Aerosol generating device having a heater module holder

Abstract

The present invention relates to an aerosol generating device (10) comprising a heater casing having a downstream heater casing section (18) and an upstream heater casing section (12), the heater casing housing a heater module (16), the heater module being mounted within the heater casing on a heater module holder (14) that is connected to the upstream heater casing section. The heater module holder allows for easier mounting of the heater module to the upstream heater casing section.

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol generating device having a heater module holder. The present disclosure further relates to a method of assembling an aerosol generating device using a heater module holder. [Background technology]

[0002] It is known to provide an aerosol-generating device for producing an inhalable vapor. Such a device may heat an aerosol-forming substrate contained in an aerosol-generating article without combustion. The aerosol-generating device may include a heating module having a heating element and including a heating chamber for receiving the aerosol-generating article. The heating module may be housed within a heater casing.

[0003] Upon heating to the target temperature, the aerosol-forming substrate vaporizes to form an aerosol. Summary of the Invention [Problem to be solved by the invention]

[0004] It would be desirable to provide an aerosol generating device that is easy to assemble and compact. It would be desirable to provide an aerosol generating device that has large manufacturing tolerances. It would be desirable to provide an aerosol generating device in which the heating module can be easily positioned within the heater casing. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 shows a schematic exploded view of the components of an aerosol generating device, including an upstream heater casing, a downstream heater casing, a heater module, and a heater module holder. [Figure 2]FIG. 2 illustrates a schematic cross-sectional view of the relative spatial arrangement of the heater module holder and heater modules with respect to the upstream components of the heater casing. [Figure 3] FIG. 3 illustrates another schematic cross-sectional view of a heater module holder with a flexible sealing element presenting an installation gap to the upstream heater casing. [Figure 4] FIG. 4 illustrates a schematic exploded view of the installation of the heater module on the heater module holder and the installation of the heater module holder in the upstream portion of the heater casing. [Figure 5] FIG. 5 shows a schematic diagram of an aerosol generating device that includes a self-supporting internal element that includes a heater casing with an airflow tube mounted to a control element. DETAILED DESCRIPTION OF THE INVENTION

[0006] According to an embodiment of the present invention, there is provided an aerosol generating device that may include a heater casing having a downstream heater casing portion and an upstream heater casing portion. The heater casing may house a heater module. The heater module may be mounted within the heater casing on a heater module holder. The heater module holder may be connected to the upstream heater casing portion.

[0007] Another embodiment of the present invention provides an aerosol generating device comprising a heater casing having a downstream heater casing portion and an upstream heater casing portion, the heater casing housing a heater module, the heater module being mounted within the heater casing on a heater module holder, and the heater module holder being connected to the upstream heater casing portion.

[0008] The heater module may be easily installed within the heater casing thanks to the heater module holder. The heater module holder may provide a secure connection between the heater module and the upstream heater casing. The heater module holder may securely position the heater module within the heater casing. The heater module holder may allow for easy positioning of the heater module relative to the upstream heater casing.

[0009] As used herein, the terms "upstream" and "downstream" are used to describe the relative location of components or portions of components of an aerosol-generating device with respect to the direction in which air flows through the aerosol-generating device along an airflow path during use of the aerosol-generating device. An aerosol-generating device according to the present invention has a proximal end through which aerosol exits the device during use. The proximal end of an aerosol-generating device may also be referred to as the mouth end or downstream end. The mouth end is downstream of the distal end. The distal end of an aerosol-generating article may also be referred to as the upstream end. Components or portions of components of an aerosol-generating device may be described as being upstream or downstream of one another based on their relative location with respect to the airflow path of the aerosol-generating device.

[0010] The heater module holder may include a protruding upstream connection section. The protruding upstream connection section may be configured for connection to the heater casing upstream portion. The heater casing upstream portion may include a mounting recess. The mounting recess may be configured to receive the protruding upstream connection section.

[0011] Such a connection system may enable a secure connection between the heater module holder and the heater casing upstream section. This may enable a simple connection between the heater module holder and the heater casing upstream section. Thanks to the protruding upstream connection section, the heater module holder may simply be placed into a mounting recess in the heater casing upstream section to provide a secure connection.

[0012] The inner surface of the mounting recess in the upstream heater casing portion may be spaced apart from the opposing outer surface of the protruding upstream connection section, which may create a mounting gap.

[0013] Specifically, the inner surface of the mounting recess of the upstream heater casing section may be spaced apart from the outer surface opposite the protruding upstream connection section when the protruding upstream connection section is received in the mounting recess. A mounting gap may be formed when the heater module holder is received in the mounting recess of the upstream heater casing section. The mounting gap may provide tolerance when connecting the heater module holder to the upstream heater casing section. This may allow the heater module holder and the upstream heater casing section to be manufactured with larger manufacturing tolerances. This may allow the heater module holder to be properly aligned with the upstream heater casing section despite the large manufacturing tolerances.

[0014] The mounting gap may be configured to allow relative movement of the heater module holder with respect to the upstream heater casing portion, which may advantageously allow for greater tolerance when positioning the heater module holder within the upstream heater casing portion.

[0015] The mounting gap may allow relative movement of the heater module holder with respect to the upstream heater casing portion during assembly of the aerosol generating device. After correct positioning of the heater module holder with respect to the upstream heater casing portion, the correct position may be fixed by employing a connecting element. This may ensure that the heater module holder is positioned in the correct position with respect to the upstream heater casing portion.

[0016] This may also allow for easy and correct positioning of the heater module relative to the upstream heater casing, which may be due to the heater module being mounted on the heater module holder during assembly of the aerosol generating device.

[0017] The width of the protruding upstream connection section of the heater module holder may be 6 to 15 percent smaller than the width of the mounting recess in the upstream portion of the heater casing. Preferably, the width of the protruding upstream connection section is 8 to 12 percent, more preferably 10 percent smaller than the width of the mounting recess in the upstream portion of the heater casing.

[0018] This may provide a mounting clearance large enough to reliably position the heater module holder relative to the heater casing upstream portion despite large manufacturing tolerances.

[0019] The aerosol generation device may have a longitudinal axis, and the mounting gap may be configured to allow relative movement of the heater module holder with respect to the upstream heater casing portion perpendicular to the longitudinal axis of the aerosol generation device.

[0020] This may allow for easy alignment of the heater module holder, and therefore the heater module, relative to the upstream heater casing part along the longitudinal axis of the aerosol generation device.

[0021] This may allow for the simple creation of a continuous airflow path leading through the heater module and the upstream portion of the heater casing. A flexible sealing element may be disposed between the protruding upstream connection section and the mounting recess. The flexible sealing element may be configured to allow relative movement of the heater module holder with respect to the heater casing upstream portion.

[0022] The flexible sealing element may be located at a downstream end of the protruding upstream connection section of the heater module holder.The heater module holder may comprise the flexible sealing element.

[0023] This may allow for easy disposition of the flexible sealing element relative to the mounting recess when mounting the protruding upstream connection section of the heater module holder in the mounting recess in the upstream part of the heater casing.

[0024] The flexible sealing element may also be configured to provide additional movement of the protruding upstream connection section of the heater module holder within the recess in the upstream portion of the heater casing due to the flexibility of the flexible sealing element.

[0025] The flexible sealing element may also be flexible. This may allow for additional movement of the heater module holder relative to the upstream heater casing. This may allow for tilting of the heater module holder relative to the upstream heater casing. Specifically, tilting of the heater module holder may be relative to the longitudinal axis of the aerosol generation device. This may provide a way for additional movement of the heater module holder relative to the upstream heater casing.

[0026] The flexible sealing element may be configured to allow relative movement of the heater module holder with respect to the upstream heater casing portion.

[0027] This may provide additional freedom of movement for the heater casing upstream relative to the heater module holder.

[0028] The flexible sealing element may also be configured to seal the mounting gap at a downstream portion of the mounting gap, which may offer the possibility of making the heater casing gastight despite the mounting gap.

[0029] The flexible sealing element may be formed from one of rubber or elastomers, in particular silicone rubber.

[0030] The heater casing upstream portion may include an airflow path for providing air into the heater casing. The heater casing downstream portion may include an airflow path for providing air into the heater casing. Similarly, the heater module holder may include through holes for providing an airflow path through the heater module holder and into the heater modules mounted on the heater module holder.

[0031] The heater casing downstream portion, the heater casing upstream portion, and the heater module holder may be tubular.

[0032] This may provide a tubular heater casing having a heater module that may also be tubular or configured to receive an aerosol-generating article formed as a rod, which may have the general shape of a cigarette.

[0033] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of emitting a volatile compound capable of forming an aerosol. For example, the aerosol-generating article may be a smoking article that generates an aerosol that can be inhaled directly through the user's mouth into the user's lungs. The aerosol-generating article may be disposable.

[0034] As used herein, "aerosol-generating device" refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate may be part of an aerosol-generating article, for example part of a smoking article. The aerosol-generating device may be a smoking device that interacts with the aerosol-forming substrate of the aerosol-generating article to generate an aerosol that is inhalable directly through the user's mouth into the user's lungs. The aerosol-generating device may also be a holder. Preferably, the device is a portable or handheld device that is comfortable to hold between the fingers of one hand.

[0035] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of emitting a volatile compound that can form an aerosol. The volatile compound may be emitted by heating or burning the aerosol-forming substrate. The aerosol-forming substrate may be solid or liquid, or may contain both solid and liquid components. The aerosol-forming substrate may be part of an aerosol-generating article.

[0036] The mounting gap may be a radial mounting gap, which may allow a simple way to rotate the heater module holder relative to the upstream heater casing part, which may allow a simple way to allow relative movement of the heater module holder relative to the upstream heater casing part perpendicular to the longitudinal axis of the aerosol generation device.

[0037] The flexible sealing element may include an O-ring. The flexible sealing element may be formed as an O-ring. This may allow for easy alignment between the flexible sealing element and the radial mounting gap. This may allow the flexible sealing element to reliably seal the downstream end of the radial mounting gap.

[0038] In the case of a radial mounting gap, the diameter of the protruding upstream connection section of the heater module holder may be 6 to 15 percent smaller than the diameter of the mounting recess in the upstream heater casing. Preferably, the diameter of the protruding upstream connection section may be 8 to 12 percent, more preferably 10 percent smaller than the width of the mounting recess in the upstream heater casing.

[0039] This may provide a radial mounting gap of sufficient size to securely position the heater module holder relative to the upstream portion of the heater casing.

[0040] One or both of the downstream heater casing and the upstream heater casing may comprise a connection. The connection may be configured to mount the downstream heater casing to the upstream heater casing. This may block the position of the heater module holder relative to the upstream heater casing. The connection may comprise a hole in both the upstream heater casing and the downstream heater casing. A connecting element may be positioned in both the hole in the upstream heater casing and the hole in the downstream heater casing to lock both parts together. This may also block further movement of the heater module holder inside the heater casing relative to the downstream heater casing. The connecting element may comprise, for example, a screw that may be configured to screw the downstream heater casing to the upstream heater casing. One or both of the hole in the upstream heater casing and the hole in the downstream heater casing may comprise a thread to accommodate the connecting element, specifically a screw.

[0041] The heater module may be mounted on the heater module holder by means of a protruding element and a corresponding groove configured to receive the protruding element.

[0042] This may provide an easy way to mount the heater module on the heater module holder, and may also provide an easy way to align the heater module on the heater module holder with the upstream portion of the heater casing.

[0043] The heater module may include a heating element. The heating element may at least partially surround a heating chamber. The heating chamber may be located within a heater casing. The heating chamber may be configured to receive an aerosol-generating article.

[0044] The heating chamber is configured to receive an aerosol-generating article including an aerosol-forming substrate. The heating chamber may comprise a cavity into which the aerosol-generating article is inserted. The cavity may be tubular. The cavity may comprise a thermally conductive material. The cavity may comprise a tube made of metal, preferably stainless steel, or the tube may comprise ceramic. The heating chamber may comprise an opening at the downstream end of the heating chamber to receive the aerosol-generating article. The opening may also function as an air outlet.

[0045] The heating chamber may comprise a heating element configured to heat the aerosol-generating article. The heating element may comprise a substrate layer of flexible material. The substrate layer may comprise a thermally stable polymer, preferably polyimide.

[0046] The heating element may be disposed on the base layer. The heating element may be a resistive heating element. The heating element may contain a wired connection configured to connect to the control element. The heating element may comprise a heating track disposed on the base layer. The heating track may comprise a thermally conductive material, preferably a metal such as stainless steel. The heating track may be electrically connected to the wired connection.

[0047] In particular, the heating chamber may comprise a tube made of metal encased within said base layer of flexible material, with the heating element disposed on the base layer.

[0048] The portion of the heating element in contact with the aerosol-forming substrate heats as a result of an electric current being passed through the heating element. The electric current is supplied by a power source. In one embodiment, this portion of the heating element is configured to reach a temperature of about 140 degrees Celsius to about 270 degrees Celsius in use. Preferably, the heating element is configured to reach a temperature of about 180 degrees Celsius to about 240 degrees Celsius.

[0049] The heating chamber configured to receive the aerosol-forming article may be housed within the heater casing and may be separated from the inner wall of the heater casing. This provides thermal insulation between the inner wall of the heater casing and the heating chamber where heat is generated. The space between the inner wall of the heater casing and the heating chamber may be airtight. The space may be filled with air. The space may also be filled with a gaseous mixture, preferably an inert gas such as nitrogen. This may provide particularly good thermal insulation between the inner wall of the heater casing and the heating chamber.

[0050] The heater casing may include a downstream heater opening for inserting the aerosol-generating article into the heating chamber. The downstream heater opening may be located at the downstream end of the airflow path through the aerosol-generating device.

[0051] The heater casing upstream portion may include an air flow tube. The air flow tube may be configured to provide air to the heater module. The air flow tube may be configured to provide air to the heater casing. The air flow tube may be configured to provide air to the heater module located within the heater casing.

[0052] The airflow tube may include a heat-stable polymer. The airflow tube may include the same heat-stable polymer as the heater casing. Specifically, a one-piece element including the upstream heater casing and the airflow tube on the one hand and the downstream heater casing on the other hand may include the same heat-stable polymer. The airflow tube or the one-piece element may each include one or both of polyphenylene sulfone (PPSU) and polyether ether ketone (PEEK).

[0053] The heater casing upstream section and the air flow tube may be formed as a one-piece element. Preferably, the heater casing upstream section and the air flow tube may be formed as a monolithic element.

[0054] This may provide the heater casing upstream section and airflow tube in one piece, which may provide a simple method for assembling the internal components of the aerosol generating device, including the heater casing with the heater module and the upstream airflow tube.

[0055] This one-piece element may be formed, for example, via molding, e.g., injection molding, which may allow for a simple one-piece connection between the upstream heater casing portion and the airflow tube, without the need to form a connection configured to mount the upstream heater casing portion to the airflow tube.

[0056] The one-piece or monolithic elements of the heater casing upstream section and airflow tube may be formed from a polymer or may be formed from a metal.

[0057] The heater casing may have an inner wall. The inner wall of the heater casing may include one or both of a thermally reflective coating and a polymer. The thermally stable polymer may be selected from the group of polymers consisting of polyphenylene sulfone (PPSU) and polyether ether ketone (PEEK). Preferably, the thermally stable polymer may include polyphenylene sulfone (PPSU). The thermally reflective coating may include a metal. Such a metal coating may reflect heat emitted from the heating chamber of the heater casing. The metal coating may include a metal such as gold or aluminum, preferably gold. The inner wall of the heater casing may also include a thermally insulating material.

[0058] The aerosol generating device may further comprise a control element. The control element may be configured to control operation of the aerosol generating device. The control element may comprise a substrate, for example a printed circuit board. The control circuit may be mounted on the substrate. The control circuit may be configured to control operation of the aerosol generating device.

[0059] The heating element of the heater module may include electrical connections for connection to a control element. Specifically, the upstream heater casing portion may include through holes for directing the electrical connections through the upstream heater casing portion.

[0060] This may provide a simple way to direct electrical connections through the upstream heater casing to the control element, which may be located adjacent to the upstream heater casing within the aerosol generating device.

[0061] The heater casing, air flow tube, and control element may be mounted to one another to form a self-supporting component of the aerosol generating device.

[0062] The self-supporting component may simplify assembly of the aerosol generation device. The self-supporting component may support itself and its own weight without the need for an external frame to arrange the heater casing, airflow tube, and control element relative to one another. The heater casing, airflow tube, and control element may hold one another in place. The self-supporting component may form a separate unit of the aerosol generation device. The self-supporting component may form an internal component of the aerosol-forming device. The internal component of the aerosol-forming device may be located partially within the external casing of the aerosol generation device.

[0063] The self-supporting components may preferably be entirely contained within the outer casing of the aerosol generating device.

[0064] Another embodiment of the present invention provides a method for assembling an aerosol generating device. The method may include the method steps of providing a heater module and a heater module holder. The method may further include providing a downstream heater casing portion and an upstream heater casing portion for assembly of the heater casing. The heater casing may house the heater module. The method may include the step of mounting the heater module holder on the upstream heater casing portion. Positioning the heater module holder relative to the upstream heater casing portion may also position the heater module relative to the upstream heater casing portion. The method may further include the method step of connecting the downstream heater casing portion to the upstream heater casing portion with the mounted heater module to form the heater casing.

[0065] Another embodiment of the present invention provides a method for assembling an aerosol generating device. The method includes the method steps of providing a heater module and a heater module holder. The method further includes the step of providing a downstream heater casing and an upstream heater casing for assembly, where the heater casing houses the heater module. The method includes the method step of mounting the heater module on the heater module holder. The method also includes mounting the heater module holder on the upstream heater casing, where the heater module is positioned relative to the upstream heater casing by positioning the heater module holder relative to the upstream heater casing. Finally, the method includes the method step of connecting the downstream heater casing to the upstream heater casing using the mounted heater module to form the heater casing.

[0066] The heater module holder may include a protruding upstream connection section. The upstream connection section may be configured for connection to the heater casing upstream section. The heater casing upstream section may include a mounting recess. The mounting recess may be configured to receive the protruding upstream connection section of the heater module holder. The protruding upstream connection section of the heater module holder may be positioned within the mounting recess when the heater module holder is mounted on the heater casing upstream section.

[0067] This may provide an easy way to mount the heater module holder onto the upstream portion of the heater casing.

[0068] The heater module may first be mounted on the heater module holder. The heater module on the heater module holder may then be positioned in the mounting recess of the upstream heater casing. The relative positioning of the heater module holder to the upstream heater casing may then also result in the positioning of the heater module already mounted on the heater module holder relative to the upstream heater casing.

[0069] Alternatively, the heater module holder may first be positioned in the mounting recess of the heater casing upstream portion, and the relative position of the heater module holder may be locked with respect to the heater casing upstream portion, after which the heater module may then be mounted on the heater module holder connected to the heater casing upstream portion.

[0070] Preferably, the heater module is first mounted on the heater module holder, and then this arrangement is subsequently positioned in the mounting recess in the upstream part of the heater casing.

[0071] The inner surface of the mounting recess may be spaced apart from the opposite outer surface of the protruding upstream connection section. This may create a mounting gap when the protruding upstream connection section of the heater module holder is received in the mounting recess of the upstream heater casing section. During installation of the heater module holder in the upstream heater casing section, the heater module holder and the upstream heater casing section may move relative to each other within the mounting gap in the mounting recess to position the heater module holder relative to the upstream heater casing section.

[0072] The aerosol generating device may have a longitudinal axis, and the heater module holders disposed in the mounting recesses of the upstream heater casing section may move relative to each other at a right angle to the longitudinal axis of the aerosol generating device when the heater module holders are mounted on the upstream heater casing section.

[0073] A flexible sealing element may be disposed between the protruding upstream connection section and the mounting recess, and the heater module holder and the heater casing upstream portion may move relative to each other on the flexible sealing element within the mounting recess to position the heater module holder relative to the heater casing upstream portion.

[0074] Specifically, the heater module holder and the upstream heater casing portion may be rotated relative to one another on the flexible sealing element, and the heater module holder and the upstream heater casing portion may also be tilted relative to one another on the flexible sealing element with respect to the longitudinal axis of the aerosol generation device.

[0075] This may provide an additional way of moving the heater module holder relative to the upstream heater casing.

[0076] Below is provided a non-exhaustive list of non-limiting examples, any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0077] [Example] Example 1: An aerosol generating device, comprising: a heater casing having a heater casing downstream portion and a heater casing upstream portion, the heater casing housing a heater module; An aerosol generating device, in which a heater module is mounted in a heater casing on a heater module holder, and the heater module holder is connected to an upstream portion of the heater casing.

[0078] Example 2: An aerosol generating device according to Example 1, wherein the heater module holder has a protruding upstream connection section configured for connection to the upstream heater casing portion, and the upstream heater casing portion has a mounting recess configured to receive the protruding upstream connection section.

[0079] Example 3: An aerosol generating device according to the preceding embodiment, wherein an inner surface of the mounting recess is spaced from an opposite outer surface of the protruding upstream connection section to create a mounting gap.

[0080] Example 4: An aerosol generating device according to a preceding embodiment, wherein the mounting gap is configured to allow relative movement of the heater module holder relative to the upstream heater casing portion, preferably wherein the aerosol generating device has a longitudinal axis and the mounting gap is configured to allow relative movement of the heater module holder relative to the upstream heater casing portion perpendicular to the longitudinal axis of the device.

[0081] Example 5: An aerosol generating device according to the preceding Example 3 or Example 4, wherein a flexible sealing element is disposed between the protruding upstream connection section and the mounting recess, the flexible sealing element being configured to allow relative movement of the heater module holder with respect to the upstream heater casing portion, preferably the sealing element being configured to allow rotational movement of the heater module holder with respect to the upstream heater casing portion.

[0082] Example 6: An aerosol generating device according to any of the preceding embodiments, wherein the heater casing downstream portion, the heater casing upstream portion, and the heater module holder are tubular, preferably further according to any of embodiments 3 to 5, and wherein the mounting gap is a radial mounting gap.

[0083] Example 7: An aerosol generating device according to any preceding embodiment, further relying on embodiment 5, wherein the flexible sealing element comprises an O-ring.

[0084] Example 8: An aerosol generating device according to any of the preceding examples, wherein one or both of the heater casing upstream portion and the heater casing downstream portion comprise a connection configured to mount the heater casing downstream portion to the heater casing upstream portion and to lock the position of the heater module holder relative to the heater casing upstream portion.

[0085] Example 9: An aerosol generating device according to any of the previous embodiments, wherein the heater module is mounted on the heater module holder by means of protruding elements and corresponding grooves configured to receive the protruding elements.

[0086] Example 10: An aerosol generating device according to any of the previous embodiments, wherein the heater module comprises a heating element, the heating element at least partially enclosing the heating chamber.

[0087] Example 11: An aerosol generating device according to any of the preceding embodiments, wherein the upstream heater casing portion comprises an airflow tube configured to provide air to the heater module, preferably the upstream heater casing portion and the airflow tube are formed as a one-piece element, more preferably the upstream heater casing portion and the airflow tube are formed as a monolithic element.

[0088] Example 12: An aerosol generation device according to any of the previous embodiments, further comprising a control element configured to control operation of the aerosol generation device.

[0089] Example 13: An aerosol generating device according to the preceding embodiment, further dependent on embodiment 10, wherein the heating element further comprises an electrical connection for connecting to a control element, and preferably the upstream heater casing portion comprises a through hole for directing the electrical connection through the upstream heater casing portion.

[0090] Example 14: An aerosol generating device according to Examples 11 and 12, wherein the heater casing, air flow tube, and control element are mounted to one another to form a self-supporting component of the aerosol generating device.

[0091] Example 15: An aerosol generating device according to any preceding embodiment, further comprising an outer casing, the self-supporting component being at least partially contained within the outer casing.

[0092] Example 16: 1. A method of assembling an aerosol generating device, comprising: providing a heater module and a heater module holder; - providing a downstream heater casing portion and an upstream heater casing portion for assembly of a heater casing, the heater casing containing the heater module; - mounting the heater module on the heater module holder; - a step of installing a heater module holder on the upstream heater casing portion, the positioning of the heater module relative to the upstream heater casing portion being performed by positioning the heater module holder relative to the upstream heater casing portion; - connecting the downstream heater casing section to the upstream heater casing section with the installed heater module to form a heater casing.

[0093] Example 17: The method according to the preceding embodiment, wherein the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream section, and the heater casing upstream section comprises a mounting recess configured to receive the protruding upstream connection section, and wherein the protruding upstream connection section is positioned within the mounting recess when mounting the heater module holder on the heater casing upstream section.

[0094] Example 18: A method according to the preceding embodiment, wherein the inner surface of the mounting recess is spaced from the opposite outer surface of the protruding upstream connection section to create a mounting gap, and the heater module holder and the heater casing upstream portion move relative to each other within the mounting gap in the mounting recess to position the heater module holder relative to the heater casing upstream portion, preferably wherein the aerosol generating device has a longitudinal axis and the heater module holder and the heater casing upstream portion move relative to each other perpendicular to the longitudinal axis.

[0095] Example 19: The method according to any of the preceding Examples 17 or 18, wherein a flexible sealing element is disposed between the protruding upstream connection section and the mounting recess, and wherein the heater module holder and the heater casing upstream portion move relative to each other on the flexible sealing element within the mounting recess to position the heater module holder relative to the heater casing upstream portion, preferably the heater module holder and the heater casing upstream portion rotate relative to each other on the flexible sealing element.

[0096] Features described with respect to one embodiment may be equally applied to other embodiments of the invention.

[0097] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0098] In the following, elements having the same functionality are designated with the same reference numerals throughout all figures.

[0099] FIG. 1 shows a schematic exploded view of a heater assembly for an aerosol generating device 10. The heater assembly includes an upstream heater casing 12, which forms a one-piece member, preferably a monolithic element, having an upstream airflow tube 12A. Additionally, there is a heater module holder 14 onto which a heater module 16, having electrical connections 22 for connection to a control element, can be mounted. A downstream heater casing 18 can be connected to the upstream heater casing 12 to form a heater casing that encloses the heater module. A connecting element 20, e.g., a screw, can connect the downstream heater casing 18 to the upstream heater casing 12. When the downstream heater casing 18 is connected to the upstream heater casing 12 via the connecting element, the heater module 16 mounted on the heater module holder 14 is also securely locked within the heater casing. The heater module holder 14 serves as a mounting element for the heater module 16 and allows for reliable alignment between the upstream heater casing 12 and the heater module 16 despite larger manufacturing tolerances for both elements.

[0100] FIG. 2 illustrates a schematic cross-sectional view of the heater module holder 14 and the heater module 16 relative to the top of the heater casing upstream section 12. The heater module holder 14 includes a protruding upstream connection section 14A. This protruding upstream connection section 14A can be received within a mounting recess 12B of the heater casing upstream section 12, as represented by the dashed line. Relative movement of the protruding upstream connection section 14A within the mounting recess 12B of the heater casing upstream section 12 allows for more reliable alignment of the heater module holder 14, and therefore the heater module 16, relative to the heater casing upstream section. The heater module holder 14 includes a heater module holder recess 14B, as represented by the dashed line, configured to receive the heater module protruding connection element 16A of the heater module 16. The heater module holder 14 allows for reliable alignment of the heater module 16 relative to the heater casing upstream section 12 along the longitudinal axis 11 of the aerosol generation device.

[0101] FIG. 3 illustrates in more detail the interaction between the heater module holder 14 and the upper portion of the upstream heater casing section 12. The inner surface 12C of the mounting recess of the upstream heater casing section 12 is spaced apart from the outer surface 14B of the protruding upstream connection section 14A. This can be achieved when the width of the protruding upstream connection section 14A is smaller than the width of the mounting recess 12B. This creates a mounting gap 13. This mounting gap 13 allows for relative movement of the upstream heater casing section 12 with respect to the heater module holder 14. Specifically, the mounting gap 13 allows for relative movement of the upstream heater casing section 12 with respect to the heater module holder 14 perpendicular to the longitudinal axis 11 of the aerosol generation device. In addition, a flexible sealing element 24, e.g., an O-ring, is present. This flexible sealing element 24 also allows for rotational movement of the heater module holder 14 with respect to the upstream heater casing section 12. The flexible sealing element 24 may also allow tilting of the heater module holder 14 relative to the heater casing upstream portion 12 about the longitudinal axis 11 of the aerosol generating device.

[0102] 4 illustrates in more detail the mounting of the heater module 16 onto the heater module holder 14, as indicated by the arrow. Additionally, the heater module holder 14 may be mounted within a recess in the heater casing upstream section 12, as indicated by the arrow.

[0103] FIG. 5 illustrates an aerosol generating device 10 having an outer casing 32. The aerosol generating device includes a self-supporting internal element made of an upstream heater casing portion 12 and a downstream heater casing portion 18 mounted to a control element 26. The airflow tube is formed as a monolithic member with the upstream heater casing portion. The airflow tube is mounted to the control element to form a self-supporting component of the aerosol generating device. The self-supporting element, including the downstream heater casing portion, the upstream heater casing portion, the airflow tube, and the control element, also includes a heater module 16 mounted on a heater module holder 14 housed within the heater casing. The control element 26 preferably includes a substrate such as a printed circuit board that also includes control circuitry 30 for controlling the operation of the aerosol generating device. There are connecting elements 22, such as screws, that connect the downstream heater casing portion 18 to the upstream heater casing portion 12 and further lock the heater module holder 14 in a fixed position within the heater casing. An electrical connection 22 is directed towards the control element through a through hole in the heater casing upstream portion 12 to provide electrical connection to the control element. Additionally, a power source 28, such as a battery, is located inside the outer casing 32 to provide energy to operate the aerosol generating device.

Claims

1. An aerosol generating device, comprising: a heater casing having a heater casing downstream portion and a heater casing upstream portion, the heater casing housing a heater module; the heater module is mounted in the heater casing on a heater module holder, the heater module holder is connected to the heater casing upstream section, the heater module holder has a protruding upstream connection section configured to be connected to the heater casing upstream section, and the heater casing upstream section has a mounting recess configured to receive the protruding upstream connection section; An aerosol generating device, wherein an inner surface of the mounting recess is spaced from an opposite outer surface of the protruding upstream connection section to create a mounting gap.

2. 2. The aerosol generating device of claim 1, wherein the mounting gap is configured to allow relative movement of the heater module holder with respect to the upstream portion of the heater casing, preferably wherein the aerosol generating device has a longitudinal axis and the mounting gap is configured to allow relative movement of the heater module holder with respect to the upstream portion of the heater casing perpendicular to the longitudinal axis of the device.

3. 3. The aerosol generating device of claim 1, wherein a flexible sealing element is arranged between the protruding upstream connection section and the mounting recess, the flexible sealing element being configured to allow relative movement of the heater module holder with respect to the upstream heater casing portion, preferably the sealing element being configured to allow rotational movement of the heater module holder with respect to the upstream heater casing portion.

4. An aerosol generating device as described in any one of claims 1 to 3, wherein the heater casing downstream part, the heater casing upstream part, and the heater module holder are tubular, and preferably the mounting gap is a radial mounting gap.

5. 5. An aerosol generating device according to claim 4 when dependent on claim 3, wherein the flexible sealing element comprises an O-ring.

6. An aerosol generating device as described in any one of claims 1 to 5, wherein one or both of the heater casing upstream section and the heater casing downstream section have connections configured to mount the heater casing downstream section to the heater casing upstream section and to lock the position of the heater module holder relative to the heater casing upstream section.

7. 7. The aerosol generating device of claim 6, wherein the heater module comprises a heating element, and the heating element further comprises an electrical connection for connecting to the control element, and preferably the upstream heater casing portion comprises a through hole for directing the electrical connection through the upstream heater casing portion.

8. An aerosol generating device as described in any one of claims 1 to 7, wherein the heater casing upstream portion comprises an air flow tube configured to provide air to the heater module, and the aerosol generating device further comprises a control element configured to control the operation of the aerosol generating device, and the heater casing, the air flow tube and the control element are attached to each other to form a self-supporting component of the aerosol generating device.

9. 9. The aerosol generating device of claim 8, further comprising an outer casing, the self-supporting component being at least partially contained within the outer casing.

10. 1. A method of assembling an aerosol generating device, comprising: - providing a heater module and a heater module holder; - providing a downstream heater casing and an upstream heater casing for assembly, said heater casing housing said heater module; - mounting the heater module on the heater module holder; - installing the heater module holder on the heater casing upstream part, the heater module being positioned relative to the heater casing upstream part by positioning the heater module holder relative to the heater casing upstream part; - connecting the downstream heater casing section to the upstream heater casing section with the installed heater module to form the heater casing; the heater module holder comprises a protruding upstream connection section configured for connection to the heater casing upstream part, and the heater casing upstream part comprises a mounting recess configured to receive the protruding upstream connection section, and the protruding upstream connection section is positioned in the mounting recess when the heater module holder is mounted on the heater casing upstream part; - an inner surface of the mounting recess is spaced from an opposite outer surface of the protruding upstream connection section to create a mounting gap, and the heater module holder and the heater casing upstream part move relative to each other within the mounting gap in the mounting recess to position the heater module holder relative to the heater casing upstream part.

11. 11. The method of claim 10, wherein the aerosol generating device has a longitudinal axis, and the heater module holder and the heater casing upstream section move relative to each other at a right angle to the longitudinal axis.

12. 12. The method according to claim 10 or 11, wherein a flexible sealing element is disposed between the protruding upstream connection section and the mounting recess, and the heater module holder and the heater casing upstream portion move relative to each other on the flexible sealing element within the mounting recess to position the heater module holder relative to the heater casing upstream portion, preferably the heater module holder and the heater casing upstream portion rotate relative to each other on the flexible sealing element.

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