Aerosol supply device

Abstract

To provide an aerosol supply device.SOLUTION: A device includes: at least one inductor coil 124; and a heater assembly 105 configured to receive an aerosol generation material. The heater assembly includes a first part having a first inner cross section, which is a first part that defines a heating chamber for receiving the aerosol generation material. The first part can be heated by the inductor coil. Also, the heater assembly includes a second part adjacent to the first part forming a passage having a second inner cross section which is smaller than the first inner cross section. A sealed fluid passage is defined between the first part and the second part.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device and an aerosol delivery system comprising an aerosol delivery device and an article containing an aerosol-generating material. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. 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. This 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 present disclosure, an aerosol delivery device is provided that includes an inductor coil and a heater assembly configured to receive an aerosol-generating material, the heater assembly including: a first portion defining a heating chamber for receiving the aerosol-generating material, the heating chamber having a first internal cross-sectional area, the first portion being heatable by the inductor coil; and a second portion adjacent to the first portion that forms a passageway having a second internal cross-sectional area smaller than the first internal cross-sectional area, the first portion and the second portion defining a sealed fluid path.

[0004] According to one aspect of the present disclosure, an aerosol delivery device is provided that includes an inductor coil and a heater assembly configured to receive an aerosol-generating material, the heater assembly including: a first portion defining a heating chamber for receiving the aerosol-generating material, the heating chamber having a first inner diameter, the first portion being heatable by the inductor coil; and a second portion adjacent to the first portion that forms a passage having a second inner diameter smaller than the first inner diameter, the first portion and the second portion defining a sealed fluid path.

[0005] The aerosol delivery device may include a receptacle forming the first portion and a funnel forming the second portion.

[0006] The receptacle may define a heating chamber configured to receive the aerosol-forming material.

[0007] The receptacle may be fluidly sealed to the funnel at the junction.

[0008] The funnel and the receptacle may overlap at the junction.

[0009] The funnel may partially overlap the receptacle at the interface, and the funnel may define a shoulder at one end of the receptacle.

[0010] The first and second parts may be fabricated as a unitary component.

[0011] The first and second parts may be fabricated as a unitary component by welding, which may be laser welding.

[0012] The first portion and the second portion may be formed from carbon steel, and the first portion and the second portion may be coaxial with each other.

[0013] The aerosol delivery device may include a first end support defining an insertion chamber at an open end of the first portion, the first end support being fluidly sealed with the first portion at the open end, such that the insertion chamber and the heating chamber define a sealed fluid pathway.

[0014] The aerosol delivery device may also include a second end support at the open end of the second portion, the second end support being fluidly sealed with the second portion at the open end.

[0015] According to one aspect of the present disclosure, an aerosol delivery device is provided that includes a heater assembly configured to receive and heat an aerosol-generating material, the heater assembly including: a first portion defining a heating chamber for receiving the aerosol-generating material, the heating chamber having a first internal cross-sectional area, the first portion configured to be heated; and a second portion adjacent to the first portion that forms a passageway having a second internal cross-sectional area smaller than the first internal cross-sectional area, the first portion and the second portion defining a sealed fluid path.

[0016] According to one aspect of the present disclosure, a heater assembly for an aerosol delivery device is provided, comprising: a first portion configured to be heated and defining a heating chamber having a first diameter for receiving an aerosol-generating material; and a second portion adjacent to the first portion forming a passageway having a second diameter smaller than the first diameter, wherein the heating chamber and the passageway define a sealed fluid path.

[0017] The first portion may be heated by an inductor coil.

[0018] According to one aspect of the present disclosure, an aerosol delivery device is provided that includes a heater assembly having a heating chamber configured to receive an aerosol-generating material, the heater assembly including a susceptor that is heatable by the penetration of a varying magnetic field; an inductor coil extending around the susceptor and configured to generate the varying magnetic field; an end support that receives one end of the heater assembly; and a fluid seal provided between the heater assembly and the end support to position and seal the heater assembly relative to the end support.

[0019] The end support may define an insert chamber at the open end of the heater assembly, and a fluid seal may fluidly seal the end support with the heater assembly such that the insert chamber and the heating chamber define a sealed fluid path.

[0020] The end support may be a first end support at a first end of the heater assembly, and the aerosol delivery device may include a second end support at a second end of the heater assembly.

[0021] The fluid seal may be a first fluid seal, and the aerosol delivery device may include a second fluid seal, the second fluid seal fluidly sealing the second end support with the heater assembly.

[0022] The second end support may include an air inlet, and the air inlet and the heating chamber may define a sealed fluid path.

[0023] A fluid seal may be formed in one of the heater assembly and the end support.

[0024] The fluid seal may be formed on the exterior of the heater assembly.

[0025] The fluid seal may be overmolded onto the outside of the heater assembly.

[0026] The fluid seal may be configured to abut a rim of the end support.

[0027] The end support may define an air inlet at an open end of the heater assembly. A fluid seal may fluidly seal the end support with the heater assembly, whereby the air inlet and the heating chamber define a sealed fluid path.

[0028] The heater assembly may include a first portion defining a heating chamber having a first internal cross-sectional area and a second portion adjacent to the first portion forming a passageway having a second internal cross-sectional area smaller than the first internal cross-sectional area, and a fluid seal may be between the second portion and the end support.

[0029] The fluid seal may position the heater assembly axially or may position the heater assembly radially.

[0030] The aerosol delivery device may include a tubular member extending around the susceptor.

[0031] The fluid seal may be positioned and sealed against the tubular member.

[0032] The fluid seal may be positioned and sealed against the interior surface of the tubular member.

[0033] The tubular member may be fixedly attached to the end support, or the tubular member may be mechanically secured to the end support.

[0034] According to one aspect of the present disclosure, an aerosol generation assembly for an aerosol generating device is provided, the aerosol generation assembly comprising: a heater assembly configured to receive an aerosol-generating material, the heater assembly having a susceptor that is heatable by penetration of a varying magnetic field generated by an inductor coil; and an end support that receives one end of the heater assembly, the heater assembly and the end support defining a sealed fluid path.

[0035] The end support may be a first end support having an insert chamber, the first end support at a first end of the heater assembly, and the assembly may include a second end support at a second end of the heater assembly, the sealed fluid path extending through the first end support, the heater assembly, and the second end support.

[0036] According to one aspect of the present disclosure, an aerosol delivery device is provided that includes a heater assembly having an air path defined therethrough, the heater assembly including a chamber configured to receive an aerosol-generating material, the heater assembly including a susceptor that is heatable by the penetration of a varying magnetic field; an insulated enclosure surrounding the heater assembly, the insulated enclosure including a first support at a first end of the heater assembly having an insertion chamber that communicates with the air path, and a second support at a second end of the heater assembly; and an inductor coil extending around the insulated enclosure and configured to generate a varying magnetic field, the insulated enclosure being integrally formed.

[0037] The insulating enclosure may include a first support, a second support, and an intermediate tubular member.

[0038] The first and second supports and the intermediate tubular member may be sealably secured to one another.

[0039] According to one aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device as described above and an article containing an aerosol-generating material, the article being dimensioned to be at least partially received within the heater assembly.

[0040] 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.

[0041] The inductor coil may be substantially helical. The inductor coil may be a helical coil. For example, the inductor coil may comprise a wire, such as a Litz wire, wound helically on a coil support.

[0042] The "outer surface" of the actual object means the surface disposed furthest from the axis of the susceptor in a direction perpendicular to the axis. Similarly, the "inner surface" of the actual object means the surface disposed closest to the axis of the susceptor in a direction perpendicular to the axis.

[0043] The "thickness" of a real object means 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 susceptor.

[0044] The inductor coil, susceptor, and thermal insulating member may be coaxial.

[0045] 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 from the susceptor by at least this distance, the temperature of the outer cover is maintained at a safe level, such as below about 60°C, below about 50°C, below about 48°C, or below about 43°C.

[0046] One or more of the coil support, barrier member, first end support, and 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.

[0047] 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.

[0048] The coil support, barrier member, first end support, and second end support may have a thermal conductivity of less than about 0.5 W / mK or less than about 0.4 W / mK. For example, the thermal conductivity may be about 0.3 W / mK. PEEK has a thermal conductivity of about 0.32 W / mK.

[0049] The coil support, barrier member, first end support, and second end support may have a melting point greater than about 320° C. (greater than about 300° C. or greater than about 340° C.) PEEK has a melting point of 343° C.

[0050] The device may be a tobacco heating device, also known as a non-combustion heating device.

[0051] 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 explanation of the drawings]

[0052] [Figure 1] FIG. 1 is a front view of an example aerosol delivery device. [Figure 2] 2 is a partially exploded side view of the aerosol delivery device of FIG. 1 showing the housing, end member, power source, aerosol generation assembly, replaceable article, and outer cover. [Figure 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. [Figure 5] 3 is another enlarged cross-sectional view of the proximal portion of the aerosol generation assembly of FIG. 2. FIG. [Figure 6] 3 is another enlarged cross-sectional view of the distal portion of the aerosol generation assembly of FIG. 2. FIG. [Figure 7] 3 is another enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. FIG. [Figure 8] 3 is another enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. FIG. [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. 9. [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 the thermocouple attachment points. DETAILED DESCRIPTION OF THE INVENTION

[0053] As used herein, the term "aerosol-generating material" includes materials that volatilize upon heating, typically 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 blend of materials. Aerosol-generating materials are sometimes known as "smoking materials."

[0054] Devices are known that heat aerosol-forming materials to volatilize at least one component of the aerosol-forming materials, typically without burning or combusting the aerosol-forming materials, to form inhalable aerosols. Such devices may be referred to as "aerosol-generating devices," "aerosol delivery devices," "non-combustion heating devices," "tobacco heating product devices," or "tobacco heating devices." Similarly, so-called e-cigarette devices exist that vaporize aerosol-forming materials, typically in liquid form (which may or may not contain nicotine). The aerosol-forming materials may be in the form of, or provided as, a part of a rod, cartridge, or cassette that can be inserted into the device. A heater that heats and volatilizes the aerosol-forming materials may be a "permanent" part of the device.

[0055] The aerosol delivery device can receive and heat an article containing an aerosol-forming material. In this context, an "article" is a component that comprises or contains the aerosol-forming material during use and is heated to volatilize the aerosol-forming 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 a specific size configured, for example, to be placed within a heating chamber of a device sized to receive the article.

[0056] 1 shows an example of an aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. Generally, device 100 may be used to heat a replaceable item 110 containing an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0057] Device 100 includes a housing 102 (including an outer cover) that encloses and houses the various components of device 100. Device 100 has an opening 104 at one end through which an item 110 can be inserted and heated by heater assembly 105 (see FIG. 2). In use, item 110 can be fully or partially inserted into heater assembly 105 and heated by one or more components of heater assembly 105.

[0058] Device 100 may also include a user-operable control element 112, such as a button or switch, that, when pressed, operates device 100. For example, a user may turn device 100 on by operating switch 112.

[0059] The device 100 defines a longitudinal axis 101 .

[0060] 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.

[0061] 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 the 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 item 110 is not in place.

[0062] Device 100 may also include electrical components, such as connector / port 114, that can accept a cable to charge a battery in 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.

[0063] 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 an article 110 may be inserted, and the article 110 may be heated by one or more components of the heater assembly 105. The aerosol generation assembly 111 and a power source 118 are mounted in the housing 109. The housing 109 is a one-piece component.

[0064] The housing 109 may be integrally formed during fabrication, for example, by an injection molding process, or two or more features of the housing 109 may be initially formed separately and then integrally formed during fabrication, for example, by a welding process, to form a one-piece component.

[0065] A unitary component refers to a component of device 100 that cannot be separated into two or more components after assembly of device 100. Integrally formed refers to two or more features that are formed as a unitary component during the fabrication stage of the component.

[0066] The first and second end members 106, 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. Alternatively, an edge of the outer cover 102 may define a portion of the end surface. The first and second end members 116 close the open end of the outer cover 102. The second end member 116 is at one end of the housing 109.

[0067] 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 the user's mouth during use. In use, a user inserts item 110 into opening 104 and operates user control 112 to initiate heating of the aerosol-generating material and utilize the aerosol generated by the device. This causes the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0068] The other end of the device furthest from opening 104 may be known as the distal end of device 100, as this is the end that will be furthest from a user's mouth during use. When a user utilizes the aerosol generated by the device, the aerosol flows in a direction toward the proximal end of device 100. The terms proximal and distal as applied to features of device 100 will be explained by reference to the relative orientation of such features to one another in the proximal-distal direction along axis 101.

[0069] 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 supply 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 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.

[0070] The power source 118 and the aerosol generation assembly 111 are disposed in an axial configuration, with the power source 118 at the distal end of the device 100 and the aerosol generation assembly 111 at the proximal end of the device 100. Other configurations are envisioned. The housing 109 includes an aerosol generation assembly mounting portion 113.

[0071] Device 100 further includes at least one electronics module 122. Electronics module 122 may include, for example, a printed circuit board (PCB) 123. PCB 123 may support at least one controller 121, such as a processor, and memory. PCB 123 may also include one or more electrical tracks that electrically connect various electronic components of device 100 together. For example, battery terminals may be electrically connected to PCB 123 so that power can be distributed throughout device 100. Connector 114 may also be electrically coupled to battery 118 via the electrical tracks. Housing 109 includes PCB mounting portion 117.

[0072] The aerosol-generating assembly 111 is an induction heating assembly that includes various components for heating the aerosol-generating material of the article 110 through an induction heating process. Induction heating is a process for heating an electrical conductor (such as a susceptor) through 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 appropriately positioned relative to the induction element, generating eddy currents inside the susceptor. Because the susceptor has an electrical resistance to the eddy currents, the flow of eddy currents against this resistance heats the susceptor through Joule heating. Additionally, 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. Induction heating allows for faster heating than, for example, conduction heating, because heat is generated inside the susceptor. Furthermore, no physical contact between the induction heater and the susceptor is required, which allows for greater flexibility in design and application.

[0073] 3 shows an enlarged, partial cross-sectional side view 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 includes 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 includes a coil support 200.

[0074] The heater assembly 105 includes a susceptor structure 132 (referred to herein as a "susceptor"). In this example, the susceptor 132 is hollow and defines a receptacle 131 in which an aerosol-generating material is received. For example, an item 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 substantially 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 outward. 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 of the susceptor 132 with other components at the first end 133. This configuration helps reduce heat transfer, for example, by conduction, when the susceptor 132 is heated. In an embodiment, the heater assembly 105 includes a susceptor and a receptacle. The susceptor may be a different mechanism than the receptacle.

[0075] 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.

[0076] In other embodiments, the feature functioning as a receptacle may not be limited to induction heating. Thus, the feature functioning as a heating element may be heatable by electrical resistance. To this end, the heater assembly 105 may include electrical contacts in electrical communication with the device to electrically activate the heating element by passing a flow of electrical energy through the heating element.

[0077] 3 shows a portion of the article 110 received in a receptacle 131 provided by a susceptor 132. The susceptor 132 and article 110 are sized to allow the article 110 to be received by the susceptor 132, which helps ensure the most efficient heating. In this example, the article 110 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, packaging, and / or cooling structure.

[0078] 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.

[0079] The funnel portion 140 has a thimble configuration. The funnel portion 140 is located at the second, 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 having a first diameter and a second portion 142 having 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 insertion of the item 110 into the receptacle. The shoulder 145 extends in a substantially vertical plane toward the longitudinal axis 101.

[0080] The first portion 141 has an inner diameter larger than the inner diameter of the second portion 142. Thus, the funnel portion 140 diverges from the first portion 141 to the second portion 142. Thus, the funnel portion 140 decreases in diameter from the susceptor end 148 to the distal end 149. The susceptor 132, which serves as the first portion of the heater assembly, defines a receptacle 131 that forms a heating chamber for the aerosol-generating material. The heating chamber has a first interior cross-sectional area. The second interior cross-sectional area is perpendicular to the axis of the air passage through the susceptor 132. The second portion 142 of the funnel portion 140, which serves as the second portion of the heater assembly 105, defines a passageway having a second interior cross-sectional area. The second interior cross-sectional area is perpendicular to the axis of the air passage through the susceptor 132. The second interior cross-sectional area is smaller than the first interior cross-sectional area.

[0081] The receptacle forms the first portion and the funnel forms the second portion.

[0082] The funnel portion 140 defines an air passage 146 therethrough. The first portion 141 and the susceptor 132 overlap at one end of the susceptor 132. In one example, the overlap is between about 1 mm and about 3 mm. In this particular example, the overlap is 2 mm. In some cases, there is no overlap. In such examples, the susceptor 132 and the funnel portion 140 are adjacent to each other. The first portion 141 overlaps the distal end 136, which is the second end 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 form a heat transfer path between the susceptor 132 and the funnel 140 .

[0083] Junction 147 is a fluidly sealed junction. A fluid seal is formed between susceptor 132 and funnel 140. A fluidly sealed fluid path is thus defined between the opposing ends of susceptor 132 and funnel 140. The receptacle defined by susceptor 132 thus forms a fluid-sealed air path with air passage 146 formed by funnel 140.

[0084] 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 understood that other methods, such as brazing, adhesive bonding, and soldering, may be used. Funnel 140 is formed from a heat-conductive material. In an embodiment, funnel 140 is formed from carbon steel. In an embodiment, funnel 140 is formed from the same material as susceptor 132. The bond is configured to maintain a fluid seal when susceptor 132 is at its predetermined operating temperature. By such a process, susceptor 132 and funnel 140 are fabricated as a unitary component.

[0085] Thus, the sealed fluid path of the susceptor 132 and 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. As such, the heater assembly 105 contains any fluid flow through the heater assembly 105. A dry zone may be defined outside the heater assembly 105.

[0086] 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 buildup in the device 100.

[0087] 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.

[0088] 4-8, device 100 includes a first end support 220 and a second end support 230. Heater assembly 105 extends between first and second end supports 230. A barrier member 250 extends between first end support 220 and second end support 230. Barrier member 250 acts as a support member.

[0089] The first end support 220 engages the first, 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 FIGS. 7 and 8 , the first end support 220 extends away from the first end of the susceptor 132 toward the opening 104. Disposed within the first end support 220 is at least a portion of a retention structure 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.

[0090] The first end support 220 includes an insert chamber 222. The insert chamber 222 is configured to receive the article 110 therein. The retaining structure 221 resides in the insert chamber 222. The insert 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. As shown in FIGS. 7 and 8, for example, the inner surface of the bore 223 defines a distally facing shoulder 225. The distally facing shoulder 225 aligns with the lip 135 of the susceptor 132 when the susceptor 132 is received by the first end support 220.

[0091] 4 and 5, the first end support 220 defines a seal rim 226 distally of the first end support 220. The distal seal rim 226 extends around the bore 223. A first mounting flange 227 extends from 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 proximal end mounting surface 229. 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 outer surface 228 and the first end mounting surface define first and second stepped surfaces.

[0092] 4-8, the device 100 further includes a second end support 230 that holds the heater assembly 105 in place by engaging the funnel 140 at the second, distal end of the susceptor 132. The second end support 230 constitutes a second, 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 toward the distal end of the device 100.

[0093] 4 and 6 , the second end support 230 includes a second end perforation 231. The second end perforation 231 acts as an air inlet. The air inlet defines a flow path through the second end support 230. The air inlet communicates with the exterior of the aerosol generation assembly 111 to provide an air passage to the exterior of the device 100. The second end support 230 is configured to at least partially receive the funnel portion 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 portion 140. The second stepped region 233 receives the second portion 142 of the funnel portion 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.

[0094] A second mounting flange 237 extends from a second outer surface, or distal outer surface 238, of the second end support 230. The second mounting flange 237 extends circumferentially and is spaced from the proximal end of the second end support 230. The second mounting flange 237 stands upright from the second end outer surface 238 to define a second end mounting surface, or distal end mounting surface 239. The second end outer surface, or distal end outer surface 238, and the second end mounting surface, or 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.

[0095] 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, which helps to thermally isolate the heater assembly 105 from the other components of the device 100. The barrier member 250 is a hollow tubular member.

[0096] 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 250. The barrier member 250 partially overlaps the first and second end supports 220, 230. In one example, this 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.

[0097] 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., weld) is formed between the barrier member 250 and each of the first and second end supports 220, 230. The fluid seal at the joint of the components is formed by a welding process, such as PEEK welding, although it will be understood that other methods, such as brazing and adhesive bonding, can be used. In an embodiment, the barrier member 250 and the first and second end supports 220, 230 are formed from the same material. The bond is configured to maintain the fluid seal when the susceptor 132 is at its predetermined operating temperature. Through this process, the barrier member 250 and the first and second end supports 220, 230 are formed as a single, integral component.

[0098] 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 also 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.

[0099] 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 can help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0100] A radial gap is provided between the susceptor 132 and the first end support 220. The diameter of the perforations 223 is larger 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.

[0101] 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 the heater assembly 105 at operating temperatures. 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 the outer surface of the susceptor 132. The first seal member 240 is spaced from the 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 132. The first seal member 240 provides an axial seal.

[0102] The first seal member 240 seals against the barrier member 250. The first seal member 240 stands upright 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.

[0103] 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 elastomeric. This material is configured to stabilize the heater assembly 105 at operating temperatures. The second seal member 245 is fixedly mounted to the funnel 140. In an embodiment, the second seal member is located 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 sealing member 245. Such a seal is formed between the second end support 230 and the heater assembly 105. The second sealing member 245 provides a radial seal.

[0104] 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.

[0105] In embodiments, the first seal member 240 is on the first end support 220 and seals with the heater assembly 105. In embodiments, the second seal member 245 is on the second end support 230 and seals with the heater assembly 105. The second seal member 245 is on the second portion 142 of the funnel 140. In embodiments, the second seal member 245 is on 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.

[0106] 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, thereby providing a gap between the barrier member 250 and the heater assembly 105. The gap provides thermal insulation from the heat generated in the susceptor 132.

[0107] 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 embodiments, the gap between the heater assembly 105 and the barrier member 105 is approximately 0.8 mm to 1 mm. In embodiments, the gap is approximately 0.9 mm.

[0108] A sensor, such as a thermocouple 265, is disposed in the fluidically sealed cavity 260. The thermocouple 265 is mounted to 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 fluidically sealed cavity 260 helps to isolate the thermocouple 265 from the atmosphere outside the fluidically sealed cavity 260. Providing the fluidically 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.

[0109] 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. Litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in 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 another shape, such as a rectangular shape. The number of inductor coils may vary. For example, in some embodiments, the inductor coil assembly 127 may include a single inductor coil. The first or second inductor coil may be omitted.

[0110] 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). The susceptor structure 132 may comprise a single susceptor or 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).

[0111] It will be apparent that in some examples, the first and second inductor coils 124, 126 may have at least one characteristic that differs from one another. For example, the first inductor coil 124 may have at least one characteristic that differs 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 FIGS. 3 and 4, the first and second inductor coils 124, 126 have different lengths such that the first inductor coil 124 is wound around the susceptor 132 by a smaller amount than the second inductor coil 126. As such, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming the spacing between 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.

[0112] 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 then the second inductor coil 126 may be activated to heat a second portion of the article 110. In some embodiments, 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 inactive coils when used in conjunction with certain types of control circuitry. 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.

[0113] It will be appreciated that the number of inductor coils may vary. In an embodiment, device 100 includes a single inductor coil.

[0114] 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.

[0115] Coil support 200 extends between first and second end supports 220, 230. Coil support 200, together with first and second end supports 220, 230, surrounds heater assembly 105, which helps to thermally isolate heater assembly 105 from other components of device 100. Coil support 200 is a hollow tubular member.

[0116] In an embodiment, the coil support 200 is formed from a non-metallic material to help limit interference with magnetic induction. In this particular example, the coil support 200 is formed from polyetheretherketone (PEEK). Other suitable materials are possible. A coil support formed from such a material ensures that the assembly remains rigid / solid when the susceptor is heated. The coil support 200 is formed from a rigid material to help support other components, such as the coils 124, 126. The coil support 200 may be formed from an insulating material, such as plastic. In one example, the coil support 200 is 1 mm to 1.5 mm thick. In this example, the thickness is approximately 1.3 mm. The coil support 200 is a one-piece construction. In an embodiment, the coil support is an assembly of two or more parts.

[0117] The coil support 200 acts as a secondary housing to aid in the assembly of the device 100. The coil support 200 provides a secondary housing that can be mounted to the housing 109. The coil support 200 acts as a mounting structure for other features of the aerosol generation assembly 111.

[0118] 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.

[0119] 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. The coil support 200 can help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0120] The coil support 200 has an outer surface 203. The outer surface 203 is spaced apart from the outer cover 102. The coil support 200 is spaced apart from the heater assembly 105. The coil support 200 has an inner surface that is spaced apart from the outer surface 203 of the susceptor 132.

[0121] The coil support 200 is fixedly attached to 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 200 overlaps the proximal end mounting surface 229, which is the first end mounting surface of the first end support 220. The distal end of coil support 220 overlaps distal end mounting surface 229 , which is the second end mounting surface of second end support 230 .

[0122] Coil support 200 is fixedly attached to first and second end supports 220, 230. Coil support 200 is held between first and second end supports 220, 230. In embodiments, coil support 200 is secured in place by a mechanically worked bond, such as welding or adhesive bonding. In embodiments, coil support 200 and first and second end supports 220, 230 are formed from the same material.

[0123] 3, 4, 9, and 10, the first and second inductor coils 124, 126 are aligned on the coil support 200 by the coil support 200. That is, the first and second inductor coils 124, 126 are held in a specific arrangement relative to the coil support 200 by a feature of the coil support 200. By way of example, the alignment feature is a channel 205. The channel 205 is formed on the radially outer surface 201 of the coil support 200. The channel 205 is a spiral channel 205. The channel 205 receives the first and second inductor coils 124, 126. The first and second inductor coils 124, 126 are held by the channel 205. The channel 205 follows a regular spiral path. The channel 205 winds multiple times 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.

[0124] The first and second inductor coils 124, 126 are each 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 each follow a helical path. The turns of the helical path of each of the first and second inductor coils 124, 126 are equally spaced.

[0125] 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 plurality of protrusions. The protrusions may define a helical path in which the support coil is received and retained.

[0126] The coil support 200 includes 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. The provision of the helical recess helps to limit heat transfer. The provision of 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 FIGS. 3 and 4.

[0127] The first and second inductor coils 124, 126 are held in the channel 205. The first and second inductor coils 124, 126 may be held in the channel 205 using a holding mechanism such as clips, bonding, or an overlayer.

[0128] The first and second inductor coils 124, 126 are each fully received in the coil support 200. That is, the first and second inductor coils 124, 126 are each flush with or recessed from the surface of the coil support 200. In an embodiment, the first and second inductor coils 124, 126 partially protrude from the channel 205.

[0129] 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.

[0130] 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.

[0131] 12, a sensor 290 such as a thermocouple is disposed on the coil support 200. The coil support 200 includes a sensor mounting portion 291, which assists 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 forms a positioning surface for mounting the thermocouple.

[0132] The alignment features in the above-described embodiments are channels, although it will be appreciated that the channels may be omitted and the alignment features may be different.

[0133] 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 channel and / or other alignment features for aligning the coil may be omitted. In such embodiments, the coil may be attached to a surface of the coil support or may be spaced apart and assembled around the coil support.

[0134] The heater assembly 105, the barrier member 250, and the coil support 200 are coaxial about the central longitudinal axis of the susceptor 132. The coil support 200 can help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0135] 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. A thermal insulating chamber 270 may be formed between the coil support 200 and the barrier member 250.

[0136] In one example, the spacing between the coil support 200 and the barrier member 250 is 0.5 mm to 1.5 mm. In this example, the thickness is approximately 0.9 mm. 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 separate different components of the device from each other in a stand-off configuration.

[0137] The barrier acts as a thermal insulator. As such, the barrier forms part of a thermal insulation 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 thermal insulator. The coil support 200 acts as a second thermal insulator. 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.

[0138] 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 by, for example, 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 by, for example, 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 a configuration, the air gap acts as an insulator.

[0139] 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 inner 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 200. By way of example, the insulating layer 271 is attached to the barrier member 250. The barrier member 250 separates the insulating layer 271 from the susceptor 132. The coil support 200 separates the insulating layer 271 from the inductor coils 124, 126.

[0140] 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 may have a thermal conductivity of about 0.25 W / mK in some instances), (iv) ceramic cloth (having a specific heat of about 1.13 kJ / kgK), or (v) thermal putty. Other suitable materials may be used.

[0141] The insulating layer 271 is formed from aerogel. Other suitable materials, such as porous foam materials, can also be used. Barrier members can be provided on either side of the aerogel to provide, for example, a protective barrier for the insulating layer 271. The barrier or barriers can help support the insulating layer 271 along its length.

[0142] The combination of the barrier member and aerogel thermal insulation layer helps limit heat transfer to the shell of the device 100 in a compact configuration by providing an enhanced thermal insulation configuration around the heater assembly 105 .

[0143] 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 has 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 contemplated. The outer insulation layer 273 allows for a predetermined thickness of insulation to be used while still allowing for variations in the distance between the coil and the susceptor 132. The outer insulation layer 273 is formed from aerogel. Other suitable materials, such as porous foam materials, may also be used.

[0144] 11 , a first end support 220 protrudes from the proximal end of the coil support 200. A second end support 230 protrudes from the distal end of the coil support 200. The first end support 220 is aligned axially. The second end support 230 is aligned axially. The aerosol generation assembly 111 is attached to the housing 109. The aerosol generation assembly 111 is attached at its proximal and distal ends. An aerosol generation assembly mounting portion 113 of the housing 109 holds the aerosol generation assembly 111. A first positioning mechanism 300 positions the aerosol generation assembly 111 at the first end, or proximal end, of the housing 109. A second positioning mechanism 301 positions the aerosol generation assembly 111 at the second end, or distal end, of the housing 109.

[0145] 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.

[0146] In the above example, the susceptor 132 has a thickness 154 of about 0.08 mm. The thickness of the susceptor 132 is the average distance between the inner surface of the susceptor 132 and the outer surface of the susceptor 132, measured in a direction perpendicular to the axis 158.

[0147] In one example, the length of the susceptor 132 is about 30 mm to about 50 mm, or about 30 mm to about 35 mm. In this particular example, the susceptor 132 has a length of about 34.8 mm and is capable of receiving the article 110 containing the aerosol-forming material. The lengths of the aerosol-forming material and the susceptor 132 are measured in a direction parallel to the axis 101.

[0148] 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.

[0149] 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 current therethrough for magnetic field induction. 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 when a ferrite shield contacts and at least partially surrounds one or more inductor coils, it can reduce the surface temperature of the outer cover by approximately 3°C.

[0150] The inner surface of the outer cover may be spaced from the outer surface of the insulating member by a distance of about 2 mm to about 3 mm. A separation distance of this size has been found to provide sufficient insulation so that the outer cover does not become too hot. Air may be present between the outer surface of the insulating member and the outer cover.

[0151] The inner surface of the outer cover may be spaced apart from the outer surface of the inductor coil by a distance of about 0.2 mm to about 1 mm.

[0152] The inner surface of the inductor coil may be spaced from the outer surface of the susceptor by a distance of about 3 mm to about 4 mm, which in this particular example is about 3.2 mm.

[0153] The outer cover may comprise aluminum.

[0154] The outer cover may have a thermal conductivity of about 140 W / mK to about 220 W / mK. For example, the thermal conductivity of aluminum is around 209 W / mK.

[0155] The outer cover may be from about 0.4 mm to about 2 mm thick. The outer cover may act as an insulating barrier.

[0156] 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 may in some instances be different from one another.

[0157] 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. Furthermore, equivalents and modifications not described above, as defined in the appended claims, may also be employed without departing from the scope of the present invention. Some embodiments of the present invention include, for example, those described in the following clauses. Clause 1 a heater assembly having a heating chamber configured to receive an aerosol-generating material, the heater assembly including a susceptor heatable by penetration of a varying magnetic field; an inductor coil extending around the susceptor and configured to generate a varying magnetic field; an end support for receiving one end of the heater assembly; a fluid seal provided between the heater assembly and the end support for positioning and sealing the heater assembly relative to the end support; An aerosol delivery device comprising: Clause 2 An aerosol delivery device as described in clause 1, wherein the end support defines an insertion chamber at the open end of the heater assembly, and the fluid seal fluidly seals the end support with the heater assembly so as to define a sealed fluid path between the insertion chamber and the heating chamber. Clause 3 The aerosol supply device of clause 2, wherein the end support is a first end support at a first end of the heater assembly, the aerosol supply device comprises a second end support at a second end of the heater assembly, the fluid seal is a first fluid seal, and the aerosol supply device comprises a second fluid seal, the second fluid seal fluidically sealing the second end support to the heater assembly. Clause 4 4. The aerosol delivery device of clause 3, wherein the second end support includes an air inlet, and a sealed fluid path is defined between the air inlet and the heating chamber. Clause 5 An aerosol delivery device as described in clause 1, wherein the end support defines an air inlet at the open end of the heater assembly, and the fluid seal fluidly seals the end support with the heater assembly, thereby defining a sealed fluid path between the air inlet and the heating chamber. Clause 6 6. The aerosol delivery device of any one of clauses 1 to 5, wherein the fluid seal positions the heater assembly in at least one of an axial direction and a radial direction. Clause 7 7. The aerosol delivery device of any one of clauses 1 to 6, comprising a tubular member extending around the susceptor, the fluid seal positioning and sealing against the tubular member. Article 8 1. An aerosol generation assembly for an aerosol generation device, comprising: a heater assembly configured to receive the aerosol-generating material, the heater assembly including a susceptor heatable by penetration of a varying magnetic field generated by an inductor coil; an end support for receiving one end of the heater assembly; Equipped with The aerosol generation assembly, wherein a sealed fluid path is defined between the heater assembly and the end support. Article 9 The aerosol generation assembly described in clause 8, wherein the end support is a first end support having an insertion chamber, the first end support being at a first end of the heater assembly, and the aerosol generation assembly comprises a second end support at a second end of the heater assembly, and the sealed fluid path extends through the first end support, the heater assembly, and the second end support. Article 10 a heater assembly having an air passage defined therethrough, the heater assembly including a chamber configured to receive an aerosol-generating material, the heater assembly including a susceptor heatable by penetration of a varying magnetic field; an insulating enclosure surrounding the heater assembly, the insulating enclosure including a first support at a first end of the heater assembly having an insertion chamber in communication with the air path, and a second support at a second end of the heater assembly; an inductor coil extending around the insulating enclosure and configured to generate a varying magnetic field; 1. An aerosol delivery device comprising: The aerosol delivery device, wherein the insulating enclosure is integrally formed. Article 11 11. The aerosol delivery device of clause 10, wherein the insulating enclosure comprises the first support, the second support and an intermediate tubular member. Article 12 an aerosol delivery device according to any one of clauses 1 to 7 and 10 to 11; an article including an aerosol-forming material, the article being sized to be at least partially received within the heater assembly; and An aerosol delivery system comprising: Article 13 an inductor coil; a heater assembly configured to receive an aerosol-generating material; and 1. An aerosol delivery device comprising: the heater assembly a first portion defining a heating chamber for receiving an aerosol-forming material, the heating chamber having a first interior cross-sectional area, the first portion heatable by the inductor coil; a second portion adjacent to the first portion, the second portion defining a passageway having a second internal cross-sectional area smaller than the first internal cross-sectional area; Equipped with An aerosol delivery device, wherein the first and second portions define a sealed fluid path extending from one open end of the heater assembly through the heater assembly to the other open end of the heater assembly by forming a fluid seal between the first and second portions. Article 14 14. The aerosol delivery device of clause 13, comprising a receptacle forming the first portion and a funnel forming the second portion. Article 15 15. The aerosol delivery device of clause 14, wherein the receptacle is fluidly sealed to the funnel at a junction. Article 16 16. The aerosol delivery device of clause 15, wherein the funnel portion and the receptacle partially overlap at the junction. Article 17 17. The aerosol delivery device of any one of clauses 13 to 16, wherein the first part and the second part are made as an integral component. Article 18 the aerosol delivery device includes a first end support defining an insertion chamber at an open end of the first portion; An aerosol delivery device described in any one of clauses 13 to 17, wherein a fluid seal is formed between the first end support and the first portion at the open end, whereby the insertion chamber and the heating chamber define the sealed fluid path. Article 19 the aerosol delivery device includes a second end support at an open end of the second portion; 19. The aerosol delivery device of any one of clauses 13 to 18, wherein the second end support is fluidly sealed with the second portion at the open end. Article 20 a first portion defining a heating chamber having a first diameter for receiving an aerosol-generating material and heatable by an inductor coil; a second portion adjacent to the first portion, the second portion defining a passageway having a second diameter smaller than the first diameter; 1. A heater assembly for an aerosol delivery device, comprising: a heater assembly, wherein the heating chamber and the passage define a sealed fluid path extending from one open end of the heater assembly through the heater assembly to the other open end of the heater assembly by forming a fluid seal between the heating chamber and the passage. Article 21 an aerosol delivery device according to any one of clauses 13 to 19; an article including an aerosol-forming material, the article being sized to be at least partially received within the heater assembly; and An aerosol delivery system comprising:

Claims

1. a heater assembly having a heating chamber configured to receive an aerosol-generating material, the heater assembly including a susceptor heatable by penetration of a varying magnetic field; an inductor coil extending around the susceptor and configured to generate the varying magnetic field; an end support for receiving one end of the heater assembly; a fluid seal provided between the heater assembly and the end support for positioning and sealing the heater assembly relative to the end support; An aerosol delivery device comprising:

2. 2. The aerosol delivery device of claim 1, wherein the end support defines an insertion chamber at an open end of the heater assembly, and the fluid seal fluidly seals the end support with the heater assembly such that a sealed fluid path is defined between the insertion chamber and the heating chamber.

3. 3. The aerosol delivery device of claim 2, wherein the end support is a first end support at a first end of the heater assembly, and the aerosol delivery device comprises a second end support at a second end of the heater assembly.

4. 4. The aerosol delivery device of claim 3, wherein the fluid seal is a first fluid seal, and the aerosol delivery device includes a second fluid seal, the second fluid seal fluidly sealing the second end support to the heater assembly.

5. 5. The aerosol delivery device of claim 4, wherein the second end support includes an air inlet, and a sealed fluid path is defined between the air inlet and the heating chamber.

6. The aerosol delivery device of any one of claims 2 to 5, wherein the fluid seal is formed in one of the heater assembly and the end support.

7. The aerosol delivery device of claim 6 , wherein the fluid seal is formed on the exterior of the heater assembly.

8. The aerosol delivery device of claim 7 , wherein the fluid seal is configured to abut a rim of the end support.

9. 2. The aerosol delivery device of claim 1, wherein the end support defines an air inlet at an open end of the heater assembly, and the fluid seal fluidly seals the end support with the heater assembly, thereby defining a sealed fluid path between the air inlet and the heating chamber.

10. 10. The aerosol delivery device of claim 9, wherein the heater assembly comprises a first portion defining the heating chamber having a first internal cross-sectional area, and a second portion adjacent to the first portion forming a passage having a second internal cross-sectional area smaller than the first internal cross-sectional area, and the fluid seal is between the second portion and the end support.

11. The aerosol delivery device of any one of claims 1 to 10, wherein the fluid seal positions the heater assembly axially and / or radially.

12. The aerosol delivery device of any one of claims 1 to 11, comprising a tubular member extending around the susceptor.

13. The aerosol delivery device of claim 12 , wherein the fluid seal positions and seals against the tubular member.

14. 14. The aerosol delivery device of claim 13, wherein the tubular member is fixedly attached to the end support.

15. 1. An aerosol generation assembly for an aerosol generation device, comprising: a heater assembly configured to receive the aerosol-generating material, the heater assembly including a susceptor heatable by penetration of a varying magnetic field generated by an inductor coil; an end support for receiving one end of the heater assembly; Equipped with The aerosol generation assembly, wherein a sealed fluid path is defined between the heater assembly and the end support.

16. 16. The aerosol generation assembly of claim 15, wherein the end support is a first end support having an insertion chamber, the first end support being at a first end of the heater assembly, and the aerosol generation assembly comprises a second end support at a second end of the heater assembly, and the sealed fluid path extends through the first end support, the heater assembly, and the second end support.

17. a heater assembly defining an air passage therethrough, the heater assembly including a chamber configured to receive an aerosol-generating material, the heater assembly including a susceptor heatable by penetration of a varying magnetic field; an insulating enclosure surrounding the heater assembly, the insulating enclosure comprising: a first support at a first end of the heater assembly having an insertion chamber in communication with the air path; and a second support at a second end of the heater assembly; an inductor coil extending around the insulating enclosure and configured to generate the varying magnetic field; 1. An aerosol delivery device comprising: The aerosol delivery device, wherein the insulating enclosure is integrally formed.

18. 18. The aerosol delivery device of claim 17, wherein the insulating enclosure comprises the first support, the second support, and an intermediate tubular member.

19. 20. The aerosol delivery device of claim 18, wherein the first support, the second support, and the intermediate tubular member are sealably secured to one another.

20. an aerosol delivery device according to any one of claims 1 to 14 and 17 to 19; an article including an aerosol-forming material, the article being sized to be at least partially received within the heater assembly; and An aerosol delivery system comprising:

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