part, such as a rod, cartridge, or cassette that can be inserted into the device. A heater that heats and volatilizes the aerosol-generating material may be provided as a "permanent" part of the device.

[0054] The aerosol delivery device can receive and heat an article that includes an aerosol-generating material. In this context, an "article" is a component that comprises or contains an aerosol-generating material during use and is heated to volatilize the aerosol-generating material and optionally other components during use. A user may insert the article into the aerosol delivery device, which may then be heated to generate an aerosol that is subsequently inhaled by the user. The article may be of a predetermined size or may be of a particular size, for example, configured to be placed in a heating chamber of a device sized to receive the article.

[0055] 1 shows an example of an aerosol delivery device 100 that generates an aerosol from an aerosol-generating medium / material. In general, device 100 may be used to heat a replaceable item 110 that contains an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0056] The device 100 comprises a housing 102 (including an outer cover) that encloses and contains various components of the device 100. The device 100 has an opening 104 at one end through which an article 110 can be inserted and heated by a heater assembly 105 (see FIG. 2). In use, the article 110 may be fully or partially inserted into the heater assembly 105 and heated by one or more components of the heater assembly 105.

[0057] Device 100 may also include user-operable controls 112, such as buttons or switches, that, when pressed, cause operation of device 100. For example, a user may turn device 100 on by operating switch 112.

[0058] The device 100 defines a longitudinal axis 101 .

[0059] Figure 2 is a schematic exploded view of the device 100 of Figure 1. The device 100 comprises an outer cover 102, a first end member 106, and a second end member 116. The device 100 comprises an aerosol generation assembly 111 including a housing 109, a power source 118, and a heater assembly 105. The device 100 further comprises at least one electronics module 122.

[0060] The outer cover 102 forms part of a device shell 108. A first end member 106 is disposed at one end of the device 100 and a second end member 116 is disposed at an opposite end of the device 100. The first and second end members 106, 116 close the outer cover 102. The first and second end members 106, 116 form part of the shell 108. The device 100 in accordance with an embodiment includes a lid (not shown) that can be moved relative to the first end member 106 to close the opening 104 when the article 110 is not in place.

[0061] Device 100 may also include electrical components, such as a connector / port 114, capable of accepting a cable to charge a battery of device 100. For example, connector 114 may be a charging port, such as a USB charging port. In some examples, connector 114 may additionally or alternatively be adapted to transfer data between device 100 and another device, such as a computing device.

[0062] The device 100 comprises a housing 109. The housing 109 is received by the outer cover 102. The aerosol generation assembly 111 comprises a heater assembly 105 into which, in use, all or part of the article 110 may be inserted, and the article 110 may be adapted to be heated by one or more components of the heater assembly 105. The aerosol generation assembly 111 and the power source 118 are mounted in the housing 109. The housing 109 is a one-piece component.

[0063] Housing 109 may be integrally formed at the time of manufacture, for example by an injection molding process, or two or more features of housing 109 may be first formed separately and then integrally formed at the manufacturing stage, for example by a welding process, to form a one-piece component.

[0064] An integral component refers to a component of device 100 that cannot be separated into two or more components after assembly of device 100. Integral formation refers to two or more features that are formed as a unitary component during the fabrication stage of the component.

[0065] The first and second end members 106, 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 the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. The first and second end members 116 close an open end of the outer cover 102. The second end member 116 is at one end of the housing 109.

[0066] The end of device 100 closest to opening 104 may be known as the proximal end (or mouth end) of device 100, as it is closest to a user's mouth during use. In use, a user inserts item 110 into opening 104 and operates user controls 112 to initiate heating of the aerosol-generating material and utilize the aerosol generated by the device, which causes the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0067] The other end of the device, furthest from the opening 104, may be known as the distal end of the device 100, as this is the end that will be furthest from a user's mouth when in use. When a user utilizes the aerosol generated by the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 will be explained by reference to the relative orientation of such features to one another in the proximal-distal direction along the axis 101.

[0068] The power source 118 is disposed at the distal end of the device 100. The housing 109 carries the power source 118. The housing 109 includes a power mounting portion 119. The housing 109 partially encloses the power source 118. The power source 118 may be 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 aerosol generation assembly 111 to provide power as needed and heat the aerosol-generating material under the control of the controller 121. In this example, the battery is connected to the housing 109, which acts as a central support to hold the battery 118 in place.

[0069] The power source 118 and the aerosol generation assembly 111 are disposed in an axial configuration, with the power source 118 at a distal end of the device 100 and the aerosol generation assembly 111 at a proximal end of the device 100. Other configurations are envisioned. The housing 109 includes an aerosol generation assembly mounting portion 113.

[0070] The device 100 further comprises at least one electronics module 122. The electronics module 122 may comprise, for example, a printed circuit board (PCB) 123. The PCB 123 may support at least one controller 121, such as a processor, and a memory. The PCB 123 may also comprise one or more electrical tracks that electrically connect together various electronic components of the device 100. For example, a battery terminal may be electrically connected to the PCB 123 so that power can be distributed throughout the device 100. The connector 114 may also be electrically coupled to a battery 118 via the electrical tracks. The housing 109 comprises a PCB mounting portion 117.

[0071] The aerosol generating assembly 111 is an induction heating assembly, which includes various components that heat the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element (e.g., one or more inductor 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. The varying magnetic field penetrates a susceptor suitably positioned relative to the induction element and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, so that the flow of eddy currents against this resistance heats the susceptor by Joule heating. Also, if the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e., the varying orientation of the magnetic dipoles of the magnetic material as a result of alignment with the varying magnetic field. Inductive heating allows for rapid heating as heat is generated inside the susceptor, as compared to, for example, heating by conduction, and furthermore does not require any physical contact between the induction heater and the susceptor, allowing greater freedom of design and application.

[0072] 3 shows an enlarged side view, partially in cross section, of a portion of the device 100. The outer cover 102 surrounds the aerosol generation assembly 111. The aerosol generation assembly 111 of the device 100 comprises a heater assembly 105 and an inductor coil assembly 127. The inductor coil assembly 127 extends around the heater assembly 105. The inductor coil assembly 127 includes a first inductor coil 124 and a second inductor coil 126. The inductor coil assembly 127 also comprises a coil support 200.

[0073] The heater assembly 105 includes a susceptor structure 132 (referred to herein as a "susceptor"). The susceptor 132 in this example is hollow and thus defines a receptacle 131 in which an aerosol-generating material is received. For example, an article 110 can be inserted into the susceptor 132. In this example, the susceptor 132 is tubular with a circular cross section. The susceptor 132 defines a first portion of the heater assembly 105. The susceptor 132 has a generally constant diameter along its axial length. The susceptor 132 has a flared portion 134 at a first, proximal end 133. The flared portion 134 flares outwardly. The flared portion 134 defines an outwardly extending lip 135. That is, the lip 135 has a diameter greater than the outer diameter of the main portion of the susceptor 132. The lip 135 acts to minimize contact with other components of the susceptor 132 at the first end 133. This configuration helps reduce heat transfer, for example by conduction, when the susceptor 132 is heated.

[0074] The susceptor 132 is made of a conductive material suitable for heating by electromagnetic induction. In this example, the susceptor is made of carbon steel. It will be appreciated that other suitable materials (e.g., ferromagnetic materials such as iron, nickel, or cobalt) may also be used.

[0075] 3 shows a portion of an article 110 received in a receptacle 131 provided by a susceptor 132. The susceptor 132 and article 110 are sized such that the article 110 is received by the susceptor 132. The article 110 in this example includes an aerosol-forming material. The aerosol-forming material is disposed within the susceptor 132. The article 110 may also include other components such as a filter, a packaging material, and / or a cooling structure.

[0076] The heater assembly 105 also includes a funnel 140. The funnel 140 is at a second, distal end 136 of the susceptor 132. The funnel 140 protrudes from the susceptor 132. In an embodiment, the susceptor 132 and the funnel 140 are an integral component.

[0077] The funnel portion 140 has a thimble configuration. The funnel portion 140 is at the second end, distal end 136, of the susceptor 132. The funnel portion 140 defines a second portion of the heater assembly 105. The funnel portion 140 includes a first portion 141 of a first diameter and a second portion 142 of a second diameter. An intermediate portion 143 extends between the first and second portions 141, 142. The first portion 141 is tubular and extends axially. The second portion 142 is tubular and extends axially. The funnel portion 140 is hollow. The intermediate portion 143 defines a shoulder 145. The shoulder 145 acts as a stop to limit the insertion of the article 110 into the receptacle. The shoulder 145 extends in a substantially vertical plane to the longitudinal axis 101.

[0078] First portion 141 has an inner diameter that is larger than the inner diameter of second portion 142. Thus, funnel 140 widens from first portion 141 to second portion 142. Thus, funnel 140 narrows in diameter from susceptor end 148 to distal end 149.

[0079] The funnel portion 140 defines an air passage 146 therethrough. The first portion 141 and the susceptor 132 overlap one another at one end of the susceptor 132. In one example, the overlap is about 1 mm to about 3 mm. In this particular example, the overlap is 2 mm. In some cases, there is no overlap. In such an example, the susceptor 132 and the funnel portion 140 are adjacent. The first portion 141 overlaps the second end, the distal end 136, of the susceptor 132. The first portion 141 is generally cylindrical and has an inner diameter that substantially corresponds to the outer diameter of the susceptor 132. The first portion 141 is adjacent to the susceptor 132. A joint 147 is formed between the first portion 141 of the funnel portion 140 and the susceptor 132. The interface 147 helps to provide a thermal path between the susceptor 132 and the funnel 140 .

[0080] Junction 147 is a fluidly sealed junction. A fluid seal is formed between susceptor 132 and funnel 140. Thus, a fluidly sealed fluid path is defined between the opposing ends of susceptor 132 and funnel 140. The receptacle defined by susceptor 132 thus constitutes a fluid sealed air passage with air passage 146 formed by funnel 140.

[0081] In an embodiment, the fluid seal at joint 147 is formed by a mechanically machined bond (e.g., welding). The fluid seal at joint 147 is formed by a laser welding process, although it will be appreciated that other methods such as brazing or adhesives may be used. Funnel 140 is formed of a heat-conducting material. In an embodiment, funnel 140 is formed of carbon steel. In an embodiment, funnel is formed of the same material as susceptor 132. The joint is configured to maintain a fluid seal when susceptor 132 is at its predetermined operating temperature. With such a process, susceptor 132 and funnel 140 are made as a unitary component.

[0082] Thus, a sealed fluid path between the susceptor 132 and the funnel 140 extends from one open end of the heater assembly 105 through the heater assembly 105 to the other open end of the heater assembly 105. Thus, the heater assembly 105 contains any fluid flow through the heater assembly 105. A dry zone may be defined outside the heater assembly 105.

[0083] The proximity of the susceptor 132 and the funnel 140 allows for conductive heat transfer from the susceptor 132 to the funnel 140, thereby assisting in passive heating of the funnel 140. Passive heating of the funnel 140 can limit the rate of condensation build-up in the device 100.

[0084] The funnel portion 140 is axially spaced from the inductor coil assembly 127. In particular, the second portion 142 of the funnel portion 140 is axially spaced from the inductor coil assembly 127. This minimizes or eliminates direct heating of the funnel portion 140 by the inductor coil assembly 127. The funnel portion 140 may be axially adjacent to the inductor coil assembly 127.

[0085] 4-8, the device 100 includes a first end support 220 and a second end support 230. The heater assembly 105 extends between the first and second end supports 230. A barrier member 250 extends between the first end support 220 and the second end support 230. The barrier member 250 acts as a support member.

[0086] The first end support 220 engages a first end, proximal end, of the heater assembly 105 to hold the susceptor 132 in place. The first end support 220 acts as an expansion chamber, as described below. With particular reference to Figures 7 and 8, the first end support 220 extends away from the first end of the susceptor 132 toward the opening 104. Located within the first end support 220 is at least a portion of a retention arrangement 221, such as a retention clip, that holds the article 110 adjacent to it when received within the device 100. The first end support 220 is connected to the end member 106.

[0087] The first end support 220 includes a chamber 222. The chamber 222 is configured to receive the article 110 therein. The retaining structure 221 is in the chamber 222. The chamber 222 has an inner diameter larger than the diameter of the article 110. The first end support 220 defines a proximal collar, which is a first collar of the heater assembly 105. A bore 223 extends therethrough. An inner surface of the bore 223 defines a distally facing shoulder 225, as shown, for example, in FIGS. 7 and 8. The distally facing shoulder 225 is aligned with the lip 135 of the susceptor 132 when the susceptor 132 is received by the first end support 220.

[0088] 4 and 5, the first end support 220 defines a seal rim 226 distally therefrom. The distal seal rim 226 extends around the bore 223. A first mounting flange 227 extends from a first end outer surface, a proximal end outer surface 228, of the first end support 220. The first mounting flange 227 extends circumferentially and is spaced apart from the seal rim 226. The first mounting flange 227 upstands from the first end outer surface 228 to define a first end mounting surface, a proximal end mounting surface 229. The first end outer surface, the proximal end outer surface 228, and the first end mounting surface 229 define a stepped configuration. The first end mounting surface 229 has a larger diameter than the first end outer surface 228. In an embodiment, the first end exterior surface 228 and the first end mounting surface define first and second step surfaces.

[0089] 4-8, the device 100 further comprises a second end support 230 which holds the heater assembly 105 in place by engaging the funnel 140 at the second end, distal end, of the susceptor 132. The second end support 230 constitutes a second collar, distal collar, of the heater assembly 105. In embodiments in which the funnel is omitted, the second end support 230 directly engages the susceptor 132. The second end support 230 acts as an air inlet, as described below. The second end support 230 extends away from the second end of the susceptor 132 towards the distal end of the device 100.

[0090] 4 and 6, the second end support 230 includes a second end perforation 231. The second end support 230 is configured to at least partially receive the funnel 140. The inner surface of the second end support 230 is stepped. The inner surface includes a first stepped region 232 with a first step and a second stepped region 233 with a second step. The first stepped region 232 receives the first portion 141 of the funnel 140. The second stepped region 233 receives the second portion 142 of the funnel 140. The second stepped region 233 includes a first sealing surface 234. The second stepped region 233 includes a second sealing surface 235. The first sealing surface 234 is an inner circumferentially extending surface. The second sealing surface 235 is a circumferentially extending surface that extends in a plane substantially perpendicular to the longitudinal axis 101 .

[0091] A second mounting flange 237 extends from a second outer surface, a distal outer surface 238, of the second end support 230. The second mounting flange 237 extends circumferentially and is spaced from a proximal end of the second end support 230. The second mounting flange 237 upstands from the second end outer surface 238 to define a second end mounting surface, a distal end mounting surface 239. The second end outer surface, a distal end outer surface 238, and the second end mounting surface, a distal end mounting surface 239, define a stepped configuration. The second end mounting surface 239 has a larger diameter than the second end outer surface 238. In an embodiment, the second end outer surface 238 and the second end mounting surface 239 define first and second stepped surfaces.

[0092] The barrier member 250 extends between the first end support 220 and the second end support 230. The barrier member 250 extends between the first and second end supports 220, 230. The barrier member 250, together with the first and second end supports 220, 230, surrounds the heater assembly 105. This acts to aid in thermal isolation of the heater assembly 105 from the other components of the device 100. The barrier member 250 is a hollow tubular member.

[0093] The barrier member 250 is fixedly attached to the first and second end supports 220, 230. The first and second end supports 220, 230 are received at the ends of the barrier member 250. The first end support 220 closes the proximal end of the barrier member 250. The second end support 230 closes the distal end of the barrier member 150. The barrier member 250 partially overlaps the first and second end supports 220, 230. In one example, the overlap is about 2 mm to about 3 mm. In this particular example, the overlap is about 2.2 mm. In some cases, there is no overlap. The proximal end of the barrier member 250 is adjacent the first end outer surface 228. The distal end of the barrier member 250 is adjacent the second end outer surface 238.

[0094] The barrier member 250 is fixedly attached to the first and second end supports 220, 230. The barrier member 250 forms a fluid seal with the first and second end supports 220, 230. In an embodiment, a mechanically worked bond (e.g., a weld) is formed between the barrier member 250 and the first and second end supports 220, 230, respectively. The fluid seal at the joint of the parts is formed by a welding process, although it will be understood that other methods such as brazing or adhesives can be used. In an embodiment, the barrier member 250 and the first and second end supports 220, 230 are made of the same material. The bond is configured to maintain a fluid seal when the susceptor 132 is at its predetermined operating temperature. By such a process, the barrier member 250 and the first and second end supports 220, 230 are made as a one-piece component.

[0095] In an embodiment, the barrier member 250 is made of a non-metallic material to help limit interference with magnetic induction. In this particular example, the barrier member 250 is made of polyetheretherketone (PEEK). The first and second end supports 220, 230 are made of PEEK. Other suitable materials are possible. Components made of such materials help the barrier member 250 maintain its rigidity / solidity when the susceptor is heated. The barrier member 250 is made of a rigid material to help support other components such as the heater assembly 105 and the end supports 220, 230. The barrier member 250 may be made of an insulating material such as plastic. In one example, the barrier member 250 has a thickness of about 0.1 mm to about 0.5 mm. In this example, the thickness is about 0.3 mm.

[0096] The heater assembly 105, the barrier member 250, and the first and second end supports 220, 230 are coaxial about a central longitudinal axis of the susceptor 132. The barrier member 250 may help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0097] A radial gap is provided between the susceptor 132 and the first end support 220. The diameter of the perforations 223 is greater than the diameter of the outer surface of the susceptor 132. The radial gap is approximately 0.2 mm, but may vary. Providing a radial gap helps minimize heat transfer between the susceptor 132 and the first end support 220.

[0098] 4-6, the first seal member 240 provides a fluid seal between the heater assembly 105 and the first end support 220. The first seal member 240 is a circumferentially extending member. The first seal member 240 includes a silicone rubber seal. Other suitable materials may be used. The first seal member 240 is elastomeric. The material is configured to stabilize when the heater assembly 105 is at operating temperature. The first seal member 240 is fixedly mounted to the susceptor 132. The first seal member 240 is attached to the susceptor 132, for example, by overmolding the first seal member 240 onto an outer surface of the susceptor 132. The first seal member 240 is spaced from a proximal end of the susceptor 132. When the proximal end of the susceptor 132 is received by the first end support 220, the seal rim 226 of the first end support 220 contacts and seals with the first seal member 240. Such a seal is formed between the first end support 220 and the susceptor 220. The first seal member 240 provides an axial seal.

[0099] The first seal member 240 seals against the barrier member 250. The first seal member 240 upstands from the susceptor 132. The first seal member 240 abuts the inner surface of the barrier member 250. Thus, a seal is formed between the susceptor 132 and the barrier member 250. The first seal member 240 provides a radial seal. The first seal member 240 acts to position and orient the susceptor relative to the first end support 220 and the barrier member 250.

[0100] The second seal member 245 provides a fluid seal between the heater assembly 105 and the second end support 230. The second seal member 245 is a circumferentially extending member. The second seal member 245 includes a silicone rubber seal. Other suitable materials can be used. The second seal member 245 is elastic. The material is configured to stabilize the heater assembly 105 when at operating temperature. The second seal member 245 is fixedly mounted to the funnel 140. In an embodiment, the second seal member is on the susceptor 132, e.g., the funnel is omitted. The second seal member 245 is attached to the susceptor 132, e.g., by overmolding the second seal member 245 onto the outer surface of the funnel 140. The second seal member 245 is adjacent to the open end of the funnel 140. When the distal end of the heater assembly is received by the second end support 230, the first sealing surface 234 of the second end support 230 contacts and seals with the second seal member 245. Such a seal is formed between the second end support 230 and the heater assembly 105. The second seal member 245 provides a radial seal.

[0101] The second seal member 245 seals against the second seal surface 235 of the second end support 230. The second seal member 245 provides an axial seal. The second seal member 245 upstands from the heater assembly 105. The second seal member 245 acts to position and orient the heater assembly 105 relative to the second end support 230 and the barrier member 250.

[0102] In embodiments, the first seal member 240 is at the first end support 220 and seals with the heater assembly 105. In embodiments, the second seal member 245 is at the second end support 230 and seals with the heater assembly 105. The second seal member 245 is at the second portion 142 of the funnel 140. In embodiments, the second seal member 245 is at the first portion 141 of the funnel 140. In such embodiments, the second seal member 245 seals with the proximal rim of the second end support 230.

[0103] The first seal member 240 and the second seal member 250 define a sealed air flow path through the second seal member 250, the heater assembly 105, and the first seal member 240. The barrier member 250 and the first and second end supports 220, 230 define a continuously sealed enclosure for the heater assembly 105. The barrier member 250 is spaced apart from the susceptor 132. The inner surface of the barrier member 250 is spaced apart from the outer surface of the susceptor 132 to provide a gap between the barrier member 250 and the heater assembly 105. The gap provides thermal insulation from heat generated in the susceptor 132.

[0104] A fluidly sealed cavity 260 is formed between the heater assembly 105 and the barrier member 105. The fluidly sealed cavity 260 constitutes a chamber. The cavity 260 provides a gap. A fluidly sealed enclosure 261 is formed around a portion of the heater assembly 105. The fluidly sealed enclosure is formed by the barrier member 105, the first and second seal members 240, 245, the heater assembly 105, and the second end support 230. In some embodiments, the first end support 220 constitutes a portion of the enclosure 261. In some embodiments, the fluidly sealed enclosure 261 is formed by the barrier member 105, the heater assembly 105, and the first and second seal members 240, 245. In an embodiment, the gap between the heater assembly 105 and the barrier member 105 is about 0.8 mm to 1 mm. In an embodiment, the gap is about 0.9 mm.

[0105] A sensor, such as a thermocouple 265, is disposed in the fluidly sealed cavity 260. The thermocouple 265 is mounted on the susceptor 132. The thermocouple 265 is configured to determine the temperature of the susceptor 132. The thermocouple 265 directly detects the temperature of the susceptor 132. The device 100 may include two or more thermocouples 132 configured to determine the temperature of the susceptor 132. Providing the fluidly sealed cavity 260 helps to isolate the thermocouple 265 from the atmosphere outside the fluidly sealed cavity 260. Providing the fluidly sealed cavity 260 helps to isolate the thermocouple 265 from the air flow path through the device 100. This limits the flow of condensate from the air flow path to the thermocouple 265.

[0106] 9 and 10, the inductor coil assembly 127 includes a first inductor coil 124 and a second inductor coil 126. The first and second inductor coils 124, 126 are constructed from a conductive material. In this example, the first and second inductor coils 124, 126 are constructed from a Litz wire / cable that is helically wound to provide the helical inductor coils 124, 126. The Litz wire comprises a number of 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 electrical conductors. In the exemplary device 100, the first and second inductor coils 124, 126 are constructed from copper Litz wire having a circular cross section. In other examples, the Litz wire may have a cross section of other shapes, such as rectangular. The number of inductor coils may be different. For example, in an embodiment, the inductor coil assembly 127 may include a single inductor coil. The first or second inductor coil may be omitted.

[0107] The first inductor coil 124 is configured to generate a first varying magnetic field that heats a first portion of the susceptor 132 (see FIG. 4), and the second inductor coil 126 is configured to generate a second varying magnetic field that heats 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 the longitudinal axis 101 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap), as shown in FIGS. 15a and 15b. The susceptor structure 132 may comprise a single susceptor or may comprise two or more separate susceptors. Ends 130 of the first and second inductor coils 124, 126 are connectable to the PCB 123 (see FIG. 2).

[0108] It will be apparent that in some examples, the first and second inductor coils 124, 126 may have at least one characteristic different from each other. For example, the first inductor coil 124 may have at least one characteristic different from the second inductor coil 126. More specifically, as an example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 3 and FIG. 4, the first and second inductor coils 124, 126 have different lengths such that the portion of the first inductor coil 124 wound around the susceptor 132 is smaller than 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.

[0109] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in the same direction. The inductor coils may be activated at different times. For example, the first inductor coil 124 may be activated first to heat a first portion of the article 110, and the second inductor coil 126 may be activated later to heat a second portion of the article 110. In an embodiment, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. Winding the coils in opposite directions helps reduce current induced in non-activated coils when used in conjunction with certain types of control circuits. In such an example, the first inductor coil 124 may be a right-handed spiral and the second inductor coil 126 may be a left-handed spiral. In another embodiment, the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0110] It will be appreciated that the number of inductor coils may vary, in an embodiment, device 100 includes a single inductor coil.

[0111] The device 100 includes a coil support 200 that acts as a support member. The support member may be generally tubular and at least partially surround the susceptor 132. The support member 200 supports the first and second inductor coils 124, 126. The coil support 200 is shown in cross section in Figure 4. Figure 9 is a side view of the coil support 200 with various components of the device 100 omitted. The coil support 200 is also shown in Figure 10.

[0112] The coil support 200 extends between the first and second end supports 220, 230. The coil support 200, together with the first and second end supports 220, 230, surrounds the heater assembly 105. This helps to thermally isolate the heater assembly 105 from the other components of the device 100. The coil support 200 is a hollow tubular member.

[0113] In an embodiment, the coil support 200 is made of a non-metallic material to help limit interference with magnetic induction. In this particular example, the coil support 200 is made of polyetheretherketone (PEEK). Other suitable materials are possible. Having the coil support made of such a material ensures that the assembly remains rigid / solid when the susceptor is heated. The coil support 200 is made of a rigid material to help support the other components, such as the coils 124, 126. The coil support 200 may be made of an insulating material, such as plastic. In one example, the coil support 200 is about 1 mm to 1.5 mm thick. In this example, the thickness is about 1.3 mm.

[0114] As shown particularly in Figures 3, 4 and 9, the first and second inductor coils 124, 126 are disposed about and adjacent to the coil support 200. The first and second inductor coils 124, 126 are on a radially outer surface 201 of the coil support 200. In an embodiment, the first and second inductor coils are on a radially inner surface 202 of the coil support 200.

[0115] The susceptor 132, the coil support 200, and the first and second inductor coils 124, 126 are coaxial about a central longitudinal axis 101 of the susceptor 132. The coil support 200 may help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0116] The coil support 200 has an outer surface 203. The outer surface 203 is spaced from the outer cover 102. The coil support 200 is spaced from the heater assembly 105. The coil support 200 has an inner surface that is disposed spaced from the outer surface 203 of the susceptor 132.

[0117] The coil support 200 is fixedly attached to the first and second end supports 220, 230. The first and second end supports 220, 230 are received at the ends of the coil support 200. The first end support 220 closes the proximal end of the coil support 200. The second end support 230 closes the distal end of the coil support 200. The coil support 200 partially overlaps the first and second end supports 220, 230. The proximal end of the barrier member 250 is adjacent the first end outer surface 228. The distal end of the barrier member 250 is adjacent the second end outer surface 238. The proximal end of the coil support 220 overlaps the first end mounting surface, the proximal end mounting surface 229, of the first end support 220. The distal end of the coil support 220 overlaps a second end mounting surface, distal end mounting surface 229 , of the second end support 230 .

[0118] The coil support 200 is fixedly attached to the first and second end supports 220, 230. The coil support 200 is held between the first and second end supports 220, 230. In an embodiment, the coil support 200 is fixed in place by a mechanically engineered bond, such as a weld or adhesive. In an embodiment, the coil support 200 and the first and second end supports 220, 230 are formed from the same material.

[0119] 3, 4, 9, and 10 in particular, the first and second inductor coils 124, 126 may be aligned with the coil support 200 by the coil support 200. That is, in some embodiments, the first and second inductor coils 124, 126 may be held in a particular arrangement with respect to the coil support 200 by features of the coil support 200. In some examples, the alignment feature may be a channel 205. The channel 205 may be formed in the radially outer surface 201 of the coil support 200. The channel 205 may be a helical channel 205. In some examples with this alignment feature, the channel 205 may receive the first and second inductor coils 124, 126. In that example, the first and second inductor coils 124, 126 may be held by the channel 205. The channel 205 follows a constant helical path. The channel 205 has multiple turns around the coil support 200. The channel 205 acting as an alignment feature provides a consistent path, e.g., consistent spacing, for the coils 214, 216, which helps maximize the performance of the inductor coil assembly and / or achieve predetermined characteristics of the coils.

[0120] The first and second inductor coils 124, 126, respectively, are aligned in a helical arrangement on the coil support 200. By way of example, one of the inductor coils may be omitted. The first and second inductor coils 124, 126, respectively, follow a helical path. The turns of the helical path of each of the first and second inductor coils 124, 126 are equally spaced.

[0121] In an embodiment, the helical channel 205 is formed by a groove in the outer surface 203 of the support coil 200. In an embodiment, the helical channel 205 is formed by a pair of adjacent ridges extending in a helical arrangement. The ridges may be discontinuous and formed by a number of protrusions. The protrusions may define a helical path in which the support coil is received and retained.

[0122] In some embodiments, the coil support 200 may include a helical recess 206 between adjacent turns of the channel 205. The helical recess 206 is an elongated groove. By way of example, the helical recess 206 includes multiple recesses. By way of example, the helical recess 206 acts as an air gap. Providing the helical recess helps to limit heat transfer. Providing the helical recess can help to minimize weight. The helical recess 206 forms a double helix configuration with the channel 205. In some embodiments, the helical recess is omitted. The helical recess is not shown in Figures 3 and 4.

[0123] The first and second inductor coils 124, 126 may be held in the channel 205. The first and second inductor coils 124, 126 may be held in the channel 205 using retention mechanisms such as clips, bonding, and overlayers.

[0124] The first and second inductor coils 124, 126, respectively, may be fully received in the coil support 200. That is, the first and second inductor coils 124, 126, respectively, may be flush with the surface of the coil support 200 or may be recessed from the surface of the coil support 200. In an embodiment, the first and second inductor coils 124, 126 protrude partially from the channel 205.

[0125] The coil support 200 comprises a single channel, although it will be appreciated that the channel 205 may be separated into two channel portions, one for each of the coils 124, 126. Each channel may have one or more different characteristics (e.g., period, width, depth, and length) to allow for different alignment between the coils 124, 126.

[0126] A ferrite shield 280 extends around the inductor coils 124, 126. The ferrite shield acts as an electromagnetic shield. Other suitable materials may be used. The ferrite shield 280 is mounted to the coil support 200. The ferrite shield 280 is adjacent to the coil support 200 and may be attached directly to the coil support 200, for example by gluing. A channel 205 recesses the coils 124, 126 into the coil support 200. The inductor coils 124, 126 are surrounded by the coil support 200 and the ferrite shield 280.

[0127] See Fig. 12. A sensor 290, such as a thermocouple, may be disposed on the coil support 200. The coil support 200 includes a sensor mounting portion 291. This aids in accurate positioning of the sensor relative to the coil, thereby enabling accurate measurements. The mounting portion 291 includes a recess. The mounting portion 291 provides a positioning surface for mounting a thermocouple.

[0128] The alignment feature in the above embodiment is a channel, although it will be appreciated that the channel may be omitted and the alignment feature may be different.

[0129] In the above-described embodiments, the coil support 200 includes a channel 205 and / or other alignment features for aligning the coil. It will be appreciated that in some embodiments, the coil alignment channels and / or other alignment features may be omitted. In such embodiments, the coil may be attached to a surface of the coil support or may be assembled around the coil support with a gap therebetween.

[0130] The heater assembly 105, the barrier member 250, and the coil support 200 are coaxial about a central longitudinal axis of the susceptor 132. The coil support 200 may help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0131] The coil support 200 is spaced apart from the susceptor 132. The coil support 200 is spaced apart from a barrier member 250. The barrier member 250 is between the heater assembly 105 and the coil support 200. An insulating chamber 270 may be formed between the coil support 200 and the barrier member 250.

[0132] In one example, the spacing between the coil support 200 and the barrier member 250 is 0.5mm to 1.5mm. In this example, the thickness is about 0.9mm. The coil support 200 acts as a second barrier member. Providing a barrier member that acts as a barrier can help provide separate chambers that help isolate different components of the device from each other in a stand-off configuration.

[0133] The barrier acts as an insulating member. Thus, the barrier forms part of an insulating stack that limits heat transfer from the susceptor 132 to the exterior of the aerosol generation assembly 111. The barrier member 250 acts as a first insulating member. The coil support 200 acts as a second insulating member. An insulating layer 271 extends between the barrier member 250 and the coil support 200. The insulating layer 271 extends around the barrier member 250. The insulating layer 271 is adjacent to the barrier member 250 and the coil support 200.

[0134] In embodiments, the insulating layer 271 is supported by the barrier member 250 and the coil support 200. In some embodiments, the insulating layer 271 is supported by the barrier member 250. In such embodiments, the insulating layer 271 may be separated from the coil support 200, for example by a small gap. In some embodiments, the insulating layer 271 is supported by the coil support 200. In such embodiments, the insulating layer 271 may be separated from the barrier member 250, for example by a small gap. The insulating layer 271 may be attached to one or both of the barrier member 250 and the coil support 200. In embodiments, the barrier member 250 may be omitted. In embodiments, the coil support 200 may be integrally formed with the insulating layer 271. The insulating layer 271 may be omitted. In such embodiments, an air gap is formed between the barrier member 250 and the coil support 200. In such configurations, the air gap acts as an insulator.

[0135] The insulating layer 271 acts as a third insulating member. In an embodiment, the insulating layer 271 is a sheet prior to assembly. In an embodiment, the insulating layer 271 is formed around the inside surface of the coil support 200 in a tubular configuration. End lips 272 (see FIG. 4) help retain the insulating layer 271. The insulating layer 271 is attached to the coil support 20. By way of example, the insulating layer 271 is attached to a barrier member 250. The barrier member 250 spaces the insulating layer 271 from the susceptor 132. The coil support 200 spaces the insulating layer 271 away from the inductor coils 124, 126.

[0136] The insulation stack may be provided by a combination of two or more of the following materials: (i) air (having a thermal conductivity of about 0.02 W / mK); (ii) aerogel (e.g., AeroZero®) (having a thermal conductivity of about 0.03 W / mK to about 0.04 W / mK); (iii) polyetheretherketone (PEEK) (which in some instances may have a thermal conductivity of about 0.25 W / mK); (iv) ceramic cloth (having a specific heat of about 1.13 kJ / kgK); and (v) thermal putty. Other suitable materials may be used.

[0137] The insulating layer 271 is formed from an aerogel. Other suitable materials may be used, such as, for example, a porous foam material. For example, a barrier member may be provided on either side of the aerogel to provide a protective barrier for the insulating layer 271. The barrier or barriers may help support the insulating layer 271 along its length.

[0138] The combination of the barrier member and the aerogel insulation layer aids in limiting heat transfer to the shell of the device 100 in a compact configuration by providing an enhanced insulation configuration around the heater assembly 105 .

[0139] The insulation layer 271 acts as an inner insulation layer 273. An outer insulation layer 273 extends around the inductor coil assembly 127. The outer insulation layer 273 is of a tubular configuration. The outer insulation layer 273 is supported by the inductor coil assembly 127. The inner and outer insulation layers 271, 273 sandwich the inductor coil assembly 127. The outer insulation layer 273 is mounted to the ferrite layer 280. The outer insulation layer 273 is attached to the ferrite layer 280, although other mounting configurations are envisioned. The provision of the outer insulation layer 273 allows for a predetermined thickness of insulation to be used while allowing for varying distances between the coil and the susceptor 132. The outer insulation layer 273 is formed of aerogel. Other suitable materials (e.g., porous foam materials) may also be used.

[0140] 11, the first end support 220 protrudes from a proximal end of the coil support 200. The second end support 230 protrudes from a distal end of the coil support 200. The first end support 220 is axially aligned. The second end support 230 is axially aligned. The aerosol generation assembly 111 is mounted to the housing 109. The aerosol generation assembly 111 is mounted at its proximal and distal ends. The aerosol generation assembly mounting portion 113 of the housing 109 holds the aerosol generation assembly 111. The first positioning mechanism 300 positions the aerosol generation assembly 111 at a first end, the proximal end, in the housing 109. The second positioning mechanism 301 positions the aerosol generation assembly 111 at a second end, the distal end, in the housing 109.

[0141] The inductor coil end 130 extends from the aerosol generation assembly 111. The inductor coil end 130 is supported by the housing 109. The inductor coil end 130 is connected to the PCB 123.

[0142] The outer cover 102 protects the internal components of the device and is typically in contact with a user's hands when the device is in use. The outer cover 102 has an inner surface and an outer surface.

[0143] In some instances, the inductor coil may itself heat up when used to induce a magnetic field, for example, by resistive heating due to the passage of electrical current to induce the magnetic field. Providing an insulating layer between the inductor coil and the outer cover helps insulate the heated inductor coil from the outer cover. A ferrite shield helps insulate the outer cover. It has been found that a ferrite shield can reduce the surface temperature of the outer cover by approximately 3° C. when in contact with and at least partially surrounding one or more inductor coils.

[0144] The susceptor 132, barrier member 250, and coil support 200 each have a circular cross-section, although the cross-sections may be any other shape and, in some instances, may be different from one another.

[0145] As mentioned above, the inductor coil end 130 extends from the aerosol generation assembly 111 and is supported on the housing 109. The inductor coil end 130 is connected to the PCB 123.

[0146] 13-16b, and as described below, the aerosol delivery device may have a housing 109 further comprising a coil wire end positioning arrangement 400 that is arranged and configured to position, hold, and align the coil wire ends 130 relative to each other and / or relative to the PCB 123. In other examples not shown, the wire positioning arrangement 400 may be used to position, hold, and align the coil wire ends 130 relative to each other and / or relative to a different electrical component that is not the PCB 123. However, in the examples shown herein and described below, the electrical component is the PCB 123.

[0147] The housing 109 includes an electrical component mount, in the example shown here a PCB mount 117 on which an electrical component or PCB 123 is positioned during use. As described above, an aerosol generation assembly 111 is provided on the housing 109, the aerosol generation assembly having a heater assembly 105 (shown in FIG. 2) configured to receive an aerosol-generating material. The heater assembly 105 further includes a susceptor 132 (shown in FIG. 3), the susceptor 304 being heatable by penetration of a varying magnetic field. In some examples, a first inductor coil 124 extends around the heater assembly 105 and the inductor coil 124 and is configured to generate a varying magnetic field.

[0148] In some embodiments, only one inductor coil 124 may be provided. The inductor coil 124 comprises a coil wire having first and second coil wire ends 130, each of which is connected and engaged to an electrical component, such as the PCB 123, in use. In some examples, the first coil wire end 130 of the inductor coil 124 may be positioned further towards the proximal end (or oral end) of the device and may be referred to as the proximal coil wire end 130. The second coil wire end 130 of the inductor coil 126 may be positioned further towards the distal end of the device in use and may be referred to as the distal coil wire end.

[0149] The coil wire end positioning arrangement 400 of the housing 109 has a first positioning means 401 and a second positioning means 402. The first positioning means 401 may be provided at a location on the housing towards the proximal end of the device than the second positioning means 402, as shown in Figure 13. As shown in Figures 13 and 14, the first positioning means 401 is configured to receive and hold in place the first or proximal end 130 of the inductor coil 124 at a proximal first location, and the second positioning means 402 is configured to receive and hold in place the second, distal end of the inductor coil at a distal second location.

[0150] In some examples, the first location and the second location are not axially aligned with one another, as shown for the first inductor coil wire 124 in FIG. 15b. In other examples, the first location and the second location are axially aligned with one another, as shown for the first inductor coil wire 124 in FIG. 16b. In examples where both ends of the same inductor coil wire 124 are axially aligned with one another, it is possible to provide a battery connector on the PCB such that the location of the battery connector is axially aligned with the location of both coil wire ends of the inductor coil 124. This provides the advantage of simplifying the PCB layout and providing more space on the PCB for additional components.

[0151] 15a, 15b, 16a, and 16b of the present application, the device also includes a second inductor coil 126 that extends around the coil support and heater assembly 105. The second inductor coil 126 includes a wire configured to generate a varying magnetic field. The second inductor coil 126 also has both a proximal first coil wire end 130 and a distal second coil wire end 130, each of which is engaged with an electrical component, such as a PCB.

[0152] In such an example where two inductor coils 124, 126 are provided, the positioning arrangement 400 is further configured to receive, hold and align the first and second coil wire ends 130 of this second inductor coil 126 with an electrical component, such as a PCB. To achieve this, the coil wire end positioning arrangement 400 comprises a third positioning means 403 configured to position and / or hold the first or proximal end of the second inductor coil 126 in a third position and a fourth positioning means 404 configured to position and / or hold the second or distal end of the second inductor coil 126 in a fourth position.

[0153] A first configuration of this type is shown in Figures 13, 14, 15a and 15b, and a second configuration of this type is shown in Figures 16a and 16b.

[0154] As discussed above and shown in these figures, the susceptor 132, the coil support 200, and the first and second inductor coils 124, 126 are coaxial about the central longitudinal axis 101 of the susceptor 132 and the device 100. The first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along the longitudinal axis 101 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap), as shown in Figures 15b and 16b. In other words, the distal coil wire end or second coil wire end of the first inductor coil wire 124 is adjacent to the proximal coil wire end or first coil wire end of the second inductor coil wire 126, as shown.

[0155] Referring now to the configurations shown in Figures 13, 14, 15a and 15b, in which the first and second locations of the first and second coil wire ends of the first inductor coil wire 124 (and in these examples also the first and second positioning means 401, 402 themselves) are not axially aligned with each other. In other words, the first and second locations are circumferentially offset from each other. In this example, this is achieved by the first positioning means 401 being provided on the housing at a first location and the second positioning means 402 being provided on the housing at a second location, where the first and second locations are not axially aligned with each other.

[0156] Similarly, the first and second coil wire ends of the second inductor 126 are also not axially aligned with one another. In this example, this is achieved by providing a third positioning means 403 on the housing at a third location and a fourth positioning means 403 on the housing at a fourth location. As can be seen in Figures 13 and 14, the third and fourth locations are not axially aligned with one another.

[0157] In this example, the positions of the ends of each of the individual inductor coils 124, 126 are not axially aligned, but the proximal ends of both inductor coils 124, 126 are axially aligned with each other, and the distal ends of both inductor coils 126 are axially aligned with each other. That is, the proximal ends of both wires are provided at first and third positions axially aligned on a first axis, and the distal ends of both inductor coil wires 124, 126 are provided at second and fourth positions axially aligned on a second axis different from the first axis. The first and second axes are parallel to the longitudinal axis 101 of the device. This configuration has the advantage that the width of the PCB can be reduced.

[0158] Next, the configuration shown in Figures 16a and 16b will be described.

[0159] In this example, the wire positioning arrangement 400 is configured to hold the wire ends 130 such that all of the coil wire ends 130 are axially aligned with one another. That is, the first, second, third and fourth coil positions of the coil wire ends 130 are axially aligned with one another (i.e. are not circumferentially offset from one another). This is shown in Figure 16b. This is achieved by providing a positioning arrangement 400 where first, second, third and fourth positioning means 401, 402, 403, 404 are provided on the housing at first, second, third and fourth positions, respectively, that are axially aligned with one another.

[0160] In this embodiment, the battery connector may also be positioned on the PCB to be axially aligned with the first, second, third and fourth positions of the coil wire ends. This configuration provides the advantage that the PCB layout is less complicated and provides additional space on the PCB since all the coil wire ends are positioned on the same axis as each other as well as the battery connector. The positioning means, battery connector and coil wire ends of this configuration may be provided along an axis extending in a direction parallel to the longitudinal axis 101 of the device.

[0161] In the examples described herein, each of the positioning means 401, 402, 403, 404 is shown to comprise a protrusion or alignment tab that protrudes from the housing 109. The alignment tab has a through hole sized and shaped to receive the coil wire end. Each alignment tab may extend inwardly from the housing 109 in a direction parallel to an electrical component, such as a PCB, as shown in FIG. 14. Also, as shown in FIG. 14, the through hole may extend in a direction perpendicular to the PCB. This means that in use, the wire coil end extends through the through hole and contacts the underside of the PCB, which is located above the housing as shown in FIG. 1. Other types of wire positioning means are also contemplated. Thus, the alignment tab is configured to provide the coil wire end in the correct position and also configured to hold the coil wire end in position in use.

[0162] A method of assembling the above-described aerosol delivery device may include positioning the aerosol generation assembly on the housing 109, inserting each of the inductor coil ends into respective positioning means 401, 402, 403, 404 so that they are held in the first to fourth positions, respectively, as described above, and connecting each of the coil ends 130 to an electrical component such as a PCB.

[0163] The above-described configurations are advantageous in that they allow for different and improved arrangements of electrical components that connect to the coil wire ends of the inductor coil.

[0164] The above-described embodiments are to be understood as illustrative examples of the present invention. Other embodiments of the present invention are also contemplated. It is to be understood that any feature described with respect to any one embodiment can be used alone or in combination with other described features, and can also be used in combination with one or more features of any other embodiment or any combination thereof. Moreover, equivalents and modifications not described above can be employed without departing from the scope of the present invention as defined in the appended claims. [Item of invention] [Item 1] an aerosol generation assembly; An electrical component; a housing for holding the aerosol generation assembly and the electrical components; and a heater assembly configured to receive an aerosol-generating material, the heater assembly including a susceptor that is heatable by penetration of a varying magnetic field; an inductor coil extending around the heater assembly, the inductor coil configured to generate a varying magnetic field; An aerosol generating device comprising: An aerosol delivery device, wherein the inductor coil has coil wire ends that engage with the electrical component, and the housing has a coil wire end positioning structure configured to hold and align the coil wire ends with respect to the electrical component. [Item 2] The aerosol delivery device of [1], wherein the coil wire end is a first end of the inductor coil, the inductor coil having a second end, and the coil wire end positioning structure has a first positioning means configured to position the first end of the inductor coil at a first position and a second positioning means configured to position the second end of the inductor coil at a second position. [Item 3] The aerosol delivery device of [2], wherein the inductor coil is a first inductor coil, and the aerosol delivery device comprises a second inductor coil extending around the coil support, the second inductor coil comprising a second coil wire having first and second coil wire ends that engage with the electrical component, and the coil wire end positioning structure is configured to hold and / or align the first and second coil wire ends of the second inductor coil with the electrical component. [Item 4] The aerosol delivery device of [3], wherein the coil wire end positioning structure has a third positioning means configured to position the first wire coil end of the second inductor coil at a third position, and a fourth positioning means configured to position the second wire coil end of the second inductor coil at a fourth position. [Item 5] The aerosol delivery device of [2], wherein the first position and the second position are not axially aligned with each other. [Item 6] The aerosol delivery device of [2], wherein the first position and the second position are axially aligned with each other. [Item 7] The aerosol delivery device of [4] or [5], wherein the third position and the fourth position are not axially aligned with each other. [Item 8] The aerosol delivery device of [4] or [6], wherein the third position and the fourth position are axially aligned with each other. [Item 9] The aerosol delivery device described in [5], wherein the first position and the third position are aligned with each other on a first axis, and the second position and the fourth position are aligned with each other on a second axis. [Item 10] The aerosol delivery device of [4], wherein the first position, the second position, the third position and the fourth position are axially aligned with each other. [Item 11] The aerosol delivery device further comprises a battery and a battery connector; The aerosol delivery device described in

[10] , wherein the battery connector is configured to receive a cable for charging the battery of the aerosol delivery device, and the battery connector is positioned on the electrical component so as to be axially aligned with the first position, the second position, the third position, and the fourth position. [Item 12] An aerosol delivery device described in any one of [2] to

[11] , wherein each of the positioning means has an alignment tab protruding from the housing, the alignment tab having a through hole sized and shaped to receive an end of the coil wire. [Item 13] The aerosol delivery device of

[12] , wherein the alignment tab extends inwardly from the housing and in a direction parallel to the electrical component. [Item 14] The aerosol delivery device of

[12] or

[13] , wherein the through hole extends in a direction perpendicular to the electrical component. [Item 15] The aerosol delivery device according to any one of [1] to

[14] , wherein the electrical component is a printed circuit board (PCB). [Item 16] 1. A housing for an aerosol delivery device, comprising: A housing comprising an electrical component mounting portion, an aerosol generation assembly mounting portion, and an inductor coil wire end positioning structure configured to hold and align a first wire end and a second wire end of an inductor coil of an aerosol generation assembly mountable to the housing relative to an electrical component mountable to the housing. [Item 17] The housing described in

[16] , wherein the inductor coil wire end positioning structure has a first positioning means configured to position the first wire end of the inductor coil at a first position and a second positioning means configured to position the second wire end of the inductor coil at a second position. [Item 18] The housing described in

[17] , wherein the coil wire end positioning structure includes a third positioning means configured to position a third inductor coil end of the inductor coil wire at a third position and to position a fourth inductor coil wire end of the inductor coil wire at a fourth position. [Item 19] The housing of

[17] or

[18] , wherein the first position and the second position are not axially aligned with each other. [Item 20] The housing of

[17] or

[18] , wherein the first position and the second position are axially aligned with each other. [Item 21] The housing of

[18] or

[19] , wherein the third position and the fourth position are not axially aligned with each other. [Item 22]

[20] The housing of claim 1, wherein the third position and the fourth position are axially aligned with each other. [Item 23] The housing of

[18] , wherein the first position and the third position are aligned with each other on a first axis, and the second position and the fourth position are aligned with each other on a second axis. [Item 24] The housing of

[18] , wherein the first position, the second position, the third position and the fourth position are axially aligned with each other. [Item 25] The housing further includes a battery and a battery connector;

[24] A housing as described in

[24] , wherein the battery connector is configured to receive a cable for charging the battery of the housing, and the battery connector is positioned on the electrical component so as to be axially aligned with the first position, the second position, the third position, and the fourth position. [Item 26] A housing described in any one of

[16] to

[25] , wherein each of the positioning means has an alignment tab protruding from the housing, the alignment tab having a through hole sized and shaped to receive an end of the coil wire. [Item 27] 26. The housing of claim 25, wherein the alignment tab extends inwardly from the housing and in a direction parallel to the electrical component. [Item 28] The housing according to

[26] or

[27] , wherein the through hole extends in a direction perpendicular to the electrical component. [Item 29] The housing according to any one of

[16] to

[28] , wherein the electrical component is a printed circuit board (PCB).

Claims

1. An electrical component; a heater assembly configured to receive an aerosol-generating material, the heater assembly including a susceptor that is heatable by penetration of a varying magnetic field; an inductor coil extending around the heater assembly, the inductor coil configured to generate a varying magnetic field; An aerosol generating device comprising: the inductor coil having coil wire ends that engage the electrical component; An aerosol delivery device, wherein the aerosol generation device comprises a coil wire end positioning arrangement configured to hold and align the coil wire ends relative to the electrical component.

2. 2. The aerosol delivery device of claim 1, wherein the coil wire end is a first end of the inductor coil, the inductor coil having a second end, and the coil wire end positioning structure has first positioning means configured to position the first end of the inductor coil at a first location and second positioning means configured to position the second end of the inductor coil at a second location.

3. 3. The aerosol delivery device of claim 1 or 2, wherein the inductor coil is a first inductor coil, and the aerosol delivery device comprises a second inductor coil extending around a coil support, the second inductor coil comprising a second coil wire having first and second coil wire ends that engage the electrical component, and the coil wire end positioning structure is configured to hold and / or align the first and second coil wire ends of the second inductor coil with the electrical component.

4. 4. The aerosol delivery device of claim 3, wherein the coil wire end positioning structure has a third positioning means configured to position the first coil wire end of the second inductor coil at a third position and a fourth positioning means configured to position the second coil wire end of the second inductor coil at a fourth position.

5. The aerosol delivery device of claim 2 , wherein the first position and the second position are axially misaligned with one another.

6. The aerosol delivery device of claim 2 , wherein the first position and the second position are axially aligned with each other.

7. The aerosol delivery device of claim 4 or 5, wherein the third position and the fourth position are axially misaligned with each other.

8. The aerosol delivery device of claim 4 or 6, wherein the third position and the fourth position are axially aligned with each other.

9. The aerosol delivery device of claim 5 , wherein the first position and the third position are aligned with each other on a first axis, and the second position and the fourth position are aligned with each other on a second axis.

10. The aerosol delivery device of claim 4 , wherein the first position, the second position, the third position, and the fourth position are axially aligned with one another.

11. The aerosol delivery device further comprises a battery and a battery connector; 11. The aerosol delivery device of claim 10, wherein the battery connector is configured to receive a cable for charging the battery of the aerosol delivery device, and the battery connector is positioned on the electrical component so as to be axially aligned with the first position, the second position, the third position, and the fourth position.

12. 12. The aerosol delivery device of claim 1, comprising a support, said support comprising said coil wire end positioning arrangement.

13. The aerosol delivery device of claim 12 , wherein the coil wire end positioning structure comprises an alignment tab.

14. 13. The aerosol delivery device of claim 12 when relying on claim 2 or 4, wherein each of the positioning means comprises an alignment tab.

15. 15. The aerosol delivery device of claim 13 or 14, wherein the or each alignment tab extends in a direction parallel to the electrical component.

16. 15. An aerosol delivery device according to claim 13 or 14, wherein the or each alignment tab has a through hole sized and shaped to receive the coil wire end.

17. The aerosol delivery device of claim 16 , wherein the through holes extend in a direction perpendicular to the electrical component.

18. The aerosol delivery device of any one of claims 1 to 17, wherein the electrical component is a printed circuit board (PCB).

19. an aerosol generation assembly; a housing for holding the aerosol generation assembly and the electrical components; and Equipped with The aerosol delivery device of claim 1 , wherein the aerosol generation assembly comprises the heater assembly.

20. 1. A housing for an aerosol delivery device, comprising: A housing comprising an electrical component mounting portion, an aerosol generation assembly mounting portion, and an inductor coil wire end positioning structure configured to hold and align a first wire end and a second wire end of an inductor coil of an aerosol generation assembly mountable to the housing with respect to an electrical component mountable to the housing.

21. 21. The package of claim 20, wherein the inductor coil wire end positioning structure has first positioning means configured to position the first wire end of the inductor coil at a first location and second positioning means configured to position the second wire end of the inductor coil at a second location.

22. 22. The package of claim 21 , wherein the coil wire end positioning arrangement comprises a third positioning means configured to position a third inductor coil end of the inductor coil wire at a third location and to position a fourth inductor coil wire end of the inductor coil wire at a fourth location.

23. 23. The housing of claim 21 or 22, wherein the first location and the second location are axially misaligned with one another.

24. 23. The housing of claim 21 or 22, wherein the first location and the second location are axially aligned with one another.

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