Aerosol Delivery Device

Abstract

An aerosol delivery device (100) is described. The device includes a body (101) and a button assembly (200) on the body. The button assembly includes a button member (202), a support frame (220), and a resilient arm (204, 212). The resilient arm connects the support frame to the button member. A flexible seal member (224) extends between the support frame and the button member. Also disclosed are a button assembly for an aerosol delivery device and a method of manufacturing a button assembly for an aerosol delivery device.

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device. The present invention also relates to a button assembly for an aerosol delivery device and a method of manufacturing a button assembly for an aerosol delivery device. [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 articles that burn tobacco by creating products that release compounds without combustion. An example of such a product is a heating device that releases compounds by heating but not burning a material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] According to some embodiments described herein, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a body; and a button assembly on the body, the button assembly comprising: a button member; a support frame; a resilient arm connecting the support frame to the button member; and a flexible seal member extending between the support frame and the button member.

[0004] The resilient arm may be elongated.

[0005] The resilient arm may extend from an outer edge of the button member. At least a portion of the resilient arm may extend at least substantially parallel to the outer edge of the button member.

[0006] The button member may be at least partially received within the support frame.

[0007] The support frame may include an inner edge, and at least a portion of the resilient arm may extend at least substantially parallel to the inner edge of the support frame.

[0008] The resilient arm may include an arm member, a first connector portion extending between the arm member and the button member, and a second connector portion extending between the arm member and the support frame.

[0009] The elastic arm may have a Z-shape between the button member and the support frame.

[0010] The elastic arm may have a thickness smaller than that of the button member.The elastic arm may have a thickness smaller than that of the support frame.

[0011] The button member and the resilient arm may form a unitary component.The support frame and the resilient arm may form a unitary component.

[0012] The resilient arm may be a first resilient arm. The button assembly may include a second resilient arm connecting the support frame to the button member. The first and second arms may extend from opposing sides of the button member.

[0013] The support frame, the resilient arm, the button member and the flexible sealing member may be integrally formed.

[0014] The flexible sealing member may form a fluid barrier.

[0015] The support frame, the resilient arms, the button member and the flexible seal member may together form a fluid barrier.

[0016] The flexible sealing member may extend around the button member.

[0017] The flexible sealing member may be an overmolded member.

[0018] The button member may be spaced from the support frame.

[0019] The flexible sealing member may fill the space between the support frame and the button member.

[0020] The body may comprise a housing and the support frame may be mounted to the housing. The support frame may be welded to the housing. The support frame may be sonic welded to the housing.

[0021] The housing may include an opening and the button member may be received in the opening.

[0022] The body may include a chassis within the housing, and the support frame may be at least partially received between the chassis and the housing.

[0023] The body may include a printed circuit board disposed behind the button assembly and connected to the button assembly by at least one alignment pin. The aerosol delivery device may include a stiffening member behind the printed circuit board.

[0024] The printed circuit board may be a flexible printed circuit.

[0025] According to some embodiments described herein, there is provided an aerosol delivery device comprising: a body; and a button assembly on the body, the button assembly comprising: a button member; a support frame; a first elastic arm extending between the support frame and the button member; and a second elastic arm extending between the support frame and the button member, wherein the first elastic member is relatively more elastic than the second elastic member.

[0026] Each resilient arm may be elongated.

[0027] Each resilient arm may extend from an outer edge of the button member. At least a portion of each resilient arm may extend at least substantially parallel to the outer edge of the button member.

[0028] The button member may be at least partially received within the support frame.

[0029] The support frame may include an inner edge, and at least a portion of each resilient arm may extend at least substantially parallel to the inner edge of the support frame.

[0030] Each resilient arm may include an arm member, a first connector portion extending between the arm member and the button member, and a second connector portion extending between the arm member and the support frame.

[0031] Each resilient arm may have a Z-shape between the button member and the support frame.

[0032] The thickness of each resilient arm may be less than the thickness of the button member. The thickness of each resilient arm may be less than the thickness of the support frame.

[0033] The button member and the resilient arm may form a unitary component.The support frame and the resilient arm may form a unitary component.

[0034] The first and second resilient arms may extend from opposite sides of the button member.

[0035] The support frame, the resilient arm, the button member and the flexible sealing member may be integrally formed.

[0036] The support frame, the resilient arms, the button member and the flexible seal member may together form a fluid barrier.

[0037] The flexible sealing member may form a fluid barrier.

[0038] The flexible sealing member may extend around the button member.

[0039] The flexible sealing member may be an overmolded member.

[0040] The button member may be spaced from the support frame.

[0041] The flexible sealing member may fill the space between the support frame and the button member.

[0042] The body may comprise a housing and the support frame may be mounted to the housing. The support frame may be welded to the housing. The support frame may be sonic welded to the housing.

[0043] The housing may include an opening and the button member may be received in the opening.

[0044] The body may include a chassis within the housing, and the support frame may be at least partially received between the chassis and the housing.

[0045] The body may include a printed circuit board disposed behind the button assembly and connected to the button assembly by at least one alignment pin. The aerosol delivery device may include a stiffening member behind the printed circuit board. The printed circuit board may be a flexible printed circuit.

[0046] According to some embodiments described herein, there is provided a button assembly for an aerosol delivery device comprising a button member, a support frame, a resilient arm connecting the support frame to the button member, and a flexible seal member extending between the support frame and the button member.

[0047] The resilient arm may be elongated.

[0048] The resilient arm may extend from an outer edge of the button member. At least a portion of the resilient arm may extend at least substantially parallel to the outer edge of the button member.

[0049] The button member may be at least partially received within the support frame.

[0050] The support frame may include an inner edge, and at least a portion of the resilient arm may extend at least substantially parallel to the inner edge of the support frame.

[0051] The resilient arm may include an arm member, a first connector portion extending between the arm member and the button member, and a second connector portion extending between the arm member and the support frame.

[0052] The elastic arm may have a Z-shape between the button member and the support frame.

[0053] The elastic arm may have a thickness smaller than that of the button member.The elastic arm may have a thickness smaller than that of the support frame.

[0054] The button member and the resilient arm may form a unitary component.The support frame and the resilient arm may form a unitary component.

[0055] The resilient arm may be a first resilient arm. The button assembly may include a second resilient arm connecting the support frame to the button member. The first and second arms may extend from opposing sides of the button member.

[0056] The support frame, the resilient arm, the button member and the flexible sealing member may be integrally formed.

[0057] The flexible sealing member may form a fluid barrier.

[0058] The support frame, the resilient arms, the button member and the flexible seal member may together form a fluid barrier.

[0059] The flexible sealing member may extend around the button member.

[0060] The flexible sealing member may be an overmolded member.

[0061] The button member may be spaced from the support frame.

[0062] The flexible sealing member may fill the space between the support frame and the button member.

[0063] According to some embodiments described herein, there is provided a method of manufacturing a button assembly for an aerosol delivery device, the method including forming a button configuration comprising a support frame, a button member at least partially received within the support frame, and an arm extending between the button member and the support frame, and overmolding a flexible seal member such that the flexible seal member extends at least partially around the button, between the button and the support frame.

[0064] The method can include sonic welding the frame to a housing of the aerosol delivery device such that the button member is received in an opening in the housing of the aerosol delivery device.

[0065] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0066] [Figure 1] FIG. 2 is a front view of the aerosol delivery device. [Diagram 2] 2 shows a schematic cross-sectional side view of the aerosol delivery device of FIG. 1. [Diagram 3] 2 shows a perspective view of a button assembly of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 4 shows a cross-sectional perspective view of the button assembly of FIG. 3. [Diagram 5] 2 shows a partially cutaway perspective view of a portion of the aerosol delivery device of FIG. 1. [Figure 6] 2 shows a partially cutaway perspective view of a portion of the aerosol delivery device of FIG. 1. [Figure 7] 2 shows a perspective view of another configuration of the button assembly of the aerosol delivery device of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067] As used herein, the term "aerosol-generating material" is a material capable of generating an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel that may or may not contain active substances and / or flavorants. The aerosol-generating material may include any plant-based material, such as a tobacco-containing material, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The aerosol-generating material may also include other non-tobacco products, which may or may not contain nicotine depending on the product. The aerosol-generating material may be, for example, in the form of a solid, liquid, gel, wax, etc. The aerosol-generating material may also be, for example, a combination or blend of materials. The aerosol-generating material may also be known as a "smokable material."

[0068] The aerosol-generating material may include a binder and an aerosol former. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In some embodiments, the aerosol-generating material is substantially free of tobacco.

[0069] The aerosol-generating material may include or be an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that may retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may include, for example, from about 50%, 60%, or 70% to about 90%, 95%, or 100% amorphous solid by weight.

[0070] The aerosol-generating material may comprise an aerosol-generating film. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially free of tobacco.

[0071] According to this disclosure, a "non-flammable" aerosol delivery system is one in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not combusted or combusted to facilitate delivery of at least one substance to a user.

[0072] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0073] In some embodiments, the non-combustible aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0074] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a heated non-combustion system, an example of such a system is a tobacco heating system.

[0075] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0076] Generally, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and a consumable for use with the non-flammable aerosol delivery device.

[0077] In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-flammable aerosol delivery devices. These consumables may also be referred to as articles throughout this disclosure.

[0078] In some embodiments, the non-flammable aerosol delivery system (such as the non-flammable aerosol delivery device) may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0079] In some embodiments, the non-flammable aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0080] In some embodiments, consumables for use with the non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage region, an aerosol generating material transfer component, an aerosol generator, an aerosol generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0081] The aerosol generating device can receive an article that includes an aerosol-generating material for heating. An "article" in this context is a component that includes or contains an aerosol-generating material that is heated in use to volatilize the aerosol-generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before the article is heated to generate an aerosol, and the user then inhales the aerosol. The article may be of a predetermined or specific size, for example, sized to receive the article and configured to be placed in a heating chamber of the device.

[0082] 1 shows an aerosol delivery device 100 for generating an aerosol from an aerosol-generating material. In general, device 100 may be used to heat a replaceable article 300 that contains an aerosol-generating material to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Article 300 and device 100 together form an aerosol delivery system.

[0083] The device 100 comprises a body 101. A housing 102 surrounds and contains the various components of the body 101. One end of the body 101 is formed with an opening 103 into which an article 300 can be inserted for heating by an aerosol generator 150 (see FIG. 2 ). In use, the article 300 may be fully or partially inserted into the aerosol generator 150 and heated by one or more components of the aerosol generator 150.

[0084] Device 100 also includes a button assembly 200 that, when pressed, operates device 100. Button assembly 200 is described in more detail below. For example, a user can turn on device 100 by manipulating button assembly 200.

[0085] The aerosol generator 150 defines a longitudinal axis X.

[0086] 2 shows a schematic cross-sectional view of device 100. Device 100 includes an electrical component, such as a connector / port 160, that can receive a cable for charging a battery of device 100. For example, connector 160 may be a charging port, such as a USB charging port. In some examples, connector 160 may additionally or alternatively be used to transfer data between device 100 and another device, such as a computing device.

[0087] The device 100 includes a power source 170, e.g., a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, e.g., lithium batteries (e.g., lithium ion batteries), nickel batteries (e.g., nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the aerosol generator 150 and provides power to heat the aerosol-generating material when needed under the control of the controller.

[0088] The chassis 110 supports a power supply 170 and other components.

[0089] The device 100 includes an electronics module 112. The electronics module 112 may include, for example, a printed circuit board (PCB). The PCB may support at least one controller, such as a processor, and a memory. The PCB may also include one or more electrical tracks for electrically connecting various electronic components of the device 100 together. For example, battery terminals may be electrically connected to the PCB such that power may be distributed throughout the device 100. The chassis 110 includes a PCB mount.

[0090] The body 102 comprises the end surface of the device 100. The end of the device 100 closest to the opening 103 may be known as the proximal end (or mouth end) 104 of the device 100, as it is closest to the user's mouth during use. In use, a user inserts the article 300 into the opening 103, activates the aerosol generator 150 to begin heating the aerosol-generating material, and inhales the aerosol that is generated within the device. This causes the aerosol to flow through the device 100 along a flow path toward the proximal end of the device 100.

[0091] The other end of the device furthest from the opening 103 may be known as the distal end 106 of the device 100, as it is the end furthest from the user's mouth when in use. When a user inhales the aerosol generated within the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 will be explained by reference to the relative orientation of such features with respect to one another in the proximal-distal direction along the longitudinal axis.

[0092] As used herein, integral component refers to a component of device 100 that is not separable into two or more components after assembly of device 100. Integrally formed refers to two or more features that are formed into the integral component during the manufacturing stage of the component.

[0093] An air passage 180 extends through the body 101. The air passage 180 extends to an opening 190. The opening 190 functions as an air inlet.

[0094] In one example, the aerosol generator 150 comprises an electromagnetic induction heating system including a magnetic field generator. The magnetic field generator comprises an inductor coil assembly. The aerosol generator 150 comprises a heating element. The heating element is also known as a susceptor.

[0095] A susceptor is a material that can be heated by penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that penetration of the susceptor by the varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that penetration thereof by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0096] The aerosol generator 150 is an induction heating assembly, which comprises various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may comprise 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 variable 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 in the susceptor. The susceptor has an electrical resistance to the eddy currents, so that the susceptor is Joule heated by the eddy currents flowing against this resistance. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., by the changing orientation of the magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. In induction heating, heat is generated inside the susceptor, allowing for rapid heating, as compared to heating by conduction, and further, there is no need for any physical contact between the induction heater and the susceptor, allowing for greater flexibility in design and application.

[0097] The inductor coil assembly includes an inductor coil. In an embodiment, the number of inductor coils varies. In an embodiment, two or more inductor coils are used. The inductor coil assembly also includes a coil support. The coil support is tubular.

[0098] The heating element is part of a heating assembly. The heating element in this example is hollow and thus defines at least a portion of a receptacle in which the aerosol-generating material is received. For example, the article 300 can be inserted into the heating element. The heating element is tubular with a circular cross section. The heating element has a generally constant diameter along its axial length.

[0099] The heating element is formed from an electrically conductive material suitable for heating by electromagnetic induction. The susceptor in this embodiment is formed from carbon steel. It will be appreciated that other suitable materials may be used, for example ferromagnetic materials such as iron, nickel or cobalt.

[0100] In other embodiments, the features acting as heating elements may not be limited to being inductively heated. Thus, the features acting as heating elements may be heatable by electrical resistance. Thus, the aerosol generator 200 may include electrical contacts for electrical connection with a device for electrically activating the heating element by passing a flow of electrical energy through the heating element.

[0101] The receptacle and article 300 are dimensioned such that the article 300 is received by the heating element. This helps ensure that heating is most efficient. The article 300 in this example includes an aerosol-generating material. The aerosol-generating material is positioned within the receptacle. The article 300 may also include other components, such as a filter, packaging material, and / or cooling structure.

[0102] An air flow path 180 extends from the heating element. The air flow path 180 is at a first distal end. The air flow path 180 protrudes from the heating element. The air flow path 180 extends from the heating element 220 and is defined by a flow path member 182. The heating element 220 and the flow path member 182 form part of an air flow path configuration 181.

[0103] The flow path member 182 extends between the heating element and the opening 190. The flow path member 182 is tubular. The flow path member 182 defines a bore. The flow path member extends axially along its length.

[0104] Figure 3 shows a perspective view of a button assembly 200 for the aerosol delivery device 100. Figure 4 shows a cross-sectional perspective view of the button assembly 200. The button assembly 200 comprises a button member 202 and a support frame 220.

[0105] The support frame 220 is a hollow rectangular member. The button member 202 is partially housed within the support frame 220. The button member 202 has a height such that it protrudes above a plane defined by the support frame 220. The button member 202 is spaced from the support frame 220. The button member 202 includes a front surface 234 for actuation by a user. The button member 202 includes a protrusion 226 on a rear surface of the button member. The rear surface of the button member is opposite the front surface 234 of the button member. That is, the protrusion 226 and the front surface 234 are located on opposite sides of the button member.

[0106] The button assembly 200 includes a first resilient arm 204 and a second resilient arm 212. The resilient arms 204, 212 are elongated. The resilient arms 204, 212 extend from an outer edge of the button member. Each resilient arm 204, 212 connects the button member 202 to a support frame 220. The resilient arms 204, 212 are connected to opposite sides of the button member 202. The resilient arms 204, 212 are flush with the support frame 220.

[0107] The first resilient arm 204 includes an arm member 206, a first connector portion 208, and a second connector portion 210. In this embodiment, the arm member 206, the first connector portion 208, and the second connector portion 210 are a unitary component. In other embodiments, they may be separate components that are joined together.

[0108] One end of the first connector portion 208 is joined to the support frame 220. The first connector portion 208 is joined to an inner edge 222 of the support frame 220. The other end of the first connector portion 208 is joined to one end of the arm member 206. An end of the second connector portion 210 is joined to the button member 202. The other end of the second connector portion 210 is joined to one end of the arm member 206. The arm member 206 is arranged parallel to the outer edge of the button member 202. The arm member 206 is arranged parallel to the inner edge 222 of the support frame 220. The first and second connector portions 208, 210 are arranged transversely to the outer edge of the button member 202. Thus, the first resilient arm has a Z-shape between the button member 202 and the support frame 220. In an embodiment, the connector portion is omitted or has a different configuration. In embodiments, the arms have different configurations, such as an L-shape or a V-shape.

[0109] The thickness of the resilient arms 204, 212 is less than the thickness of the button member 202. In other embodiments, the thickness of the resilient arms 204, 212 is greater than the thickness of the button member 202. The thickness of the resilient arms 204, 212 is less than the thickness of the support frame 220. In other embodiments, the thickness of the resilient arms 204, 212 is greater than the thickness of the support frame 220.

[0110] The second resilient arm 212 also includes an arm member 214, a first connector portion 216, and a second connector portion 218. The arm member 214, the first connector portion 216, and the second connector portion 218 of the second resilient arm 212 are similar to those of the first resilient arm 204.

[0111] The button assembly 200 includes a flexible seal member 224. The flexible seal member is bonded to the support frame 220. The flexible seal member is bonded to the inner edge 222 of the support frame 220. The flexible seal member seals the space within the support frame 220. The flexible seal member fills the space between the support frame 220 and the button member 202. The flexible seal member 224 is also bonded to the resilient arms 204, 212 and the button member 202. In this embodiment, the flexible seal member 224 is overmolded on the support frame 220, the button member 202, and the resilient arms 204, 212. In other embodiments, the flexible seal member 224 extends around the button member 202. That is, the button member protrudes through and is coupled to the flexible seal member 224, which is disposed on the back surface of the button assembly 200. The rear surface is opposite the front surface and is provided by a surface of the button member 202 and is operated by a user. A flexible sealing member 224 provides a fluid barrier to prevent fluid ingress into the interior of the device 100.

[0112] The flexible seal member 224 is made of a plastic material. In an embodiment, the flexible seal member may be made of silicone. The flexible seal member may be made of any substantially flexible material capable of providing a seal.

[0113] The button member 202, the resilient arms 204, 212 and the support frame 232 are an integral component. In this embodiment, the button member 202, the resilient arms 204, 212 and the support frame 232 are made from a plastic material. In other embodiments, the button member 202, the resilient arms 204, 212 and the support frame 232 may be separate components. The button member 202, the resilient arms 204, 212 and the support frame 232 may be made from a metal material.

[0114] The flexible seal member 224 includes an opening 228. The opening 228 is disposed behind the button member 202. The opening 228 is sealed by the button member 202. The protrusion 226 of the button member 202 is received within the opening 228.

[0115] The support frame 220 includes a plurality of lugs 230. The lugs 230 are protrusions from the inner edge 222 of the support frame. In this embodiment, the lugs 230 and the support frame 220 are a unitary component. The lugs 230 provide a stronger bond between the flexible seal member 224 and the support frame 220.

[0116] The support frame 220 includes a ridge 232. The ridge 232 is provided on a front surface of the support frame. The ridge 232 extends around the periphery of the support frame 220. The ridge 232 forms a closed passage. The ridge 232 helps provide a fluid-tight seal between the support frame 220 and the housing 102.

[0117] The button assembly 200 provides a fluid seal that prevents moisture or debris from entering the interior of the aerosol delivery device through the button assembly 200. In an embodiment, the fluid seal is provided entirely by the flexible seal member 224. In an embodiment, the fluid seal is provided by the flexible seal member 224 in combination with one or more of the resilient arms 204, 212, the button member 202, and the support frame 220.

[0118] Housing 102 of aerosol delivery device 100 includes an opening 108. Button assembly 200 is disposed adjacent opening 108. Button member 202 protrudes through opening 108. Support frame 220 is joined to housing 102. Support frame 220 is sonically welded to housing 102.

[0119] Figure 5 shows a cutaway perspective view of a portion of the aerosol delivery device of Figure 1. Button assembly 200 is mechanically aligned with a button actuator component on electronics module 112 such that button assembly 200 can be used to control aerosol delivery device 100.

[0120] The reinforcement member 116 is provided behind the button assembly 200. In this embodiment, the electronics module 112 is disposed between the reinforcement member 116 and the button assembly 200. The button assembly 200 is disposed between the reinforcement member 116 and the housing 102. Thus, the reinforcement member 116 holds the electronics module 112 and the button assembly 200 to the housing 102.

[0121] The reinforcing member 116 is a plate. The reinforcing member is bonded to the housing 102 (see FIG. 6). The housing 102 includes a plurality of pins 118 that extend through a plurality of openings in the reinforcing member 116. The pins 118 are formed from a plastic material. The reinforcing member 116 is heat staked to the pins 118 to bond it to the housing 102. In this embodiment, twelve pins 118 are provided. The button assembly 200 is disposed between the reinforcing member 116 and the housing 112. The reinforcing member 116 is formed from stainless steel. In other embodiments, the reinforcing member 116 is formed from another material, for example, polyetheretherketone. The reinforcing member 116 provides additional support to the button assembly 200 when it is under compression during actuation.

[0122] Alignment pins 114 protrude from housing 102. The alignment pins pass through openings in reinforcement member 116.

[0123] 7 shows a perspective view of a second embodiment of a button assembly 200 for the aerosol delivery device of FIG. 1. The second embodiment is similar to the button assembly 200 of FIG. 3, except that two button members 202 are provided. A support frame extends around both button members 202. It will be understood that the number of button members 202 may vary. Each button member is connected to a support frame 220 by respective first and second resilient arms 204, 212. The first and second resilient arms are similar to those described in connection with FIG. 3.

[0124] Also disclosed is a method of manufacturing a button assembly for an aerosol delivery device, the method including forming a button configuration comprising a support frame, a button member at least partially received within the support frame, and an arm extending between the button member and the support frame.

[0125] The method further includes overmolding the flexible seal member such that the flexible seal member extends at least partially around the button between the button and the support frame.

[0126] The method further includes sonic welding the frame to a housing of the aerosol delivery device such that the button member is received in an opening in the housing of the aerosol delivery device.

[0127] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only 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 limitations on the scope of the invention as defined by the claims, or limitations on the equivalents to the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the invention as claimed. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. The main body, a button assembly on the body, the button assembly comprising: A button member; A support frame; a resilient arm connecting the support frame to the button member; a flexible seal member extending between the support frame and the button member; 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising:

2. The aerosol delivery device of claim 1 , wherein the resilient arm is elongated.

3. 3. The aerosol delivery device of claim 1, wherein the resilient arm extends from an outer edge of the button member, and at least a portion of the resilient arm extends at least substantially parallel to the outer edge of the button member.

4. The aerosol delivery device of any one of claims 1 to 3, wherein the button member is at least partially received within the support frame.

5. The aerosol delivery device of any one of claims 1 to 4, wherein the support frame has an inner edge and at least a portion of the resilient arm extends at least substantially parallel to the inner edge of the support frame.

6. The aerosol delivery device of any one of claims 1 to 5, wherein the elastic arm comprises an arm member, a first connector portion extending between the arm member and the button member, and a second connector portion extending between the arm member and the support frame.

7. The aerosol delivery device according to any one of claims 1 to 6, wherein the elastic arm has a substantially Z-shape between the button member and the support frame.

8. The aerosol delivery device of any one of claims 1 to 7, wherein the thickness of the elastic arm is smaller than the thickness of the support frame.

9. The aerosol delivery device of any one of claims 1 to 8, wherein the button member and the resilient arm form an integral component.

10. The aerosol delivery device of any one of claims 1 to 9, wherein the support frame and the resilient arms form an integral component.

11. The aerosol delivery device of any one of claims 1 to 10, wherein the resilient arm is a first resilient arm and the button assembly comprises a second resilient arm connecting the support frame to the button member.

12. The aerosol delivery device of any one of claims 1 to 11, wherein the support frame, the elastic arm, the button member, and the flexible sealing member are integrally formed.

13. The aerosol delivery device of any one of claims 1 to 12, wherein the flexible sealing member forms a fluid barrier.

14. The aerosol delivery device of any one of claims 1 to 13, wherein the flexible sealing member extends around the button member.

15. The aerosol delivery device of any one of claims 1 to 14, wherein the body comprises a housing and a chassis within the housing, and the support frame is attached to the housing and at least partially received between the chassis and the housing.

16. The aerosol delivery device of any one of claims 1 to 15, wherein the body comprises a printed circuit board disposed behind the button assembly and connected to the button assembly by at least one alignment pin.

17. The aerosol delivery device of claim 16 , further comprising a stiffening member behind the printed circuit board.

18. The main body, a button assembly on the body, the button assembly comprising: A button member; A support frame; a first elastic member extending between the support frame and the button member, and a second elastic member extending between the support frame and the button member, The first elastic member is relatively more elastic than the second elastic member. An aerosol delivery device for generating an aerosol from an aerosol-generating material.

19. A button member; A support frame; a resilient arm connecting the support frame to the button member; a flexible seal member extending between the support frame and the button member; A button assembly for an aerosol delivery device comprising:

20. forming a button arrangement comprising a support frame, a button member at least partially received within the support frame, and an arm extending between the button member and the support frame; overmolding the flexible seal member such that the flexible seal member extends at least partially around the button between the button and the support frame; A method for manufacturing a button assembly for an aerosol delivery device, comprising:

Images