Heater for aerosol supply device

Abstract

A heater for an aerosol supply device is provided, configured to heat an aerosol product containing an aerosol-generating material. The heater comprises a housing, an elongated support, and a heating coil. The housing defines the article contact surface. The elongated support is located within the housing. The heating coil extends within the housing, around at least a portion of the elongated support. The elongated support supports at least a portion of the heating coil and defines a void within the volume defined by the heating coil.

Description

Technical Field

[0001] The present invention relates to a heater for an aerosol supply device, an aerosol supply device, an aerosol supply system, and a method of assembling a heater for an aerosol supply device.

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

[0003] Aerosol supply systems covering the above-described devices or products are known. A common system uses a heater to generate an aerosol from a suitable medium, and then the aerosol is inhaled by the user. In many cases, it is necessary to exchange or change the medium used in order to supply different aerosols for inhalation. It is known to use a resistive heating system as a heater for generating an aerosol from a suitable medium. Separately from this, it is known that an induction heating system is used as a heater.

[0004] [Summary] According to one aspect, there is provided a heater for an aerosol supply device, comprising a housing defining an article contact surface, an elongate support within the housing, and a heating coil extending around at least a portion of the elongate support within the housing, the elongate support supporting at least a portion of the heating coil and defining a void within a volume defined by the heating coil, the heater being configured to heat an aerosol-generating article containing an aerosol-generating material.

[0005] The article contact surface may define a heating surface.

[0006] The elongated support may also be tubular.

[0007] The elongated support structure may include a hollow tube.

[0008] The void can be defined by a hollow tube.

[0009] The void can be defined by the inner surface of the tube.

[0010] The support structure may include multiple arms extending from a central portion.

[0011] The gap can be defined between adjacent arms of multiple arms.

[0012] The void may be either a fully filled void or a partially filled void.

[0013] The elongated support can be configured to position the heating coil at the center of the housing.

[0014] The housing may include an overlay formed on the heating coil.

[0015] The overlay may also be an overformed component.

[0016] Overformed components can be formed by overmolding or casting.

[0017] The overlay may also be a surrounding member.

[0018] The surrounding member can be formed by wrapping.

[0019] Wrap may include a sheet-like material. The sheet-like material may be a film.

[0020] The housing may include pre-formed components.

[0021] The pre-formed member may be a casing.

[0022] The pre-formed member may be configured to receive a heating coil.

[0023] The pre-formed member may define an inner void.

[0024] The volume defined by the heating coil may be defined within the inner void.

[0025] The housing may comprise a thermally conductive material.

[0026] The elongate support may comprise a heat insulating material.

[0027] The elongate support may be electrically insulating.

[0028] The housing may be electrically insulating.

[0029] The elongate support may be integral with the housing or may be fixed to the housing.

[0030] The elongate support may extend from an end of the housing. The elongate support may stand up into the housing from a closed end.

[0031] The heating coil may comprise a helical coil portion. The heater may comprise a return electrical path.

[0032] The elongate support may be spaced apart from at least a portion of the return electrical path from the helical portion.

[0033] At least a portion of the article contact surface may include a low friction material.

[0034] The low friction material may be provided by a coating or surface finish.

[0035] At least 50%, at least 70%, or at least 80% of the article contact surface may include low-friction material.

[0036] The contact surface of the article may have a coefficient of friction of less than 1.4, less than 0.7, or less than 0.15.

[0037] Low-friction materials may include one or more of the following: diamond-like carbon (DLC), copper, glass, graphite, aluminum, and aluminum-magnesium boride (BAM).

[0038] The heater may be a resistance heater.

[0039] The heating coil may also be a resistance heating coil.

[0040] The heater may be an induction heater.

[0041] The heating element may be an induction heating element.

[0042] The coil may also be an induction coil.

[0043] According to one embodiment, an aerosol supply device is provided which is configured to heat an article containing an aerosol-generating material, the device comprising a heater as described above. The aerosol supply device may comprise a heating chamber provided with a heater.

[0044] According to one embodiment, an aerosol supply device is provided, comprising a receptacle disposed to receive at least a portion of an aerosol product, an elongated support extending from the receptacle, and a heating member extending from the receptacle, the elongated support supporting at least a portion of the heating coil and configured to heat an aerosol product containing an aerosol-generating material, defining a void within a volume defined by the heating coil.

[0045] The aerosol supply device may comprise a power supply, a controller, and a heating chamber in which the aerosol product is removably received. The power supply may be aligned along the longitudinal axis of the heating chamber. The power supply may be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0046] The aerosol supply device may be configured for wireless charging.

[0047] According to one embodiment, an aerosol supply system is provided, comprising the above-described aerosol supply device and an article containing an aerosol generating material.

[0048] The aerosol supply system may include a charging unit having a cavity for removably receiving an aerosol supply device. The charging unit may include a movable lid that covers the aerosol supply device in a closed configuration. The charging unit may include a user display. The user display is visible to the user when the movable lid is in the closed position, and is partially or completely hidden or obscured by the lid when the lid is in the open position.

[0049] In another embodiment, a method for assembling a heater for an aerosol supply device configured to heat an aerosol product comprising an aerosol-generating material is provided, comprising the steps of: positioning the heating coil around at least a portion of the elongated support such that the elongated support supports at least a portion of the heating coil and defines a void within a volume defined by the heating coil, the method further comprising at least one of the steps of: inserting the heating coil and the elongated support into at least a portion of the housing; and forming at least a portion of the housing around the heating coil, wherein the housing defines an article contact surface and the heating coil extends into the housing.

[0050] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0051] [Figure 1] This shows a perspective view of the aerosol supply device located within the charging unit. [Figure 2] Figure 1 shows a schematic cross-sectional view of a portion of the aerosol supply device. [Figure 3] Figure 1 shows a schematic cross-sectional view of a portion of the aerosol supply device and the aerosol products of the aerosol supply system. [Figure 4] A perspective view of another aerosol supply device is shown. [Figure 5] Figure 4 shows a schematic cross-sectional view of the device. [Figure 6] Figure 1 or Figure 4 shows a schematic cross-sectional view of the heater of the device. [Figure 7] A perspective view of the elongated support for the heater is shown. [Figure 8] Figure 7 shows a schematic cross-sectional view of a heater equipped with an elongated support. [Figure 9] A flowchart showing the assembly method for a heater for an aerosol supply device is provided.

[0052] [Detailed explanation] According to this disclosure, a “non-flammable” aerosol supply system is a system in which the constituent aerosol-generating materials (or components of the constituent aerosol-generating materials) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0053] In some embodiments, the delivery system is a non-flammable aerosol supply system, such as a powered non-flammable aerosol supply system.

[0054] In some embodiments, the non-flammable aerosol supply system is an electronic cigarette, also known as a vaporization device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0055] In some embodiments, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0056] In some embodiments, the non-flammable aerosol supply system is a hybrid system that generates aerosols using a combination of one or more aerosol-generating materials that can be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0057] Typically, a non-flammable aerosol supply system may comprise a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0058] In some embodiments, the non-flammable aerosol supply device may comprise a region for receiving consumables, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0059] In some embodiments, consumables for use with a non-flammable aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material transfer component, aerosol generator, aerosol generating area, housing, packaging material, filter, suction nozzle, and / or aerosol modifier.

[0060] As used herein, the term “aerosol-generating material” refers to a material that can generate an aerosol when energy is supplied, for example, by heating, irradiation, or any other means. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0061] The aerosol-generating material may comprise one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0062] The aerosol-generating material may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers 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-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0063] The aerosol-generating material may include an aerosol-generating film, or may be in the form of an aerosol-generating film. The aerosol-generating film may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers may also be present. The aerosol-generating film does not have to contain substantially plant-based materials. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0064] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.5 mm or 0.3 mm.

[0065] The aerosol-generating film may be continuous. For example, the film may contain a continuous sheet of material. The sheet may be in the form of packaging material, gathered to form a gathered sheet, or shredded to form a shredded sheet. The shredded sheet may contain one or more strands or strips of the aerosol-generating material.

[0066] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of aerosol-generating material, such as dots, stripes, or lines, which may be supported on a support. In such embodiments, the support may be a flat or non-flat surface.

[0067] An aerosol-generating film can be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other components, such as one or more substances to be delivered, in order to form a slurry, and then by heating the slurry to volatilize at least some of the solvent in order to form an aerosol-generating film.

[0068] An aerosol supply device can receive an article containing an aerosol-generating material for heating. In this context, “article” means a component that contains or is contained with an aerosol-generating material at the time of use, which is heated to volatilize the aerosol-generating material, and optionally, other components at the time of use. The user can insert the article into or on top of the aerosol supply device before it is heated to produce an aerosol, and the user then inhales the aerosol. The article may be of a predetermined or specific size, for example, configured to be placed inside or on top of a heater of a device sized to receive the article.

[0069] 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 supply thermal energy to the aerosol-generating material in order to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0070] Consumables are articles containing or consisting of aerosol-generating materials, some or all of which are intended to be consumed by the user during use. Consumables may comprise 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, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which generates heat to cause the aerosol-generating material to produce an aerosol during use. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0071] A susceptor is a heating material that can be heated by penetration due to a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and as a result, penetration of the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and as a result, penetration of the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and as a result, the susceptor can be heated by both heating mechanisms. An aerosol supply device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0072] A non-flammable aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and replaceable aerosol products. In some implementations, the non-flammable aerosol supply device may include a power supply and a controller (or control circuit). The power supply may include a power source such as a battery or rechargeable battery. In some implementations, the non-flammable aerosol supply device may also include an aerosol generating component. However, in other implementations, the aerosol product may comprise the aerosol generating component partially or entirely.

[0073] Figure 1 shows an aerosol supply system 10 comprising an aerosol supply device 100 and a charging unit 101. The device is shown located within the cavity of the charging unit 101. The aerosol supply device 100 is arranged to generate an aerosol from an aerosol product (see Figure 3) that can be inserted into the aerosol supply device 100 when in use. In the embodiment, the article forms part of the aerosol supply system 10.

[0074] The aerosol supply device 100 is an elongated structure extending along its longitudinal axis. Furthermore, the aerosol supply device has a proximal end that is closest to the user (e.g., the user's mouth) when the user inhales the aerosol produced by the aerosol supply device 100, and a distal end that is furthest from the user when the aerosol supply device 100 is used. The proximal end may also be called the “mouth end.” The aerosol supply device 100 also accordingly defines a proximal direction that faces toward the user when used. Furthermore, the aerosol supply device 100 also similarly defines a distal direction that faces away from the user when used. The terms proximal and distal applied to the function of the device 100 are explained by referring to the relative arrangement of such functions to each other in the proximal-distal direction along the longitudinal axis. The aerosol supply device 100 has an opening at its distal end that leads into a heating chamber.

[0075] The aerosol supply device 100 can be removably inserted into the charging unit 101 for charging. The charging unit 101 includes a cavity (see Figure 2) for receiving the aerosol supply device 100. The aerosol supply device 100 can be inserted into the cavity through an opening. The cavity may also include a longitudinal opening. A portion of the aerosol supply device 100 may include a first side surface. One or more user-operable control elements, such as a button 106, which can be used to operate the aerosol supply device 100, may be provided on the first side surface of the aerosol supply device 100. The first side surface of the aerosol supply device 100 may be received by a longitudinal opening provided in the charging unit 101.

[0076] According to one embodiment, the cavity of the charging unit 101 may have a cross-sectional profile that allows the aerosol supply device 100 to be inserted into the charging unit 101 in only one orientation. According to one embodiment, the outer profile of the aerosol supply device 100 may include a curved portion and a straight portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also include a similar curved portion and a straight portion. The straight portion of the cross-sectional profile of the cavity may correspond to a longitudinal opening.

[0077] The charging unit 101 may include a sliding lid 103. When the aerosol supply device 100 is inserted into the charging unit 101 for recharging, the sliding lid 103 may be closed to cover the opening into the aerosol supply device 100. In other embodiments, the charging unit 101 may have an alternative lid configuration, such as a hinged or pivoted lid, or it may not have a lid at all.

[0078] The charging unit 101 may include a user interface such as a display 108, which can be installed in any convenient location, such as the position shown in Figure 1.

[0079] Figure 2 shows a cross-sectional view of a portion of the aerosol supply device 100. The aerosol supply device 100 comprises a main housing 200. The main housing 200 defines the device body of the device 100. The device 100 defines a heating chamber 201. A receptacle 205 defines the heating chamber 201. An opening 203 is provided to provide access to the heating chamber 201. The receptacle 205 comprises a wall configuration including a receptacle side wall 205a and a receptacle base 205b. The base 205b is at the distal end of the receptacle 205. The heating zone 201a is configured to receive at least a portion of an article for heating.

[0080] The heating element 301 may be provided on a portion of the main housing 200, and the heating element 301 may extend into or protrude into the heating chamber 201. The heating element 301 may have a base 301a that can be located in a recess provided on a portion of the body of the device 100. The heating element 301 stands upright within the heating chamber 201. The heating element 301 stands upright from its distal end.

[0081] The heating element 301 comprises an elongated heating element in the form of a pin. In other embodiments, the heating element 301 may include other elongated components such as blades. The heating element 301 may be inserted into the distal end of the aerosol product 50 (see Figure 3) received in the heating chamber 201 in order to heat the aerosol product internally during use.

[0082] The housing comprises a housing wall 200a. The housing wall 200a extends along the longitudinal axis of the aerosol supply device 100 and surrounds the heating chamber 201. The housing wall 200a can define, at least in part, the receiving chamber of the aerosol supply device 100 as a volume enclosed within the wall 200a. The housing base 200b is at the distal end of the housing wall 200a. In the illustrated embodiment, the heating member 301 rises from the housing base 200b. The heating member 301 protrudes from the receptacle base 205b. The receptacle base 205b has a hole 206 from which the heating member 301 protrudes. In the embodiment, the heating member 301 rests on the receptacle base 205b. The heating member 301 rises from the receptacle base 205b.

[0083] The aerosol supply device 100 further comprises a removal mechanism 204 which can be detachably held in the main housing 200 of the aerosol supply device 100. In embodiments, the removal mechanism 204 is omitted. In embodiments, the housing wall 200a defines a receptacle 205 in at least part of it. The removal mechanism 204 may be held in the main housing 200, so that at least part of the removal mechanism 204 extends into the heating chamber 201. In this embodiment, the removal mechanism 204 may comprise a longitudinal portion such as a tubular peripheral wall portion 207a and a base wall portion 207b. The wall 207a may have a shape other than tubular and may be any shape that encloses (e.g., surrounds) and defines the heating chamber 201 internally.

[0084] In embodiments having a removal mechanism 204, the removal mechanism 204 defines the heating chamber 201. The removal mechanism 204 forms the receptacle 205. In embodiments where the removal mechanism 204 is omitted, other functions of the device 100 define the heating chamber 201, for example, the housing side wall 200a and the housing base 200b.

[0085] The base portion 207b has a hole 206 from which the heating element 301 can protrude. In order to hold the removal mechanism 204 in the main housing 200, the removal mechanism 204 is pushed distally, i.e., toward the distal end of the main housing 200, to engage with the main housing 200 until the removal mechanism 204 can no longer move distally. In the following description, when the removal mechanism 204 is referred to as "held in" the main housing 200, this means that the removal mechanism 204 is engaged with the main housing 200 and cannot move distally.

[0086] The peripheral portion 207a and the base portion 207b may together define and enclose an article chamber for receiving the aerosol product 50, as shown in Figure 3. The article chamber comprises an inner surface configured to contact the aerosol product, the inner surface comprising a longitudinally extending portion provided by the tubular portion 207a and an end portion provided by the base portion 207b. In embodiments, the article chamber and the heating chamber are the same. When the aerosol product 50 is received in the heating chamber, the aerosol product may come into contact with both the longitudinally extending portion and the end portion of the inner surface. In particular, the article chamber (i.e., the peripheral portion 207a and the base portion 207b) may be configured to receive at least a portion of a rod-shaped aerosol product 50 that is longitudinally extending and cylindrical, such that the longitudinal axis of the article is parallel to (and optionally aligned in a line with) the longitudinal axis of the aerosol supply device 100 when received in the article chamber.

[0087] The article chamber may also be called the receiving portion. When the removal mechanism 204 is held in the main housing 200, the article chamber of the removal mechanism 204 is positioned at least partially within the heating chamber 201 during use. The heating member 301 may be positioned to protrude into the article chamber through a hole 206 provided in the base portion 207b of the removal mechanism 204. Thus, the removal mechanism 204 is configured to receive at least a portion of the aerosol product during use.

[0088] In this embodiment, the removal mechanism 204 may include a first magnet or magnetizable material 208. The main housing 200 may include a second magnet or magnetizable material 209. During use, the removal mechanism 204 may be magnetically held to the main housing 200 by the interaction between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209.

[0089] In the embodiment, the removal mechanism 204 is completely separable from the main housing 200. The removal mechanism 204 may be held in the main housing 200 by the magnetic attraction between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209. The removal mechanism 204 may be separated from the main housing 200 by overcoming the magnetic force between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209. In the embodiment, the removal mechanism 204 is removably held in the main housing 200 by other means. For example, the removal mechanism 204 may be configured to be removably held in the main housing 200 by an interlocking fit with the main housing.

[0090] The removal mechanism 204 may comprise an internal element (comprising a tubular portion 207a and a base portion 207b) and an outer cap portion 210, and when held in the main housing 200, the outer cap portion 210 encloses (e.g., covers) at least a portion of the main housing, such as the wall 200a of the main housing 200. The tubular portion 207a, the base portion 207b, and the outer cap portion 210 may comprise a single (e.g., a single) component (e.g., formed by molding). Alternatively, the tubular portion 207a and the base portion 207b may comprise a first component, and the outer cap portion 210 may comprise a second separate component. The first and second components may then be fixed to each other.

[0091] Figure 4 shows another aerosol supply system 40. System 40 comprises an integrated aerosol supply device 400 for generating aerosols from aerosol-generating material, and an aerosol product 50 containing the aerosol-generating material. Device 400 can be used to heat the aerosol product 50 containing the aerosol-generating material to generate an aerosol or other inhalable medium that can be inhaled by a user of device 400.

[0092] The device 400 comprises a housing 500 that surrounds and houses various components of the device 400. The housing 500 is elongated. The device 400 has an opening 504 at one end into which an article 50 can be inserted for heating by the device 400. The article 50 can be fully or partially inserted into the device 400 for heating by the device 400.

[0093] The device 400 may include user-operable control elements 506, such as buttons or switches, which activate when these are activated, for example, pressed. For example, a user can activate the device 400 by pressing a switch 406.

[0094] The device 400 defines a longitudinal axis 509 along which the article 50 may extend when it is inserted into the device 400. The opening 504 is aligned on the longitudinal axis 509.

[0095] Figure 5 shows a schematic cross-sectional view of the aerosol supply system 400. The functions described with reference to Figure 5 in the embodiments are applicable to the embodiments described above. The aerosol supply device may include a power supply 410, a controller 420, and a heating chamber 401 in which the aerosol product 50 is removably received.

[0096] The integrated device in Figure 5 shows a power supply 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of the integrated aerosol supply device 400, the power supply is aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0097] The heating element 301 comprises an elongated heating element in the form of a pin. In embodiments, the heating element 301 comprises other elongated forms such as a blade. The heating element 301 is provided in the heating chamber. The heating element 301 in Figure 5 and the heating element 301 described above with reference to Figures 1 to 3 may each be subject to the details described herein. The heating element 301 extends into or protrudes within the heating chamber 401.

[0098] The heating element 301 can be inserted into the distal end of the aerosol product received in the heating chamber 401 in order to heat the aerosol product internally during use.

[0099] The aerosol supply devices 100,400 include a heating configuration 300. The heating configuration 300 includes a heater. The heating member 301 functions as a heater. The heater includes a heating element 350 (see Figure 6), which includes, for example, a resistance heating coil arranged to operate to heat the heating member.

[0100] The heating configuration 300 is a resistance heating configuration. The heater is a resistance heating heater. Heating elements such as heating coils, described later, are resistance heating elements. In such a configuration, the heating assembly comprises a resistance heating generator which includes components for heating the heating elements via a resistance heating process. In this case, current is applied directly to the resistance heating elements, and as a result, the current flowing through the heating elements functions as heating components, and the heating elements are heated by Joule heating. The resistance heating elements include a resistance material configured to generate heat when an appropriate current passes through the resistance heating elements, and the heating configuration comprises electrical contacts for supplying current to the resistance material. In the embodiment, the heating elements form at least a portion of the resistance heating member itself. In the embodiment, the resistance heating elements transfer heat to the heating member, for example, by conduction. By providing a resistance heating configuration, a compact configuration is possible. Resistance heating provides an efficient form.

[0101] Figure 6 shows a heating element 301 for use in the aerosol supply device described above. The heating element 301 functions as a heater or forms at least part of a heater. The heating configuration 300 comprises the heating element 301. The heating element 301 comprises a housing 302 and a heating element 350.

[0102] The housing 302 is formed from a thermally conductive material such as aluminum. Other suitable materials such as stainless steel or ceramic may be used. The housing 302 is configured to transfer heat from the heating element 350 to the heating zone 201a. The housing 302 extends around the heating element 350. The housing 302 at least partially encloses the heating element 350. In embodiments, the housing 302 is formed from an electrically insulating material. In embodiments, the housing 302 is provided with an electrically insulating coating, such as ceramic, to electrically insulate the housing 302 from the heating element 350. The coating may include a vitreous layer. The coating has a thickness of less than 200 μm. The coating may be a vitreous glaze. The coating may include a vitreous enamel layer. In embodiments, the coating is a vitreous material bonded to the housing 302. In embodiments, the housing 302 is provided with an electrically insulating surface finish, for example, the surface of the housing 302 may be anodized.

[0103] The housing 302 is an elongated member defining a longitudinal axis 315. The housing 302 has a base end 303 and a free end 304. The base end 304 is mounted on the device body. The mounting portion 305 of the base end 303 supports the heating member 301. It will be understood that different mounting configurations may be used, such as bonding including fixing, molding, and adhesive. The mounting portion 305 may be a separate component or may be formed integrally with the housing 302.

[0104] The free end 304 of the housing 302 extends toward the proximal end of the heating chambers 201,401. The free end 304 of the heating member 301 is closed. The tip 311 is provided on the free end 304. The tip 311 extends to the apex 312. Other shapes and forms of the tip 311 may be provided, for example, the tip 311 may define a flat surface.

[0105] The heating element 350 extends to the heating member 301. The heating element 350 extends to the housing 302. The heating element 350 extends between the base end 303 and the distal end 304. In the embodiment, the heating element 350 extends partially along the length of the housing 302. In the embodiment, the heating element 350 extends to or beyond the base end 303.

[0106] The heating element 301 comprises an elongated support 360. The elongated support 360 is an elongated member that defines a longitudinal axis. The longitudinal axis of the elongated support 360 is coaxial with the longitudinal axis 315 of the housing 302. The elongated support 360 extends within the housing 302. In the embodiment, the elongated support 360 extends partially along the length of the housing 302. In the embodiment, the elongated support 360 extends to or beyond the base end 303.

[0107] The elongated support 360 supports the heating element 350. At least a portion of the elongated support 360 is in contact with at least a portion of the heating element 350. The elongated support 360 is a rigid element. The elongated support 360 is self-supporting. The heating element 350 is positioned to at least partially surround the elongated support 360. The heating element 350 extends within the housing 302 around at least a portion of the elongated support 360.

[0108] The heating configuration 300 includes electrical connection paths. The electrical connection paths extend from each end of the heating element 350. A base electrical connection path 352 extends from the distal end of the heating element 350. A return electrical connection path 353 extends from the proximal end of the heating element 350. The return electrical connection path overlaps the longitudinal range of the heating element 350. The electrical connection paths are formed integrally with the heating element, for example, as a single wire. In embodiments, a connector connects the electrical connection paths to the heating element 350. The heating element 350 is formed from a resistant material such as a nickel / chromium alloy like nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0109] In the embodiment, the heating element 350 comprises a heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. In the embodiment, the heating coil 351 comprises an electrically insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the housing 302. In the embodiment, the electrically insulating coating is thermally conductive to provide heat transfer from the heating element 350 to the housing 302. In the embodiment, the electrically insulating coating is omitted. In the embodiment, a separate electrically insulating configuration is provided, such as at least one of an electrically insulating member and an electrically insulating filler. In the embodiment, the electrically insulating member and the electrically insulating filler are thermally conductive to provide heat transfer from the heating element 350 to the housing 302. In the embodiment, the electrically insulating member is provided by the housing 302.

[0110] The heating coil 351 is a resistance heating coil. The heating coil 351 is a helical coil. The heating coil 351 has a helical portion. The heating coil 351 has a rectangular cross-sectional shape. It will be understood that other coil configurations are also possible. In the embodiment, the heating coil 351 has a circular cross-sectional profile. In the embodiment, the heating configuration 300 comprises two or more heating coils.

[0111] The heating coil 351 is wound spirally around the elongated support 360. The heating coil 351 surrounds the elongated support 360. The heating coil 351 defines a longitudinal axis. The longitudinal axis of the heating coil 351 is the longitudinal axis of the elongated support 360. The heating coil 351 defines a roughly tubular shape. The elongated support 360 extends through the center of the heating coil 351. The elongated support 360 is located at the center of the heating coil 351.

[0112] It will be understood that the elongated support 360 improves the rigidity of the heating element 301. The elongated support 360 functions as an internal support element. The elongated support 360 is positioned to prevent deformation of the heating element 301 during the manufacturing of the heater and / or during the use of the device. However, in order to improve the heating efficiency of the heater, the thermal mass of the heating element 301 needs to be reduced.

[0113] The elongated support 360 is formed from an insulating material. The elongated support 360 may be formed from a suitable material such as ceramic or silicone. Other suitable materials are also possible. The elongated support 360 is configured to limit heat transfer between the heating element 350 and other components of the heating configuration 300. By forming the elongated support 360 from an insulating material, the heating efficiency of the heating configuration is improved. Preferably, this embodiment facilitates heat transfer between the heating element 350 and the housing 302. In embodiments, the elongated support 360 is formed from an electrically insulating material. In embodiments, the elongated support 360 is provided with an electrically insulating coating, such as ceramic, to electrically insulate the elongated support 360 from the heating element 350.

[0114] The elongated support 360 defines a void 362. The heating coil 351 extends around at least a portion of the elongated element 360 so that the void 362 is defined within a volume 354. The void 362 defines an air gap. In embodiments, the void 362 is at least partially filled with, for example, a filler. In some embodiments, the filler is a thermal paste or another thermally conductive material. In embodiments, the void 362 accommodates one or more of the electrical connection paths. In embodiments, the return electrical path 353 is housed in the void 362. In embodiments, the elongated support 360 is positioned at least a portion of the return electrical path 353 away from the heating coil 351. One or more further components may extend into the void 362. In such embodiments, the elongated support 360 functions to position at least a portion of such further components at a distance from the heating coil 351.

[0115] In the embodiment, the elongated support 360 comprises a tube 361. The tube 361 defines the longitudinal axis of the elongated support 360. The tube 361 is hollow. The inner surface of the tube 361 defines a cavity 363. The cavity 363 functions as a gap 362. The cavity 363 defines an air gap. In the embodiment, the cavity 363 is at least partially filled with, for example, a filler. In some embodiments, the filler is a thermal paste or another thermally conductive material. In the embodiment, the cavity 363 accommodates one or more of the electrical connection paths. In the embodiment, the tube 361 may have one or more holes 368 for the electrical connection paths to pass through. The tube 361 has a circular cross-sectional shape. It will be understood that other forms are also possible. In the embodiment, the cross-section of the tube 361 is triangular, rectangular, or other polygonal.

[0116] In embodiments shown in Figures 7 and 8, the elongated support 360 comprises a central portion 365 and an arm configuration 366. In embodiments, the arm configuration comprises a plurality of arms 366a. The central portion 365 defines the longitudinal axis of the elongated support 360. The central portion 365 is elongated. The central portion 365 is substantially cylindrical, but other shapes are also conceivable. The central portion 365 is defined as the joint of two or more of the plurality of arms 366a. In embodiments, the cross-section of the central portion 365 is triangular, rectangular, or other polygonal. In embodiments, the central portion 365 comprises a hollow tube.

[0117] The arm configuration 366 comprises one or more arms 366a. In the illustrated embodiment, the plurality of arms 366a comprises three arms. Each arm of the plurality of arms 366a extends from the central portion 365. Each arm of the plurality of arms 366a extends radially outward from the central portion 365. Each arm of the plurality of arms 366a contacts and supports at least a portion of the heating coil 351. Each arm of the plurality of arms 366a has a longitudinal extension. In the embodiment, the arms or each arm extends in a helical configuration in the longitudinal direction. The plurality of arms 366a are formed integrally with the central portion 365, but other configurations are also conceivable. The elongated support 360 may define at least one pocket 367. In configurations with multiple arms, multiple pockets are defined. The pockets or multiple pockets function as gaps 362. Each pocket 367 is defined by the space between adjacent arms 366a. One or more of the pockets 367 may define an air gap. In some embodiments, one or more of the pockets 367 may be at least partially filled with, for example, a filler. In some embodiments, the filler is a thermal paste or another thermally conductive material. In some embodiments, one or more of the pockets 367 may accommodate one or more electrical connection paths.

[0118] The housing 302 includes an article contact surface 313. The article contact surface 313 is the outer surface of the housing 302. At least a portion of the article contact surface 313 is in contact with the aerosol-generating material received by the device for heating. The article contact surface 313 defines a heating surface for heating the aerosol-generating material. The article contact surface 313 defines a boundary with the heating member 301. The article contact surface 313 defines the periphery of the heating member 301. The article contact surface 313 extends between the base end 303 and the free end 304 of the housing 302.

[0119] The article contact surface 313 has a low coefficient of friction to prevent aerosol-generating material from adhering to the heating member 301. Such a surface may be formed, for example, from a coating or finish, and helps to realize a surface that allows self-cleaning when the article 50 is inserted into the heating chamber 201. In embodiments, the article contact surface 313 includes a low-friction material. In embodiments, the article contact surface 313 may include a different material from the body of the housing 302. The low-friction material may be provided by a coating or a surface finish. In embodiments, the entire body of the housing 302 is provided by a low-friction material.

[0120] In embodiments, the article contact surface 313 has a coefficient of friction of less than 1.4, less than 0.7, or less than 0.15. In embodiments, a low-friction material forms the article contact surface 313. In some embodiments, the low-friction material is, for example, diamond-like carbon (DLC). Other suitable materials include copper, glass, graphite, aluminum, and aluminum-magnesium boride (BAM). In embodiments, the low-friction material includes copper, and the body of the housing 302 includes glass. In embodiments, the low-friction material includes either glass or diamond-like carbon (DLC), and the body of the housing 302 includes a metal such as aluminum. In embodiments, the low-friction material includes aluminum, and the body of the housing 302 includes ceramic. However, other combinations of materials are also conceivable. Providing a low-friction article contact surface helps to prevent one or more components of the article, such as glycerol, from adhering to the surface and degrading the heater's performance over time.

[0121] It will be understood that the structural rigidity of the heating element 350 limits the selection of manufacturing processes available for assembling the heating member 301. Providing an elongated support 360 broadens the selection of available processes. Providing an elongated support 360 facilitates the assembly of the heating member 301. The elongated support 360 is configured to prevent deformation of the heating element 360 during assembly. In embodiments, the elongated support 360 is positioned within the heating member 301 to either centrally or elsewhere position the heating element 350. In embodiments, providing an elongated support 360 makes it possible to form a housing 302 on the heating element 350.

[0122] In some embodiments, the housing 302 includes a pre-formed member 306. The pre-formed member 306 is tubular. In some embodiments, the pre-formed member 306 is formed from a film-like or sheet-like thermal conductive material. In some embodiments, the pre-formed member 306 includes a casing. Other configurations are also possible. The pre-formed member 306 includes a bore 307. The bore 307 defines an inner void 308 of the heating member 301. The inner void 308 extends in the longitudinal direction. In some embodiments, the inner void 308 is at least partially filled with, for example, a filler. In some embodiments, the filler is a thermal paste or another thermal conductive material. In some embodiments, the inner void 308 defines an air gap. The inner surface 309 is defined on the inside of the housing 302. The base end 303 is provided with an open end 310 to the inner void 308. The inner void 308 does not penetrate the free end 304. The heating element 350 is received in the inner void 308. The elongated support 360 is received in the inner void 308. In the embodiment, the heating element 350 extends to or beyond the open end 310. In the embodiment, the elongated support 360 extends to or beyond the open end 310. The elongated support 360 is positioned within a pre-formed member 306 so as to center the heating element 350 or elsewhere. The volume 354 defined by the heating coil 351 is defined within the inner void 308.

[0123] In the embodiment, the elongated support 360 is fixed in position relative to the housing 302. In the embodiment, the elongated support 360 forms part of a pre-formed member 306. In the embodiment, the elongated support 360 can be mounted on a pre-formed member 306 by fixing, molding, or joining. In the embodiment, the elongated support 360 may have one or more positioning functions for positioning relative to the pre-formed member 306. In the embodiment, the support forms at least part of the front or base of the housing 302. In such an embodiment, the housing portion extends from at least one of the front and base.

[0124] In this embodiment, the housing 302 includes an overlay instead of a pre-formed member 306. The overlay is formed on top of the heating element 350. The elongated support 360 supports the heating element 350 while the overlay is formed around it. Thus, the elongated support 360 is configured to provide the structural stability necessary for forming the overlay on the heating element 350.

[0125] It will be understood that the overlay may be formed using different configurations. In one embodiment, the overlay is an overformed member. The overformed member is formed by overmolding or casting. In another embodiment, the overlay is a surrounding member. The surrounding member is formed by a wrap. The wrap may comprise one or more layers of material. In one embodiment, the wrap comprises a film-like or sheet-like material. The film or sheet is formed around the heating element 350. In another embodiment, the film or sheet is wrapped around the heating component 350. In yet another embodiment, the overlay may instead be formed by lamination or coating.

[0126] The overlay ensures consistent contact between the heating element 350 and the housing 302. In this embodiment, the heating element 350 is held against the elongated support 360 by the overlay.

[0127] A method for assembling a heater for an aerosol supply device, such as device 100,400, is illustrated in Figure 9. In step 610, the heating coil 351 is positioned around at least a portion of the elongated support 360 such that the elongated support 360 supports at least a portion of the heating coil 351 and defines a gap 362 within the volume defined by the heating coil 351. In embodiments, the gap 362 defines an air gap. In embodiments, the method includes at least partially filling the gap 362 with, for example, a filler. In some embodiments, the filler is a thermal paste or another thermally conductive material. In embodiments, the volume defined by the heating coil 351 defines an air gap. In embodiments, the method includes at least partially filling the volume defined by the heating coil 351 with, for example, a filler. In some embodiments, the filler is a thermal paste or another thermally conductive material. The heating coil 351 and the elongated support 360 form a central configuration. The heating coil 351 may be loosely positioned on the elongated support 360, but other embodiments are also conceivable. For example, the heating coil 351 may be joined to the elongated support 360 to form a central configuration. In step 620, the central configuration is inserted into the housing 302. In step 620, the heating coil 351 and the elongated support 360 are inserted into the housing 302 so that the housing 302 defines the article contact surface 313. In step 620, the heating coil 351 and the elongated support 360 are inserted into the housing 302 so that the heating coil 351 extends within the housing.

[0128] Instead of step 620, the housing may be formed around the central configuration (step 630). In step 630, the housing is formed around the heating coil 351 and the elongated support 360 so as to define the article contact surface 313. In step 630, the housing is formed around the heating coil 351 and the elongated support 360 so as to extend the heating coil 351 into the housing.

[0129] In the embodiments described above, the heating configuration is induction heating. Other types of heating configurations, such as induction heating, are used in the embodiments. The device configuration is generally as described above, so a detailed description is omitted.

[0130] An induction heating configuration comprises various components for heating the aerosol-generating material of an article via an induction heating process. Induction heating is a process of heating a conductive heating element (such as a susceptor) by electromagnetic induction. An induction heating configuration may comprise an induction element, for example, one or more induction coils, and a device for passing a fluctuating current, such as an alternating current, through the induction element. The fluctuating current within the induction element creates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor (heating element) that is suitably positioned relative to the induction element. Compared to heating by conduction, for example, induction heating allows for rapid heating because heat is generated inside the susceptor. Furthermore, since no physical contact is required between the induction element and the susceptor, it increases the freedom of construction and application.

[0131] In induction heating, heat is generated in the susceptor (heating element), whereas in resistance heating, heat is generated in the coil (heating element).

[0132] In this embodiment, the heating element of the aerosol supply system is not part of the aerosol supply device, but rather part of the aerosol product. The heating element may be a resistive heating element, for example, in the form of a resistive coil as described above, provided as part of the aerosol product. Electrical connections allow current to flow through the resistive heating element.

[0133] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed functions. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, actions, functions, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims, or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, disclosed elements, components, functions, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A heater for an aerosol supply device configured to heat an aerosol product containing an aerosol generating material, A housing that defines the contact surface of the article, The elongated support within the housing, A heating coil extending within the housing around at least a portion of the elongated support, Equipped with, The elongated support supports at least a portion of the heating coil and defines a void within the volume defined by the heating coil. Heater for aerosol supply devices.

2. The heater for an aerosol supply device according to claim 1, wherein the article contact surface defines a heating surface.

3. The heater for an aerosol supply device according to claim 1 or 2, wherein the elongated support is tubular.

4. The heater for an aerosol supply device according to claim 1 or 2, wherein the support body comprises a plurality of arms extending from a central portion.

5. The heater for an aerosol supply device according to any one of claims 1 to 4, wherein the void is one of a filled void and a partially filled void.

6. The heater for an aerosol supply device according to any one of claims 1 to 5, wherein the elongated support is configured to position the heating coil at the center of the housing.

7. The heater for an aerosol supply device according to any one of claims 1 to 6, wherein the housing comprises an overlay formed on the heating coil.

8. The heater for an aerosol supply device according to claim 7, wherein the overlay is an overformed member.

9. The heater for an aerosol supply device according to claim 7, wherein the overlay is a surrounding member.

10. The heater for an aerosol supply device according to any one of claims 1 to 6, wherein the housing comprises a pre-formed member.

11. The heater for an aerosol supply device according to any one of claims 1 to 10, wherein the housing comprises a thermally conductive material.

12. The heater for an aerosol supply device according to any one of claims 1 to 11, wherein the elongated support comprises a heat insulating material.

13. A heater for an aerosol supply device according to any one of claims 1 to 12, wherein the heating coil comprises a helical coil portion, the heater comprises a return electrical path, and the elongated support is positioned such that at least a portion of the return electrical path is spaced apart from the helical coil portion.

14. A heater for an aerosol supply device according to any one of claims 1 to 13, wherein at least a portion of the article contact surface includes a low-friction material.

15. The heater for an aerosol supply device according to any one of claims 1 to 14, wherein the heater is a resistance heating heater.

16. The heater for an aerosol supply device according to any one of claims 1 to 15, wherein the heating coil is a resistance heating coil.

17. An aerosol supply device configured to heat an article containing an aerosol-generating material, comprising a heater according to any one of claims 1 to 16.

18. An aerosol supply device configured to heat an aerosol product containing an aerosol generating material, A receptacle arranged to receive at least a portion of the aerosol product, A heating member extending within the receptacle, comprising an elongated support extending within the receptacle, and a heating coil around at least a portion of the elongated support; Equipped with, The elongated support supports at least a portion of the heating coil and defines a void within the volume defined by the heating coil. Aerosol supply device.

19. A system comprising an article containing a heater according to any one of claims 1 to 16, one of the aerosol supply devices according to claim 17 or 18, and an aerosol generating material.

20. A method for assembling a heater for an aerosol supply device configured to heat an aerosol product containing an aerosol generating material, The steps include: an elongated support supporting at least a portion of the heating coil, and arranging the heating coil around at least a portion of the elongated support such that the elongated support defines a void within the volume defined by the heating coil; Includes, The steps include inserting the heating coil and the elongated support into a portion of the housing, The steps include forming a portion of the housing around the heating coil, It further includes at least one of the following: A method for assembling a heater for an aerosol supply device, wherein the housing defines an article contact surface and the heating coil extends into the housing.

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