Heater element and aerosol supply device

Abstract

To provide a heater element for an aerosol supply device.SOLUTION: A heater element (600) for heating an aerosol product is disclosed. The heater element (600) according to the present invention comprises a support (36), and a heating substance (602) capable of being heated by variable magnetic field incidence. The heating substance (602) is made of a layer on the support (36). The heating substance (602), which contains nickel, has a thickness of 50 microns or less.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a heater element, a method of forming a heater element, an aerosol supply device, and an aerosol supply system.

Background Art

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

Summary of the Invention

[0003] According to a first aspect of the present disclosure, there is provided a heater element for an aerosol supply device, comprising a support and a heating substance that can be heated by the incidence of a variable magnetic field, wherein the heating substance consists of electroless plating on the support.

[0004] The support may be made of a non-conductive material. The support may be made of a polymer, such as a polyimide such as Zytel® high temperature nylon (HTN) or Kapton®.

[0005] The support may be made of a material having a melting point higher than 300°C. The support may contain polyetheretherketone (PEEK).

[0006] The heating substance may contain at least one of nickel and cobalt.

[0007] The heating substance may have a thickness of 100 microns or less in a direction perpendicular to the surface of the support. The heating substance may have a thickness of 50 microns or less, 20 microns or less, or 10 microns or less in a direction perpendicular to the surface of the support. The heating substance may have a thickness of about 15 microns when the liner contains nickel and about 10 microns when the heating substance contains cobalt.

[0008] The support may include a tubular support. For example, the support may be hollow and may have open longitudinal ends that allow the insertion of consumables.

[0009] The heating substance may be disposed on a surface facing radially inward of the support.

[0010] The heater element may include yet another heating substance attached to the heating substance. The yet another heating substance includes a substance different from the heating substance, and the heating substance is disposed between the yet another heating substance and the support.

[0011] The yet another heating substance may be heatable by the incidence of a variable magnetic field. The yet another heating substance may include any one of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze, or any combination of these substances.

[0012] The heater element may include a plurality of regions of the heating substance, and the plurality of regions are spaced apart from the support. The plurality of regions may be uniformly spaced apart from the support.

[0013] When disposed within the aerosol supply device, the heater element may form a chamber for receiving a consumable containing an aerosol product substance.

[0014] A heater element for use in an aerosol supply device comprising a chamber and a heating assembly for applying heat to a consumable containing an aerosol-forming substance to generate an aerosol from the aerosol-forming substance when the consumable is disposed within the chamber, the heater element being selectively insertable into the chamber so as to at least partially cover the inside of the chamber may be included.

[0015] The heater element is moldable into a first shape wound by a first diameter and may be moldable into a second shape wound by a second diameter larger than the first diameter and is translatable from the first shape to the second shape when inserted into the chamber so as to at least partially cover the inside of the chamber.

[0016] The outer surface of the heater element can form a substantially cylindrical shape in the first shape, for example having a first diameter. The outer surface of the heater element can form a substantially cylindrical shape in the second shape, for example having a second diameter.

[0017] The first diameter may consist of the maximum distance between two opposing points on the surface facing outward of the heater element in the first shape, for example the radially outward facing surface. The second diameter may consist of the maximum distance between two opposing points on the surface facing outward of the liner in the second shape, for example the radially outward facing surface.

[0018] The heater element may comprise first and second free ends, one of the first and second free ends being wound towards the other of the first and second free ends to form the first shape. In the second shape, one of the first and second free ends may be at least partially wound towards the other of the first and second free ends.

[0019] In the first shape, the first free end and the second free end can overlap. In the first shape, the heater element may comprise an outward-facing surface and an inward-facing surface, such as a radially outward-facing surface and a radially inward-facing surface, and the outward-facing surface and the inward-facing surface extend between the first free end and the second free end. In the first shape, the first free end and the second free end can overlap, whereby, in the first shape, the outward-facing surface and the inward-facing surface overlap. In the first shape, the outward-facing surface can contact the inward-facing surface.

[0020] The first free end and the second free end can be substantially connected or overlap in the second shape, for example, whereby the heater element is inserted into the chamber and, in the second shape, covers the entire inner circumference of the chamber. The heater element may comprise an outward-facing surface and an inward-facing surface in the second shape, and the outward-facing surface and the inward-facing surface extend between the first free end and the second free end. The first free end and the second free end can overlap in the second shape, whereby the outward-facing surface and the inward-facing surface overlap in the second shape. In the second shape, the outward-facing surface can contact the inward-facing surface.

[0021] The first free end and the second free end can be spaced apart in the second shape, for example, whereby the heater element is inserted into the chamber and, in the second shape, partially covers the inner circumference of the chamber. The first free end and the second free end can be spaced apart in the second shape, whereby the outward-facing surface and the inward-facing surface do not overlap in the second shape.

[0022] In the first shape, the heater element may have a spiral shape when viewed in the direction along the longitudinal axis of the liner. In the second shape, the heater element may have a spiral shape or a circular shape when viewed in the direction along the longitudinal axis of the liner. The heater element may be elongated in the first and second shapes, for example, having an overall length greater than the diameter in the first and second shapes.

[0023] The second diameter may be in the range of 5.0 to 6.0 mm, for example, in the range of 5.3 to 5.7 mm. The second diameter may be in the range of 6.5 to 7.5 mm, for example, in the range of 6.7 to 7.3 mm. The second diameter may be substantially equal to the diameter of the chamber.

[0024] When inserted into the chamber, the heater element may be expandable by at least partial unwinding to transition from the first shape to the second shape.

[0025] In the first and second shapes, the heater element may include both ends in the longitudinal direction of the opening.

[0026] The heater element may be elastically deformable.

[0027] According to a second aspect of the present disclosure, there is provided an aerosol supply device including a heater element for heating a consumable containing an aerosol generating substance to generate an aerosol from the aerosol generating substance, the heater element including a support and a heating substance that can be heated by the incidence of a variable magnetic field, the heating substance being formed by electroless plating on the support, and the heater element at least partially forming a chamber into which the consumable can be inserted for heating by the heating substance.

[0028] The heater element may be tubular in shape, for example, the support being formed of a tubular support.

[0029] The heating substance can be arranged on the surface facing radially inward of the heater element, for example, thereby causing the heating substance to at least partially form a chamber. The heating substance can be arranged on the surface facing radially inward of the support.

[0030] According to a third aspect of the present disclosure, there is provided an aerosol supply system comprising a chamber, a heating assembly for applying heat to a consumable to generate an aerosol from the aerosol generating substance when the consumable containing the aerosol generating substance is disposed within the chamber, and a heater element according to the first aspect of the present disclosure.

[0031] According to a fourth aspect of the present disclosure, there is provided a method of forming a heater element for an aerosol supply device, the method comprising providing a support and electroless plating a heating substance on the support, the heating substance being heatable by the incidence of a varying magnetic field.

[0032] The support may be made of a non-conductive material.

[0033] The method may include electroless plating the heating substance on the surface of the support facing radially inward.

[0034] The method may include attaching yet another heating substance to the heating substance, the yet another heating substance including a substance different from the first heating substance and the first heating substance being disposed between the yet another heating substance and the support.

[0035] The method may include masking (covering) a part of the support before electroless plating.

[0036] Further features and advantages of the present invention will become apparent from the following description of the preferred embodiments of the present invention, given by way of example only and with reference to the accompanying drawings.

Brief Description of the Drawings

[0037]

Figure 1

Figure 2a

Figure 2b

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8a

Figure 8b

Figure 8c

Figure 8d

Figure 9a

Figure 9b

Figure 10

Figure 11

DETAILED DESCRIPTION OF THE INVENTION

[0038] An aerosol supply device according to an example of the present disclosure is schematically shown in FIG. 1 and is generally designated by 12.

[0039] The aerosol supply device 12 includes a housing 16, a power source 18, a heating assembly 20, a chamber 22, a processor 24, a computer-readable memory 25, and a user-operable control element 26.

[0040] The housing 16 forms an outer cover of the aerosol supply device 12 and surrounds and houses various components of the aerosol supply device 12.

[0041] The power source 18 supplies power to various components of the aerosol supply device 12, including, for example, the heating assembly 20. In the embodiment of FIG. 1, the power source 18 includes a battery 28 and a DC-AC converter 30 for supplying an AC current to the heating assembly 20. It should be understood that in alternative embodiments, the heating assembly 20 may require a DC current, and as a result, the DC-AC converter 30 may be omitted or, as appropriate, replaced with a DC-DC converter, such as a buck or boost converter.

[0042] The aerosol supply device 12 may further include electrical components, such as a socket / port (not shown) that can receive a cable for charging the battery 28. For example, the socket may include a charging port, such as a USB charging port. In some examples, in addition to or instead of this, the socket can be used to transmit data between the aerosol supply device 12 and another device, such as a computer device. The socket can further be electrically coupled to the battery 28 through an electrical circuit.

[0043] Processor 24 is in data communication with computer-readable memory 25. Processor 24 is configured to control various aspects of the operation of aerosol supply device 12. Processor 24 controls various aspects by executing instructions stored in computer-readable memory 25. For example, processor 24 can control the operation of heating assembly 20. For example, the processor can control the delivery of power from power supply 18 to heating assembly 20 by controlling various electrical components (not shown in FIG. 1) such as switches.

[0044] A user-operable control element 26 is, for example, a button or switch that, when pressed, activates aerosol supply device 12. For example, the user can activate aerosol supply device 12 by operating user-operable control element 26, or the user can change the settings of heating assembly 20 by operating user-operable control element 26.

[0045] Heating assembly 20 of FIG. 1 is an induction heating assembly and includes a plurality of heating coils 32. The plurality of heating coils 32 are individually controllable and are spaced along chamber 22 and are configured to interact with susceptor 34, which is described below.

[0046] A susceptor is a substance that can be heated when a varying magnetic field, such as an alternating magnetic field, impinges thereon. The susceptor may be a conductive substance, such that when a varying magnetic field impinges, induction heating of the heating substance occurs. The heating substance may be a magnetic substance, such that when a varying magnetic field impinges, magnetic hysteresis heating of the heating substance occurs. The susceptor may be both conductive and ferromagnetic, such that the susceptor can be heated by both heating mechanisms.

[0047] To heat chamber 22 and thereby heat the consumables placed therein, DC-AC converter 30 passes an AC current through a plurality of heating coils 32, whereby the plurality of heating coils 32 generate a varying magnetic field. The varying magnetic field interacts with susceptor 34 to cause an overcurrent in susceptor 34, and as the overcurrent flows, heating of susceptor 34 occurs.

[0048] As can be seen in the cross-section of FIG. 2a, chamber 22 is generally formed by a hollow tubular member 36. The tubular member 36 comprises an elongated hollow body. The inner wall of the tubular member 36 defines chamber 22, and chamber 22 has a proximal end 40 and a distal end 42. The extent of chamber 22 between proximal end 40 and distal end 42 can be referred to as the main portion 23 of chamber 22. The distal end 42 comprises a tapered wall 44 that tapers towards the central axis A-A of chamber 22. The opening 46 of the tapered wall 44 is in fluid communication with the air inlet 47 of the aerosol supply device 12.

[0049] The proximal end 40 of chamber 22 comprises an opening 48 through which consumables (not shown in FIG. 2a) can be inserted into chamber 22.

[0050] To prevent the tubular member 36 from deforming due to heat during use, the tubular member 36 is formed from a material with a melting point higher than 300°C and in the example of FIG. 2a is formed from PEEK. The material of the tubular member 36 is also a non-conductive material to prevent an overcurrent from being generated within the tubular member due to interaction with the magnetic field generated by the plurality of coils 32, thereby preventing heating of the tubular member 36 by induction heating during use.

[0051] In use, chamber 22 is configured to receive one consumable containing aerosol-producing material at a time, and heating assembly 20 is used to generate an aerosol for the user to inhale from the aerosol-producing material. Chamber 22 can thus be considered a heating chamber.

[0052] An aerosol - forming substance is a substance that can produce an aerosol when, for example, heated, irradiated, or activated in some other way. The aerosol - forming substance may be in the form of, for example, a solid, a liquid, or a gel, and those forms may or may not contain an active substance and / or a flavorant. In some embodiments, the aerosol - forming substance may include an "amorphous body", which may also be separately called a "monolithic solid" (i.e., non - fibrous). In some embodiments, the amorphous body may be a dry gel. The amorphous body is a solid that may incorporate some fluid, such as a liquid. In some embodiments, the aerosol - forming substance may include, for example, from about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of the amorphous body.

[0053] The aerosol - forming substance may include one or more active substances and / or fragrances, one or more aerosol - forming substances, or optionally one or more other functional substances.

[0054] A consumable is an article that contains or is composed of an aerosol - forming substance that is designed to be partially or fully consumed during use by a user. The consumable may include one or more other components, such as an aerosol - forming substance storage region, an aerosol - forming substance transfer component, an aerosol - generation region, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol conditioner. The consumable may further include an aerosol - generation part that radiates heat to cause the aerosol - forming substance to generate an aerosol during use, such as a heater. The heater may include, for example, a combustible substance, a substance that can be heated by electrical conduction, or a susceptor. Such a consumable is usually elongated and generally cylindrical as a whole.

[0055] The consumable is designed to be inserted into chamber 22 during use, and since chamber 22 is designed to be used as a heating chamber, it is desirable to position the susceptor 34 near chamber 22.

[0056] In the embodiments of FIGS. 2a and 2b, susceptor 34 is provided as a layer of heating material plated on the inner wall of tubular member 36 by electroless plating. The heating material means a material that can be heated by the incidence of a varying magnetic field, i.e., a material that can be heated as part of an induction heating process. The heating material in the examples of FIGS. 2a and 2b is either nickel or cobalt. Generally, the combination of susceptor 34 and tubular member 36 can be considered as a heater element for aerosol supply device 12. In such an example, susceptor 34 can also be considered as the wall of chamber 22.

[0057] Electroless plating is a chemical process that deposits a uniform layer of metallic substance on the surface of a solid substrate such as metal or plastic. In electroless nickel plating, the process includes the step of immersing the substrate in an aqueous solution containing a nickel salt and a phosphorus-containing reducing agent, usually hypophosphite. Generally, in an electroless plating process, there is no need to pass an electric current through the solution tank and the substrate, and the reduction of metal cations in the solution to metal is achieved by purely chemical means through an autocatalytic reaction. Thus, electroless plating can produce a uniform layer of metal regardless of the shape of the surface and can be applied to non-conductive surfaces.

[0058] In the case of the present disclosure, electroless plating can provide a uniform layer of heating material inside tubular member 36, and that layer can form a susceptor 34 of substantially constant thickness. This can improve the heating characteristics during use, for example, by providing more uniform heating inside chamber 22 along the length of susceptor 34. Electroless plating can also enable the placement of metal susceptor 34 on plastic tubular member 36 without the need for, for example, an adhesive, otherwise the adhesive would increase the distance from susceptor 34 to the plurality of coils 32, and thus the increased distance between susceptor 34 and the plurality of coils 32 would adversely affect the heating during use.

[0059] Conductive (and magnetizable) media, such as a heating substance, have a specific depth (skin depth) into which an electromagnetic field can penetrate. Thus, the thickness of the heating substance forming the susceptor 34 is at least an effective portion of that skin depth for that heating substance at the operating frequency of the induction system. For example, a thickness corresponding to one or more skin depths should help ensure that most of the effective energy is introduced into the heating substance forming the susceptor 34. In some examples, the heating substance has a thickness of 100 microns or less, 50 microns or less, or 20 microns or less as measured in a direction orthogonal to the plastic tubular member 36. When the heating substance includes nickel, the thickness of the heating substance can be about 15 microns. When the heating substance includes cobalt, the thickness of the heating substance can be about 10 microns.

[0060] A method 300 for forming a heater element for the aerosol supply device 12 is shown in the flowchart of FIG. 3. The method 300 includes a step 302 of providing a support in the form of a tubular member 36 and a step 304 of electroless plating a heating substance onto the tubular member 36 in the form of a susceptor 34.

[0061] As shown in FIGS. 2a and 2b, the susceptor 34 is formed by electroless plating over substantially the entire length and the entire circumferential extent of the chamber 22.

[0062] In another example, as schematically shown in FIG. 4, the susceptor 34 is provided by electroless plating nickel or cobalt in a plurality of regions inside the tubular member 36, and those regions are spaced apart on the circumference of the tubular member 36. Again, overall, the susceptor 34 and the tubular member 36 form the heater element 400. The regions without the susceptor 34 are masked with wax during the plating process. By providing a plurality of regions, the susceptor 34 is provided only where needed, thereby obtaining better heating characteristics, for example, compared to a configuration where the susceptor 34 extends over the entire circumferential extent of the tubular member 36.

[0063] A method 500 of forming a heater element 400 of FIG. 4 is shown in the flowchart of FIG. 5. The method 500 includes a step 502 of providing a support in the form of a tubular member 36 and a step 504 of masking a plurality of portions of the tubular member 36. The method 500 includes a step 506 of electroless plating a heating substance in the form of a susceptor 34 on the unmasked regions of the tubular member 36.

[0064] Another form of the heater element 600 is schematically shown in the cross-section of FIG. 6. In this case, the heater element comprises a tubular member 36 as a support, a first layer 602 of a heating substance, and a second layer 604 of a heating substance. Overall, the first layer 602 and the second layer 604 of the heating substance form the susceptor 34.

[0065] The first layer 602 of the heating substance includes one of nickel or cobalt, and the second layer 604 of the heating substance includes one or more substances from the list of aluminum, gold, iron, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze. The first layer 602 of the heating substance is electroless plated on the tubular member 36 as described above. The second layer 604 of the heating substance may have better induction heating characteristics compared to the first layer 602 of the heating substance and can be attached to the first layer 602 of the heating substance by any suitable bonding method.

[0066] A method 700 of forming the heater element 600 of FIG. 6 is shown in the flowchart of FIG. 7. The method 700 includes a step 702 of providing a support in the form of a tubular member 36 and a step 704 of electroless plating the first layer 602 of the heating substance on the tubular member 36. The method 700 includes a step 706 of bonding the second layer 604 of the heating substance to the tubular member 36.

[0067] As described above, the combination of the tubular member 36 and the susceptor 34 forms a heater element, and the tubular member 36 and the susceptor form a chamber 22 for accommodating consumables during use. In an alternative embodiment, the tubular member 36 can still form the chamber 22, but the heater element can be provided as a removable liner 800 that is selectively inserted into the chamber 22, as schematically shown in FIGS. 8a - d.

[0068] The liner 800 comprises a support layer 802 that is a rectangular sheet of a high - heat - resistant polymer, such as a polyimide like Zytel® high - temperature nylon (HTN) or Kapton®. Such a material can be considered non - conductive and can prevent the formation of overcurrents. The liner 800 comprises a layer 804 of a heating material, either nickel or cobalt, which is electrolessly plated onto the support layer 802 as described above.

[0069] The liner 800 is elastically deformable and has a first free end 806 and a second free end 808. The rectangle of the liner 800 shown in FIG. 8a can, in some examples, be considered the free shape of the liner 800.

[0070] The liner 800 is moldable into a first shape shown in FIG. 8b and a second shape shown in FIG. 8c. The interface between the support layer 802 and the layer 804 of the heating material is not shown in FIGS. 8b and 8c for clarity. The thickness or material of the layers 802, 804 can be selected such that the liner 800 can be molded into either the first shape of FIG. 8b or the second shape of FIGS. 8c and 8d. The layer 804 of the heating material is arranged to form the surface facing the inside of the liner 800 in the first and second shapes.

[0071] In the first shape of FIG. 8b, the first free end 806 is wound towards the second free end 808, whereby the liner 800 is shaped, for example wound up, to have a spiral shape as seen in FIG. 8b, which is a view taken in a direction parallel to the longitudinal direction of the first free end 806 and the second free end 808. The liner 800 in the first shape has a generally cylindrical shape with a first diameter A. The first diameter A is the maximum distance between two opposing points on the support layer 802 of the liner 800 in the first shape. In the first shape of FIG. 8b, the support layer 802 of the liner 800 overlaps the layer 804 of the heating substance of the liner 800, showing a spiral shape.

[0072] In the second shape of FIG. 8c, the first free end 806 is unwound relative to the first shape of FIG. 3b, and the liner 800 retains the spiral shape of FIG. 8b but is wound more loosely. Thus, it can be considered that the first shape is partially unwound to achieve the second shape. The liner 800 in the second shape has a generally cylindrical shape with a second diameter B, and the second diameter B is larger than the first diameter A. The second diameter B is the maximum distance between two opposing points on the support layer 802 of the liner 800 in the second shape. In the second shape of FIG. 8c, the support layer 802 of the liner 800 overlaps the layer 804 of the heating substance of the liner 800, retaining the spiral shape.

[0073] In use, the liner 800 is first wound into the first shape of FIG. 8b and then inserted into the chamber 22. When the user releases the liner 800, the elastic deformation characteristics of the liner 800 cause the liner 800 to be partially unwound from the first shape to take the second shape of FIG. 8c. The second diameter B of the second shape of the liner 800 becomes substantially equal to the diameter of the chamber 22, and due to the spiral shape of the shape in FIG. 8c, the liner 800 covers the inside of the entire circumferential range of the chamber 22. The longitudinal ends of the opening of the liner 800 enable the consumable to be inserted into the liner 800 and thus into the chamber 22 through the opening 48.

[0074] When inserted into the chamber 22 in this way, the liner 800 can prevent the accumulation of deposits on the wall of the chamber 22 caused by the secondary flow from the heated consumable, and the liner 800 is removable and replaceable as needed. This can realize a convenient means of protecting the wall of the chamber 22. At the same time, for the user, the use of the aerosol supply device 12 itself becomes easier and the maintenance is reduced. The overlap of the liner 800 in the second shape of FIG. 8c can surely protect the entire circumferential range of the wall of the chamber 22, and the overlap may even extend to form a labyrinth seal that prevents the secondary flow from exiting the liner 800.

[0075] The degree to which the liner 800 can be unrolled from the first shape to the second shape can be determined by many factors, including but not limited to the initial dimensions of the liner 800, the material of the liner 800, and the dimensions of the chamber 22 such as the diameter of the chamber 22, which will be understood by those skilled in the art. In some examples, these factors can result in another second shape of the liner 800.

[0076] One such another second shape of the liner 800 is shown in FIG. 8d. In the shape of FIG. 8d, the liner 800 is unrolled until the first free end 806 and the second free end 808 are substantially connected. In such an embodiment, the support layer 802 and the layer 804 of the heating substance do not overlap. In this case, the liner 800 has a generally cylindrical shape with a substantially circular cross-sectional shape, and such a shape can still be considered to be rolled when viewed from the relative positions of the first free end 806 and the second free end 808.

[0077] Although the liner 800 is shown in FIG. 8a as initially having the form of a rectangular sheet, the liner 800 can be supplied to the consumer, i.e., the user, of the aerosol supply device 12 in a pre-rolled shape, such as the first shape of FIG. 8b or the second shape of FIG. 8c.

[0078] In one example, the material of the liner 800 can be selected such that the liner 800 can hold the liner in a wound shape, such as the second shape of FIG. 8c. In this case, the liner 800 is formed into the first shape of FIG. 8b by tightly winding it before being inserted into the chamber 22, and then inserted into the chamber 22, and when the user releases it, it can unwind and take the second shape of FIG. 8c.

[0079] In other examples, the liner 800 may include a retaining member to hold the liner 800 in the first shape. One such retaining member 900 shown in FIG. 9a is a relatively rigid material simple annular ring having an inner diameter substantially corresponding to the diameter A of the liner 800 in the first shape of FIG. 8b. The retaining member 900 of FIG. 9a can be easily removed from the liner 800 during insertion into the chamber 22, allowing the liner 800 to unwind from the first shape of FIG. 8b to either the second shape of FIGS. 8c and 8d.

[0080] A second embodiment 902 of the retaining member is shown in FIG. 9b. In this case, the retaining member 902 includes a strip 904 and a clamp 906 that can selectively hold the strip 904 in an annular configuration of variable diameter. Such a retaining member 902 may be similar to, for example, a jubilee clip. The engagement of the clamp 906 with the strip 904 can be varied to allow the liner to be movable between the first shape of FIG. 8b and either of the second shapes of FIGS. 8c and 8d as desired.

[0081] An alternative embodiment 1000 of the liner is schematically shown in FIG. 10. The liner 1000 includes a first layer 1002 of a high heat resistant polymer, a second layer 1004 of a heating substance, and a third layer 1006 of a heating substance. The second layer 1004 of the heating substance includes one of nickel or cobalt, and the third layer 1006 of the heating substance includes one or more substances from the list of aluminum, gold, iron, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze. The second layer 1004 of the heating substance is electroless plated on the first layer 1002 of the high heat resistant polymer as described above. The third layer 1006 of the heating substance may have better induction heating characteristics compared to the second layer 1004 of the heating substance and can be attached to the second layer 1006 of the heating substance by any suitable bonding method.

[0082] As described above, the liner 1000 of FIG. 10 may be shaped into the shapes of FIGS. 8a - d.

[0083] Yet another alternative embodiment 1100 of the liner is schematically shown in FIG. 11. The liner 1100 includes a support layer 1102 which is a rectangular sheet of a high heat resistant polymer such as a polyimide like Zytel® High Temperature Nylon (HTN) or Kapton®. Such a substance can be considered non - conductive and can prevent the formation of overcurrents within the substance. The liner 1100 includes a plurality of regions 1104 of a heating substance which is either nickel or cobalt, and the heating substance is electroless plated on the support layer 1102 as described above. The regions intermediate the plurality of regions 1104 are masked by wax during the electroless plating process. By using the plurality of regions 1104, the deformability of the liner 1100 can be promoted and the transition between the first shape and the second shape described above can be facilitated.

[0084] The various embodiments described herein are presented merely to assist in the understanding and teaching of the features recited in the claims. These embodiments are shown merely as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limiting the scope of the invention defined by the claims or equivalent matters of the claims, and it should be understood that other embodiments can be used and modifications can be made without departing from the scope of the invention recited in the claims. The various embodiments of the present invention appropriately include suitable combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein, and can be composed of or essentially composed of those combinations. Furthermore, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future. [Item of Invention] [Item 1] A heater element for an aerosol supply device, comprising a support and a heating substance that can be heated by the incidence of a variable magnetic field, wherein the heating substance consists of electroless plating on the support, the heater element. [Item 2] The heater element according to Item 1, wherein the support is made of a non-conductive material. [Item 3] The heater element according to Item 1 or 2, wherein the support is made of a substance having a melting point higher than 300°C. [Item 4] The heater element according to any one of Items 1 to 3, wherein the heating substance contains at least one of nickel and cobalt. [Item 5] The heater element according to any one of Items 1 to 4, wherein the heating substance has a thickness of 100 microns or less in a direction perpendicular to the surface of the support. [Item 6] The heater element according to any one of Items 1 to 5, wherein the support includes a tubular support. [Item 7] The heater element according to any one of items 1 to 6, wherein the heating substance is disposed on a surface facing radially inward of the support. [Item 8] Further comprising another heating substance attached to the heating substance, The heater element according to any one of items 1 to 7, wherein the further different heating substance includes a substance different from the heating substance, and the heating substance is disposed between the further different heating substance and the support. [Item 9] The heater element according to item 8, wherein the further different heating substance includes any one of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze, or any arbitrary combination thereof. [Item 10] Comprising a plurality of regions of the heating substance, The heater element according to any one of items 1 to 9, wherein the plurality of regions are spaced apart from the support. [Item 11] The heater element according to any one of items 1 to 10, which, when disposed in the aerosol supply device, defines a chamber for receiving a consumable containing an aerosol product substance. [Item 12] The heater element is for use in an aerosol supply device comprising a chamber and a heating assembly for applying heat to the consumable to generate an aerosol from the aerosol product substance when the consumable containing the aerosol product substance is disposed in the chamber, and the heater element is for selectively inserting into the chamber so as to at least partially cover the inside of the chamber. The heater element according to any one of items 1 to 10. [Item 13] It is possible to be formed into a first shape wound by a first diameter and also possible to be formed into a second shape wound by a second diameter larger than the first diameter, and when inserted into the chamber so as to at least partially cover the inside of the chamber, it is possible to transition from the first shape to the second shape, the heater element according to item 12. [Item 14] When inserted into the chamber, the heater element according to item 13, which is expandable by at least partial unwinding in order to transition from the first shape to the second shape. [Item 15] The heater element according to item 13 or 14, which has open longitudinal ends in the first shape and the second shape. [Item 16] The heater element according to any one of items 12 to 15, which is elastically deformable. [Item 17] An aerosol supply device comprising a heater element for heating a consumable containing an aerosol generating substance to generate an aerosol from the aerosol generating substance, The heater element includes a support and a heating substance that can be heated by the incidence of a variable magnetic field, the heating substance consists of electroless plating on the support, and the heater element at least partially forms a chamber into which a consumable can be inserted to be heated by the heating substance. [Item 18] A chamber, a heating assembly for heating a consumable containing an aerosol generating substance to generate an aerosol from the aerosol generating substance when the consumable is disposed in the chamber, and a heater element according to any one of items 12 to 16. [Item 19] A method for forming a heater element for an aerosol supply device, The step of preparing a support, The step of electroless plating a heating substance on the support, the heating substance being heatable by the incidence of a variable magnetic field. A method including [Item 20] The method according to item 19, wherein the support is made of a non-conductive material. [Item 21] The method according to item 19 or item 20, wherein the heating substance contains at least one of nickel and cobalt. [Item 22] The method according to any one of items 19 to 21, wherein the heating substance has a thickness of 100 microns or less in a direction perpendicular to the surface of the support. [Item 23] The method according to any one of items 19 to 22, wherein the support includes a tubular support. [Item 24] The method according to any one of items 19 to 23, including the step of electroless plating the heating substance on the surface facing the inner side in the radial direction of the support. [Item 25] A step of attaching another heating substance to the heating substance (hereinafter referred to as "the first heating substance"), wherein the another heating substance contains a substance different from the first heating substance, and the first heating substance is disposed between the another heating substance and the support. The method according to any one of items 19 to 24, including the step. [Item 26] The method according to item 25, wherein the another heating substance includes any one of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze, or any combination thereof. [Item 27] The method according to any one of items 19 to 26, wherein the heater element includes a plurality of regions of the heating substance, and the plurality of regions are spaced apart from each other on the support. [Item 28] The method according to any one of items 19 to 27, including the step of masking a part of the support before the electroless plating.

Claims

Claim 1 A heater element for heating an aerosol product substance, comprising a support and a heating substance that can be heated by the incidence of a variable magnetic field, wherein the heating substance consists of a layer on the support, the heating substance contains nickel and has a thickness of 50 microns or less, the heater element. Claim 2 The heater element according to claim 1, wherein the support consists of a non-conductive substance. Claim 3 The heater element according to claim 1, wherein the support consists of a substance having a melting point higher than 300°C. Claim 4 The heater element according to claim 1, wherein the heating substance contains nickel and cobalt. Claim 5 The heater element according to claim 1, wherein the heating substance has a thickness of 20 microns or less. Claim 6 The heater element according to claim 5, wherein the heating substance has a thickness of 15 to 20 microns. Claim 7 The heater element according to claim 1, wherein the heating substance has a constant thickness on the support. Claim 8 Further comprising another heating substance attached to the heating substance, wherein the further heating substance contains a substance different from the heating substance, and the heating substance is disposed between the further heating substance and the support, the heater element according to claim 1. Claim 9 The heater element according to claim 8, wherein the further heating substance contains any one of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze, or any arbitrary combination thereof. Claim 10 The heater element according to claim 1, wherein the support contains a metal. Claim 11 The heater element according to claim 1 or 10, wherein the heating substance is both conductive and ferromagnetic. Claim 12 The heater element according to claim 1, wherein the support has the form of a rectangular sheet. Claim 13 The heater element according to claim 1 or 12, wherein the heater element has the form of a rectangular sheet. Claim 14 The heater element according to claim 1, wherein the heater element is for selectively inserting into an aerosol supply device. Claim 15 An aerosol supply device comprising the heater element according to claim 1. Claim 16 The aerosol supply device according to claim 15, comprising a chamber and a heating assembly for applying heat to a consumable containing an aerosol generating substance to generate an aerosol from the aerosol generating substance when the consumable is disposed within the chamber.

17. The aerosol supply device according to claim 16, wherein the heater element is for selectively inserting into the chamber.

18. An aerosol supply system, comprising a chamber, a heating assembly for applying heat to a consumable containing an aerosol generating substance to generate an aerosol from the aerosol generating substance when the consumable is disposed within the chamber, and a heater element according to claim 1.

Images