Methods for manufacturing components of an aerosol delivery device

Abstract

A method of manufacturing a component of an aerosol delivery device is disclosed, the method including providing a non-planar substrate (220) and laser activating at least a portion of the substrate (220) to form one or more laser activated regions.

Description

[Technical Field]

[0001] The present invention relates to methods of manufacturing aerosol delivery devices, components of aerosol delivery devices, aerosol generators, aerosol delivery devices, aerosol delivery systems, and methods of generating aerosols. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these items by creating products that release compounds without combustion. Examples of such products are so-called "heat-not-burn" products, or tobacco heating devices or products, which release compounds by heating materials without burning them. The materials may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] Aerosol delivery systems are known, including those covering the above-mentioned devices and products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user.

[0004] It is known to use an induction heater in the form of a spiral inductor coil to heat a medium.

[0005] Conventional aerosol delivery devices include a cylindrical heating chamber surrounded by a helical inductor coil into which a rod-shaped consumable is inserted, the size of the device being largely determined by the diameter of the helical inductor coil.

[0006] It would be desirable to provide an improved induction heating assembly for an aerosol delivery device. Summary of the Invention

[0007] According to one aspect, providing a non-planar support; laser activating at least a portion of the substrate to form one or more laser activated regions; A method of manufacturing a component of an aerosol delivery device is provided, comprising:

[0008] According to various embodiments, the inductor coil is formed by directing a laser onto a surface of a substrate to form a laser-activated region. The substrate may be formed from a thermoplastic material such as polyetheretherketone (PEEK) doped with a metallic inorganic compound. The laser creates the laser-activated region on the substrate, which can then optionally be (further) metallized, for example, using an electroless plating process, to build up one or more conductive layers, for example, of copper.

[0009] According to various embodiments, a laser is positioned to form a conductor track structure on a non-conductive support. The conductor track structure can be formed from metal nuclei generated by decomposing very finely distributed non-conductive metal compounds contained in the support. The non-conductive metal compounds contained in the support material can be decomposed or otherwise activated by irradiating a portion of the support material with electromagnetic radiation. After the laser strikes the support, the surface of the support is microscopically roughened and the laser direct structuring additives present in the support are activated. As a result of the surface condition, an electroless metallization process can be performed, and a metal layer is plated on the base layer or support.

[0010] The non-conductive metal compound may comprise a thermally stable inorganic oxide selected from the group consisting of higher oxides that are stable and insoluble in aqueous, acidic or alkaline metallization baths, contain at least two different cations, have a spinel or spinel-related structure, and remain unchanged in the unirradiated areas of the support material.

[0011] Standard spinels are mixed metal oxides of magnesium and aluminum, but the magnesium may be replaced in whole or in part by iron, zinc, and / or manganese, and the aluminum may be replaced by iron and / or chromium. Spinel-related mixed oxide structures may also contain nickel and / or cobalt cations.

[0012] The one or more laser activated regions may comprise one or more conductive traces or tracks. According to various embodiments, the one or more conductive traces or tracks may include one or more copper traces or tracks, which may be formed on a support, which may comprise an insulator.

[0013] According to various embodiments, a method of manufacturing a component of an aerosol delivery device is disclosed in which a laser beam from a laser is directed onto a substrate made of, for example, a thermoplastic material doped with a non-conductive metallic inorganic compound. The substrate may be non-planar, i.e., curved, or may comprise a three-dimensional support as opposed to a flat, two-dimensional support.

[0014] A laser may be positioned to impinge on a surface of the substrate and to form one or more laser-activated regions on at least a portion of the substrate. According to various embodiments, the one or more laser-activated regions comprise one or more conductive traces or tracks. The one or more conductive traces or tracks may form one or more electrodes on the surface of the substrate.

[0015] Once formed on the support, the one or more laser-activated regions essentially form catalyst or adhesion sites, onto which one or more (further) conductive layers (e.g., of copper) may optionally be deposited to form electrodes on the surface of the support. The process employed is sometimes referred to as a laser direct structuring ("LDS") process. In particular, the formed electrodes may be arranged to form a spiral or helical inductive coil.

[0016] According to various embodiments, one or more laser-activated regions on a substrate may include a spiral or helical coil electrode configuration. Embodiments are contemplated in which the thickness of the electrode configuration may be increased by depositing one or more conductive layers on the one or more laser-activated regions.

[0017] According to various embodiments, one or more laser-activated regions formed on the surface of the support may be essentially flush with the surface of the support (or may form at least a microscopically roughened surface), although it will be understood that if one or more conductive layers are deposited on the laser-activated regions, the conductive layers may protrude from the remainder of the surface of the support.

[0018] Embodiments are also contemplated in which the support includes a groove and one or more laser-activated regions are formed within the groove. One or more conductive layers may then be deposited over the laser-activated regions within the groove. For example, the one or more conductive layers deposited within the groove may be positioned such that, upon completion of the deposition process, the one or more conductive layers are flush with the remainder of the surface of the support.

[0019] Optionally, one or more laser-activated layers may have a thickness of (i) <1 μm, (ii) 1-2 μm, (iii) 2-3 μm, (iv) 3-4 μm, (v) 4-5 μm, (vi) 5-6 μm, (vii) 6-7 μm, (viii) 7-8 μm, (ix) 8-9 μm, or (x) 9-10 μm. According to other embodiments, one or more laser-activated layers may have a thickness of (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, or (x) 90-100 μm.

[0020] According to another embodiment, there is provided a method of manufacturing a component of an aerosol delivery device, comprising providing a support and laser activating at least a portion of the support to form one or more laser-activated regions, wherein the laser-activated regions comprise a metal core.

[0021] Optionally, the method further comprises depositing one or more conductive layers on top of one or more laser activation regions.

[0022] According to various embodiments, the ability to form a conductive layer on a support using a laser direct structuring (“LDS”) process enables the components of an aerosol delivery device to be manufactured with a high degree of customization. For example, the thickness and / or width of an electrode can be readily varied so as to be able to form a novel electrode structure on the support.

[0023] According to one embodiment, a relatively thin electrode can first be formed on the support by an initial laser activation process. According to other embodiments, one or more conductive layers may then optionally be further deposited on top of the initial electrode formed within the support such that a thicker electrode structure can be formed. One or more conductive layers that can be deposited on the laser activation region may be arranged to have the same or a different template as the template of the laser activation region. For example, a novel electrode structure may be formed that comprises a laser activation region having a base layer of an electrode with a thickness d1 and a width w1, and a first conductive layer deposited on top of the base layer. The first conductive layer may have a thickness d2, for example d2 > d1. Also, the first conductive layer may have a width w2, for example, w2 < w1. As a result, the first conductive layer may include an electrode layer that is thicker (deeper) but narrower than the underlying base layer. Optionally, a second conductive layer having a thickness d3 and a width w3 may be deposited on top of the first conductive layer. According to one embodiment, d3 > d2 or alternatively d3 < d2. According to one embodiment, w3 < w2. Thus, an embodiment is envisioned in which the second conductive layer is provided on top of the first conductive layer. The second conductive layer may be thicker (deeper) or shallower than the first conductive layer. The second conductive layer may be narrower in the width direction than both the first conductive layer and the base layer.

[0024] According to embodiments, a spiral inductor coil may be formed on a support, and the thickness of the formed inductor coil may be configured to vary at different locations along the axial length of the inductor coil. Embodiments are also contemplated in which the pitch of the formed inductor coil and / or the number of turns of the inductor coil per unit length may be configured to vary at different locations.

[0025] Forming one or more conductive layers directly on the surface of the support also allows for the formation of components that exhibit improved cooling efficiency while potentially allowing for a more compact design of the inductor coil. It will be understood that conventional inductor coils may include coils made from Litz wire, where the wire has a fixed diameter. Thus, the disclosed method, which can utilize depositing a conductive layer on the laser-activated region of the support, increases design flexibility and freedom.

[0026] Optionally, one or more of the conductive layers comprises a metal or a metal alloy.

[0027] Optionally, the one or more conductive layers comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0028] Optionally, one or more conductive layers have a thickness of (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, or (x) 90-100 μm.

[0029] Optionally, one or more of the conductive layers have a rectangular, oblong, or polygonal cross-sectional profile.

[0030] Optionally, the support comprises a tubular or hollow structure.

[0031] Optionally, the support comprises an electrical insulator.

[0032] Optionally, the support comprises a thermoplastic material.

[0033] Optionally, the thermoplastic material includes polyetheretherketone (PEEK).

[0034] Optionally, the support is doped with a non-conductive metallic inorganic compound.

[0035] Optionally, one or more of the laser activated regions comprises a metal nucleus.

[0036] Optionally, laser activating at least a portion of the support to form one or more laser activated regions includes laser activating at least a portion of a first surface and / or at least a portion of a second, different surface of the support.

[0037] Optionally, depositing one or more conductive layers on the one or more laser activated regions includes depositing one or more conductive layers on at least a portion of a first surface and / or on at least a portion of a second, different surface of the support.

[0038] Optionally, the first surface comprises an outer surface of a support.

[0039] Optionally, the second surface comprises an interior surface of a support.

[0040] Optionally, the method further comprises providing an insulator layer or portion on or adjacent to the one or more conductive layers.

[0041] Optionally, the one or more laser activated regions and / or the one or more conductive layers may be arranged to form one or more helical coils.

[0042] Optionally, the one or more helical coils have a substantially constant pitch, a substantially constant number of turns per unit length, or the height of a single completed helical turn is substantially constant along at least 90% of the axial length of the one or more helical coils.

[0043] Optionally, the one or more helical coils comprise: a first helical section having a first pitch P1 or P1 turns per unit length, or a height of one completed helical turn P1; a second different helical section having a second pitch P2 or P2 turns per unit length or a height of one completed helical turn P2; Here, P1≠P2.

[0044] Optionally, the one or more helical coils have a substantially constant width and / or a substantially constant length and / or a substantially constant thickness along at least 90% of the axial length of the one or more helical coils.

[0045] Optionally, the one or more helical coils comprise: a first spiral section having a width W1 and / or a length L1 and / or a thickness T1; a second different spiral section having a width W2 and / or a length L2 and / or a thickness T2; Here, W1≠W2 and / or L1≠L2 and / or T1≠T2.

[0046] Optionally, depositing one or more conductive layers on the one or more laser activated regions includes using an electroless plating process, an electroless plating process, a galvanic plating process, or an autocatalytic plating process.

[0047] Optionally, the electroless, electroless, galvanic, or autocatalytic plating process comprises: This involves contacting one or more laser-activated regions with a liquid solution to cause a chemical or catalytic reaction that deposits metal particles present in the liquid solution onto the one or more laser-activated regions to form one or more conductive layers.

[0048] According to another aspect, a non-planar support having one or more laser activated regions is provided. Components of an aerosol delivery device are provided.

[0049] Optionally, the component further comprises one or more conductive layers deposited on the one or more laser activated regions.

[0050] Optionally, the support comprises a tubular or hollow structure.

[0051] Optionally, the support comprises an electrical insulator.

[0052] Optionally, the support comprises a thermoplastic material.

[0053] Optionally, the thermoplastic material includes polyetheretherketone (PEEK).

[0054] Optionally, the support is doped with a non-conductive metallic inorganic compound.

[0055] Optionally, one or more of the laser activated regions comprises a metal nucleus.

[0056] Optionally, the one or more laser activated regions are located on at least a portion of a first surface of the substrate and / or on at least a portion of a second, different surface of the substrate.

[0057] Optionally, the one or more conductive layers deposited on the one or more laser activated regions are located on at least a portion of a first surface of the support and / or on at least a portion of a second, different surface of the support.

[0058] Optionally, the first surface comprises an outer surface of a support.

[0059] Optionally, the second surface comprises an interior surface of a support.

[0060] Optionally, the component further comprises an insulator layer or insulator portion on or adjacent to the one or more laser activated regions and / or the one or more conductive layers.

[0061] Optionally, the one or more laser activated regions and / or the one or more conductive layers are arranged to form one or more helical coils.

[0062] Optionally, the one or more helical coils have a substantially constant pitch, a substantially constant number of turns per unit length, or the height of a single completed helical turn is substantially constant along at least 90% of the axial length of the one or more helical coils.

[0063] Optionally, the one or more helical coils comprise: a first helical section having a first pitch P1 or P1 turns per unit length, or a height of one completed helical turn P1; a second different helical section having a second pitch P2 or P2 turns per unit length or a height of one completed helical turn P2; Here, P1≠P2.

[0064] Optionally, the one or more helical coils have a substantially constant width and / or a substantially constant length and / or a substantially constant thickness along at least 90% of the axial length of the one or more helical coils.

[0065] Optionally, the one or more helical coils comprise: a first spiral section having a width W1 and / or a length L1 and / or a thickness T1; a second different spiral section having a width W2 and / or a length L2 and / or a thickness T2; Here, W1≠W2 and / or L1≠L2 and / or T1≠T2.

[0066] Optionally, one or more of the conductive layers comprises a metal or a metal alloy.

[0067] Optionally, the one or more conductive layers comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0068] Optionally, one or more conductive layers have a thickness of (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, or (x) 90-100 μm.

[0069] Optionally, one or more of the conductive layers have a rectangular, oblong, or polygonal cross-sectional profile.

[0070] According to another aspect, the aerosol delivery device comprises the components of the aerosol delivery device described above. An aerosol generator is provided.

[0071] Optionally, the aerosol generator comprises one or more inductive heating elements.

[0072] According to another aspect, the aerosol generator described above An aerosol delivery device is provided, comprising:

[0073] According to another aspect, the aerosol delivery device described above; an aerosol production article for generating an aerosol; An aerosol delivery system is provided, comprising:

[0074] According to another aspect, providing an aerosol delivery device as described above; at least partially inserting an aerosol production article into an aerosol delivery device for generating an aerosol; A method for generating an aerosol is provided, comprising:

[0075] The method may further include activating the aerosol delivery device.

[0076] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0077] [Figure 1A] FIG. 1 is a schematic diagram of a known heating assembly for an aerosol delivery device comprising a single inductor coil formed from wire wrapped around a tubular support, showing the aerosol product article partially inserted within the tubular support. [Figure 1B] 1B illustrates a cross-sectional view of the heating assembly shown in FIG. 1A, showing a tubular susceptor positioned within a tubular support and an aerosol production article partially inserted within the tubular susceptor. [Figure 2] 1 illustrates an induction heating assembly for an aerosol delivery device according to one embodiment in which a helical inductor coil is formed on a tubular support by a laser direct structuring ("LDS") process. [Figure 3] 3 illustrates a cross-sectional view of the induction heating assembly shown in FIG. 2, showing a tubular susceptor positioned within a support. [Figure 4] 1 is a flowchart illustrating various aspects of a laser direct structuring ("LDS") process that may be utilized to form one or more conductive layers on a substrate, according to various embodiments. [Figure 5A] 1 is a schematic diagram of an inductor coil formed on a support according to one embodiment, in which one or more conductive layers forming the inductor coil have a first width and the inductor coil has a first pitch. [Figure 5B]FIG. 10 is a schematic diagram of an inductor coil formed on a support according to another embodiment in which one or more conductive layers have a second, smaller width and the inductor coil has a second, smaller pitch. DETAILED DESCRIPTION OF THE INVENTION

[0078] Aspects and features of particular examples and embodiments are discussed or described herein. Some aspects and features of particular examples and embodiments may be conventionally implemented and, for the sake of brevity, will not be discussed or described in detail. Thus, it will be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented in accordance with conventional techniques for implementing such aspects and features.

[0079] 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.

[0080] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system. In some embodiments, the non-combustion aerosol delivery system is a vaping device or an electronic cigarette, also known as an electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0081] 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.

[0082] 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 can be heated. Each of the aerosol-generating materials can be, for example, in solid, liquid, or gel form and can contain nicotine or not. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material can include, for example, tobacco or a non-tobacco product.

[0083] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0084] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that comprise aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices.

[0085] 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, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0086] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0087] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0088] An aerosol-forming material is, for example, a material that can generate an aerosol when heated, irradiated, or energized in any other way. The aerosol-forming material may be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain an active agent and / or flavoring.

[0089] 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, may also be 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 particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0090] The aerosol-generating materials may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0091] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to provide thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to provide one or more of vibration, pressure increase, or electrostatic energy to the aerosol-generating material.

[0092] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which is intended to be consumed upon use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that generates heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0093] The non-combustion aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some implementations, the non-combustion aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may comprise a power source, such as, for example, a battery or a rechargeable battery. In some implementations, the non-combustion aerosol delivery device may also comprise an aerosol generating component. However, in other implementations, the aerosol product article may comprise, in part or entirely, the aerosol generating component.

[0094] For completeness, aerosol delivery devices comprising inductive elements are known. The aerosol delivery device may comprise one or more inductors and a susceptor configured to be heated by the one or more inductors.

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

[0096] FIG. 1A illustrates a conventional induction heating assembly 100 for an aerosol delivery device, and FIG. 1B illustrates a cross-section of the induction heating assembly 100 for the aerosol delivery device shown in FIG. 1A. The heating assembly 100 includes a tubular support having a helical inductor coil 112 formed thereon from wire. The heating assembly 100 has a first, or proximal or mouth end 102 and a second, or distal end 104. An aerosol product 130 is shown inserted within the tubular support. As shown in FIG. 1B, a tubular susceptor 140 is positioned within the tubular support, and the aerosol product 130 is shown partially positioned within the tubular susceptor 140.

[0097] In use, an AC current is passed through the helical inductor coil 112, resulting in a varying magnetic field that generates eddy currents within the susceptor 140, thereby rapidly heating the susceptor 140. As a result, an aerosol production article 130 inserted at least partially within the susceptor 140 is rapidly heated and an aerosol is generated.

[0098] In use, a user inhales the aerosol formed within the aerosol delivery device through mouth end 102 of the aerosol delivery device, which may be open-ended. Heating assembly 100 may be considered to comprise an induction heating unit that includes inductor coil 112 and susceptor 140.

[0099] 1A and 1B also show the aerosol product article 130 partially received within a susceptor 140. The susceptor 140 may be formed from any material suitable for heating by induction. For example, the susceptor 140 may include a metal. In some embodiments, the susceptor 140 may include a non-ferrous metal such as copper, nickel, titanium, aluminum, tin, or zinc, and / or an iron-based material such as iron, nickel, or cobalt. Additionally or alternatively, the susceptor 140 may include a semiconductor such as silicon carbide, carbon, or graphite.

[0100] The susceptor 140 surrounds the aerosol product article 130 and defines a receptacle for externally heating the aerosol product article 130 .

[0101] The inductor coil 112 is made from Litz wire that is helically wound to provide the helical inductor coil 112. Litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. The inductor coil 112 is made from copper Litz wire with a circular cross section.

[0102] The inductor coil 112 is configured to generate a varying magnetic field for heating the inductive element 114. Together, the inductor coil 112 and the susceptor 140 form an induction heating unit.

[0103] The susceptor 140 is hollow and defines a receptacle in which the aerosol-generating material is received. For example, the aerosol-producing article 130 can be inserted into the susceptor 140. The susceptor 140 is tubular with a circular cross-section.

[0104] The susceptor 140 is positioned to surround the aerosol product article 130 and heat the aerosol product article 130 externally. The aerosol delivery device is configured such that when the aerosol product article 130 is received within the susceptor 140, the outer surface of the aerosol product article 130 abuts the inner surface of the susceptor 140. This ensures that heating occurs most efficiently. The aerosol product article 130 includes an aerosol-generating material. The aerosol-generating material is positioned within the susceptor 140. The aerosol product article 130 may also include other components, such as a filter, packaging material, and / or cooling structure.

[0105] It will be appreciated that litz wire is limited to only one diameter, i.e., the diameter of the litz wire cannot be easily varied over its length. The diameter, number of turns, and thickness of the litz wire are selected based on the desired target operating temperature for heating the aerosol product. These limitations dictate the overall size of the aerosol generating device, as it must be large enough to accommodate the litz wire.

[0106] In addition, the diameter of the litz wire also determines the sheath temperature of the aerosol generation device, which may be defined as the temperature of the exterior surface of the aerosol delivery device, e.g., the surface that a user will come into contact with when using the aerosol delivery device.

[0107] During use, when the aerosol product heats up, it is desirable to cool the sheath temperature as quickly as possible to prevent the sheath from actually heating up. To facilitate this when using conventional Litz wire as the inductor coil, a sufficiently large air gap is required. It will be appreciated that the presence of the air gap therefore further increases the size of the aerosol delivery device.

[0108] 2 shows an inductive heating assembly 200 for an aerosol delivery device according to one embodiment. The heating assembly 200 comprises a support 220 having a spiral layer of metal formed thereon to form an inductor coil 212.

[0109] The inductor coil 212 is formed by directing a laser (not shown) onto the surface of the substrate 220 to create a laser-activated region. The substrate 220 may be formed from a thermoplastic material such as polyetheretherketone (PEEK) doped with a metallic inorganic compound. The laser creates the laser-activated region on the substrate 220, which may then be (further) metallized, for example, using an electroless plating process, to build up one or more conductive layers, for example, of copper.

[0110] According to various embodiments, the laser is arranged to form a conductor track structure on the non-conductive support 220. The conductor track structure may be formed from metal nuclei generated by decomposing very finely distributed non-conductive metal compounds contained in the support 220. The non-conductive metal compounds contained in the support material may be decomposed or otherwise activated by irradiating a portion of the support material with electromagnetic radiation.

[0111] The non-conductive metal compound may comprise a thermally stable inorganic oxide selected from the group consisting of higher oxides that are stable and insoluble in aqueous, acidic or alkaline metallization baths, contain at least two different cations, have a spinel or spinel-related structure, and remain unchanged in the unirradiated areas of the support material.

[0112] Standard spinels are mixed metal oxides of magnesium and aluminum, but the magnesium may be replaced in whole or in part by iron, zinc, and / or manganese, and the aluminum may be replaced by iron and / or chromium. Spinel-related mixed oxide structures may also contain nickel and / or cobalt cations.

[0113] Figure 3 shows a cross-sectional view of the induction heating assembly 200 of Figure 2. The heating assembly 200 further includes a susceptor 240 within which an aerosol product article (not shown) can be received. The susceptor 240 operates in the same manner as the susceptor 140 described above with reference to Figures 1A and 1B.

[0114] The susceptor 240 may be formed from any material suitable for inductive heating. For example, the susceptor 240 may include a metal. In some examples, the susceptor 240 may include a non-ferrous metal such as copper, nickel, titanium, aluminum, tin, or zinc, and / or an iron-based material such as iron, nickel, or cobalt. Additionally or alternatively, the susceptor 240 may include a semiconductor such as silicon carbide, carbon, or graphite.

[0115] The susceptor 240 may have any suitable shape. In the embodiment shown in Figure 3, the susceptor 240 surrounds the aerosol product article (not shown) and defines a receptacle for externally heating the aerosol product article. In other embodiments (not shown), one or more susceptors may be substantially elongated and positioned to penetrate the aerosol product article and heat the aerosol product article internally.

[0116] The inductor coil 212 is configured to generate a varying magnetic field for heating the susceptor 240 and operates in substantially the same manner as the inductor coil 112 described above with reference to Figures 1A and 1B. The varying magnetic field generates eddy currents in the susceptor 240, which rapidly heats the susceptor 240 to its maximum operating temperature within a short period of time, e.g., 20, 15, 12, 10, 5, or 2 seconds, after supplying alternating current to the inductor coil 212. The susceptor 240 may comprise a single susceptor. Alternatively, multiple susceptors 240 may be provided.

[0117] The ends (not shown) of the inductor coil 212 may be connected to a controller, such as a PCB (not shown), which may comprise a proportional-integral-derivative ("PID") controller.

[0118] According to various embodiments, the susceptor 240 may be hollow and may form or define a receptacle within which the aerosol-generating material may be received. For example, an aerosol product article (not shown) may be inserted into the susceptor 240. In this example, the susceptor 240 is tubular with a circular cross section. The susceptor 240 is positioned to surround the aerosol product article and to externally heat the aerosol product article.

[0119] According to various embodiments, the inductor coil 212 may be formed on the support 220 using a process known as laser direct structuring ("LDS"), which is described in more detail below with reference to FIG.

[0120] According to various embodiments, a laser is used to activate the surface of a substrate 220, which comprises a thermoplastic material such as polyetheretherketone (PEEK), which may be doped with a metallic inorganic compound. The laser creates one or more laser-activated regions on the substrate 220, which can then be (further) metallized, for example, using an electroless plating process, to build up one or more conductive layers, for example, of copper.

[0121] 2 and 3, the inductor coil 212 is deposited on the support 220 to form a uniform spiral inductor coil 212. However, other embodiments are contemplated in which the inductor coil 212 may be formed on the support 220 to have different configurations.

[0122] 2 and 3 may be formed by depositing one or more conductive layers over the laser-activated regions of support 220, although it should be understood that depositing one or more conductive layers over the laser-activated regions is not required. For example, embodiments are contemplated in which the laser-activated regions form conductive traces or tracks that form the electrode structure of inductor coil 212.

[0123] It is also contemplated that a variety of novel electrode configurations may be created. For example, the coil 212 may be arranged to have different or varying thicknesses along the length of the coil 212. For example, it is contemplated that the thickness of the coil 212 may not be constant. It is known that the magnetic field strength of a coil is given by:

[0124]

number

[0125] It is known that the resistance R of a wire (electrode) is inversely proportional to the cross-sectional area of ​​the wire (electrode).

[0126]

number

[0127] It will therefore be appreciated that the resistance of a wire (electrode) will decrease as the cross-sectional area A of the wire (electrode) increases. As a result, for a given voltage, a larger current can flow through a wire (electrode) having a relatively larger cross-sectional area compared to a wire (electrode) having a relatively smaller cross-sectional area.

[0128] From equation 1 above, it follows that for wires (electrodes) with a relatively large cross-sectional area, the magnetic field strength will increase.

[0129] Thus, by providing a coil or electrode structure 212 in which the thickness of the coil or electrode varies at different locations along the length of the coil or electrode 212, it is possible to vary the magnetic field strength along the length of the coil or electrode 212. For example, according to one embodiment, the coil or electrode 212 may include a first section having a first cross-sectional area and a second section having a second, different cross-sectional area. As a result, the resulting magnetic field strength resulting from an alternating current flowing through the two sections may also be different. As a result, a first current may be induced in a first corresponding portion of the susceptor, and a second, different current may be induced in a second, different portion of the susceptor (or in separate susceptors). This allows the resulting heating effect to be different in the two different sections of the susceptor.

[0130] According to various embodiments, providing a coil or electrode 212 having a portion with an increased thickness or cross-sectional area allows for the generation of a magnetic field of a larger magnitude than a coil or electrode 212 having a smaller thickness or cross-sectional area. As a result, a coil or electrode 212 may be provided that provides different heating characteristics at different axial locations along the axial length of the aerosol delivery device. For example, an area of ​​increased thickness will heat an adjacent area of ​​the susceptor 240 to a higher temperature than an area of ​​reduced thickness.

[0131] According to various embodiments, the coil or electrode 212 may have a uniform thickness and / or width or a variable thickness and / or width along the length of the coil or electrode 212. According to various embodiments, the coil or electrode 212 may have a rectangular cross-sectional profile with a width parallel to the surface of the support 220 and a depth or thickness perpendicular to the surface of the support 220. The coil or electrode 212 may have a width (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, (x) 90-100 μm, or (xi) >100 μm. The coil or electrode 212 may have a depth or thickness of (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, (x) 90-100 μm, or (xi) >100 μm.

[0132] According to various embodiments, when the coil or electrode 212 comprises only the laser-activated region of the support 220, the coil or electrode 212 may have a relatively thin thickness (e.g., <1 μm). The thickness of the coil or electrode 212 may be increased by depositing one or more conductive layers on the laser-activated region. The one or more conductive layers deposited on the laser-activated region may have a thickness >10 μm.

[0133] According to various embodiments, the coil or electrode 212 has a thickness of (i) <100 μm 2 (ii) 100 to 200 μm 2 (iii) 200 to 300 μm 2 (iv) 300 to 400 μm 2 (v) 400-500 μm 2 (vi) 500 to 600 μm 2 (vii) 600 to 700 μm 2 (viii) 700 to 800 μm 2, (ix) 800 to 900 μm 2 , (x) 900~1000μm 2 , or (xi) >1000 μm 2 The cross-sectional area may be selected from the group consisting of:

[0134] According to various embodiments, the coil or electrode 212 may have a constant number of turns per unit length, or the number of turns per unit length may vary in different sections of the coil or electrode 212. For example, with reference to FIG. 2 , the coil has an overall length L, and the coil may be considered to comprise two sections. In the example shown in FIG. 2 , the coil 212 comprises two equal sections L1 and L2, i.e., length L1 is the same as length L2, and the number of turns per unit length in section L1 is the same as the number of turns per unit length in section L2. However, embodiments are contemplated in which the number of turns per unit length in section L1 may be greater than the number of turns per unit length in section L2, or vice versa. Embodiments are contemplated in which the coil 212 may include multiple sections, at least some of which may have different or the same number of turns per unit length.

[0135] Varying the number of turns can increase or decrease the rate at which the susceptor 240 can reach its maximum operating temperature. Such a configuration can provide asymmetric heating of the aerosol product article along the length of the aerosol product article, if desired.

[0136] In an example, the pitch of coil 212 may not remain constant. Varying the pitch of coil 212 can change the heating characteristics of the aerosol delivery device at different locations on coil 212. For example, an area with reduced pitch would mean an increased number of turns per unit length, thereby heating the area adjacent to susceptor 240 to a higher temperature than an area adjacent to a section of coil 212 with fewer turns per unit length.

[0137] As will be appreciated, the number of turns in the coil is inversely proportional to the pitch of the coil. Thus, a change in the pitch of the coil 212 will in turn result in a change in the number of turns in the coil 212, which can increase or decrease the rate at which the susceptor 240 can reach its maximum operating temperature. Such a configuration can provide asymmetric heating of the aerosol product article along the length of the aerosol product article, if desired.

[0138] According to various embodiments, the coil 212 may have a substantially constant pitch per unit length and therefore a substantially constant number of turns per unit length. The height of a single completed helical turn in the coil 212 may be substantially constant along at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the axial length of the coil 212.

[0139] In an example, the coil 212 may have a helical section having a first pitch P1 or P1 turns per unit length, i.e., the height of one completed helical turn is P1, and a second, different helical section having a second pitch P2 or P2 turns per unit length, i.e., the height of one completed helical turn is P2, such that P1≠P2.

[0140] In examples, the coils 212 can have a substantially constant width and / or a substantially constant length and / or a substantially constant thickness along at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the axial length of each coil.

[0141] In an example, coil 212 may have a first spiral section having a width W1 and / or length L1 and / or thickness T1, and a second, different spiral section having a width W2 and / or length L2 and / or thickness T2, such that W1 ≠ W2 and / or L1 ≠ L2 and / or T1 ≠ T2. It will be appreciated that such a configuration is not possible with conventional inductor coils, such as those described with reference to Figures 1A and 1B, because they have a fixed number of turns per unit length and LITZ coils have a fixed thickness and diameter.

[0142] The coil 212 (or more generally the electrode structure) may be formed, deposited, or coated in and / or on the support 220 such that the coil 212 or electrode structure has a square, rectangular, or polygonal cross-sectional shape. The support 220 may comprise a thermoplastic material such as polyetheretherketone ("PEEK2"). According to various embodiments, the diameter of the coil 212 or electrode structure may be in the range of <10 mm, 10-11 mm, 11-12 mm, 12-13 mm, or 14-15 mm.

[0143] Forming the coil 212 or electrode configuration in and / or on the support 220 using a laser direct structuring process results in the formation of a coil 212 or electrode configuration that is integral with or embedded in the support 220. This advantageously reduces the diameter of the support 220 required (if the support 220 has a tubular structure) compared to conventional configurations such as those described with reference to Figures 1A and 1B. It will be appreciated that incorporating the coil 212 into a molded support 220 allows for a more compact configuration to be provided.

[0144] The compact support 220 of the disclosed arrangement also means that any air gap between the support 220 and the housing of the aerosol delivery device can be reduced compared to conventional arrangements, such as those described with reference to FIGS. 1A and 1B. This also results in more efficient cooling. The improved efficiency allows for a smaller battery to be utilized to power the aerosol delivery device during use, thereby reducing recharge times. Overall, a more compact, lighter, more robust, customizable, and more energy-efficient heating arrangement can be provided.

[0145] 2 and 3, the coil or electrode 212 may be formed by depositing, coating, or otherwise forming an electrode structure on the outer surface of the support 220. However, in other examples, the coil 212 or electrode structure may be deposited, coated, or otherwise formed on the inner surface of the support 220 by a laser direct structuring process.

[0146] According to one embodiment, the length L of coil 212 may be substantially 585 mm, the total number of turns may be 18, and the coil pitch may be substantially 2 mm. However, other embodiments are contemplated in which the length L of coil 221 may be less than or greater than 585 mm. Similarly, the number of turns may be less than or greater than 18. It is also contemplated that the coil pitch may be less than or greater than 2 mm.

[0147] 4 shows a flowchart illustrating the steps involved in a laser direct structuring process 300 utilized according to various embodiments to form, for example, a helical induction coil on a substrate. According to a first step 310, a laser pattern structuring is performed using a laser to selectively activate areas of the substrate. The substrate may comprise a thermoplastic material such as polyetheretherketone (PEEK). The substrate may be formed by an injection molding process.

[0148] According to various embodiments, the support may be molded from a material that has high thermal stability, good isotropic behavior, and is suitable for metallization. PEEK has been found to be particularly suitable for this process, but other materials may also be used, including polyphthalamide (PPA) or liquid crystal polymer (LCP).

[0149] The support may be formed from a thermoplastic material doped with a non-conductive metallic inorganic compound. For example, the non-conductive metallic inorganic compound may include copper. However, other embodiments are contemplated in which the additive may include nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0150] According to various embodiments, the substrate may be made from a thermoplastic material having a composition including (i) 20-90 wt % thermoplastic resin, (ii) a laser direct structuring additive, and (iii) optionally, ceramic filler particles that may not have laser direct structuring additive functionality.

[0151] According to various embodiments, the laser direct structuring additive may comprise a non-conductive metal inorganic compound. However, other embodiments are contemplated in which the laser direct structuring additive may comprise a conductive metal oxide. The conductive metal oxide may have a maximum of 5×10 3The conductive metal oxide may have a resistivity of Ω·cm. The conductive metal oxide may include at least a metal from Group n and / or Group n+1 of the periodic table, where n is an integer between 3 and 13. Suitable metals from Group n and / or Group n+1 of the periodic table include, for example, Group 4 (titanium, zirconium), Group 5 (vanadium, niobium), Group 6 (chromium, molybdenum), Group 7 (manganese), Group 8 (iron, ruthenium), Group 9 (cobalt, rhodium, iridium), Group 10 (nickel, palladium, platinum), Group 11 (copper, silver, gold), Group 12 (zinc, cadmium), and Group 13 (aluminum, gallium, indium). Suitable metals from Group n of the periodic table further include metals from Group 3 (scandium, yttrium). Suitable metals from Group n+1 of the periodic table further include metals from Group 14 (germanium, tin). The conductive metal oxide may include zinc and aluminum. For example, the conductive metal oxide may include aluminum-doped zinc oxide.

[0152] According to another embodiment, the laser direct structuring additive may include calcium copper titanate. The thermoplastic resin may include resins such as polycarbonate, especially aromatic polycarbonate, polyamide, polyester, polyesteramide, polystyrene, polymethyl methacrylate, polyphenylene ether, liquid crystal polymer (LCP), polyether ether ketone (PEEK), cyclic olefin (co)polymer (COP), or combinations thereof. The resin may be a homopolymer, copolymer, or mixture thereof, and may be branched or unbranched.

[0153] According to various embodiments, a conductor track structure may be formed on a non-conductive support material comprising a metallization layer applied to metal nuclei generated by decomposing very finely distributed non-conductive metal compounds contained in the support material. The non-conductive metal compounds contained in the support material may be decomposed or otherwise activated by irradiating a portion of the support material with electromagnetic radiation. The non-conductive metal compounds may include thermally stable inorganic oxides selected from the group consisting of higher oxides that are stable and insoluble in aqueous, acidic, or alkaline metallization baths, contain at least two different cations, have a spinel or spinel-related structure, and remain unchanged in unirradiated areas of the support material. While standard spinels are mixed metal oxides of magnesium and aluminum, magnesium may be replaced in whole or in part by iron, zinc, and / or manganese, and aluminum may be replaced by iron and / or chromium. The spinel-related mixed oxide structure may also contain nickel and / or cobalt cations.

[0154] According to various embodiments, conductor track structures may be formed on a non-conductive support having a surface formed of a non-conductive support material with at least one thermally stable, spinel-based non-conductive metal oxide that is stable and insoluble and dispersed in an aqueous, acidic, or alkaline metallization bath. This process involves irradiating the areas of the support on which the conductive tracks are to be formed with electromagnetic radiation to decompose the non-conductive metal oxide and release metal nuclei, followed by metallization of the irradiated areas by chemical reduction. According to various embodiments, thermally very stable inorganic oxide non-conductive metal compounds may be used that are stable and insoluble in aqueous, acidic, or alkaline metallization baths and are high oxides with a spinel structure or a structure similar to a spinel structure. As a result, these metal compounds may remain unchanged on the surface of the support material even in unirradiated areas. The inorganic oxides used may be resistant to heat, so that they remain stable, i.e., do not become conductive, even after exposure to soldering temperatures and remain stable in the baths used for metallization.

[0155] According to various embodiments, the spinel or spinel-related structures may contain copper, chromium, iron, cobalt, nickel, or a mixture of two or more of the foregoing. In particular, the spinel or spinel-related structures may include copper.

[0156] The electrically non-conductive support material may comprise a thermoplastic or thermosetting synthetic resin material. The non-conductive support material may contain one or more inorganic fillers, such as silicic acid and / or silicic acid derivatives.

[0157] According to various embodiments, spinel-based, thermally stable, non-conductive high oxides containing at least two different cations may be utilized, which are stable and insoluble in aqueous, acidic, or alkaline metallization baths. The cations are mixed with a support material, which may then be processed into a component or applied to a component as a coating. During the laser direct structuring process, metal nuclei are released using electromagnetic radiation in the areas of the conductor structure to be created, which are then metallized by chemical reduction, while inorganic metal compounds in the form of spinel-based high oxides can remain on the surface of the support material in the non-irradiated areas. Furthermore, the inorganic high oxides containing at least two different types of cations used are sufficiently heat-resistant and therefore can be used in the compounding or injection molding of modern high-temperature plastics.

[0158] Electromagnetic radiation may be used to simultaneously release and ablate metal nuclei while forming an adhesion-promoting surface, providing a simple means to achieve excellent adhesion strength of subsequently deposited metal conductor tracks.

[0159] The inorganic oxide may contain copper, chromium, iron, cobalt, nickel, or mixtures thereof. The non-conductive support material may include a thermoplastic or thermosetting synthetic resin material. However, other embodiments are contemplated in which the support material may include a non-conductive material, such as a ceramic. The non-conductive support material may contain one or more inorganic fillers, such as silicic acid and / or silicic acid derivatives.

[0160] According to various embodiments, a laser may be used to generate a beam of electromagnetic radiation that can be directed onto the surface of the substrate to release metal nuclei where the laser beam strikes the surface of the substrate. The released metal nuclei effectively form catalysts or anchors for the subsequent (optional) deposition of one or more conductive layers on the laser-activated areas by immersing the substrate 220 in a bath. The wavelength of the laser may be, for example, 248 nm, 308 nm, 355 nm, 532 nm, 1064 nm, or 10600 nm.

[0161] It will be appreciated that, according to various embodiments, it is not necessary to deposit one or more conductive layers on the laser-activated region. Instead, embodiments are contemplated in which the resulting laser-activated region may comprise metal nuclei, such as copper atoms, essentially liberated from the doped thermoplastic substrate. The metal nuclei forming the laser-activated region may have a depth of <1 μm or 1-10 μm and may form conductive traces or tracks on the surface of the substrate.

[0162] In the first step 310, a laser beam is directed onto a portion of the substrate. The laser activates the surface of the thermoplastic material of the substrate, resulting in the formation of metal nuclei on the surface of the substrate or the liberation of metal nuclei from the substrate. The metal nuclei may form a thin surface layer with a thickness of <5 μm or <1 μm. In addition to activating the additive in the substrate to form laser-activated regions containing metal nuclei, the laser beam may also form a micro-roughened surface, which helps one or more layers of conductive material adhere to the laser-activated regions during the subsequent optional metallization step 320.

[0163] It is contemplated that the surface roughness of the conductive pattern surface may be in the range of <0.025 μm, 0.025-0.05 μm, 0.05-1 μm, 0.1-1 μm, 1-5 μm, 5-10 μm, 10-15 μm, or >15 μm. According to other embodiments, the surface roughness may be in the range of <0.1 μm, 0.1-1 μm, 1-10 μm, 10-20 μm, 20-30 μm, 30-40 μm, 40-50 μm, or >50 μm.

[0164] If the desired thickness of the electrode structure desired to be formed on the substrate is greater than the thickness of the laser-activated region formed in step 310 using the laser structuring and activation process, an optional metallization step 320 can be used to further increase the thickness of the electrode structure formed on the surface of the substrate. Prior to performing the second step 320, the substrate having the laser-activated region formed therein may be cleaned. The substrate may be cleaned by any suitable conventional process, including spraying with an aqueous, semi-aqueous, or solvent-based cleaning solution, or by ultrasonic cleaning methods known in the art. Once the cleaning process is complete, the metallization step 320 may begin, which may act to deposit one or more conductive layers on the conductive tracks initially formed on the substrate.

[0165] In the metallization step 320, an electroless metallization process is used to add to the laser-activated additive layer. The substrate can be positioned in a bath configured to perform the electroless metallization. The bath may contain, for example, copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc. When positioned in the bath, the conductive tracks or traces formed on the substrate can increase in thickness at a rate ranging from 8 to 12 μm / h. This process can be performed until an electrode structure of the desired thickness is obtained.

[0166] It will be understood that each conductive layer may comprise the same conductive material, for example, copper, or a series of layers may be deposited, each comprising a different material selected from copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc. The one or more conductive layers deposited on the laser activated region may each have a thickness of (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, or (x) 90-100 μm.

[0167] After the metallization step 320 is completed, a final (and optional) surface finishing step 330 may be performed. In step 330, an optional application-specific coating may be deposited on top of the constructed conductive tracks or electrodes using the same or similar electroless metallization process as described above with reference to step 320. For example, the support 220 may be positioned in a bath containing the desired coating. The coating may include copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0168] While steps 320, 330 above refer to electroless metallization, other plating techniques are contemplated, including electroless plating, galvanic plating, or autocatalytic plating processes, in which one or more laser-activated regions may be contacted with a liquid solution to cause a chemical or catalytic reaction that deposits metal particles present in the liquid solution onto the one or more laser-activated regions to form one or more conductive layers.

[0169] 5A and 5B illustrate other inductor coil variations on a substrate formed using the laser direct structuring process described above in accordance with various embodiments. As described above with reference to the embodiments shown in FIGS. 2 and 3, an inductor coil can be deposited, coated, or formed on a substrate by laser direct structuring in the form of a spiral inductor coil, such as coil 212. It will be appreciated that by applying laser direct structuring, the inductor coil can be deposited, coated, or alternatively formed on a substrate in several different configurations.

[0170] For example, coil 412a formed on support 420a as shown in Figure 5A has a larger coil pitch than coil 412b formed on support 420b as shown in Figure 5B. Thus, the number of turns per unit length of coil 412a is fewer than the number of turns per unit length of coil 412b.

[0171] Although coils 412a and 412b are shown as having a constant pitch along their respective lengths, coils 412a and 412b may have pitches that vary along their respective lengths, i.e., the pitch of coils 412a and 412b may not be constant. Varying the pitch of coils 412a and 412b can vary the heating characteristics of the aerosol delivery device at different locations on coils 412a and 412b. For example, an area with reduced pitch may mean an increased number of turns per unit length, thereby heating a corresponding region or area adjacent to a susceptor (not shown) to a higher temperature than a region or area of ​​the susceptor adjacent to a section of the coil with fewer turns per unit length.

[0172] As will be appreciated, the number of turns in a coil is inversely proportional to the coil pitch. Therefore, varying the pitch of coils 412a, 412b will in turn result in a variation in the number of turns in each coil 412, 412b, which can increase or decrease the rate at which the susceptor (not shown) can reach its maximum operating temperature. Such a configuration can provide asymmetric heating of the aerosol product article along the length of the aerosol product article, if desired.

[0173] In an example, coils 412a, 412b can have a substantially constant pitch and therefore a substantially constant number of turns per unit length. The height of one completed helical turn in coils 412a, 412b can be substantially constant along at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the axial length of one or more helical coils. In an example, coil 412a and / or coil 412b can have a helical section having a first pitch P1 or P1 turns per unit length, i.e., a height of one completed helical turn P1, and a second, different helical section having a second pitch P2 or P2 turns per unit length, i.e., a height of one completed helical turn P2, such that P1≠P2. In examples, coil 412a and / or coil 412b have a first helical section having a width W1 and / or length L1 and / or thickness T1 and a second, different helical section having a width W2 and / or length L2 and / or thickness T2, such that W1≠W2 and / or L1≠L2 and / or T1≠T2. Alternatively, coil 412a and / or coil 412b can have a substantially constant width and / or a substantially constant length and / or a substantially constant thickness along at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the axial length of the respective coil.

[0174] The various embodiments described herein are presented solely 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 construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it should be 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 comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. providing a non-planar support; laser activating at least a portion of the substrate to form one or more laser activated regions; A method of manufacturing a component of an aerosol delivery device, comprising:

2. The method of claim 1 , further comprising depositing one or more conductive layers over the one or more laser activated regions.

3. The method of claim 2 , wherein the one or more conductive layers comprise a metal or a metal alloy.

4. The method of claim 2 or 3, wherein the one or more conductive layers comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

5. 5. The method of claim 2, 3, or 4, wherein the one or more conductive layers have a thickness of: (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, or (x) 90-100 μm.

6. The method of any one of claims 2 to 5, wherein the one or more conductive layers have a square, rectangular, or polygonal cross-sectional profile.

7. The method of any one of claims 1 to 6, wherein the support comprises a tubular or hollow structure.

8. The method of any one of claims 1 to 7, wherein the support comprises an electrical insulator.

9. The method of any one of claims 1 to 8, wherein the support comprises a thermoplastic material.

10. The method of claim 9 , wherein the thermoplastic material comprises polyetheretherketone (PEEK).

11. The method according to any one of claims 1 to 10, wherein the support is doped with a non-conductive metallic inorganic compound.

12. The method of any one of claims 1 to 11, wherein the one or more laser activated regions comprise metal nuclei.

13. 13. The method of any one of claims 1 to 12, wherein laser activating at least a portion of the substrate to form one or more laser activated regions comprises laser activating at least a portion of a first surface and / or at least a portion of a second, different surface of the substrate.

14. 14. The method of claim 13, wherein depositing one or more conductive layers on the one or more laser activated regions comprises depositing one or more conductive layers on at least a portion of the first surface and / or on at least a portion of the second, different surface of the support.

15. 15. The method of claim 13 or 14, wherein the first surface comprises an outer surface of the support.

16. 16. The method of claim 13, 14, or 15, wherein the second surface comprises an interior surface of the support.

17. 17. The method of any one of claims 1 to 16, further comprising providing an insulator layer or portion on or adjacent to the one or more laser activated regions and / or one or more conductive layers.

18. 18. A method according to any one of the preceding claims, wherein the one or more laser activated regions and / or the one or more conductive layers are arranged to form one or more helical coils.

19. 19. The method of claim 18, wherein the one or more helical coils have a substantially constant pitch, a substantially constant number of turns per unit length, or the height of a single completed helical turn is substantially constant along at least 90% of the axial length of the one or more helical coils.

20. the one or more helical coils a first helical section having a first pitch P1 or P1 turns per unit length, or a height of one completed helical turn P1; a second different helical section having a second pitch P2 or P2 turns per unit length, or the height of one completed helical turn is P2; P1≠P2, 20. The method of claim 18.

21. 21. The method of claim 18, 19, or 20, wherein the one or more helical coils have a substantially constant width and / or a substantially constant length and / or a substantially constant thickness along at least 90% of the axial length of the one or more helical coils.

22. the one or more helical coils a first spiral section having a width W1 and / or a length L1 and / or a thickness T1; a second different spiral section having a width W2 and / or a length L2 and / or a thickness T2; W1≠W2 and / or L1≠L2 and / or T1≠T2; 21. The method of claim 18, 19, or 20.

23. 23. The method of any one of claims 2 to 22, wherein depositing one or more conductive layers on the one or more laser activated regions comprises using an electroless plating process, an electroless plating process, a galvanic plating process, or an autocatalytic plating process.

24. the electroless, electroless, galvanic, or autocatalytic plating process, contacting the one or more laser activated regions with a liquid solution to cause a chemical or catalytic reaction that deposits metal particles present in the liquid solution onto the one or more laser activated regions to form the one or more conductive layers.

24. The method of claim 23.

25. a non-planar support having one or more laser activated regions; Components of an aerosol delivery device.

26. 26. The component of claim 25, further comprising one or more conductive layers deposited on the one or more laser activated regions.

27. 27. The component of claim 26, wherein the one or more conductive layers comprise a metal or a metal alloy.

28. 28. The component of claim 26 or 27, wherein the one or more conductive layers comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

29. 29. The component of claim 26, 27, or 28, wherein the one or more conductive layers have a thickness of: (i) <10 μm, (ii) 10-20 μm, (iii) 20-30 μm, (iv) 30-40 μm, (v) 40-50 μm, (vi) 50-60 μm, (vii) 60-70 μm, (viii) 70-80 μm, (ix) 80-90 μm, or (x) 90-100 μm.

30. 30. The component of any one of claims 26 to 29, wherein the one or more conductive layers have a square, rectangular, or polygonal cross-sectional profile.

31. Component according to any one of claims 25 to 30, wherein the support comprises a tubular or hollow structure.

32. Component according to any one of claims 25 to 31, wherein the support comprises an electrical insulator.

33. The component of any one of claims 25 to 32, wherein the support comprises a thermoplastic material.

34. 34. The component of claim 33, wherein the thermoplastic material comprises polyetheretherketone (PEEK).

35. Component according to any one of claims 25 to 34, wherein the support is doped with a non-conductive metallic inorganic compound.

36. Component according to any one of claims 25 to 35, wherein the one or more laser activated regions comprise a metal nucleus.

37. 37. The component of any one of claims 25 to 36, wherein the one or more laser activated regions are located on at least a portion of a first surface of the support and / or on at least a portion of a second, different surface of the support.

38. 38. The component of claim 37, wherein the one or more conductive layers deposited on the one or more laser activated regions are located on at least a portion of the first surface of the support and / or on at least a portion of the second, different surface of the support.

39. 39. The component of claim 37 or 38, wherein the first surface comprises an outer surface of the support.

40. 40. The component of claim 37, 38, or 39, wherein the second surface comprises an interior surface of the support.

41. 41. The component of any one of claims 25 to 40, further comprising an insulator layer or portion on or adjacent to the one or more laser activated regions and / or one or more conductive layers.

42. 42. The component of any one of claims 25 to 41, wherein the one or more laser activated regions and / or the one or more conductive layers are arranged to form one or more helical coils.

43. 43. The component of claim 42, wherein the one or more helical coils have a substantially constant pitch, a substantially constant number of turns per unit length, or the height of a single completed helical turn is substantially constant along at least 90% of the axial length of the one or more helical coils.

44. the one or more helical coils a first helical section having a first pitch P1 or P1 turns per unit length, or the height of said one completed helical turn is P1; a second different helical section having a second pitch P2 or P2 turns per unit length, or the height of one completed helical turn is P2; P1≠P2, 44. The component of claim 43.

45. 45. The component of claim 42, 43, or 44, wherein the one or more helical coils have a substantially constant width and / or a substantially constant length and / or a substantially constant thickness along at least 90% of the axial length of the one or more helical coils.

46. the one or more helical coils a first spiral section having a width W1 and / or a length L1 and / or a thickness T1; a second different spiral section having a width W2 and / or a length L2 and / or a thickness T2; W1≠W2 and / or L1≠L2 and / or T1≠T2; 45. The component of claim 42, 43, or 44.

47. 47. A device comprising the components of an aerosol delivery device according to any one of claims 25 to 46. Aerosol generator.

48. 48. The aerosol generator of claim 47, wherein the aerosol generator comprises one or more inductive heating elements.

49. 49. An aerosol generator comprising the aerosol generator of claim 47 or 48. Aerosol delivery device.

50. 50. The aerosol delivery device of claim 49; an aerosol production article for generating an aerosol; An aerosol delivery system comprising:

51. Providing an aerosol delivery device according to claim 50; at least partially inserting an aerosol production article into the aerosol delivery device for generating an aerosol; A method for generating an aerosol, comprising:

52. 52. The method of claim 51, further comprising activating the aerosol delivery device.

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