Aerosol Delivery Device

Abstract

An aerosol delivery device (100) for generating an aerosol from an aerosol-generating material is provided. The device includes a heating element (220) defining a heating zone (222) configured to receive at least a portion of an article containing the aerosol-generating material. The device includes a holding element (240) arranged to hold the heating element, and a plurality of contact features (242, 244) between the holding element and the heating element, each contact feature defining a contact point between the holding element and the heating element.

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device, an aerosol delivery system comprising the aerosol delivery device and an article containing an aerosol-generating material. The present invention also relates to a method of manufacturing a heating element for use in an aerosol delivery device. [Background technology]

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

[0003] According to one aspect, an aerosol delivery device for generating an aerosol from an aerosol-generating material is provided, the aerosol delivery device comprising: a heating element defining a heating zone configured to receive at least a portion of an article including the aerosol-generating material; a retaining element arranged to hold the heating element; and a plurality of contact features between the retaining element and the heating element, each contact feature defining a contact point between the retaining element and the heating element.

[0004] The retaining element may comprise at least one of a plurality of contact features.

[0005] The retaining element may include at least three contact features.

[0006] Each contact feature of the retaining element may define a contact point with the heating element.

[0007] The heating element may not include contact features.

[0008] The plurality of contact features may be integrally formed with the retaining element.

[0009] The plurality of contact features may form an integral component with the retention element.

[0010] Here, the heating element may comprise at least one of the plurality of contact features.

[0011] The heating element includes at least three contact features.

[0012] Each contact feature of the heating element may define a contact point with the retaining element.

[0013] The retaining element may not include a contact feature.

[0014] The plurality of contact features may be integrally formed with the heating element.

[0015] The plurality of contact features may form an integral component with the heating element.

[0016] The retaining element may be a support member arranged to support one end of the heating element.

[0017] The retaining element may include a passageway in communication with the heating zone defined by the heating element.

[0018] The retaining element may include an opening through which at least a portion of the article including the aerosol-forming material is insertable so as to be received in the heating zone.

[0019] The retention element may define an expansion chamber.

[0020] A plurality of contact features may space the heating element from the surface of the holding element.

[0021] A plurality of contact features may space the heating element from the inner surface of the retaining element.

[0022] At least a portion of the inner surface of the retaining element may lie in a plane perpendicular to the longitudinal axis of the heating element.

[0023] The inner surface of the retaining element may define a shoulder.

[0024] At least a portion of the inner surface may extend longitudinally of the heating element.

[0025] At least a portion of the inner surface may be an inner cylindrical surface.

[0026] The heating element may be spaced from the retaining element by a contact feature.

[0027] The plurality of contact features may space the heating element from the outer surface of the holding element.

[0028] The plurality of contact features may contact the heating element and / or the retaining element around a portion of the circumference of the heating element.

[0029] The plurality of contact features may contact the heating element and / or the retaining element in less than 10% of the circumference of the heating element.

[0030] The plurality of contact features may include a plurality of axial contact features arranged to axially contact the heating element / retaining element.

[0031] The plurality of axial contact features may include three axial contact features.

[0032] The plurality of axial contact features may contact an end portion of the heating element.

[0033] The plurality of axial contact features may define an axial extent of the heating element.

[0034] The plurality of contact features may include a plurality of radial contact features arranged to contact the heating element in a radial direction.

[0035] The plurality of radial contact features may define a radial extent of the heating element.

[0036] The plurality of radial contact features may include three radial contact features.

[0037] The plurality of radial contact features may contact the heating element at end regions of the heating element.

[0038] The plurality of contact features may be evenly spaced around the circumference of the heating element.

[0039] The plurality of contact features may be provided by a plurality of protrusions on the retaining element.

[0040] A portion of the retaining element may surround the heating element.

[0041] A portion of the retaining element may be received by the heating element.

[0042] The plurality of contact features may extend radially outward.

[0043] The plurality of contact features may extend radially inward.

[0044] The plurality of contact features may be formed from a thermally insulating material.

[0045] A seal may be provided between the retaining element and the heating element.

[0046] The seal may be formed from a thermally insulating material.

[0047] The plurality of contact features may be provided by a plurality of protrusions on the heating element.

[0048] According to one aspect, a method for manufacturing a heating element for use in an aerosol delivery device is provided, the method including providing a plurality of contact features on the heating element, each contact feature being positioned to define a contact point with a holding element of the aerosol delivery device.

[0049] The step of providing a plurality of contact features may include deforming a plurality of portions of the heating element.

[0050] The step of providing a plurality of contact features may include removing a plurality of portions of the heating element such that the removed portions define a plurality of contact features.

[0051] According to some embodiments described herein, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating element defining a heating zone configured to receive at least a portion of an article including the aerosol-generating material; a retaining element arranged to hold the heating element; and a thermal barrier member between the retaining element and the heating element.

[0052] The retaining element may be spaced from the heating element by a thermal barrier member.

[0053] The thermal barrier member may form a seal between the retaining element and the heating element.

[0054] The thermal barrier member may comprise a material with low thermal conductivity.

[0055] The material may be silicone or aerogel.

[0056] The thermal barrier member may contact the heating element around the periphery of the heating element.

[0057] The thermal barrier member may contact the retaining element around a periphery of the retaining element.

[0058] The retaining element is a support member positioned to support one end of the heating element.

[0059] The retaining element may include a passageway in communication with the heating zone defined by the heating element.

[0060] The retaining element may include an opening through which at least a portion of the article including the aerosol-forming material is insertable so as to be received in the heating zone.

[0061] The retention element may define an expansion chamber. [Brief explanation of the drawings]

[0062] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0063] [Figure 1] FIG. 1 is a front view of an aerosol delivery device. [Figure 2] FIG. 2 is a schematic side view of the aerosol generator of the device of FIG. 1. [Figure 3] FIG. 2 is a side cross-sectional view of a retaining element and a heating element. [Figure 4] FIG. 4 is a top view of the holding element and heating element of FIG. 3. [Figure 5] FIG. 2 is a top view of a retaining element and a heating element according to one aspect of the present invention. [Figure 6] FIG. 10 is a top view of a retaining element and a heating element according to another aspect of the present invention. [Figure 7] FIG. 7 is a side view of the holding element and heating element of FIG. 6. [Figure 8] FIG. 10 is a cross-sectional side view of a retaining element and a heating element according to another aspect of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0064] As used herein, the term "aerosol-forming material" refers to a material that can generate an aerosol when, for example, heated, irradiated, or excited in any other manner. Aerosol-forming materials may be in the form of, for example, a solid, liquid, or gel, which may or may not contain active substances and / or flavorings. Aerosol-forming materials may include any plant-based material, such as tobacco-containing materials, and may also include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-forming materials may also be, for example, a combination or mixture of materials. Aerosol-forming materials are also sometimes known as "smoking materials."

[0065] The aerosol-forming material may include a binder and an aerosol former. Optionally, additional actives and / or fillers may be present. Optionally, additional solvents, such as water, may be present, in which one or more components of the aerosol-forming material may or may not be dissolved. In some embodiments, the aerosol-forming material is substantially free of plant material. In some embodiments, the aerosol-forming material is substantially free of tobacco.

[0066] The aerosol-forming material may include or be an "amorphous solid." An amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some amount of fluid, such as a liquid, within it. In some embodiments, the aerosol-forming material may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0067] The aerosol-generating material may include an aerosol-generating film. The aerosol-generating film may include or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially free of tobacco.

[0068] According to the present disclosure, a "non-combustion" aerosol delivery system is an aerosol delivery system in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0069] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery.

[0070] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0071] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0072] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-forming materials, where one or more of the aerosol-forming materials may be heated. Each of the aerosol-forming materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include, for example, a tobacco product or a non-tobacco product.

[0073] Typically, a non-combustion aerosol delivery system can include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0074] In some embodiments, the present disclosure relates to consumables that include an aerosol-generating material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0075] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon substrate that can be excited to deliver power in the form of heat to the aerosol-generating material or to a heat transfer material proximate to the exothermic power source.

[0076] 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.

[0077] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may comprise an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0078] The aerosol delivery device can accept an article that includes an aerosol-forming material for heating. An "article" in this context is a component that, when used, includes or contains the aerosol-forming material, which is heated to volatilize the aerosol-forming material and optionally other components. A user can insert the article into the aerosol delivery device before the article is heated to generate an aerosol that the user then inhales. The article can be of a predetermined or specific size, for example, configured to be placed in or on a heater of a device sized to receive the article.

[0079] 1 shows an aerosol delivery device 100 for generating an aerosol from an aerosol-generating material. Broadly speaking, device 100 is used to heat a replaceable item 110 comprising an aerosol-generating material to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0080] The device 100 comprises a body 102. An elongated housing arrangement 120 surrounds the body 102 and houses the components. An article opening 104 is formed at one end of the body through which an article is inserted for heating by an aerosol generator (see FIG. 2 ) housed in the body 102 of the device 100.

[0081] In use, the article 110 is fully or partially inserted into the aerosol generator 200, where the article 110 may be heated by one or more components of the aerosol generator. The article 110 and the device 100 together form an aerosol delivery system 101.

[0082] Device 100 includes a user-operable switch 150. Switch 150 acts as a user-operable control element that, when pressed, operates device 100. In use, a user can turn device 100 on by operating switch 150. Switch 150 may be replaced by, for example, a button or other user-operable control element.

[0083] The end surface of device 100 is defined by the end surface of body 102. The end of device 100 closest to article opening 104 is the proximal end 106 of device 100. Proximal end 106 is sometimes known as the mouth end of device 100, as it is the end closest to the user's mouth during use.

[0084] The other end of device 100, farthest from opening 104, is distal end 108 of device 100. Distal end 108 is the end farthest from a user's mouth in use. The terms proximal and distal when applied to features of device 100 are described by reference to the relative positions of such features with respect to one another in the proximal-distal direction along longitudinal axis Y.

[0085] In use, a user inserts article 110 into opening 104 and activates the device using switch 150, which activates aerosol generator 200 (see FIG. 2). Activation of aerosol generator 200 initiates heating of the aerosol-generating material within article 110, thereby generating an aerosol, which the user inhales. The aerosol then flows through device 100 along a flow path in a direction toward proximal end 106 of device 100.

[0086] As used herein, one-piece component means a component of device 100 that is formed as a single, separate component during the manufacturing process and cannot be separated into two or more components after manufacturing. For example, a one-piece component may be formed of a single material during a manufacturing process that involves molding.

[0087] Integrally formed refers to two or more features, at least one of which is formed separately in an initial step, that are formed together in a subsequent step and cannot be separated after fabrication. The features may be made of different materials.

[0088] 2, the aerosol generator 200 defines a longitudinal axis Y, along which the article 110 extends when inserted into the device 100. The opening 104 is aligned with the longitudinal axis Y. An airflow passage 210 extends through the aerosol generator 200 along the longitudinal axis Y.

[0089] The aerosol generator 200 includes various components for generating an aerosol from an article received therein. In one example, the article 110 is heated by a heater assembly 201 to generate an aerosol. An opening 104 is located at a proximal end 206 through which an article can be inserted for heating. In use, the article 110 can be fully or partially inserted into the device, where it can be heated by one or more components. The device includes the heating assembly 201, a controller, and a power source (not shown). The heating assembly 201 is configured to heat the aerosol-generating material of the article 110 inserted into the device 100 so that an aerosol is generated from the aerosol-generating material. The power source provides electrical power to the heating assembly 201, which converts the provided electrical energy into thermal energy for heating the aerosol-generating material. The power source may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. A power source may be electrically coupled to the heating assembly 201 to provide power to heat the aerosol-generating material when needed under the control of the controller. The control circuitry may be configured to activate and deactivate the heating assembly 201 based on a user operating the control switch 150. For example, the controller may activate the heating assembly 201 in response to a user operating the switch 150.

[0090] The aerosol generator 200 comprises an induction heater that includes a magnetic field generator. The magnetic field generator comprises an inductor coil 212. The aerosol generator 200 comprises a heating element 220. The heating element 220 is also known as a susceptor.

[0091] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material, such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. Herein, a device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0092] The heating assembly 201 includes various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is the process of heating an electrically conductive heating element via electromagnetic induction. In this embodiment, the heating element is a tubular member. The induction heating assembly includes an inductor coil 212, e.g., one or more inductor coils, that acts as the inductor element, and a device for passing a varying current, such as an alternating current, through the inductor element. The varying current in the inductor element creates a varying magnetic field. The varying magnetic field penetrates a susceptor (heating element) appropriately positioned relative to the inductor element, generating eddy currents inside the susceptor. The susceptor has an electrical resistance to eddy currents, and therefore, the flow of eddy currents against this resistance causes the susceptor to heat via Joule heating. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, additional heat can be generated due to magnetic hysteresis losses in the susceptor—that is, due to the varying orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. In comparison with, for example, heating by conduction, in induction heating, heat is generated inside the susceptor, allowing for rapid heating. Furthermore, no physical contact between the inductive element and the susceptor is required, allowing for increased flexibility in design and application.

[0093] The heating assembly includes a heating element 220. The heating element 220 is a tubular member. The heating element 220 is elongated along the Y-axis from its proximal end 206 to its distal end 208 and defines a heating zone 222. In use, the aerosol product article 110 is located within the heating zone 222.

[0094] The heating element 220 is heatable by the penetration of a fluctuating magnetic field. The heating element 220 comprises a conductive material suitable for heating by electromagnetic induction. The heating element 220 acts as a susceptor. By way of example, the heating element 220 in the present apparatus is formed from carbon steel. It will be appreciated that other suitable materials may be used, such as ferromagnetic materials such as iron, nickel, or cobalt.

[0095] In other embodiments, the features serving as the heating element 220 may not be limited to those that are inductively heated. In some embodiments, the heating element 220 is a resistive heater. Other heating elements for other heating means are envisioned. The heating element may be heatable by electrical resistance. The aerosol generator 200 may include electrical contacts for electrical connection with a device for electrically activating the heating element 220 by passing a flow of electrical energy through the heating element.

[0096] The inductor coil 212 is a helical coil. As shown, the induction heating assembly includes a single inductor coil 212. In some embodiments, other inductor coil shapes and arrangements are contemplated. In some embodiments, the number of inductor coils varies. In some embodiments, the induction heating assembly includes two or more coils. In some embodiments, the two or more coils may be positioned next to each other and coaxially aligned along an axis.

[0097] In some examples, the inductor coil 212 is configured to heat the heating element 220 to a temperature between about 200°C and about 350°C, such as between about 240°C and about 300°C or between about 250°C and about 280°C, during use.

[0098] The inductor coil 212 is disposed outside the heating zone 222. The inductor coil 212 surrounds the heating zone 222. The inductor coil 212 is configured to generate a varying magnetic field that penetrates the heating element 220. The inductor coil 212 is disposed coaxially with the heating zone 222. The inductor coil assembly includes a coil support 214. The coil support 214 is tubular. The coil support 214 includes a guide for the coil 212. The guide includes a channel on the outside of the coil support 214.

[0099] In use, a power source supplies alternating current to the inductor coil 212. The alternating current in the inductor coil 212 generates a varying magnetic flux adjacent the heating element 220. The magnetic flux generates a current in the heating element 220, which causes the heating element to heat.

[0100] In this example, article 110 is generally cylindrical, and heating zone 222 is sized to receive article 110. Heating element 220 in this example is hollow, thus defining at least a portion of heating zone 222 in which aerosol-generating material is received via proximal end 106. For example, article 110 can be inserted into heating element 220 at proximal end 206 of heating element 220. Heating element 220 is tubular with a circular cross-section. Heating element 220 has a generally constant diameter along its axial length. Article 110 may include other components, such as a filter, wrapping material, and / or cooling structure.

[0101] A retaining element 240 is provided within the body 102 to engage and retain the heating element 220 at the proximal end 206 of the heating element 220 .

[0102] 3, the retaining element 240 is generally hollow and defines the opening 104. The retaining element 240 is generally tubular. The retaining element 240 has a cylindrical surrounding wall 246. The inner surface of the surrounding wall 246 is a substantially cylindrical surface. The surrounding wall 246 defines a receiving space (passageway) 248 therethrough. The ends of the retaining element 240 are open. In use, the receiving space 248 communicates with the heating zone 222 defined by the heating element 220. The retaining element 240 is a unitary component. It will be understood that in some embodiments, the retaining element 240 can be an integrally formed component.

[0103] The surrounding wall 246 of the retention element 240 comprises a first section 250 and a second section 252. The first section 250 is closest to the proximal end 106 of the device. The diameter of the first section 250 is wider than the diameter of the second section 252. The surrounding wall 246 comprises, in cross section, a tapered section 256 between the first section 250 and the second section 252.

[0104] The retaining element 240 includes a shoulder 260. The shoulder 260 is formed in the surrounding wall 246. The shoulder 260 defines a stepped portion of the surrounding wall 246 of the second section 252. The shoulder 260 extends around the interior surface of the second section 252. The shoulder extends in a circumferential direction. The shoulder 260 defines a heating element receiving portion. The portion of the retaining element 240 extending between the shoulder 260 and the distal end of the retaining element 240 is configured to have a diameter that allows the heating element 220 to overlap the retaining element 240. The inside of the heating element receiving portion has a larger diameter than the outside of the heating element 220.

[0105] The heating element 220 is positioned to fit snugly within the retaining element 240. The heating element 220 is retained by contact features 242, 244. The number and arrangement of the contact features 242, 244 may vary, for example, as described below.

[0106] The shoulder 260 comprises a contact configuration. The contact feature configuration comprises contact features 242, 244. For example, in the configuration described with reference to FIGS. 3-5 , the contact feature 242 includes both a longitudinal alignment contact feature and a radial alignment contact feature. In some embodiments, one of the longitudinal alignment contact feature and the radial alignment contact feature may be omitted. The contact feature includes a notch 242 and a rib 244. It will be understood that the contact feature may be any feature that defines a contact point between the retaining element 240 and the heating element 220. The contact feature spaces at least one surface of the heating element from at least one surface of the retaining element.

[0107] The shoulder 260 includes three notches 242, as shown in FIG. 5 . The notches 242 protrude from the shoulder 260. The notches act as longitudinal alignment contact features. The notches 242 are evenly spaced around the interior surface of the shoulder 260. It will be understood that more or less than three notches 242 may be provided. In some embodiments, one notch is provided. The notch 242 protrudes from the shoulder 260. The notch 242 is in the shape of an inverted triangle. That is, the notch 242 converges to a tip. The notch 242 may be formed as a unitary component of the same material. In one embodiment, the retaining element 240 may be integrally formed, and the notch 242 may be a different material than the surrounding wall 246 of the retaining element 240.

[0108] The notch 242 acts as a longitudinally extending protrusion.

[0109] The notches 242 each abut the heating element 220 to define a contact point. The contact point is defined between the retaining element 240 and the heating element 220 at the end region of the heating element 220. The surface area of ​​the contact point with the heating element 220 defined by the notches 242 is minimal. The contact features contact at least one of the heating element and the retaining element around a portion of the circumference of the heating element. This reduces thermal transfer of the heating element 220 to the retaining element in the longitudinal direction. The notches contact at least one of the heating element and the retaining element together around less than 10% of the circumference of the heating element. Optionally, the notches contact at least one of the heating element and the retaining element together around less than 7%, and optionally less than 5%, of the circumference of the heating element.

[0110] The notch 242 is positioned to support the proximal end 206 of the heating element 220 and to control the vertical position of the heating element 220 relative to the body 102 of the device 100 .

[0111] Referring to FIG. 4 , the retention element 240 includes three ribs 244. Each rib 244 is evenly spaced around the inner surface of the periphery of the enclosure 246 at the distal end. Each rib 244 extends longitudinally and protrudes from the inner surface into the receiving space 280. It will be understood that more or less than three ribs 244 may be provided. In some embodiments, a single rib is provided. Each rib 244 extends longitudinally relative to the Y-axis. The lengths of the ribs may vary. The ribs may converge toward their proximal ends to aid in positioning the heating element.

[0112] The ribs 244 may be manufactured integrally with the surrounding wall 246 of the retaining element 240 as a one-piece component. It will be appreciated that the retaining element 240 may be integrally formed and the ribs 244 may be a different material than the surrounding wall 246 of the retaining element 240.

[0113] Each rib 244 provides a contact point with the heating element 220 around the proximal end 206 of the heating element 220 .

[0114] The ribs 244 each abut the heating element 220 to define contact points between the retaining element 240 and the heating element 220 at the end regions of the heating element 220. The surface area of ​​the contact points with the heating element 220 defined by the ribs 244 is minimized. This reduces movement of the heating element 220 toward the retaining element in the radial direction. The contact features contact at least one of the heating element and the retaining element around a portion of the circumference of the heating element. This reduces thermal transfer of the heating element 220 to the retaining element in the longitudinal direction. The ribs contact at least one of the heating element and the retaining element together around less than 10% of the circumference of the heating element. Optionally, the ribs 244 contact at least one of the heating element and the retaining element together around less than 7%, and optionally less than 5%, of the circumference of the heating element.

[0115] The ribs 244 are positioned to space the heating element 220 from the inner surface of the retaining element 240. The ribs 244 are positioned to maintain the concentricity of the heating element 220. The ribs 244 reduce thermal contact between the heating element 220 and the retaining element 240.

[0116] It will be appreciated that the ribs 244 may be located on any portion of the inner surface of the surrounding wall 246 of the retaining element 240 so long as they define a point of contact with the heating element 220 .

[0117] In use, the contact features provide a contact point between the retaining element 240 and the heating element 220. This provides sufficient support to the proximal end 206 of the heating element 220 to maintain the shape and position of the heating element 220 within the device 100, while providing minimal contact between the heating element 220 and the retaining element 240 to reduce heat transfer between the elements.

[0118] The retaining element 240 may include three ribs 244 and three notches 242. One or more of the ribs 244 or notches 242 may be omitted. In one embodiment, the retaining element 240 may include only ribs or only notches. In another embodiment, the retaining element 240 may include any number of ribs and any number of notches. Figure 4 shows the retaining element 240 of Figure 3 in contact with the heating element 220.

[0119] The notch 242 controls the longitudinal position of the heating element 220 relative to the body 102 of the device 100 and the interior surfaces of the holding element 240. The notch 242 is triangular with a point extending along the Y-axis. The point of the triangle defines a contact point with the heating element 222. This triangular contact point minimizes the surface area of ​​the contact point and reduces heat transfer. In particular, longitudinal heat transfer from the heating element 220 to the holding element 240 is reduced. This reduces heat loss from the device 100 and increases the energy efficiency of the device 100.

[0120] The ribs 244 may be arranged to support the proximal end 206 of the heating element 220 at the end region of the heating element 220. The ribs 244 can control the radial position of the heating element 220 relative to the inner surface of the retaining element. The ribs 244 are arranged to space the heating element 220 from the inner surface of the retaining element 240. The ribs 244 are arranged to maintain the concentricity of the heating element 220. The ribs 244 reduce thermal contact between the heating element 220 and the retaining element 240 by providing minimal contact points. In particular, radial heat transfer from the heating element 220 to the retaining element 240 is reduced. This reduces heat loss from the device 100 and increases the energy efficiency of the device 100.

[0121] The contact features 242, 244 support the proximal end 206 of the heating element 220 to maintain its shape and radial position within the device 100. The contact features provide minimal contact between the heating element 220 and the retaining element 240, reducing heat transfer between the elements. The heating element 220 is held in a position where it does not contact the housing 102 of the device 100. This reduces heat loss from the heating element 220 to the surroundings, thus providing a more efficient system.

[0122] 5, and in another embodiment, the surrounding wall 346 of the retaining element 340 does not include contact features. The heating element 320 includes ribs 344 that extend longitudinally around the proximal end 322 of the heating element 320 and project radially relative to the Y-axis. It will be understood that the ribs 344 may form an integral component with the retaining element 340. It will be understood that the ribs may be formed integrally with the heating element. Each rib 344 provides a point of contact with the inner surface of the surrounding wall 346 of the retaining element 340 and spaces the outer surface of the heating element 320 from the surrounding wall 346.

[0123] It will be appreciated that the heating element 320 may be in contact with the retaining element 240 of FIGS. 2 and 3, which may include ribs 244 and / or notches 242.

[0124] In another embodiment, the heating element 324 may include a protrusion extending longitudinally from the proximal end 322 of the heating element. The protrusion may contact an inner surface of the retention element 230. The protrusion may contact a shoulder formed on the surrounding wall 346 of the retention element 340. With reference to FIGS. 7 and 8 , in another embodiment, a rib 444 may be disposed on an outer surface of the surrounding wall 446 of the second section 452 of the retention element 440.

[0125] 8 , the heating element 420 has a stepped side profile. The proximal end 426 of the heating element 420 extends radially at a shoulder 428. The proximal end 446 of the heating element 420 is dimensioned to receive the retaining element 440 such that the ribs 444 of the retaining element radially abut the inner surface of the stepped proximal end 426 of the heating element 420. The ribs 444 axially abut the inner surface of the heating element 420 at the shoulder 428 of the heating element 420.

[0126] 9 , in one embodiment, a sealing element 600 is provided. The retaining element 540 includes a first section 550 and a second section 552 and is positioned to support an end of the heating element 520. The sealing element 600 is positioned between the inner surface of the enclosure 546 of the second section 552 and the outer surface of the heating element 520 and contacts the retaining element 540 around the periphery of the heating element 520. The sealing element 600 is formed of a thermally insulating material.

[0127] The sealing element 600 may alternatively or additionally be defined as a thermal barrier used to space the retaining element 540 from the heating element 520. The sealing element 600 comprises silicone, a material with low thermal conductivity, which reduces heat transfer from the heating element 520 and increases the efficiency of the device. Alternatively, or additionally, the sealing element may comprise aerogel.

[0128] In another embodiment, the sealing element 600 may be configured to be disposed between the inner surface of the heating element 520 and the outer surface of the enclosure 546 of the retaining element 540. Thus, the sealing element 600 contacts the retaining element 540 around the periphery of the retaining element 540.

[0129] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as a representative sample of embodiments and are not intended to be all-inclusive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations on the scope of the invention, which is defined by the claims, or limitations on the equivalents of the claims, and that other embodiments may be used and changes 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. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heating element defining a heating zone configured to receive at least a portion of an article including an aerosol-forming material; a holding element arranged to hold the heating element; a plurality of contact features between the retaining element and the heating element; Equipped with An aerosol delivery device, wherein each contact feature defines a contact point between the retaining element and the heating element.

2. The aerosol delivery device of claim 1 , wherein the retaining element comprises at least one of the plurality of contact features.

3. The aerosol delivery device of claim 2 , wherein the plurality of contact features form an integral component with the retaining element.

4. The aerosol delivery device of claim 1 , wherein the heating element comprises at least one of the plurality of contact features.

5. The aerosol delivery device of claim 4 , wherein the plurality of contact features form an integral component with the heating element.

6. The aerosol delivery device of any one of claims 1 to 5, comprising at least three contact features.

7. The aerosol delivery device according to any one of claims 1 to 6, wherein the holding element is a support member arranged to support an end of the heating element.

8. The aerosol delivery device of any one of claims 1 to 7, wherein the retaining element comprises a passageway in communication with the heating zone defined by the heating element.

9. The aerosol delivery device of any one of claims 1 to 8, wherein the heating element is spaced from the surface of the holding element by the plurality of contact features.

10. The aerosol delivery device of any one of claims 1 to 9, wherein the plurality of contact features space the heating element from a surface of the holding element.

11. The aerosol delivery device of any one of claims 1 to 10, wherein the plurality of contact features contact at least one of the heating element and the retaining element around a portion of the circumference of the heating element.

12. 12. The aerosol delivery device of claim 11, wherein the plurality of contact features contact at least one of the heating element and the retaining element around less than 10% of the circumference of the heating element.

13. The aerosol delivery device of any one of claims 1 to 12, wherein the plurality of contact features includes a plurality of axial contact features arranged to contact the heating element / retaining element in an axial direction.

14. The aerosol delivery device of any one of claims 1 to 13, wherein the plurality of contact features comprises a plurality of radial contact features arranged to contact the heating element in a radial direction.

15. The aerosol delivery device of any one of claims 1 to 14, comprising a seal between the retaining element and the heating element.

16. The aerosol delivery device of any one of claims 1 to 15, wherein the plurality of contact features and / or the seal are formed from a thermally insulating material.

17. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heating element defining a heating zone configured to receive at least a portion of an article including an aerosol-forming material; a holding element arranged to hold the heating element; a thermal barrier member between the holding element and the heating element; An aerosol delivery device comprising:

18. 18. The aerosol delivery device of claim 17, wherein the holding element is spaced from the heating element by the thermal barrier member and / or the thermal barrier member forms a seal between the holding element and the heating element.

19. An aerosol delivery system comprising the aerosol delivery device of any one of claims 1 to 18 and an article containing an aerosol-generating material.

20. A method for manufacturing a heating element for use in an aerosol delivery device, the method comprising the step of providing a plurality of contact features on the heating element, each contact feature being positioned to define a contact point with a holding element of the aerosol delivery device.

21. 21. The method of claim 20, wherein the step of providing a plurality of contact features comprises deforming a plurality of portions of the heating element.

22. 22. The method of claim 21, wherein the step of providing a plurality of contact features comprises removing portions of the heating element such that the removed portions define the plurality of contact features.

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