Heater for aerosol supply device

Abstract

A method for manufacturing a heater for an aerosol supply device, the heater being configured to be inserted into an article to heat an aerosol-generating material of the article. The method comprises the steps of: providing an elongated housing (302) defining a longitudinal axis, the housing defining a cavity (308) inside thereof, the cavity having an internal dimension D1 measured in a direction perpendicular to the longitudinal axis, and the housing comprising an opening (310) to allow access to the cavity; providing a coil (351) having a width D2 greater than the internal dimension D1 when unstressed; applying a stretching force to the coil to provide a stretched coil (351) having a reduced width D3; and inserting the stretched coil into the cavity through the opening such that the coil has an internal dimension D1 inside the cavity.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a heater for an aerosol supply device and a heater for an aerosol supply device.

Background Art

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

[0003] Aerosol supply systems incorporating the aforementioned devices or products are known. A common system uses a heater to create an aerosol from a suitable medium, which is then inhaled by the user. The medium used often needs to be exchanged or changed to provide different aerosols for inhalation. It is known to use a resistive heating system as a heater to generate an aerosol from a suitable medium. Separately from this, it is known that an inductive heating system is used as a heater.

Summary of the Invention

[0004] According to one aspect, a method for manufacturing a heater for an aerosol supply device is provided. The heater is configured to be at least partially inserted into the article to heat the aerosol-generating material of the article. The method comprises A step of providing an elongated housing, wherein the elongated housing defines a longitudinal axis, the elongated housing defines a cavity inside the housing, the cavity has an internal dimension D1 measured in a direction perpendicular to the longitudinal axis, and the elongated housing has an opening that allows access to the cavity, A step of providing a heating element in the form of a coil, wherein the coil has a width D2 greater than the inner dimension D1 when the coil is in a stress-free state. The steps include: applying a stretching force to the coil to provide a stretched coil having a reduced width D3; The steps include inserting the stretched coil into the cavity through the opening such that the coil is located within the cavity having the internal dimension D1, It is equipped with.

[0005] This method may include a step of stopping the application of stretching force to the coil after the coil has been inserted into the cavity.

[0006] This method may include a step of applying a compressive force to the coil in order to further push the coil into the internal cavity after the coil has been inserted into the cavity.

[0007] The compressive force may be applied by pressing one end of the coil.

[0008] This method may include a step of stopping the application of compressive force.

[0009] The stretching force may be stopped after the entire coil has been inserted into the cavity.

[0010] The compressive force may be stopped after the entire coil has been inserted into the cavity.

[0011] The stretching force may be applied by a tool that holds the ends of the coil and maintains the coil in a stretched state.

[0012] The stretched coil may be inserted through the opening using a tool.

[0013] D3 can be smaller than D1.

[0014] This method may include a step of introducing a material mass into the cavity after the coil has been inserted, the material mass holding the coil in place within the cavity.

[0015] The material block may be configured to hold the coil in a fixed position relative to the housing.

[0016] The mass of material may contain adhesive.

[0017] The material mass may close the opening.

[0018] The material mass may be introduced as a liquid configured to harden and form a solid. The compressive force may be removed after this liquid has hardened.

[0019] The heater may be a resistance heater. The coil may be configured to provide heat for heating the aerosol-generating material when current is passed through the coil. The coil may include a first electrical connector that is electrically conductive to a first end of the coil. The coil may include a second electrical connector that is electrically conductive to a second end of the electrical coil. The first and second electrical connectors may extend in a common direction away from the coil. The step of inserting the stretched coil through the opening may include the step of inserting the stretched coil such that the first and second electrical connectors extend from the coil to the opening.

[0020] The housing may be equipped with an electrical insulator to prevent current from flowing from the coil into the housing. The housing may be formed from an electrical insulating material. The inner surface of the housing may be coated with an electrical insulating material.

[0021] The coil comprises an electrical insulator for preventing current from flowing from the coil into the housing. This electrical insulator may be a coating on the outer surface of the coil.

[0022] The heater may be a resistive heating heater.

[0023] The heating member may be a resistive heating member.

[0024] The heating element may be a resistive heating element.

[0025] The coil may be a resistive heating heater coil.

[0026] The heater may be an induction heating heater.

[0027] The heating element may be an induction heating element.

[0028] The coil may be an induction coil.

[0029] A heater for an aerosol supply device, configured to be inserted into the article to heat an aerosol generating material of the article, An elongated housing, the elongated housing defining a longitudinal axis, the elongated housing defining a cavity inside the housing, the cavity having an inner dimension D1 measured in a direction perpendicular to the longitudinal axis, the elongated housing, and A coil located inside the cavity, the coil having a width D2 greater than the inner dimension D1 when the coil is in a stress-free state, and thereby being configured to be pressed against the housing.

[0030] The aerosol supply device may comprise any of the features described above with respect to this method.

[0031] According to one aspect, an aerosol supply device is provided which is configured to heat an article containing an aerosol-generating material, and the device comprises the heater described above. The aerosol supply device may also comprise a heating chamber, in which the heater is located.

[0032] The aerosol supply device may comprise a power source, a controller, and a heating chamber in which the aerosol product is removably housed. The power source may be positioned along the longitudinal axis of the heating chamber. The power source may also be positioned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0033] The aerosol supply device may be configured to support wireless charging. The aerosol supply device may be provided with a charging port (e.g., a USB port) used to connect the power source to an external power source for recharging.

[0034] According to one aspect, an aerosol supply system is provided comprising the aerosol supply device described above and an article containing an aerosol generating material.

[0035] The aerosol supply system may include a charging unit having a cavity for detachably receiving an aerosol supply device. The charging unit may include a movable lid, which 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 from view by the lid when the lid is in the open position.

[0036] In another aspect, a method for generating an aerosol is provided. This method comprises the steps of providing an aerosol supply device equipped with the heater described above, and inserting at least partially the aerosol product into the receiving portion of the heating chamber.

[0037] The aerosol supply device may have any of the heater features described above.

[0038] The aerosol supply system may have any of the heater features described above.

[0039] A method for generating an aerosol may include any of the features or steps described above with respect to the heater. [Brief explanation of the drawing]

[0040] Although these are merely examples, various embodiments will be explained with reference to the following drawings.

[0041] [Figure 1] This is a perspective view of an aerosol supply system, including an aerosol supply device located within a charging unit. [Figure 2] Figure 1 is 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 product of the aerosol supply system. [Figure 4] This is a perspective view of another aerosol supply device. [Figure 5] Figure 4 is a schematic cross-sectional view of the device. [Figure 6] This is a schematic cross-sectional view of the heater of the device shown in Figure 1 or Figure 4. [Figure 7] This is a schematic cross-sectional view of the coil. [Figure 8] This is a schematic cross-sectional view of the stretched coil. [Figure 9] This is a schematic diagram of the method for manufacturing a heater. [Modes for carrying out the invention]

[0042] According to this disclosure, a “non-combustible” aerosol supply system means a system in which the constituent aerosol-generating materials of the aerosol supply system (or its components) are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0043] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as an energy-supplied non-combustible aerosol delivery system.

[0044] In some embodiments, non-combustible aerosol delivery systems are also known as e-cigarettes, vaping devices, or electronic nicotine delivery systems (ENDs), but it is not essential that the aerosol-generating material contains nicotine.

[0045] In some embodiments, a non-combustion 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.

[0046] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of multiple aerosol-generating materials, where one or more of these aerosol-generating materials may be heated. Each of these aerosol-generating materials may be in the form of, for example, 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 contain, for example, tobacco or a non-tobacco product.

[0047] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables used in conjunction with this non-combustible aerosol supply device.

[0048] In some embodiments, the non-combustible aerosol supply device may include a region for receiving consumables, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0049] In some embodiments, consumables used with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0050] As used in this book, the term “aerosol-generating material” refers to a material capable of generating aerosols when, for example, heated, irradiated, or otherwise supplied with energy. Aerosol-generating materials may be in the form of, for example, a solid, liquid, or semi-solid (e.g., a gel), and may or may not contain active substances and / or fragrances.

[0051] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-generating agents, and optionally one or more other functional materials.

[0052] The aerosol-generating material may contain a binder (e.g., a gelling agent) and an aerosol-generating agent. Optionally, a substance to be delivered and / or a filler may also be present. Optionally, a solvent (e.g., water) may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0053] The aerosol-generating material comprises an aerosol-generating film, or may be in the form of an aerosol-generating film. The aerosol-generating film may contain a binder (e.g., a gelling agent) and an aerosol-generating agent. Optionally, a substance to be delivered and / or a filler may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0054] 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.

[0055] The aerosol-generating film may be continuous. For example, the film may comprise a continuous material sheet, or a continuous material sheet. This sheet may be in the form of a wrapper, assembled to form a composite sheet, or shredded to form shredded sheets. The shredded sheets may comprise one or more strands or strips made of the aerosol-generating material.

[0056] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete parts or regions (e.g., dots, stripes, or lines) made of aerosol-generating material, which may be supported on a support. In such embodiments, the support may be planar or nonplanar.

[0057] An aerosol-generating film can be formed by mixing a binder (e.g., a gelling agent) with a solvent (e.g., water), an aerosol-generating agent, and one or more other components (e.g., one or more substances to be delivered) to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film.

[0058] An aerosol supply device can receive an article containing an aerosol-generating material for heating. In this context, “article” means a component containing or containing an aerosol-generating material at the time of use, which is heated at the time of use to volatilize the aerosol-generating material, and optionally other components. The user inserts this article into the aerosol supply device, which then heats the article to generate an aerosol, which the user then inhales. The article may have a predetermined or specific size, for example, designed to be placed in or on a heater of a device having a size that receives the article.

[0059] 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, causing one or more volatile substances to be released from the aerosol-generating material to form an aerosol.

[0060] Consumables are articles comprising or consisting of aerosol-generating material, which are intended to be consumed by the user in whole or in part 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, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may comprise 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.

[0061] A susceptor is a heating element that can be heated by the intrusion of a fluctuating magnetic field (e.g., an alternating magnetic field). The susceptor may be a conductive material that induces inductive heating of the heating element upon intrusion of a fluctuating magnetic field. The heating element may be a magnetic material that induces magnetic hysteresis heating upon intrusion of a fluctuating magnetic field. The susceptor may have both conductivity and magnetism so that it can be heated by both heating mechanisms. In this document, an aerosol supply device configured to generate a fluctuating magnetic field is referred to as a magnetic field generator.

[0062] A non-combustible aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and replaceable aerosol products. In some embodiments, the non-combustible aerosol supply device may include a power source and a controller (or control circuit). The power source may include, for example, a battery or rechargeable battery. In some embodiments, the non-combustible aerosol supply device may also include an aerosol generating component. However, in other embodiments, the aerosol product may partially or completely comprise the aerosol generating component.

[0063] Figure 1 shows an aerosol supply system 10 comprising an aerosol supply device 100 and a charging unit 101. The device is shown positioned within the cavity of the charging unit 101. The aerosol supply device 100 is configured to generate an aerosol from an aerosol product (see Figure 3). This aerosol product can be inserted into the aerosol supply device 100 when in use. In some embodiments, this article forms part of the aerosol supply system 10.

[0064] The aerosol supply device 100 is an elongated structure extending along its longitudinal axis. Furthermore, this 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 generated by the aerosol supply device 100 during use, and a distal end that is furthest from the user during use. The proximal end is also called the "mouth end." Thus, the aerosol supply device 100 also has a proximal direction that approaches the user during use. Furthermore, the aerosol supply device 100 also has a distal direction that moves away from the user during use. The terms proximal and distal applied to the features of the device 100 refer to the relative positional relationship of those features in the proximal-distal direction along the longitudinal axis. The aerosol supply device 100 has an opening at its distal end that leads to a heating chamber.

[0065] The aerosol supply device 100 can be removably inserted into the charging unit 101 for charging. The charging unit 101 has a cavity (see Figure 2) for receiving the aerosol supply device 100. The aerosol supply device 100 may be inserted into this cavity through an opening. This cavity may also have a longitudinal opening. A portion of the aerosol supply device 100 may have a first side. One or more user-operable control elements (e.g., buttons 106) that can be used to operate the aerosol supply device 100 may be provided on the first side of the aerosol supply device 100. The first side of the aerosol supply device 100 may be housed in a longitudinal opening provided in the charging unit 101.

[0066] In some embodiments, 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 have an arc-shaped portion and a straight portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also have a similar arc-shaped portion and a straight portion. The straight portion of the cavity's cross-sectional profile may correspond to a longitudinal opening.

[0067] The charging unit 101 includes a sliding lid 103. When the aerosol supply device 100 is inserted into the charging unit 101 for charging, the sliding lid 103 may be closed to cover the opening to the aerosol supply device 100. In other embodiments, the charging unit 101 may have other lid configurations (e.g., a hinged lid) or may not have a lid at all.

[0068] The charging unit 101 may include a user interface such as a display 108, and this user interface can be provided in any convenient location, such as the location shown in Figure 1.

[0069] Figure 2 is a cross-sectional view of a portion of the aerosol supply device 100. The aerosol supply device 100 comprises a main housing 200, which 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 structure including a receptacle side wall 205a and a receptacle bottom 205b. The bottom 205b is located 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.

[0070] The heating element 301 is provided in a part of the main housing 200, and the heating element 301 extends or protrudes into the heating chamber 201. The heating element 301 may have a base portion 301a, which may be located in a recess provided in a part of the main body of the device 100. The heating element 301 is erected in the heating chamber 201. The heating element 301 is upright from its distal end.

[0071] The heating element 301 comprises an elongated heating element in the form of a pin. In other embodiments, the heating element 301 comprises other elongated configurations (e.g., blades). The heating element 301 may be inserted into the distal end of the aerosol product 50 (see Figure 3) when in use, and the aerosol product 50 is housed in the heating chamber 201 to heat the aerosol product from the inside.

[0072] 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 may, in at least a portion thereof, define the receiving chamber of the aerosol supply device 100 as a space confined 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 is upright from the housing base 200b. The heating member 301 protrudes through the receptacle base 205b. A hole 206 is formed in the receptacle base 205b, and the heating member 301 protrudes through the hole 206. In some embodiments, the heating member 301 is attached to the receptacle base 205b. The heating member 301 is upright from the receptacle base 205b.

[0073] The aerosol supply device 100 further comprises a removal mechanism 204, which may be detachably held in the main housing 200 of the aerosol supply device 100. In some embodiments, the removal mechanism 204 is omitted. In some embodiments, at least a portion of the housing wall 200a defines the receptacle 205. The removal mechanism 204 may be held in the main housing 200 such that at least a portion of the removal mechanism 204 extends into the heating chamber 201. The removal mechanism 204 may comprise a longitudinal portion, such as a peripheral wall portion 207a (which is tubular in the present embodiment), 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) the heating chamber 201 and defines the heating chamber 201 internally.

[0074] In embodiments with 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 features of the device 100, such as the housing sidewall 200a and the housing base 200b, define the heating chamber 201.

[0075] The base portion 207b has a hole 206, and the heating member 301 may protrude through this hole 206. 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, until the removal mechanism 204 can no longer move distally, and engages with the main housing 200. In the following description, when the removal mechanism 204 is said to be "held" in the main housing 200, it means that the removal mechanism 204 is engaged with the main housing 200 and cannot move distally any further.

[0076] 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 includes an inner surface configured to contact the aerosol product, which includes a longitudinally extending portion provided by the tubular portion 207a and an end portion provided by the base portion 207b. In some embodiments, the article chamber and the heating chamber are the same. When the aerosol product 50 is contained in the heating chamber, it 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) is configured to contain at least a portion of the aerosol product 50 that takes the form of a longitudinally extending cylindrical rod, so that when the article is contained in the article chamber, the longitudinal axis of the article is parallel (optionally in a straight line) to the longitudinal axis of the aerosol supply device 100.

[0077] The material chamber is also called the receiving section. When the removal mechanism 204 is held in the main housing 200 during use, the material chamber of the removal mechanism 204 is positioned at least partially within the heating chamber 201. The heating member 301 may be configured to protrude into the material 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.

[0078] 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.

[0079] In some embodiments, the removal mechanism 204 is completely removable from the main housing 200. The removal mechanism 204 may be held in the main housing 200 by an attractive magnetic force between a first magnet or magnetizable material 208 and a second magnet or magnetizable material 209. The removal mechanism 204 can be removed 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 some embodiments, the removal mechanism 204 is detachably held in the main housing 200 by other means. For example, the removal mechanism 204 may be configured to be detachably held in the main housing 200 by an interference fit with the main housing.

[0080] 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, wherein when the removal mechanism 204 is held in the main housing 200, the outer cap portion 210 encloses (e.g., covers) at least a portion of the main housing 200 (e.g., the wall 200a of the main housing). The tubular portion 207a, the base portion 207b, and the outer cap portion 210 may constitute a single (e.g., a single unit) part (e.g., formed by molding). Alternatively, the tubular portion 207a and the base portion 207b may constitute a first part, and the outer cap portion 210 may constitute a second separate part. The first and second parts may then be joined together.

[0081] Figure 4 shows another aerosol supply system 40. System 40 comprises an integrated aerosol supply device 400 for generating an aerosol from an 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 produce an aerosol or other inhalable medium that can be inhaled by the user of device 400.

[0082] The device 400 includes 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 through which an article 50 can be inserted for heating by the device 400. The article 50 may be fully inserted into the device 400 or partially inserted for heating by the device 400.

[0083] Device 400 may include a user-operable control element 506, such as a button or switch, which operates device 400 when operated (e.g., pressed). For example, a user may activate device 400 by pressing a switch 406.

[0084] The device 400 defines a longitudinal axis 509, and when the article 50 is inserted into the device 400, it extends along this longitudinal axis 509. The opening 504 is positioned along the longitudinal axis 509.

[0085] Figure 5 is a schematic cross-sectional view of the aerosol supply system 40. Features described with reference to Figure 5 are applicable to the embodiments described above. The aerosol supply device 400 comprises a power supply 410, a controller 420, and a heating chamber 401, in which the aerosol product 50 is removably housed.

[0086] The integrated device in Figure 5 shows a power supply 410 positioned along the longitudinal axis of the heating chamber 401. In other embodiments of the integrated aerosol generation device, the power supply is positioned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0087] The heating element 301 comprises an elongated heating element in the form of a pin. In some embodiments, the heating element 301 comprises other elongated components, such as a blade. The heating element 301 is located within the heating chamber. The heating element 301 shown in Figure 5 and the heating element 301 described with reference to Figures 1 to 3 may be applied to each of the details described herein. The heating element 301 extends into or protrudes into the heating chamber 401.

[0088] The heating element 301 heats the aerosol product from the inside, and may be inserted into the distal end of the aerosol product contained in the heating chamber 401 during use.

[0089] The aerosol supply devices 100 and 400 include a heating device 300. The heating device 300 includes a heater. The heating member 301 functions as a heater. This heater includes a heating element 350 (see Figure 6), such as a resistance heating coil, configured to act to heat the heating member.

[0090] The heating device 300 is a resistance heating device. The heater is a resistance heating heater. The heating element (e.g., a heating coil) is a resistance heating element, as described below. In such a configuration, the heating assembly comprises a resistance heating generator which includes components for heating the heating element by a resistance heating process. In this case, current is applied directly to the resistance heating element, and the resulting flow of current within the heating element (which functions as a heating component) causes the heating element to be heated by Joule heating. The resistance heating element comprises a resistance material configured to generate heat when a suitable current passes through it, and the heating device comprises electrical contacts for supplying current to the resistance material. In some embodiments, the heating element forms at least a portion of the resistance heating member itself. In some embodiments, the resistance heating element transfers heat to the heating member, for example, by conduction. Adopting a resistance heating device allows for a compact device. Resistance heating provides an efficient configuration.

[0091] Figure 6 shows a heating element 301 used in the aerosol supply device described above. The heating element 301 functions as or forms at least part of the heater 300. The heater 300 comprises the heating element 301. The heating element 301 comprises an elongated housing 302 and a heating element 350. The elongated housing 302 defines a longitudinal axis.

[0092] The elongated housing 302 is formed from a thermally conductive material such as stainless steel. The elongated housing may have a coating on its outer surface. The elongated housing 302 is configured to transfer heat from the heating element 350 to the heating zone 201a.

[0093] The elongated housing 302 has a base end 303 and a free end 304. The base end 304 is attached to the device body. A mount 305 located at the base end 303 mounts the heating element 301. It will be understood that different mounting configurations (e.g., fixed, molded, and bonded (including adhesive)) may be used. The mount 305 may be a separate part or may be formed integrally with the elongated housing 302.

[0094] The elongated housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body 306 has a lumen 307. The lumen 307 defines a cavity 308 of the heating member 301. The cavity 308 is located inside the housing 302. The cavity 308 extends in the longitudinal direction. In some embodiments, the cavity 308 is at least partially filled, for example, with a filler. In some embodiments, the cavity 308 is completely filled, for example, with one or more fillers and / or members. In some embodiments, the internal cavity 308 defines an air gap. The inner surface 309 is defined on the inner surface of the elongated housing 302. The opening 310 of the cavity 308 is provided at the base end 303.

[0095] The free end 304 of the elongated housing 302 extends toward the proximal end of the heating chamber. The free end 304 of the heating member 301 is closed. The cavity 308 does not penetrate the free end 304. The tip 311 is provided at the free end 304. The tip 311 extends toward the apex 312. The tip 311 is conical. The tip 311 may have other shapes and configurations; for example, the tip 311 may define a flat surface.

[0096] The heating element 350 extends within the heating member 301. The heating element 350 extends longitudinally within the elongated housing 302. The heating element 350 is housed in a cavity 308. The heating element 350 extends between the base end 303 and the distal end 304. In some embodiments, the heating element 350 extends partially along the length of the cavity 308. In some embodiments, the heating element 350 extends to the open end 310 or extends beyond the open end 310.

[0097] In some embodiments, the heating element 350 comprises a heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. In some embodiments, the heating coil 351 comprises an electrically insulating coating, such as ceramic, for electrically insulating the heating coil 351 from the elongated housing 302. In some embodiments, the electrically insulating coating is thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In some embodiments, the electrically insulating coating is omitted. In some embodiments, a separate electrical insulation configuration (e.g., at least one of an electrically insulating member and an electrically insulating filler) is provided. In some embodiments, the electrically insulating member and the electrically insulating filler are thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302.

[0098] The heating coil 351 is a resistance heating coil. The heating coil 351 is a helical coil. The heating coil 351 has a rectangular cross-sectional profile. It will be understood that other coil configurations are possible. In some embodiments, the heating coil 351 has a circular cross-sectional profile. In some embodiments, the heating device 300 comprises two or more heating coils.

[0099] The heating device 300 is equipped with electrical connectors. The electrical connectors extend from each end of the heating element 350. A base electrical connector 352 extends from the distal end of the heating element 350. A return electrical connector 353 extends from the proximal end of the heating element 350. The return electrical connector overlaps with the longitudinal region of the heating element 350. These electrical connectors are formed integrally with the heating element, for example, as a single wire. The heating coil 351 is formed from a resistive material such as a nickel / chromium alloy (e.g., nichrome 80 / 20 (80% nickel, 20% chromium)), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0100] The cavity 308 has an internal dimension D1. The internal dimension D1 is measured in a direction perpendicular to the longitudinal axis 312. The internal dimension D1 is the width of the cavity 308. The internal dimension D1 is the diameter of the cavity 308. The internal dimension D1 is the minimum width of the cavity 308 between the opening 310 and the proximal end of the heating element 305. In this example, the cavity 308 has a substantially constant width.

[0101] The heating element 301 comprises a material block 312. The material block 312 contains an adhesive. The material block 312 is formed from the adhesive. The adhesive may be a potting compound. The material block 312 extends across the cavity 308. The material block 312 substantially seals the cavity 308. The material block 312 holds the coil 351 in place within the cavity 308. Electrical connectors 352 and 353 extend through the material block 312. The material block 312 holds the coil 351 in place within the cavity 308 by holding the electrical connectors 352 and 353.

[0102] Referring to Figure 7, coil 351 is shown in a stress-free state. In the stress-free state, coil 351 has a width D2. The width D2 is measured in a direction perpendicular to the longitudinal axis 312. Since coil 351 is a helical coil, the width D2 is the diameter of coil 351. The width of coil 351 is substantially constant. The width D2 of coil 351 is greater than the internal dimension D1.

[0103] Referring to Figure 8, the stretched coil 351', i.e., the coil 351 in a stretched state, is shown. In the stretched state, a stretching force is applied to the coil 351, causing it to stretch. This increases the length of the coil 351 and decreases its width (here again measured in a direction perpendicular to the longitudinal axis 312). In this way, the stretched coil 351' has a width (diameter in this example) D3. The width D3 of the stretched coil 351' is smaller than the width D2 of the coil 351. Furthermore, the width D3 of the stretched coil 351' is smaller than the inner dimension D1 of the cavity 308, which means that the stretched coil 351' can be inserted into the cavity 308 more easily.

[0104] Referring to Figure 9, a method 500 for manufacturing a heating element 300 from an elongated housing 302 and a coil 351 is shown. The method comprises a first step 502, a second step 504, a third step 506, a fourth step 508, a fifth step 510, and a sixth step 512.

[0105] In the first step 502, a stretching force is applied to the coil 351 to provide a stretched coil 351'. The stretching force acts to increase the distance between the proximal and distal ends of the coil 351. In this example, this force is applied using electrical connectors 352 and 353, where a pushing force is applied to the return electrical connector 353 and a relative pulling force is applied to the distal electrical connector 352. In other examples, a tool may be used to apply the stretching force. The tool may maintain the increased distance between the proximal and distal ends of the coil 351, thereby maintaining the coil as a stretched coil 351'. The tool may apply force to the electrical connectors 352 and 353 as described above. Alternatively, the tool may extend through the inside of the coil and grip the ends of the coil to apply the stretching force. As described above, the stretched coil 351' has a width D3 that is reduced compared to the width D2 when the coil 351 is stress-free.

[0106] In the second step 504, the stretched coil 351' is inserted into the cavity 308 through the opening 310. The stretched coil 351' is maintained in a stretched state during insertion, and the width D3 of the stretched coil 351' remains smaller than the inner dimension D1 of the cavity 308. In other examples, a tool may be used to apply a stretching force between the proximal and distal ends of the stretched coil 351'.

[0107] In the third step 506, the stretching force is removed. This increases the width of the coil 351. However, since the stress-free width D2 of the coil 351 is greater than the internal dimension D1 of the cavity 308, the coil 351 cannot return to a stress-free state. The coil 351 is pressed against the elongated housing 306, which may help to hold the coil 351 within the cavity 308 and to increase heat conduction between the coil 351 and the elongated housing 306.

[0108] In the fourth step 508, a compressive force is applied to the coil 351, pushing it further into the cavity 308.

[0109] In the fifth step 512, the material mass 312 is introduced into the cavity 308. The material mass 312 extends across the width of the cavity 308, substantially sealing the cavity 308 and closing the opening 310. The material mass 312 is introduced in liquid form and then hardens to form a solid. The material mass 312 is an adhesive. The material mass 312 is a potting compound. The electrical connectors 352 and 353 extend through the material mass 312. This allows the material mass 312 to hold the coil 351 in place within the cavity 308.

[0110] In the sixth step 510, the compressive force is removed after the material mass 312 has hardened. In some examples, if the coil 351 can be easily inserted into the cavity 308 for a sufficient distance in the third step 506, the fourth step 508 and the fifth step 510 may not be performed.

[0111] In the embodiments described above, the heating device is a resistance heating device. In some embodiments, other types of heating devices, such as induction heating devices, are used. The configuration of the device is generally as described above, and a detailed explanation is omitted.

[0112] An induction heating apparatus comprises various components for heating an aerosol-generating material of an article by an induction heating process. Induction heating is a process of heating a conductive heating element (e.g., a susceptor) by electromagnetic induction. An induction heating apparatus may comprise an induction element (e.g., one or more induction coils) and a device that passes a fluctuating current (e.g., alternating current) through the induction element. The fluctuating current within the induction element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor (heating element) appropriately 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, there is a high degree of freedom in construction and application.

[0113] In induction heating, heat is generated within the susceptor (heating element), whereas in resistance heating, heat is generated within the coil (heating element).

[0114] In some embodiments, the heating element of the aerosol supply system is part of the aerosol product and not part of the aerosol supply device. The heating element may be a resistive heating element (e.g., in the form of the resistive coil described above) provided as part of the aerosol product. Electrical connections may be made to allow current to flow through this resistive heating element.

[0115] The various embodiments described herein are presented solely to aid in the understanding and teaching of the features described in the claims. These embodiments are provided only as representative examples of the embodiments and are neither exhaustive nor exclusive. The advantages, embodiments, examples, functions, features, structures and / or other aspects described herein should not be considered as limitations to the scope of the invention as defined by the claims or to equivalents thereof, and other embodiments may be used or modified without departing from the scope of the invention as described in the claims. Various embodiments of the present invention may appropriately comprise, have, or essentially comprise appropriate combinations of disclosed elements, parts, features, parts, processes, means, etc., other than those specifically described herein. Furthermore, this disclosure may include other inventions that are not currently described in the claims but may be described in the claims in the future.

Claims

1. A method for manufacturing a heater for an aerosol supply device, wherein the heater is configured to be at least partially inserted into an article to heat an aerosol-generating material of the article, A step of providing an elongated housing, wherein the elongated housing defines a longitudinal axis, the elongated housing defines a cavity inside the housing, the cavity has an internal dimension D1 measured in a direction perpendicular to the longitudinal axis, and the elongated housing has an opening that allows access to the cavity, A step of providing a heating element in the form of a coil, wherein the coil has a width D2 greater than the inner dimension D1 when the coil is in a stress-free state. The steps include: applying stretching force to the coil to provide a stretched coil having a reduced width D3; The steps include inserting the stretched coil into the cavity through the opening such that the coil is located within the cavity having the internal dimension D1, A method for providing this.

2. The method according to claim 1, further comprising the step of stopping the application of the stretching force to the coil after the coil has been inserted into the cavity.

3. The method according to claim 1 or 2, further comprising the step of applying a compressive force to the coil in order to push the coil further into the cavity after the coil has been inserted into the cavity.

4. The method according to claim 3, wherein the compressive force is applied by pressing one end of the coil.

5. The method according to claim 3 or 4, further comprising the step of stopping the application of the compressive force.

6. The method according to any one of claims 1 to 5, wherein the stretching force is applied by a tool, and the tool holds the end of the coil and maintains the coil in a stretched state.

7. The method according to claim 6, wherein the stretched coil is inserted through the opening using the tool.

8. The method according to any one of claims 1 to 7, further comprising the step of introducing a mass of material into the cavity after inserting the coil, wherein the mass of material holds the coil in the cavity.

9. The method according to claim 8, wherein the material mass is configured to hold the coil in a fixed position relative to the housing.

10. The method according to claim 8 or 9, wherein the material mass includes an adhesive.

11. The method according to any one of claims 8 to 10, wherein the material mass closes the opening.

12. The method according to any one of claims 8 to 11, wherein the material mass is introduced as a liquid configured to harden and form a solid, and the compressive force is removed after the liquid has hardened.

13. The method according to any one of claims 1 to 12, wherein the heater is a resistance heater, the coil is configured to provide heat for heating the aerosol-generating material when current is passed through the coil, the coil comprises a first electrical connector electrically connected to a first end of the coil and a second electrical connector electrically connected to a second end of the coil, the first and second electrical connectors extending in a common direction away from the coil.

14. The method according to any one of claims 1 to 13, wherein the housing and / or the coil are provided with an electrical insulator for preventing current from flowing from the coil into the housing.

15. A heater for an aerosol supply device, configured to be inserted into an article to heat the aerosol-generating material of the article, An elongated housing, wherein the elongated housing defines a longitudinal axis, the elongated housing defines a cavity inside the housing, and the cavity has an internal dimension D1 measured in a direction perpendicular to the longitudinal axis, A coil located inside the cavity, having a width D2 greater than the internal dimension D1 when the coil is in a stress-free state, A heater equipped with this feature.

16. A system comprising the aerosol supply device described in claim 15 and an aerosol product.

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