Heating assembly for an aerosol generating device - Patent application

Abstract

A heating assembly (10) for an aerosol-generating device (8) is disclosed. The heating assembly (10) comprises an insulator (12) having an inner wall (14) and an outer wall (20), the inner wall (14) of the insulator (12) defining a cavity (26) having an opening (28) configured to receive an aerosol-generating substrate (32). The heating assembly (10) further comprises a heater (34) located on the outer surface (18) of the inner wall (14) of the insulator (12), the heater (34) being configured to heat the aerosol-generating substrate (32) received within the cavity (26) by thermal conduction to generate an aerosol. The heating assembly (10) further includes a first electrical connector (36) and a second electrical connector (38), each of which extends through the outer wall (20) of the insulator (12) to the heater (34), such that an electrical path is formed between the first electrical connector (36) and the second electrical connector (38) through the heater (34).

Description

[Technical field]

[0001] The present invention relates to a heating assembly for an aerosol generating device, a method for manufacturing a heating assembly for an aerosol generating device, and an aerosol generating device including a heating assembly. The present disclosure is particularly applicable to portable aerosol generating devices that may be self-contained and low-temperature. Such devices may heat tobacco or other suitable aerosol substrate material by conduction, convection, and / or radiation, rather than combustion, to generate an aerosol for inhalation. [Background technology]

[0002] The popularity and use of risk reduction or risk modification devices (also known as vaporizers) has grown rapidly in recent years as an aid to assist habitual smokers wishing to quit using traditional tobacco products such as cigarettes, cigars, cigarillos, and roll-in cigarettes. A variety of devices and systems are available that heat or warm an aerosolizable substrate, as opposed to burning tobacco in traditional tobacco products.

[0003] Commonly available risk reduction or risk modification devices are substrate heated aerosol generating devices or heated non-combustion devices. This type of device generates an aerosol or vapor by heating an aerosol substrate, i.e., a consumable, which typically comprises moist tobacco or other suitable aerosolizable material, to a temperature typically ranging from 150°C to 300°C. By heating rather than burning or combusting the aerosol substrate, an aerosol is released that contains the components desired by the user but does not contain the undesirable by-products of combustion. In addition, aerosols generated by heating tobacco or other aerosolizable material typically do not contain the burnt or bitter taste that can result from combustion, which can be unpleasant to the user.

[0004] Within such aerosol generating devices, it is desirable to improve the efficiency of the heating operation so that the battery life of the device can be extended. To this end, vacuum insulation has been implemented within the aerosol generating device to insulate the cavity in which the aerosol substrate is heated, thereby limiting heat loss to the external environment.

[0005] However, heating assemblies that include vacuum insulation are difficult to manufacture, an object of the present invention is to address this problem. Summary of the Invention [Means for solving the problem]

[0006] According to a first aspect of the present invention, there is provided a heating assembly for an aerosol generating device comprising: an insulator having an inner wall and an outer wall, the inner wall of the insulator defining a cavity having an opening configured to receive an aerosol-generating substrate; a heater located on an outer surface of the inner wall of the insulator, the heater configured to heat the aerosol-generating substrate received in the cavity by thermal conduction to generate an aerosol; and first and second electrical connectors extending through the outer wall of the insulator to the heater, respectively, wherein an electrical path is formed between the first and second electrical connectors via the heater.

[0007] In a preferred embodiment, the insulation is vacuum insulation, where a vacuum is trapped between the inner and outer walls. In an alternative embodiment, an insulating material may be disposed between the inner and outer walls of the insulation. Examples of insulating materials include powders, fibrous materials such as aerogel, or air.

[0008] Also described herein is a heating assembly for an aerosol generating device, comprising: a vacuum insulator having inner and outer walls between which a vacuum is sealed, the inner wall of the vacuum insulator defining a cavity having an opening configured to receive an aerosol-generating substrate; a heater located on an outer surface of the inner wall of the vacuum insulator, the heater configured to heat the aerosol-generating substrate received in the cavity by thermal conduction to generate an aerosol; and first and second electrical connectors, respectively, extending through the outer wall of the vacuum insulator to the heater, wherein an electrical path is formed between the first and second electrical connectors via the heater.

[0009] In this way, a passage for electricity to be supplied to the heater sealed in the vacuum is provided through the outer wall of the vacuum insulation. This eliminates the need to wire electrical connectors or extend the heater between the inner and outer walls of the vacuum insulation, thereby simplifying the manufacturing process and improving the durability of the heating assembly. In particular, the outer wall of the vacuum insulation is formed such that the first and second electrical connectors extend through the outer wall, respectively, so that the heater isolated in the vacuum may be connected to an external power source via the first and second electrical connectors. Thus, the ease of manufacturing is improved, since the attachment of the outer wall (in combination with the heater) to the inner wall (in combination with the first and second electrical connectors extending therethrough) results in a fully functional heating assembly with an isolated heater. In contrast, in a heating assembly in which the heater is connectable to an external power source, for example via a connector or an extension of the heater that extends between the inner and outer walls, the attachment of the inner wall to the outer wall may not isolate the heater, and a further sealing operation may be required to seal the gap between the inner and outer walls through which the connector extends.

[0010] Furthermore, by providing the heater in the vacuum between the inner and outer walls, rather than in the cavity, the compactness and thermal efficiency of the heating assembly is optimized. The heater is in thermal contact with the inner wall of the vacuum insulation and can heat the aerosol-generating substrate through the inner wall. The vacuum inhibits heat from escaping the cavity by conduction through the outer wall. The inner wall of the vacuum insulation can thus serve the dual purpose of transferring heat to the aerosol-generating substrate received in the cavity while maintaining an insulating vacuum to insulate the cavity. This creates an efficient and compact heating assembly for an aerosol-generating device.

[0011] Preferably, the first and second electrical connectors are resiliently biased towards the heater. More preferably, the first and second electrical connectors are configured to apply a constant (e.g., perpendicular) force to the heater, thereby counteracting any undesired movement that may otherwise cause an intermittent connection. In this way, it is ensured that the first and second electrical connectors remain in electrical contact with the heater. This is particularly important due to the portability of the aerosol generating device, which means that the heating assembly is likely to experience frequent mechanical shocks and vibrations.

[0012] Preferably, the first electrical connector and the second electrical connector comprise spring-loaded pins that are resiliently biased towards the heater. In this way, a reliable and durable form of electrical connector is provided. Those skilled in the art will appreciate that spring-loaded pins may also be referred to as pogo pins.

[0013] Preferably, the cavity defined by the inner wall of the vacuum insulation is tubular and extends from the base to the opening. For example, the inner wall defining the opening and the base may be generally cylindrical, i.e. cup-shaped. The base may be described as a closed base. In this manner, the cavity is configured to receive the rod of the aerosol-generating substrate such that the major portion of the rod of the aerosol-generating substrate, including the ends of the rod, is completely surrounded by the inner wall. Thus, a more effective means of insulation is provided, as the vacuum insulation completely surrounds the major portion of the aerosol-generating substrate, as opposed to, for example, a sleeve-shaped inner wall that is open at both longitudinal ends. In other words, the inner wall of the present invention defines a blind hole, rather than a through hole. Advantageously, providing a heater on the inner wall around the entire circumference of the cavity allows for more uniform heating of the aerosol-generating substrate, which may generate a better quality aerosol for the user to enjoy. This may also allow the aerosol-generating substrate to be heated to the aerosol-generating temperature more quickly.

[0014] Preferably, the base is formed as a flat surface that is arranged perpendicular to the longitudinal axis of the insulator. In this way, the shape of the insulator including the base results in a stable and reliable connection between the electrical connector and the heater (e.g., electrical contact pads located on the base) due to the perpendicular reaction force acting on the electrical connector. This is especially true when the first electrical connector and the second electrical connector are elastically biased towards the heater, i.e. when the first electrical connector and the second electrical connector are elastically biased towards the flat surface of the base.

[0015] Preferably, the first electrical connector and the second electrical connector extend in a direction parallel to the tubular cavity.

[0016] Preferably, the first and second electrical connectors connect to the heater adjacent the base. In other words, the first and second electrical connectors connect to the heater at the base of the inner wall. In this way, the heating portion of the heater may be provided around the circumference of the cavity, while the electrical connection portion of the heater is located at the base where it joins the end of the rod aerosol-generating substrate, an area that is less desirable for heating.

[0017] Preferably, the first electrical connector and the second electrical connector are aligned with the cavity such that the first electrical connector and the second electrical connector connect to a heater that coincides with the (closed) base of the inner wall, in this manner the first electrical connector and the second electrical connector are disposed perpendicular to the base of the inner wall.

[0018] Preferably, the heater comprises a heating track extending between a first electrical contact pad and a second electrical contact pad, and the first electrical connector and the second electrical connector connect to the heater via the first electrical contact pad and the second electrical contact pad, respectively.

[0019] Preferably the heater is a resistive heater, thus providing a compact, simple and easily powered form of heater. Alternatively the heater may be an induction heater powered by a coil surrounding the vacuum insulation.

[0020] Preferably, the heater is printed or coated on the outer surface of the inner wall of the vacuum insulation, thus providing reliable thermal contact between the heater and the inner wall, which may further improve manufacturability.

[0021] Preferably, the outer wall of the vacuum insulation has one or more apertures through which the first and second electrical connectors extend. In this manner, the one or more apertures provide a passageway for supplying electricity to the vacuum-sealed heater. This eliminates the need to wire electrical connectors between the inner and outer walls of the vacuum insulation, thereby simplifying the manufacturing process and improving the durability of the heating assembly.

[0022] In one embodiment, the vacuum insulation exterior wall may have a first aperture through which the first electrical connector extends and a second aperture through which the second electrical connector extends. In another embodiment, the vacuum insulation exterior wall may have apertures through which the first electrical connector and the second electrical connector each extend.

[0023] Preferably, an electrically insulating material is provided within one or more apertures surrounding the first and second electrical connectors, in this manner preventing any contact between the first and second electrical connectors and the outer wall of the vacuum insulation, thereby preventing electricity from being conducted to the outer wall of the vacuum insulation.

[0024] Preferably, the outer wall of the vacuum insulation comprises a metal, such as stainless steel, and / or a plastic, such as polyetheretherketone, PEEK.

[0025] According to a second aspect of the present invention there is provided an aerosol generating device comprising the heating assembly of the first aspect.

[0026] According to a third aspect of the present invention, there is provided a method of manufacturing a heating assembly for an aerosol generating device, the method comprising: providing an outer wall having one or more apertures; arranging a first electrical connector and a second electrical connector such that the first electrical connector and the second electrical connector extend through the one or more apertures in the outer wall; providing an inner wall; providing a heater on an outer surface of the inner wall; and coupling the inner wall to the outer wall to form an enclosed space between the outer wall and the inner wall in which the heater is located, wherein an electrical path is formed between the first electrical connector and the second electrical connector via the heater. [Brief description of the drawings]

[0027] Embodiments of the invention will now be described, by way of example only, with reference to the drawings in which:

[0028] [Figure 1] FIG. 1 is a perspective view of an aerosol generating device including a heating assembly according to one embodiment of the present invention. [Diagram 2] 1 is a schematic perspective view of a heating assembly according to one embodiment of the present invention; [Diagram 3] 3 is a cross-sectional schematic diagram of the heating assembly of FIG. 2. [Figure 4] FIG. 2 is a flow diagram illustrating method steps for manufacturing a heating assembly according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] As explained herein, a vapor is generally understood to refer to a substance that is in the gas phase below its critical temperature, meaning that the vapor can be condensed into a liquid by increasing the pressure without decreasing the temperature, whereas an aerosol is fine solid particles or liquid droplets suspended in air or another gas. However, it should be noted that the terms "aerosol" and "vapor" may be used interchangeably herein, particularly with respect to the form of inhalable medium that is produced for inhalation by a user.

[0030] FIG. 1 illustrates an aerosol generating device 8 according to an embodiment of the present invention. The aerosol generating device 8 is illustrated in an assembled configuration to expose exemplary internal components. The aerosol generating device 8 is a heat-non-combustion device, which may also be referred to as a tobacco vapor device, and includes a heating assembly 10 configured to receive an aerosol-generating material, e.g., an aerosol substrate, such as a rod of tobacco. The aerosol generating device 8 may include a power source, such as a battery, and control circuitry for controlling the supply of power from the power source to the heating assembly 10. The heating assembly 10 is operable to heat, rather than burn, the rod of aerosol-generating material to generate a vapor or aerosol for inhalation by a user. Of course, those skilled in the art will appreciate that the aerosol generating device 8 illustrated in FIG. 1 is merely an exemplary aerosol generating device according to the present invention. Other types and configurations of tobacco vapor products, vaporizers, or electronic cigarettes may also be used as aerosol generating devices according to the present invention.

[0031] Figure 2 shows a perspective view of the heating assembly 10 according to one embodiment of the present invention. Similarly, Figure 3 shows a simplified cross-sectional view of the heating assembly 10.

[0032] The heating assembly 10 comprises a vacuum insulation 12 having an inner wall 14 and an outer wall 20 between which a vacuum is enclosed. The vacuum insulation 12 extends from a first end 11 to a second end 13, i.e., the vacuum insulation 12 is elongated and defines a longitudinal axis. The vacuum insulation 12 defines a cavity 26 that may receive an aerosol-generating substrate 32. Specifically, a top 15 of the vacuum insulation 12 at the first end 11 has an opening 28 through which the aerosol-generating substrate 26 may be inserted into the cavity 26. The vacuum insulation 12 may therefore be referred to as cup-shaped.

[0033] The vacuum insulation material 12 has a generally elliptical or circular cross-section when viewed along one of its ends 11, 13 parallel to its longitudinal axis. In particular, in the illustrated embodiment, the vacuum insulation material 12 is generally cylindrical. However, in alternative embodiments, the vacuum insulation material 12 may be formed in other types of cross-sectional shapes, for example, shapes that are generally square or polygonal.

[0034] The inner wall 14 of the vacuum insulation 12 is tubular, e.g., generally cylindrical, and has an outer (e.g., circumferential) surface 18 and an inner (e.g., circumferential) surface 16. The inner wall 14 further comprises a base 30. The outer wall 20 is tubular, e.g., generally cylindrical, and has an outer (e.g., circumferential) surface 24 and an inner (e.g., circumferential) surface 22. The outer wall 20 comprises a base 17 at the second end 13 of the vacuum insulation 12.

[0035] The inner wall 14 and the outer wall 20 are radially spaced apart from each other to define an enclosed space in which a vacuum is formed therebetween. Specifically, in the illustrated embodiment, the inner wall 14 and the outer wall 20 are formed as concentric cylinders that are joined at the first end 11 of the vacuum insulation material 12. In a first embodiment, the top 15 of the vacuum insulation material 12 may be an integral part of the outer wall 20 that is attached to the inner wall 14 at the first end 11. In a second embodiment, the top 15 of the vacuum insulation material 12 may be an integral part of the inner wall 14 that is attached to the outer wall 20 at the first end 11. In a third embodiment, the top 15 of the vacuum insulation material 12 may be an additional component that joins the inner wall 14 and the outer wall 20 at the first end 11.

[0036] Those skilled in the art will understand that the term "vacuum" refers to a space in which the pressure is significantly less than atmospheric pressure due to the removal of free matter, particularly air. The quality of the vacuum formed between the inner wall 14 and the outer wall 20 may be a rough vacuum, a medium vacuum, or a high vacuum.

[0037] In an alternative embodiment, the vacuum insulation 12 may be more generally referred to as insulation 12. That is, insulation 12 is not limited to vacuum insulation. For example, instead of a vacuum, an insulating material may be disposed between the inner wall 14 and the outer wall 20 of insulation 12. Examples of insulating materials include powders, fibrous materials such as aerogel, and / or air.

[0038] The inner wall 14 of the vacuum insulation material 12 defines a cavity 26 that may receive an aerosol-generating substrate 32. In particular, the cavity defined by the inner wall 14 of the vacuum insulation material 12 is tubular (e.g., cylindrical) and extends from a base 30 to the opening 26. In this manner, an aerosol-generating substrate 32 in the form of an elongated rod (e.g., cylinder) may be inserted into the cavity 26 via the opening 28 such that the aerosol-generating substrate 32 interfaces with the inner surface 16 and the base 30 of the inner wall 14. In this manner, the vacuum insulation material 12 completely surrounds the aerosol-generating substrate 32, except for a portion of the aerosol-generating substrate 32 that protrudes through the opening 28 and is received in the mouth of a user, thus maximizing the effectiveness of the insulation.

[0039] Typically, the aerosol-forming substrate 32 is a disposable and replaceable item (also known as a "consumable") that may include, for example, tobacco as the aerosol-forming substrate 32 .

[0040] The heating assembly 10 further comprises a heater 34 disposed on the outer surface 18 of the inner wall 14 of the vacuum insulation 12. That is, the heater 34 is located within the vacuum between the inner wall 14 and the outer wall 20 of the vacuum insulation 12. The heater 34 is configured to heat the inner wall 14 of the vacuum insulation 12 by conduction, such that the inner wall 14 heats the aerosol-generating substrate 32 and the air inside the cavity 26 by conduction and radiation. The heater 34 may be powered by a battery or any other power source provided in the aerosol-generating device, as discussed further below.

[0041] The heater 34 is a resistive heating element that generates heat by resistive heating (also referred to as Joule heating). The heater 34 includes a heating track (e.g., a wave-like heating pattern) that at least partially surrounds the cavity 26 on the outer surface 18 of the inner wall 14 of the vacuum insulation 12. Specifically, the heating track is wrapped circumferentially around the inner wall 14 of the vacuum insulation 12, preferably around the entire circumference of the cavity 26. Advantageously, surrounding the cavity 26 substantially around its entire circumference results in the aerosol-generating substrate 32 being heated more quickly or more uniformly. Of course, one skilled in the art will appreciate that the specific shape and arrangement of the heater 34 may vary. For example, the heater 34 may include a heating sheet that partially or entirely surrounds the outer surface 18 of the inner wall 14 of the vacuum insulation 12.

[0042] The heater 34 may be printed, coated, or otherwise attached onto the exterior surface 18 of the interior wall 14 of the vacuum insulation 12. The heater 34 may thus provide "trace heating" to the cavity 26.

[0043] The heater 34 may comprise a metal (e.g., nichrome, kanthal, or cupronickel), ceramic, or any other suitable resistive heating material. As will be appreciated by those skilled in the art, the heater 34 is not limited to resistive heating elements, and the heater 34 may be of various types. For example, the heater 34 may be an induction heater powered by a coil that surrounds the vacuum insulation 12.

[0044] The heater 34 further comprises a first electrical contact pad 40 and a second electrical contact pad 42 located on the base 30 of the vacuum interior of the inner wall 14. A heating track of the heater 34 connects the first electrical contact pad 40 to the second electrical contact pad 42.

[0045] The heating assembly 10 further includes a first electrical connector 36 and a second electrical connector 38, each of which extends across the vacuum from the heater 34 and through the outer wall 20 of the vacuum insulation 12 to exit the vacuum insulation 12. Specifically, the outer wall 20 of the vacuum insulation 12 includes a first aperture 44 and a second aperture 44 through which the first electrical connector 36 and the second electrical connector 38 extend, respectively. Those skilled in the art will appreciate that in an alternative embodiment, the outer wall 20 of the vacuum insulation 12 may include only a single aperture through which both the first electrical connector 36 and the second electrical connector 38 extend.

[0046] The aperture 44 is located at the base 17 of the exterior wall 20 such that the first electrical connector 36 and the second electrical connector 38 extend through the base 17. However, the first electrical connector 36 and the second electrical connector 38 are not limited to extending through the base 17 of the exterior wall 20, and the location of the aperture 44 within the exterior wall 20 may vary. For example, one or more apertures 44 may be provided on a circumferential portion of the exterior wall 20.

[0047] The first electrical connector 36 and the second electrical connector 38 each connect to the heater 34 adjacent the inner wall 14 of the vacuum insulation 12. In this manner, an electrical path is formed between the first electrical connector 36 and the second electrical connector 38 through the heater 34. In particular, the first electrical connector 36 and the second electrical connector 38 connect to first electrical contact pads 40 and second electrical contact pads 42 of the heater 34 adjacent the base 30, although one skilled in the art will appreciate that the location of the connections to the heater 34 relative to the cavity 26 may vary.

[0048] Although the first electrical contact 40 and the second electrical contact pad 42 are illustrated as square electrical contact pads, in alternative embodiments, the first electrical connector 36 and the second electrical connector 38 may connect to the heater 34 by other configurations and arrangements of electrical contacts.

[0049] The first electrical connector 36 and the second electrical connector 38 include a first electrical terminal 48 and a second electrical terminal 50, respectively, that are at least partially located outside the vacuum insulation 12. The first electrical connector 36 and the second electrical connector 38 are connectable to an external circuit via the first electrical terminal 48 and the second electrical terminal 50. That is, the first electrical terminal 48 and the second electrical terminal 50 are configured to be connected to complementary external electrical terminals.

[0050] In particular, the first electrical terminal 48 and the second electrical terminal 50 may be connectable to the aerosol generating device 8, which includes a control circuit and a power source, such as a battery. In this manner, an electrical circuit may be formed between the power source and the heater 34 via the first electrical connector 36 and the second electrical connector 38. In use, the heater 34 is powered from the power source of the aerosol generating device 8 through the outer wall 20 of the vacuum insulation 12, thereby generating heat by Joule heating. The heat is transferred through the inner wall 14 to the aerosol-generating substrate 32 received within the cavity 26 to generate an aerosol for inhalation by a user.

[0051] An electrically insulating material 54, such as polyetheretherketone (PEEK), is provided within the first aperture 44 and the second aperture 44. The electrically insulating material 54 surrounds the first electrical connector 36 and the second electrical connector 38 and prevents any contact between the first electrical connector 36 and the second electrical connector 38 and the outer wall 20 of the vacuum insulation 12. In this manner, the electrically insulating material 54 prevents electricity from being conducted through the first electrical connector 36 and the second electrical connector 38 to the outer wall 20 of the vacuum insulation 12.

[0052] 3, the first electrical connector 36 and the second electrical connector 38 each include a spring-loaded pin 52, also known as a pogo pin. Each spring-loaded pin 52 is positioned adjacent to the heater 34 such that the first electrical connector 36 and the second electrical connector 38 make electrical contact with the heater 34 through the spring-loaded pin 52. Each spring-loaded pin 52, by means of an integrated spring, applies a constant normal force to the heater 34, particularly to the first electrical contact 40 and second electrical contact pads 42, thereby counteracting any undesired movement that may otherwise cause an intermittent connection.

[0053] Of course, those skilled in the art will appreciate that the first electrical connector 36 and the second electrical connector 38 are not limited to including spring-loaded pins 52, and that other forms of electrical connector mechanisms may be used. For example, the first electrical connector 36 and the second electrical connector 38 may each include other types of electrical connector mechanisms configured to maintain electrical contact with the heater 34, such as any form of electrical connector that may be resiliently biased toward the heater 34.

[0054] In the illustrated embodiment, the first electrical connector 36 and the second electrical connector 38 are a pair of adjacent connectors arranged parallel to each other. In particular, the first electrical connector 36 and the second electrical connector 38 are arranged parallel to the longitudinal direction of the heating assembly 10, i.e., parallel to the tubular cavity 26, and connect to the heater 34 adjacent to the base 30 of the inner wall 14. In this manner, an efficient arrangement of components is provided, resulting in a compact and durable heating assembly 10. However, in alternative embodiments, the first electrical connector 36 and the second electrical connector 38 may connect to the heater 34 at alternative locations relative to the inner wall 14, for example, adjacent to the (e.g., circumferential) outer surface 18 of the inner wall 14. The first electrical connector 36 and the second electrical connector 38 are also not limited to being arranged parallel to each other and / or to the tubular cavity 26.

[0055] The inner wall 14 of the vacuum insulation 12 may comprise any suitable material having suitable properties for transferring heat from the heater 34 into the cavity 26, such as stainless steel or other metals, metal alloys, or ceramics.

[0056] Examples of suitable materials for the outer wall 20 include stainless steel and / or a plastic such as polyetheretherketone (PEEK). Those skilled in the art will appreciate that if the outer wall 20 is made from an electrically insulating material such as PEEK, there may be no need to provide an additional electrically insulating material 54 within the aperture 44.

[0057] FIG. 4 shows a flow diagram of a method 60 for manufacturing a heating assembly according to one embodiment of the present invention.

[0058] The method 60 begins at step 62 where the exterior wall 20 is provided. Specifically, the exterior wall 20 is provided having one or more apertures 44.

[0059] At step 64, the first electrical connector 36 and the second electrical connector 38 are positioned to extend through the exterior wall 20. The first electrical connector 36 and the second electrical connector 38 pass through the one or more apertures 44 such that the first electrical connector 36 and the second electrical connector, respectively, provide an electrical path through the exterior wall 20. Preferably, an electrically insulating material 54 is positioned within the one or more apertures 44 to surround the first electrical connector 36 and the second electrical connector 38. The electrically insulating material 54 prevents any contact between the first electrical connector 36 and the second electrical connector 38 and the exterior wall 20. The electrically insulating material 54 may also act to secure the first electrical connector 36 and the second electrical connector 38 in place relative to the exterior wall 20.

[0060] At step 66, the interior wall 14 is provided. At step 68, the heater 34 is provided on the exterior surface 18 of the interior wall 14. For example, the heater 34 may be printed, coated, or otherwise secured to the exterior surface 18 of the interior wall 14.

[0061] At step 70, the inner wall 14 is bonded to the outer wall 20 to form an enclosed space between the outer wall 20 and the inner wall 14 in which the heater 34 is located. The heater 34 is positioned to form an electrical connection with each of the first electrical connector 36 and the second electrical connector 38 such that an electrical path is formed between the first electrical connector 36 and the second electrical connector 38 through the heater 34.

[0062] Finally, in step 72, a vacuum is formed in the enclosed space between the outer wall 20 and the inner wall 14.

[0063] Those skilled in the art will appreciate that the shapes, properties, and configurations of the features discussed with reference to FIGS. 2 and 3 apply equally to the features discussed with reference to method 60.

Claims

1. A heating assembly for an aerosol generating device, an insulator having an inner wall and an outer wall, wherein the inner wall of the insulator defines a cavity having an opening configured to receive an aerosol generating substrate, the insulator; a heater located on an outer surface of the inner wall of the insulator, the heater being configured to generate an aerosol by heating the aerosol generating substrate received in the cavity by heat conduction; a first electrical connector and a second electrical connector each extending through the outer wall of the insulator to the heater, an electrical path being formed between the first electrical connector and the second electrical connector via the heater, the first electrical connector and the second electrical connector; A heating assembly comprising.

2. The heating assembly according to claim 1, wherein the insulator is a vacuum insulation material and a vacuum is enclosed between the inner wall and the outer wall.

3. The heating assembly according to claim 1, wherein the first electrical connector and the second electrical connector are elastically biased toward the heater.

4. The heating assembly according to claim 3, wherein the first electrical connector and the second electrical connector comprise spring-loaded pins elastically biased toward the heater.

5. The heating assembly according to claim 1, wherein the cavity defined by the inner wall of the insulator is tubular, and extends from a base of the inner wall to the opening such that an end of the received aerosol generating substrate is completely surrounded by the inner wall.

6. The heating assembly according to claim 5, wherein the base is formed as a flat surface disposed perpendicular to a length of the cavity.

7. The first electrical connector and the second electrical connector extend in a direction parallel to the tubular cavity, the heating assembly according to claim 5.

8. The first electrical connector and the second electrical connector are arranged in alignment with the tubular cavity, the heating assembly according to claim 7.

9. The first electrical connector and the second electrical connector are connected to the heater that coincides with the base, the heating assembly according to claim 5.

10. The heater includes a heating track extending between a first electrical contact pad and a second electrical contact pad, and the first electrical connector and the second electrical connector are each connected to the heater via the first electrical contact pad and the second electrical contact pad, the heating assembly according to claim 1.

11. The cavity defined by the inner wall of the insulator is tubular and extends from the base of the inner wall to the opening so that the end of the received aerosol generating substrate is completely surrounded by the inner wall. The first electrical contact pad and the second electrical contact pad are located at the base of the inner wall, the heating assembly according to claim 10.

12. The heater is a resistance heater, the heating assembly according to claim 1.

13. The heater is printed or coated on the outer surface of the inner wall of the insulator, the heating assembly according to claim 1.

14. The outer wall of the insulator has one or more apertures through which the first electrical connector and the second electrical connector extend, the heating assembly according to claim 1.

15. An electrically insulating material is provided in the one or more apertures surrounding the first electrical connector and the second electrical connector, the heating assembly according to claim 14.

16. An aerosol generating device comprising the heating assembly according to any one of claims 1 to 15.

17. The aerosol generating device according to claim 16, wherein the insulator is fixed within the aerosol generating device by a fixing member configured to limit movement of the insulator in the longitudinal direction of the insulator.

18. A method of manufacturing a heating assembly for an aerosol generating device, comprising: providing an outer wall having one or more apertures; arranging the first electrical connector and the second electrical connector such that the first electrical connector and the second electrical connector extend through the one or more apertures of the outer wall; providing an inner wall; providing a heater on an outer surface of the inner wall; coupling the inner wall to the outer wall to form a sealed space in which the heater is located between the outer wall and the inner wall, wherein an electrical path is formed between the first electrical connector and the second electrical connector via the heater.

19. The method according to claim 18, further comprising forming a vacuum in the sealed space between the outer wall and the inner wall.

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