Aerosol Delivery Device

Abstract

An aerosol delivery device (100) for generating an aerosol from an aerosol-generating material is described. The device comprises a housing (120) and a heating assembly (140). The heating assembly comprises a heating chamber (142) arranged to receive at least a portion of an article comprising the aerosol-generating material, an inductor coil (144) surrounding at least a portion of the heating chamber, and a coil support (150) having at least a portion of the inductor coil positioned on the coil support (150). The coil support comprises a positioning mechanism (154) that engages the housing to position the heating assembly in a position within the housing.

Description

[Technical field]

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

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

[0003] According to some embodiments described herein, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material comprising a housing and a heating assembly, the heating assembly comprising: a heating chamber arranged to receive at least a portion of an article comprising the aerosol-generating material; an inductor coil surrounding at least a portion of the heating chamber; and a coil support, at least a portion of the inductor coil being positioned on the coil support, the coil support comprising a positioning mechanism that engages with the housing to position the heating assembly at a position within the housing.

[0004] The positioning feature may project outwardly from the coil support. The housing may include a receiving feature disposed to engage the positioning feature. The receiving feature on the housing may include at least one of a channel and a groove. The receiving feature may extend axially in a direction from the first end to the second end of the housing.

[0005] The positioning feature may comprise a protrusion or tab. The positioning feature may comprise a first protrusion and a second protrusion. The first protrusion may be radially offset from the second protrusion.

[0006] The receiving feature may include a first receiving element arranged to engage the first protrusion and a second receiving element arranged to engage the second protrusion.

[0007] The housing may include an axially extending aperture, and the first and second receiving elements may be on opposite sides of the axially extending aperture. The housing may be a first housing, and the device may include a second housing assembled to the first housing. The second housing may cover the axially extending aperture. The device may include a second housing mount, and the second housing mount may define the receiving feature. The second housing mount may be attached to the first housing and arranged to attach the first housing to the second housing.

[0008] Each positioning feature may have a corresponding receiving feature in the housing for receiving and positioning the coil support within the housing.

[0009] The heating assembly may include an end support. The end support may be arranged to at least partially support the heating element. The end support may be arranged to at least partially support the coil support.

[0010] The device may include a connection arrangement arranged to connect the coil support and the end support. The connection arrangement may rotationally align the coil support and the end support. The connection arrangement may be arranged to limit axial separation of the coil support and the end support. The connection arrangement may comprise at least one of a clip, a latch, a fastener, or a hook. The connection arrangement may be attached to an attachment feature on the end support. The attachment feature may comprise a protrusion or a hook.

[0011] The end support may be at least one of the second end and proximal to the second end of the coil support.

[0012] The positioning mechanism may be at least one of the first end of the coil support and proximal to the first end. The positioning mechanism may comprise a first positioning mechanism and the end support may comprise a second positioning mechanism. The first and second positioning mechanisms may be axially aligned. The first and second positioning mechanisms may be axially offset.

[0013] The receiving mechanism may be disposed to engage a second positioning mechanism. The first positioning mechanism may limit relative rotation between the housing and the coil support. The second positioning mechanism may limit relative rotation between the housing and the end support. The receiving mechanism may allow axial movement of the coil support and the end support within the housing during assembly.

[0014] The end support may include an engagement feature arranged to engage with the housing. The engagement feature may include a clip, latch, fastener, or hook.

[0015] The housing may include a retention feature arranged to engage the engagement feature. The retention feature may include a protrusion or recess on or within which the engagement feature is mounted. The engagement feature may limit axial movement of the end support relative to the housing. The housing may include a locating feature that contacts the end support when the end support is fully inserted into the housing.

[0016] According to some embodiments described herein, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material comprising a housing and a heating assembly, the heating assembly comprising: a heating chamber arranged to receive at least a portion of an article comprising the aerosol-generating material; an inductor coil surrounding at least a portion of the heating chamber; and a coil support, at least a portion of the inductor coil being positioned on the coil support, the coil support comprising a positioning mechanism that engages with the housing to position the heating assembly at a position within the housing.

[0017] According to some embodiments described herein, there is provided an aerosol delivery system comprising the aerosol delivery device described above and an article comprising an aerosol-generating material.

[0018] According to some embodiments described herein, there is provided a method of manufacturing an aerosol delivery device for generating an aerosol from an aerosol-generating material, the method including assembling a heating assembly including a heating chamber arranged to receive at least a portion of an article comprising the aerosol-generating material, an inductor coil surrounding at least a portion of the heating chamber, and a coil support, where at least a portion of the inductor coil is positioned on the coil support, the method including engaging a positioning feature on the coil support with a receiving feature on the housing to position the coil support and the housing, and axially inserting the heating assembly into the housing.

[0019] The method may include attaching a coil support to an end support. The positioning mechanism may be a first positioning mechanism, and the method may include engaging a second positioning mechanism on the end support with a receiving mechanism on the housing to position the end support and the housing. The method may include engaging an engaging mechanism with the housing to prevent axial movement. The method may include inserting a heating assembly into the housing until the end support contacts a positioning mechanism on the housing.

[0020] Next, embodiments of the present invention will be described merely as examples with reference to the accompanying drawings.

Brief Description of the Drawings

[0021] [Figure 1] A perspective view of an aerosol supply device in which the housing is shown partially cut away is shown. [Diagram 2] An exploded perspective view of the aerosol supply device of FIG. 1 is shown. [Figure 3a] A perspective view of the coil support of the aerosol supply device of FIG. 1 is shown. [Figure 3b] A perspective view of the coil support of the aerosol supply device of FIG. 1 is shown. [Figure 4] An exploded perspective view of a heating assembly including the coil support and the end support of the aerosol supply device of FIG. 1 is shown. [Figure 5a] A side view of the heating assembly of the aerosol supply device of FIG. 1 is shown. [Figure 5b] A cross-sectional view taken along line X-X of the heating assembly of FIG. 5b is shown. [Figure 6] A perspective view of the heating assembly of the aerosol supply device of FIG. 1 is shown. [Figure 7] A perspective view of the heating assembly and the housing of the aerosol supply device of FIG. 1 is shown. [Figure 8] A top view of the heating assembly and the housing of the aerosol supply device of FIG. 1 is shown. [Figure 9a]2 shows a cross-sectional view of the heating assembly and housing of the aerosol delivery device of FIG. 1. [Figure 9b] Detail view AA of the heating assembly and housing of FIG. 9a is shown. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] As used herein, the term "aerosol-generating material" is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other way. The aerosol-generating material may be in the form of, for example, a solid, liquid, or gel, which may or may not contain active substances and / or flavorings. 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 in the form of, for example, a solid, liquid, gel, or wax. 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."

[0023] The aerosol-generating material may include a binder and an aerosol-forming agent. 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.

[0024] An aerosol-generating material may include or be an "amorphous solid." An amorphous solid may be a "monolithic solid." In some embodiments, an amorphous solid may be a dry gel. An amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, an aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0025] The aerosol-generating material may include an aerosol-generating film. The aerosol-generating film may include or be a sheet that may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially free of tobacco.

[0026] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0027] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0028] In some embodiments, the non-combustion aerosol delivery system is an electronic 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.

[0029] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0030] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, where one or more aerosol-generating materials 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 comprises 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.

[0031] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0032] In some embodiments, the present disclosure relates to consumables, which may be referred to as articles throughout this disclosure, that include aerosol generating materials and are configured for use with non-combustion aerosol delivery devices.

[0033] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a 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 proximate to the heat generating power source.

[0034] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0035] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transport components, aerosol generators, aerosol generating areas, housings, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0036] The aerosol generating device can receive an article comprising an aerosol-generating material for heating. An "article" in this context is a component that includes or contains an aerosol-generating material when used, which is heated to volatilize the aerosol-generating material, and optionally other components when used. A user can insert the article into the aerosol generating device before the article is heated to generate an aerosol, which the user then inhales. The article may be of a predetermined or specific size, for example, configured to be placed in a heating chamber of the device sized to receive the article.

[0037] 1 shows an aerosol delivery device 100 for generating an aerosol from an aerosol-generating material. Device 100 can be used to heat a replaceable article (not shown) comprising the aerosol-generating material to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0038] The device 100 comprises a body 104. The body 104 comprises a housing 120. In FIG. 1, the housing 120 is shown partially cut away. The housing 120 surrounds and houses various components of the device 100. An article aperture 115 is formed in one end of the body 104 through which an article can be inserted for heating by the aerosol generator 102 (see FIG. 2). In use, the article can be fully or partially inserted into the aerosol generator 102 and can be heated by one or more components of the aerosol generator 102. The aerosol generator 102 comprises a heating assembly. The article and the device 100 together form an aerosol delivery system 101.

[0039] The housing 120 includes a first housing 121 and a second housing 122. The first housing 121 is attached to the second housing 122.

[0040] The device 100 may also include user-operable controls 106, such as buttons or switches that, when pressed, operate the device 100. For example, a user may turn on the device by operating a switch.

[0041] The body 104 comprises an end surface of the device 100. The end of the device 100 closest to the article aperture 115 may be known as the proximal end (or mouth end) 114 of the device 100, as it is closest to the user's mouth during use. During use, a user inserts an article into the aperture 115, operates the aerosol generator 102 to begin heating the aerosol-generating material, and inhales the aerosol generated within the device 100. This causes the aerosol to flow through the device 100 along a flow path toward the proximal end 114 of the device 100.

[0042] The other end of the device furthest from aperture 115 may be known as the distal end 116 of device 100, as it is the end furthest from the user's mouth when in use. When a user inhales the aerosol generated in the device, the aerosol flows in a direction towards the proximal end 114 of device 100. The terms proximal and distal as applied to features of device 100 are explained by reference to the relative positioning of such features with respect to one another in the proximal-distal direction along longitudinal axis 112.

[0043] As used herein, 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 into the unitary component during the manufacturing stage of the component.

[0044] 2 shows a perspective view of the heating assembly 140 and housing 120 in axial alignment prior to assembly. The heating assembly 140 defines a longitudinal axis 112. The heating assembly 140 defines a heating chamber 142. An article is received within the heating chamber 142 and heated by the heating assembly 140. The aerosol generator 102 is received by the first housing 121. The heating chamber 142 is axially inserted within the first housing 121.

[0045] The device 100 comprises a first housing 121 and a second housing 122. The first housing 121 houses a heating assembly 140. The second housing 122 houses a power source and at least one electronics module. The first and second housings 121, 122 are fixedly assembled.

[0046] The power source is contained within the second housing 122. The power source may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the aerosol generator 102 to provide power to heat the aerosol-generating material as needed under the control of the controller.

[0047] The electronics module 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 together various electronic components of device 100. For example, battery terminals may be electrically connected to the PCB such that power may be distributed throughout device 100.

[0048] The heating assembly 140 comprises an induction heating system including a magnetic field generator comprising an inductor coil assembly. The heating assembly 140 comprises a heating element, also known as a susceptor.

[0049] A susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that penetration of the electrically conductive material by the varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material 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.

[0050] The heating assembly 140 forming part of the aerosol generator 102 is an induction heating assembly, comprising various components for heating the aerosol-generating material of an article by 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, for example one or more inductor coils, and a device for passing a variable 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 suitably positioned relative to the induction element and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore the flow of eddy currents against this resistance causes the susceptor to heat by Joule heating. If the susceptor comprises a ferromagnetic material such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the change in orientation of the magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. Induction heating generates heat inside the susceptor, allowing for rapid heating compared to, for example, heating by conduction, and does not require any physical contact between the induction heater and the susceptor, allowing for greater freedom of design and application.

[0051] The heating element may be hollow, thus defining at least a portion of a receptacle in which the aerosol-generating material is received. For example, the article may be inserted into the heating element. The heating element is tubular with a circular cross-section. The heating element has a substantially constant diameter along the axial length of the heating element. In an embodiment, the heating element protrudes into the receptacle. Other configurations are envisioned.

[0052] The heating element is formed from a conductive material suitable for heating by electromagnetic induction. The susceptor in this example 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. The heating element may be an elongated member that protrudes into the heating zone defined by the receptacle.

[0053] In other embodiments, the feature acting as the heating element may not be limited to being inductively heated. Thus, the feature acting as the heating element may be heatable by electrical resistance. Thus, the aerosol generator 102 may include electrical contacts for electrically connecting with a device for electrically activating the heating element by passing a flow of electrical energy through the heating element.

[0054] The heating assembly 140 comprises an inductor coil assembly 143 (shown in FIG. 4) and an end support 160. The inductor coil assembly 143 includes an inductor coil 144. The inductor coil assembly 143 also comprises a coil support 150. FIGS. 3a and 3b show the coil support 150. FIG. 4 shows the inductor coil assembly 143 and the end support 160 axially aligned prior to assembly. The inductor coil may comprise a first inductor coil and a second inductor coil. In embodiments, the number of inductor coils is different. In an embodiment, a single inductor coil 144 is used. The coil support 150 is tubular. The coil support 150 comprises a guide for the coil 144. The guide 151 comprises a channel on the outside of the coil support 150.

[0055] 3a and 3b show the coil support 150. The coil support 150 comprises a first positioning mechanism 154. The first positioning mechanism 154 functions as a positioning mechanism, and in an embodiment, in the heating assembly, the positioning mechanism is a single positioning mechanism. The first positioning mechanism comprises a first positioning protrusion 154a and a second positioning protrusion 154b that protrude outwardly from the coil support 150. The positioning protrusions 154a, 154b extend tangentially from the tubular sidewall 152 of the coil support 150. The positioning protrusions 154a, 154b extend in opposite directions away from the coil support 150. The positioning protrusions 154a, 154b extend along a plane that is tangent to the tubular sidewall of the coil support 150. The locating projections 154a, 154b extend away from the coil support 150 and are received by corresponding receiving features 124 in the housing 120 (see FIG. 7). The locating projections 154a, 154b are disposed at the proximal end 114 of the coil support 150. The locating projections 154a, 154b are formed as integral components with the coil support 150. In embodiments, the locating projections 154a, 154b include tabs and / or the first locating projection is radially offset from the second locating projection. The locating projections may be formed separately from the coil support. In embodiments, the first locating feature may comprise a single locating projection.

[0056] A connecting arrangement 155 is disposed at the distal end 116 of the coil support 150. The connecting arrangement 155 comprises connecting clips 155a, 155b. The connecting clips 155a, 155b extend axially away from the coil support 150 at the distal end 116. The connecting clips 155a, 155b are diametrically opposed on the coil support 150. The connecting arrangement is arranged to connect with a corresponding feature on the end support 150. The connecting clips 155a, 155b extend axially from a side wall of the coil support 150. The connecting arrangement is formed as an integral component with the coil support 150. In alternative embodiments, the connecting clips are not diametrically opposed on the coil support 150. The connecting arrangement may comprise a latch, hook, or fastener. The connecting arrangement may be formed separately from the coil support 150. The number of clips may, for example, be different. In an embodiment, the connecting arrangement may comprise a single connecting clip.

[0057] FIG. 4 shows the inductor coil assembly 143 and end support 160 in axial alignment prior to assembly. The inductor coil assembly 143 includes a coil 144 assembled on the coil support 150. The inductor coil assembly 143 is placed in axial alignment with and engages the end support 160. The end support 160 includes an attachment mechanism 165. The attachment mechanism 165 includes attachment protrusions 165a, 165b. The attachment protrusions 165a, 165b may extend, for example, radially away from a portion of the end support 160 to allow attachment to the connection configuration 155. The attachment protrusions 165a, 165b are integrally formed with the end support 160. The attachment protrusions 165a, 165b are axially aligned with the connection clips 155a, 155b. In an embodiment, the attachment mechanism may extend axially from a portion of the end support 160 to connect to the connection configuration 155. The attachment mechanism may comprise a protrusion or a hook. The attachment protrusion may be formed separately from the end support 160. In an embodiment, the attachment mechanism may comprise a single attachment protrusion. In an embodiment, the attachment mechanism may comprise a corresponding single connection structure.

[0058] The end support 160 includes a second positioning mechanism 164. The second positioning mechanism 164 includes third and fourth positioning projections 164a, 164b. The positioning projections 164a, 164b project outwardly from the end support 160. The positioning projections 164a, 164b extend along a plane that is tangent to the tubular sidewall of the coil support 150, in the same plane in which the first and second positioning projections 154a, 154b extend. The third and fourth positioning projections 164a, 164b extend away from the end support 160 and are received by corresponding receiving mechanisms 124 in the housing 120 (see FIG. 7). In an embodiment, the second positioning mechanism may include a single positioning projection. In an embodiment, the second positioning mechanism is omitted.

[0059] 5a, 5b, and 6 show an assembled heating assembly 140 including coil support 150, coil 144, and end support 160. End support 160 provides support for the heating element (not shown) and inductor coil assembly 143. Connection structure 155 engages attachment mechanism 165 to limit axial separation of inductor coil assembly 143 and end support 160. Connection clips 155a, 155b fit around attachment projections 165a, 165b. Connection structure 155 engages attachment mechanism 165 to limit relative rotation of inductor coil assembly 143 and end support 160.

[0060] The end support 160 is attached to the distal end 116 of the coil support 150. The end support 160 includes an engagement mechanism 166. The engagement mechanism 166 extends axially from a portion of the end support 160. The engagement mechanism 166 includes a latch that extends axially in alignment with a sidewall of the coil support 160. The latch 166 is positioned to engage a corresponding retention mechanism 126 in the housing 120 (see FIGS. 9a and 9b). The latch 166 is radially elastically deformable such that when the latch 166 is passed over the retention mechanism 126 in the housing 120 (see FIG. 7), the latch is temporarily deformed before returning to its original position and engaging the retention mechanism 126. The engagement mechanism 166 is integrally formed with the end support 160. In alternative embodiments, the engagement mechanism includes a clip, fastener, or hook. The engagement mechanism 166 may be formed separately from the end support 160.

[0061] The inductor coil assembly 143 is attached to the end support 160 by a connecting arrangement 155 and an attachment mechanism 165. The engagement of the connecting arrangement 155 and the attachment mechanism 165 prevents relative axial movement and relative rotation between the inductor coil assembly 143 and the end support 160.

[0062] 7 shows the heating assembly 140 axially aligned with the first housing 121 prior to assembly of the heating assembly 140 within the first housing 121. In this embodiment, the housing 120 includes a second housing mount 123 on the first housing. The second housing mount 123 attaches the first housing 121 to the second housing 122. The first housing 121 includes an axially extending aperture 130. The second housing 122 covers the aperture 130. The aperture 130 allows for electrical connection between components within the first and second housings 121, 122.

[0063] The housing 120 includes a receiving feature 124. The receiving feature 124 extends axially along the length of the housing 120. The receiving feature 124 extends axially from the distal end 116 to the proximal end 114 of the housing 120. The receiving feature 124 includes a first groove 124a acting as a first receiving element and a second groove 124b acting as a second receiving element. The first and second grooves 124a, 124b are on either side of the housing aperture 130. The grooves 124a, 124b are positioned within the second housing mount 123. The receiving feature 124 engages with a first positioning feature 154 on the coil support 150 and a second positioning feature 164 on the end support. The grooves 124a, 124b receive the positioning projections 154a, 154b, 164a, 164b. The positioning projections 154a, 154b, 164a, 164b are in planar alignment with one another.

[0064] The receiving feature 124 on the housing 120 allows the coil support to be inserted into and assembled directly onto the housing 120. This eliminates the need for additional components or mounting features, such as intermediate mounting components onto which the coil support is assembled. This reduces the amount of material required to manufacture the device. Assembly of the device is also simplified by reducing the number of assembly steps. A compact device may be provided.

[0065] The first positioning projection 154a and the third positioning projection 164a are axially aligned with each other. The second positioning projection 154b and the fourth positioning projection 164b are axially aligned with each other. The first groove 124a receives both the first positioning projection 154a and the third positioning projection 164a. The second groove 124b receives both the second positioning projection 154b and the fourth positioning projection 164b. In an embodiment, the first and second receiving elements include channels. The first and second positioning features may not be in planar alignment. The receiving feature may include multiple receiving features. The receiving feature may be on or within the first housing 121.

[0066] A positioning mechanism 127 is positioned on the inner surface of the housing 121. The positioning mechanism 127 limits insertion of the heating assembly 140 into the first housing 121. The positioning mechanism 127 includes a protrusion on the inner surface of the first housing 121. The positioning mechanism 127 is positioned to contact a portion of the end support 160 to limit axial insertion beyond a point of contact between the positioning mechanism 127 and the portion of the end support. In an embodiment, the positioning mechanism extends continuously around the inner surface of the coil support. The positioning mechanism may include a protrusion, rib, step, or tab that projects axially inward from the inner surface of the coil support 150.

[0067] FIG. 8 shows a top view of the heating assembly in the first housing 121. The first locating projection 154a is received by the groove 124a and the second locating projection 154b is received by the groove 124b. The second housing mount 123 includes grooves 154a, 154b. The first and third locating projections 154a, 164a are axially aligned with each other to be axially received by the groove 124a. The second and fourth locating projections 154b, 164b are axially aligned with each other to be axially received by the groove 124b. The heating assembly 140 is assembled in the first housing 121 by axially aligning the third and fourth locating projections 164a, 164b with the corresponding grooves 124a, 124b and inserting them into the grooves 124a, 124b.

[0068] The heating assembly is axially inserted into the first housing 121, and as a result, the first and second locating projections 154a, 154b are also inserted into the grooves 124a, 124b. The heating assembly 140 is inserted into the proximal end 114 of the first housing 121. The grooves 124a, 124b allow relative axial movement between the heating assembly 140 and the first housing 121. The grooves 124a, 124b and the locating projections 154a, 154b, 164a, 164b prevent relative rotation between the heating assembly 140 and the first housing 121.

[0069] 9a and 9b show a cross-sectional view of the heating assembly 140 in the first housing 121, and a detailed view of the engagement feature 166 and the positioning feature 127, respectively. When the heating assembly 140 is inserted into the first housing 121, the shape of the retention feature 126 causes the resiliently deformable engagement feature, the latch 166, to deform radially inward as it passes through the retention feature. As the engagement feature 166 advances axially past the retention feature 126, the latch 166 snaps back to its original position and engages with the retention feature 126. The latch 166 engages the retention feature 126 to prevent removal of the heating assembly 140 from the first housing 121 after insertion, i.e., removal of the heating assembly 140 from the proximal end 114 of the first housing 121. The positioning feature 127 prevents the heating assembly 140 from being inserted too far into the first housing 121. After the latch 166 engages the retention feature 126, the positioning feature 127 on the first housing 121 contacts a portion of the end support 160 to prevent further axial insertion of the heating assembly 140. The positioning feature 127 prevents the end support 160 from contacting and damaging any components in the distal end 116 of the first housing 121. In an alternative embodiment, the retention feature comprises a recess into which the engagement feature engages. The engagement feature 166 and the attachment of the coil support 150 to the end support 160 allow for fewer assembly steps and therefore a more efficient assembly process. The heating assembly 140 is inserted directly into the housing 120 and attached directly to the retention feature 126 and the receiving feature 124. The number of steps in the assembly process is reduced and no intermediate attachment feature is required between the heating assembly 140 and the housing 120. This helps provide cost and material benefits during the manufacturing process.

[0070] The device is assembled according to the following steps:

[0071] 1. Axially align the inductor coil assembly 143 with the coil support 150 with the end support 160 and engage the connecting structure 155 with the attachment mechanism 165. The connecting structure 155 is on the distal end 116 of the coil support 150 and is attached to the attachment mechanism 165 on the end support 160. The connecting structure 155 and the attachment mechanism 165 axially align the coil support 150 with the end support 160 and limit the relative axial and rotational movement of the coil support 150 and the end support 160. Aligning the coil support 150 with the end support 160 also axially aligns the first positioning mechanism 154 on the coil support 150 with the second positioning mechanism 164 on the end support 160.

[0072] 2. Axially align the heating assembly 140 with the housing 120 and engage the second positioning feature 164 with the receiving feature 124 on the housing 120.

[0073] 3. Insert the heating assembly 140 axially into the housing 120. The first positioning mechanism 154 is engaged with the receiving mechanism 124 while the second positioning mechanism 164 remains engaged with the receiving mechanism 124. The engagement of the first and second positioning mechanisms 154, 164 prevents relative rotation between the heating assembly 140 and the housing 120 during assembly and in use. The first positioning mechanism 154 prevents relative rotation between the coil support 150 and the housing 120. The second positioning mechanism 164 prevents relative rotation between the end support 160 and the housing 120. The second positioning mechanism 164 engages with the receiving mechanism 124 before the first positioning mechanism 154 engages with the receiving mechanism 124. The engagement of the second positioning mechanism 164 aligns the heating assembly 140 such that the first positioning mechanism 154 is axially aligned with the receiving mechanism 124.

[0074] 4. Engage engagement feature 166 with retention feature 126 and bring end support 160 into contact with positioning feature 127. Engagement of engagement feature 166 with retention feature 126 prevents axial separation of housing 120 and heating assembly 140. Interaction between end support 160 and positioning feature 127 prevents further insertion of heating assembly 140 into housing 120.

[0075] Alignment of the heating assembly 140 within the first housing 121 by the first and second positioning mechanisms 154 , 164 and the receiving mechanism aligns the engagement mechanism 166 with the retention mechanism 126 and aligns a portion of the end support 160 with the positioning mechanism 127 .

[0076] Relative rotation between the heating assembly 140 and the first housing 121 is limited by the positioning of the first and second positioning features 154, 164 within the receiving feature 124. Relative rotation and axial separation between the coil support 150 and the end support 160 is limited by the attachment of the coil support 150 to the end support 160 by the connecting arrangement 155 and the attachment feature 165. The heating assembly 140 is slid axially within the first housing 121, so that axial movement between the heating assembly 140 and the housing 121 is not restricted during assembly. Once assembled, the engagement feature 166 engages the retention feature 126 to limit axial separation between the heating assembly 140 and the housing 121. The heating assembly 140 is held in a fixed position within the housing 121 such that no axial separation or rotation can occur between the components of the heating assembly 140 and between the heating assembly 140 and the housing 121.

[0077] The direct attachment of the heating assembly 140 allows for a more efficient method of assembly of the device. No intermediate attachment components are required between the housing 120 and the heating assembly 140. This saves materials and costs during manufacturing. Additionally, the absence of intermediate attachment components reduces the number of assembly steps.

[0078] 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 a representative sample 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 of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably include, 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. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a housing and a heating assembly, the heating assembly comprising: a heating chamber positioned to receive at least a portion of the article comprising the aerosol-forming material; an inductor coil surrounding at least a portion of the heating chamber; a coil support, at least a portion of the inductor coil being positioned on the coil support; Equipped with the coil support includes a positioning mechanism that engages the housing to position the heating assembly in a position within the housing; Aerosol delivery device.

2. The aerosol delivery device of claim 1 , wherein the positioning mechanism projects outwardly from the coil support.

3. The aerosol delivery device of claim 1 or 2, wherein the housing comprises a receiving mechanism arranged to engage the positioning mechanism.

4. The aerosol delivery device of any one of claims 1 to 3, wherein the receiving mechanism extends axially in a direction from the first end to the second end of the housing.

5. The aerosol delivery device of any one of claims 1 to 4, wherein the positioning mechanism comprises a first protrusion and a second protrusion.

6. The aerosol delivery device of claim 5 , wherein the first protrusion is radially offset from the second protrusion.

7. The aerosol delivery device of any one of claims 3 to 6, wherein the receiving mechanism comprises a first receiving element arranged to engage with the first protrusion and a second receiving element arranged to engage with the second protrusion.

8. 8. The aerosol delivery device of claim 7, wherein the housing includes an axially extending aperture, the first and second receiving elements being on opposite sides of the axially extending aperture.

9. The aerosol delivery device of any one of claims 1 to 8, wherein the heating assembly comprises an end support.

10. The aerosol delivery device of claim 9 , wherein the positioning mechanism comprises a first positioning mechanism and the end support comprises a second positioning mechanism.

11. The aerosol delivery device of claim 10 , wherein a receiving feature is positioned to engage the second positioning feature.

12. An aerosol delivery device according to any one of claims 9 to 11, wherein the end support comprises an engagement mechanism arranged to engage the housing to limit axial movement.

13. 13. The aerosol delivery device of any one of claims 9 to 12, wherein the housing comprises a positioning mechanism that contacts the end support when the end support is fully inserted into the housing.

14. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a housing and a heating assembly, the heating assembly comprising: a heating chamber positioned to receive at least a portion of the article comprising the aerosol-forming material; an inductor coil surrounding at least a portion of the heating chamber; a coil support, at least a portion of the inductor coil being positioned on the coil support; Equipped with the coil support includes a positioning mechanism that engages the housing to position the heating assembly in a position within the housing; Aerosol delivery device.

15. 13. An aerosol delivery system comprising the aerosol delivery device of claim 1 and an article comprising an aerosol-generating material.

16. 1. A method of manufacturing an aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heating chamber positioned to receive at least a portion of the article comprising the aerosol-forming material; an inductor coil surrounding at least a portion of the heating chamber; a coil support, at least a portion of the inductor coil being positioned on the coil support; [0023] comprising assembling a heating assembly comprising: The method further comprising: engaging a positioning feature on the coil support with a receiving feature on the housing to position the coil support and the housing; axially inserting the heating assembly into the housing; A method comprising:

17. The method of claim 16 including the step of attaching the coil support to the end support.

18. 18. The method of claim 17, wherein the positioning mechanism is a first positioning mechanism, the method including engaging a second positioning mechanism on the end support with the receiving mechanism on the housing to position the end support and the housing.

19. A method according to any one of claims 16 to 18, comprising engaging an engagement mechanism with the housing to prevent axial movement.

20. A method according to any one of claims 17 to 19, comprising inserting the heating assembly into the housing until the end supports contact locating features on the housing.

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