Heater for aerosol supply device

Abstract

A heater (301) for an aerosol supply device is provided, configured to heat an article (50) containing an aerosol-generating material. The heater (301) comprises an elongated housing (302) and a heating element (350) located within the elongated housing (302). The elongated housing (302) includes an overmolded portion (313) overmolded over the heating element (350).

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 forming 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 include so-called "non-combustion heating type" products that release compounds by heating a material without burning it, 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-mentioned devices and 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 replace 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.

Summary of the Invention

[0004] According to one aspect, there is provided a heater for an aerosol supply device configured to heat an article containing an aerosol-generating material, the heater comprising an elongated housing and a heating element within the elongated housing, the elongated housing comprising an overmoulded portion overmoulded over the heating element.

[0005] The overmolded portion may be overmolded onto the heating element.

[0006] The elongated housing may have a base, and the overmolded portion may extend from the base toward the free end of the heater.

[0007] The elongated housing may have a tip, and the overmolded portion may extend from the top of the heater towards the base.

[0008] The elongated housing may have a defined longitudinal axis, and the overmolded portion may define the longitudinal range of the elongated housing.

[0009] The overmolded portion may extend between at least two portions of the heating element.

[0010] The heating element may include a coil. The coil may be a resistive coil. The coil may be a helical coil.

[0011] The heating element may include a base end electrical path and a return end electrical path. The overmolded portion may be overmolded on at least a portion of the return end electrical path.

[0012] The overmolded portion may extend between at least two turns of the coil.

[0013] The heating element may define the void at least partially, and the overmolded portion may extend into the void. The heating element may define the void. The overmolded portion may fill the void.

[0014] The overmolded portion may be electrically insulating.

[0015] The heating element may be provided with an electrical insulating cover, and the overmolded portion may be overmolded onto the electrical insulating cover.

[0016] The overmolded portion may be conductive.

[0017] The overmolded portion may be thermally conductive and configured to conduct heat from the heating element to the outer surface of the overmolded portion.

[0018] The overmolded portion may be formed from an overmolding composition. The overmolded portion may contain polyethylene nanofibers. The overmolded portion may contain a matrix and a particulate material. The particulate material may have a lower thermal capacitance than the matrix. The matrix may be a resin. The matrix may contain one or more of polyether ether ketone (PEEK), polytetrafluoroethylene (PTFE), polyamide, and liquid crystal polymer (LCP). The particulate material may contain at least one of glass and ceramic. The ceramic may contain aluminum nitride.

[0019] The particulate material does not need to be conductive.

[0020] The particulate material may contain microspheres. The microspheres may contain at least one of glass and ceramic. The ceramic may contain aluminum nitride.

[0021] The heater element may include a resistive material of at least one length, an electrical input, and an electrical output.

[0022] The overmolded portion may be configured to support the heating element.

[0023] The heater may comprise a support, the heater element is supported on the support, and the overmolded portion extends over the heater element and the support. The support may comprise a shaft extending in the longitudinal direction of the elongated housing. The support may define a support cavity that does not include the overmolded portion. The support may be tubular.

[0024] The overmolded portion may be overmolded on at least a portion of the support.

[0025] The overmolded portion may be overmolded on at least a portion of the support.

[0026] The support may comprise a proximal end portion and a free end portion, and the free end portion is configured to be easily inserted into the aerosol generating article.

[0027] The support may comprise a shaft.

[0028] The support may comprise a first portion and a second portion, each portion having a different diameter from the other, and the housing abuts against only one of the first or second portions.

[0029] The support may comprise a stepped change in diameter. The overmolded portion may abut against the first portion at the proximal end portion of the support member. The overmolded portion may abut against the stepped change.

[0030] The overmolded portion may define at least a portion of the outer surface of the housing.

[0031] The housing may comprise an outer surface of the housing, and at least a part of the outer surface comprises a coating having a coefficient of friction lower than that of the outer surface of the housing.

[0032] The housing may have a smooth outer surface.

[0033] At least 50%, at least 70%, or at least 80% of the outer surface area of ​​the housing may support a coating having a coefficient of friction lower than that of the outer surface of the housing.

[0034] The heater may be a resistance heater.

[0035] The heating element may also be a resistance heating element.

[0036] The heating element may also be a resistive heating element.

[0037] The coil may also be a resistance heating coil.

[0038] The heater may be an induction heater.

[0039] The heating element may be an induction heating element.

[0040] The coil may also be an induction coil.

[0041] In another embodiment, a heater for an aerosol supply device is provided, configured to heat an article containing an aerosol-generating material, the heater comprising an elongated housing and a heating element within the elongated housing, the elongated housing comprising a sintered portion, and at least a portion of the heating element being embedded in the sintered portion.

[0042] The sintered portion can be sintered after the heating element has been embedded inside.

[0043] The heater may be a resistance heater. The heating member may be a resistance heater. The heating element may be a resistance heater. The coil may be a resistance heater coil. The heater may be an induction heater. The heating element may be an induction heater. The coil may be an induction coil.

[0044] In another embodiment, a heater for an aerosol supply device is provided, configured to heat an article containing an aerosol-generating material, the heater comprising an elongated housing and a heating element within the elongated housing, the elongated housing comprising a formed portion, at least a portion of the heating element being embedded in the formed portion. In this embodiment, the formed portion is a sintered portion.

[0045] In this embodiment, the formed portion is an overmolded portion.

[0046] 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.

[0047] According to one embodiment, an aerosol supply device is provided configured to heat an article containing an aerosol-generating material, the aerosol supply device comprising a receptacle configured to receive at least a portion of the article containing the aerosol-generating material, and a heater protruding into the receptacle, the heater comprising a housing and a heating element within the housing, the housing comprising a sintered portion provided on at least a portion of the heating element protruding into the receptacle.

[0048] According to one embodiment, an aerosol supply device is provided configured to heat an article containing an aerosol-generating material, the aerosol supply device comprising a heater protruding into the receptacle, a receptacle configured to receive at least a portion of the article containing the aerosol-generating material, a housing, and a heating element within the housing, the housing comprising an overmolded portion overmolded onto at least a portion of the heating element protruding into the receptacle.

[0049] At least a portion of the overmolded section may protrude into the receptacle.

[0050] The receptacle may define the heating chamber.

[0051] The overmolded portion may be fluidly isolated from the heating chamber.

[0052] According to one embodiment, a system is provided comprising either the heater or aerosol supply device described above and an article comprising an aerosol generating material.

[0053] According to one embodiment, a method is provided for forming a heater for an aerosol supply device configured to heat an article containing an aerosol generating material, the method comprising providing an elongated heating element and overmolding a molding material onto at least a portion of the heating element to form an elongated housing.

[0054] According to one embodiment, a method is provided for forming a heater for an aerosol supply device configured to heat an article containing an aerosol generating material, the method comprising providing an elongated heating element and sintering a sintered material onto at least a portion of the heating element to form an elongated housing.

[0055] According to one embodiment, an aerosol supply device is provided that is configured to heat an article comprising an aerosol-generating material, the device comprising a heater as described above. The aerosol supply device may also comprise a heating chamber provided with the heater.

[0056] The aerosol supply device may comprise a power source, a controller, and a heating chamber, and the aerosol product is removably received. The power source may be aligned along the longitudinal axis of the heating chamber. The power source may also be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0057] The aerosol supply device may be configured for wireless charging.

[0058] According to one embodiment, an aerosol supply system is provided which comprises the above-described aerosol supply device and an article comprising an aerosol generating material.

[0059] 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 may be visible to the user when the movable lid is in the closed position, and may be partially or completely hidden by the lid or hidden from view when the lid is in the open position.

[0060] In another embodiment, a method for generating an aerosol is provided, comprising providing an aerosol supply device equipped with the heater described above, and inserting at least partially the aerosol product into a receiving portion of a heating chamber.

[0061] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0062] [Figure 1] A perspective view of the aerosol supply system, including the aerosol supply device located within the charging unit, is shown. [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] Figure 1 or Figure 4 shows a schematic cross-sectional view of another heater. [Modes for carrying out the invention]

[0063] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or their components) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0064] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0065] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping 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.

[0066] In some embodiments, the 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.

[0067] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of one or more aerosol-generating materials, each of which may 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.

[0068] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0069] In some embodiments, the non-combustion aerosol supply device may comprise an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a suction port, a filter, and / or an aerosol modifier.

[0070] In some embodiments, consumables for use 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, packaging material, a filter, a suction nozzle, and / or an aerosol modifier.

[0071] As used herein, the term “aerosol-generating material” refers to a material that can generate an aerosol when heated, irradiated, or energized in any other way. 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.

[0072] 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.

[0073] 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.

[0074] 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 may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0075] 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.

[0076] The aerosol-generating film may be continuous. For example, the film may include a continuous sheet of material, or may be a continuous sheet of material. The sheet may be in the form of packaging material, may be gathered to form a gathered sheet, or may be shredded to form a shredded sheet. The shredded sheet may include one or more strands or strips of the aerosol-generating material.

[0077] 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 can be supported on a support. In such embodiments, the support may be planar or non-planar.

[0078] 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 to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form an aerosol-generating film.

[0079] An aerosol supply device can receive an article comprising an aerosol-generating material for heating. In this context, “article” refers to a component that contains or is equipped with an aerosol-generating material at the time of use, and optionally other components at the time of use, which is heated to volatilize the aerosol-generating material. The user may insert the article into or onto the aerosol supply device before the article is heated to generate an aerosol, after which the user inhales the aerosol. The article may be of a predetermined or specific size, for example, configured to be placed in or on a heater of a device sized to receive the article.

[0080] 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 so that it releases one or more volatile substances from the material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to supply one or more of the following to the aerosol-generating material: vibration, pressure increase, or electrostatic energy.

[0081] Consumables are articles comprising or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. 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 comprise an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0082] A susceptor is a heating material that can be heated by penetration by 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 a 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 a 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.

[0083] 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 implementations, the non-combustible aerosol supply device may comprise a power source and a controller (or control circuit). The power source may comprise a power source such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol supply device may also comprise an aerosol generating component. However, in other implementations, the aerosol product may comprise the aerosol generating component partially or entirely.

[0084] 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 arranged to generate aerosols 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.

[0085] 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 used by a user inhaling the aerosol produced by the aerosol supply device 100, and a distal end that is furthest from the user when used. The proximal end may also be called the “mouthpiece end”. Thus, the aerosol supply device 100 also defines a proximal direction that is oriented toward the user when used. Furthermore, the aerosol supply device 100 similarly defines a distal direction that is oriented away from the user when used. The terms proximal and distal applied to the features of the device 100 are explained by referring to the relative positioning of such features relative 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.

[0086] The aerosol supply device 100 may be removably inserted into a 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 may 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 have 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 into a longitudinal opening provided in the charging unit 101.

[0087] In 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 comprise a curved portion and a straight portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also comprise a similar curved portion and a straight portion. The straight portion of the cavity's cross-sectional profile may correspond to a longitudinal opening.

[0088] The charging unit 101 includes 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 to 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 may not have a lid at all.

[0089] 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.

[0090] 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, 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 base 205b. The base 205b is located at the distal end of the receptacle 205. A heating zone 201a is configured to heat at least a portion of an article.

[0091] The heating element 301 is provided within a portion of the main housing 200, and the heating element 301 extends into or protrudes into the heating chamber 201. The heating element 301 functions as a heater. The heating element 301 may include a base portion 301a that can be positioned in a recess provided within 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.

[0092] The heating element 301 includes an elongated heating element in the form of a pin. In other embodiments, the heating element 301 includes other elongated configurations such as blades. The heating element 301 can be inserted into the distal end of the aerosol product 50 (see Figure 3) housed in the heating chamber 201 to heat the aerosol product from the inside when in use.

[0093] 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 at least partially define the receiving chamber of the aerosol supply device 100 as a volume enclosed within the wall 200a. A housing base 200b is located 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 through the receptacle base 205b. An aperture 206 is formed within the receptacle base 205b, and the heating member 301 protrudes through the aperture 206. In the embodiment, the heating member 301 is attached to the receptacle base 205b. The heating member 301 rises from the receptacle base 205b.

[0094] 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. The removal mechanism 204 in the embodiment is omitted. In the embodiment, the housing wall 200a defines the receptacle 205 at least partially. The removal mechanism 204 may be held in the main housing 200, so that at least a portion 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 inside.

[0095] 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 features of the device 100 define the heating chamber 201, such as the housing side wall 200a and the housing base 200b.

[0096] The base portion 207b has an aperture 206, and the heating element 301 may protrude through the aperture 206. In order to retain 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 "retained" 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.

[0097] As shown in Figure 3, the circumferential portion 207a and the base portion 207b together may define and enclose an article chamber for receiving the aerosol product 50. The article chamber has 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 50 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 circumferential portion 207a and the base portion 207b) may be configured to receive at least a portion of the aerosol product 50, which is in the form of a longitudinally extending cylindrical rod, 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 the article is received in the article chamber.

[0098] The article chamber may also be called the receiving portion. When the removal mechanism 204 is held in the main housing 200 during use, the article chamber of the removal mechanism 204 is at least partially located within the heating chamber 201. The heating member 301 may be positioned to protrude into the article chamber through an aperture 206 provided within 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.

[0099] 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.

[0100] In the embodiment, the removal mechanism 204 is completely separable from the main housing 200. The removal mechanism 204 may be held in place 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 place by the main housing 200 by other means. For example, the removal mechanism 204 may be configured to be removably held in place by an interlocking fit with the main housing.

[0101] The removal mechanism 204 may comprise an internal element (having 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 unit) component (formed by molding, having, for example, one or two features fixed in the molding process). 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. In this case, the first and second components may be fixed to each other.

[0102] Figure 4 shows another aerosol generation system 40. System 40 comprises an integrated aerosol generation device 400 for generating an aerosol from an aerosol-generating material, and the aerosol product 50 comprises an aerosol-generating medium. Device 400 can be used to heat the aerosol product 50, which comprises the aerosol-generating medium, to generate an aerosol or other inhalable medium that can be inhaled by the user of device 400.

[0103] 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, through 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.

[0104] The device 400 may include a user-operable control element 506, such as a button or switch, which operates the device 400 when operated, for example, when pressed. For example, the user may activate the device 400 by pressing a switch 406.

[0105] The device 400 defines a longitudinal axis 509, and the article 50 may extend along the longitudinal axis 509 when inserted into the device 400. The opening 504 is aligned on the longitudinal axis 509.

[0106] Figure 5 is a schematic cross-sectional view of the aerosol generation system 40. Features described with reference to Figure 5 in the embodiments are applicable to the embodiments described above. The aerosol generation device comprises a power source 410, a controller 420, and a heating chamber 401 in which the aerosol product 50 is removably received.

[0107] The integrated device in Figure 5 shows a power source 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of the integrated aerosol generating device, the power source is aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0108] The heating element 301 includes an elongated heating element in the form of a pin. In embodiments, the heating element 301 includes other elongated configurations such as blades. The heating element 301 is provided within the heating chamber. The heating element 301 in Figure 5 and the heating element 301 described above with reference to Figures 1 to 3 can each be applied as described in detail herein. The heating element 301 extends into or protrudes into the heating chamber 401.

[0109] 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 from the inside when in use.

[0110] The aerosol supply devices 100 and 400 include a heating component 300. The heating component 300 includes a heater. The heating element 301 functions as a heater. The heater includes a heating element 350 (see Figure 6), such as a resistance heating coil, which is arranged to operate to heat the heating element.

[0111] The heating component 300 is a resistance heating component. The heater is a resistance heating heater. The heating element, such as the heating coil described later, is a resistance heating element. In such a component, the heating assembly includes a resistance heating generator which includes components for heating the heating element by a resistance heating process. In this case, current is passed directly through the resistance heating element, and the resulting current flow within the heating element acts as a heating component, heating the heating element by Joule heating. The resistance heating element includes a resistance material configured to generate heat when a suitable current passes through the resistance heating element, and the heating component includes electrical contacts for supplying current to the resistance material. In the embodiment, the heating element forms at least a part of the resistance heating member itself. In the embodiment, the resistance heating element transfers heat to the heating member, for example, by conduction. By providing a resistance heating component, a compact component is possible. Resistance heating provides an efficient configuration.

[0112] Figure 6 shows a heating element 301 for use in the aerosol supply device described above. The heating element 301 acts as a heater or forms at least part of a heater. The heating component 300 comprises the heating element 301. The heating element 301 comprises an elongated housing 302 and a heating element 350. The elongated housing 302 is an elongated member that defines a longitudinal axis. The housing 302 forms a cover for the heating element 350. The housing 302 and the heating element 350 are integrally formed. The housing 302 and the heating element 350 are inseparable after the manufacturing process of the heating element 301.

[0113] The elongated housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body is cylindrical. Other external shapes are also conceivable.

[0114] The elongated housing 302 is formed by overmolding. The elongated housing 302 includes an overmolded portion 313. The overmolded portion 313 functions as a formed part. In Figures 6 and 7, the entire elongated housing 302 is formed by the overmolded portion 313. In embodiments, at least a portion of the elongated housing includes the overmolded portion. In some embodiments described below, the housing comprises the overmolded portion 313 and further components such as a base, a tip, and a portion of at least one of a support.

[0115] The overmolded portion 313 is overmolded onto the heating element 350. In the configuration shown in Figure 6, the overmolded portion 313 is overmolded onto the heating element 350. The overmolded portion 313 is in contact with the heating element 350. In the embodiment, the heating element 350 includes an electrical insulating layer, such as a ceramic coating. In the embodiment, the overmolded portion 313 is formed from the electrical insulating layer. In such embodiments, the electrical insulating layer of the heating coil may be omitted. The overmolded portion 313 is in contact with at least the outer surface of the heating element 350. The housing 302 functions to support the heating element 350.

[0116] The overmolded portion 313 defines at least a portion of the outer surface 307 of the elongated housing 302. The elongated housing may have a coating on its outer surface. In this embodiment, the overmolded portion 313 is overmolded onto the heating element 350 such that the heating element does not come into direct contact with the overmolded portion, as described below.

[0117] The elongated housing 302 is formed from a thermally conductive material. The elongated housing 302 is configured to transfer heat from the heating element 350 to the heating zone 201a. The overmolded portion 313 is configured to transfer heat from the heating element to the outer surface 307 of the elongated housing 302. The overmolded portion 313 is thermally conductive.

[0118] 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 heating element 301 is attached to a mounting base 305 of the base end 303. The mounting base in the embodiment may be formed from an insulating material. It will be understood that at least one of different mounting configurations, such as fixing, molding, and bonding including adhesive, may be used. The mounting base 305 may be a separate component or may be formed integrally with the elongated housing 302. The mounting base may form part of an overmolded portion.

[0119] 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 free end 304 is provided with a tip 311. The tip 311 extends to a vertex 312. The tip 311 defines a conical shape. Other shapes and configurations of the tip 311 may be provided, for example, the tip 311 may define a plane, a frustoconical surface, or a dome-shaped surface. Forming the tip from an overmolded portion 313 helps in forming a suitably molded tip 311.

[0120] The heating element 350 extends within the overmolded portion 313. The heating element 350 extends longitudinally within the elongated housing 302. The heating element 350 extends between the base end 303 and the free end 304. In the embodiment, the heating element 350 extends to or beyond the base end 303.

[0121] The overmolded portion 313 extends around the heating element 350 from the base of the heating member 301 toward the free end 304. The overmolded portion 313 may also extend around the heating element 350 from the top of the heating member 301 toward the base. The heating element 350 is surrounded by the overmolded portion 313. The overmolded portion 313 improves the heating of the article and improves the heat path between the coil and the article. Overmolding provides a simple manufacturing method to ensure the impermeability of fluids passing through the elongated housing. Overmolding helps prevent moisture accumulated in the heating chamber 201, such as condensates, from reaching the heating element 350. The overmolded portion 313 can provide support to the heating element 350 so that no further supporting elements are required.

[0122] The elongated housing 302 defines the outer surface 307 of the housing. In this embodiment, at least a portion of the outer surface 307 is coated. The coating may have a lower coefficient of friction than the outer surface of the elongated housing 302. This improves the insertion of articles and allows the user to clean the heating assembly 300, including the heating element 301.

[0123] The overmolded portion 313 extends longitudinally along the extent of the elongated housing 302. The overmolded portion 313 extends along the longitudinal axis 509. The overmolded portion 313 extends to at least 50%, 70%, or 90% of the longitudinal length of the elongated housing 302. At least 50%, 70%, or 80% of the outer surface area of ​​the elongated housing 302 may be provided with a material coating.

[0124] The heating element 350 comprises a heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. In embodiments, the heating coil 351 is provided with an electrical insulating coating, such as ceramic, to electrically insulate the heating coil 351. In embodiments, the electrical insulating coating is thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In embodiments, the electrical insulating coating is omitted. In embodiments, a separate electrical insulating structure is provided, such as at least one of an electrical insulating member and an electrical insulating filler. In embodiments, the electrical insulating member and the electrical insulating filler are thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In embodiments such as that shown in Figure 6, the overmolded portion 313 functions as an electrical insulating structure.

[0125] 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 also possible. In the embodiment, the heating coil 351 has a circular cross-sectional profile. In the embodiment, the heating component 300 comprises two or more heating coils.

[0126] In Figure 6, the overmolded portion 313 is overmolded so as to extend between portions of the heating coil 351. The heating coil 351 comprises multiple turns 356. The overmolded portion 313 extends between consecutive turns of the heating coil 351. The overmolded portion 311 may extend throughout the consecutive coil turns of the heating coil 351. In embodiments, the overmolded portion may extend at least partially between consecutive coil turns. The overmolded portion 313 fills the central range of the heating coil 351. The overmolded portion 313 is solid. The overmolded portion 313 does not contain a chamber. This helps ensure uniform heat distribution.

[0127] The overmolded portion 313 contains a thermally conductive material. The overmolded portion 313 may also contain an electrically insulating material. The overmolded portion 313 may also contain a conductive material, and the heating element 350 has an electrically insulating coating. The overmolded portion 313 contains a composition comprising a matrix and a particulate material. In the embodiment, the matrix contains a high-temperature plastic. The matrix may also be a resin. The matrix may contain one or more of polyether ether ketone (PEEK), polytetrafluoroethylene (PTFE), polyamide, and liquid crystal polymer (LCP). The overmolded portion may contain polyethylene nanofibers. The matrix may be formed of one or more other suitable materials, and may contain one or more other suitable materials.

[0128] The particulate material may have a thermal capacitance lower than that of the matrix. The particulate material may include an electrically insulating material such as glass. The particulate material may include microspheres, more specifically glass or ceramic microspheres. In embodiments, the particulate material includes at least one of glass and ceramic. The ceramic may include, for example, aluminum nitride. The particulate material may be formed of one or more other suitable materials and may include one or more other suitable materials. Figure 7 shows one embodiment of a heating structure 600 in which the overmolded portion 613 is overmolded such that at least a portion of the heating member does not include the overmolded portion 613. Features described below with reference to the embodiments with reference to Figure 7 are applicable to the above features unless otherwise indicated, and vice versa. In the illustrated embodiment, the overmolded portion 613 does not extend between portions of the heating coil 351. As shown in the figure, the overmolded portion 613 does not extend between turns of the heating coil 351 so that the inner surface 609 of the overmolded portion 613 does not extend radially inward from the outer surface of the heating coil 351. To achieve this, the heating coil 351 may be provided with a cover 614, such as a wrap, to restrict the overmolding material of the overmolded portion 613 from entering the space between turns of the heating coil 351. In the embodiment, the pitch of the turns of the heating coil has a narrow pitch such that the overmolding material of the overmolded portion is restricted from entering between turns of the heating coil.

[0129] The elongated housing 602 comprises a housing body 606. The housing body 606 is tubular. The housing body 606 comprises a bore 607. The housing body is cylindrical. Other external shapes are also conceivable. The bore 607 defines an internal void 608 of the heating member 601. The internal void 608 extends in the longitudinal direction. In the embodiment, the internal void 608 is at least partially filled with, for example, a filler. In the embodiment, the internal void 608 is completely filled with, for example, one or more fillers and / or components. In the embodiment, the internal void 608 defines an air gap. The inner surface 609 is defined on the inside of the elongated housing 602. The base end 303 is provided with an opening end 310 to the internal void 608. The overmolded portion 613 does not extend radially inward of the bore 607.

[0130] Figure 7 also shows a support member 616. The support element extends along the longitudinal axis 509. In the illustrated embodiment, the support element extends into the heating element 350. In the embodiment, the support element is omitted. The support member 616 extends axially and radially within the heating element 350. The support member 616 extends into the internal void 608 of the heating element 601. The heating coil 351 is wound around the support member 616 so as to be positioned between the support member 616 and the overmolded portion 613. The heating coil 351 is positioned on the support member 616. The overmolded portion 613 is overmolded on the support member 616 and the heating element 350. The overmolded portion 613 abuts against the support member 616 and holds the heating element.

[0131] The support member 616 comprises a longitudinally extending shaft that extends longitudinally along the longitudinal axis 509. The support member 616 is tubular. The support member 616 may have another component, such as a solid member, e.g., a cylinder. The support member 616 may have a shaft. In the embodiment, the heating element 350 is self-supporting. In the embodiment, the support element extends from the receptacle. In the embodiment, the support element is spaced apart from the receptacle. In the embodiment, the overmolded portion supports the heating element 350. In the embodiment, the overmolded portion may extend radially within the outer surface of the heating coil 351 and contact the support member 616.

[0132] The support member 616 has a base end 314 and a free end 315. The support member 616 has two parts: a first part of the base end 314 and a second part of the free end 315. In the embodiment, the heating element 350 is supported on only one of the first or second parts. In the embodiment, the two parts have different outer diameters such that the base end 314 has a different diameter from the free end 315. In the embodiment, the support member 616 has a stepped transition between the base end 314 and the free end 315. The overmolded portion 313 may abut the first part at the base end 314 of the support member 316.

[0133] In the described embodiments, the tip and base are formed from an overmolded portion. In the embodiments, a portion of the free end 304, such as the tip 311, is formed from a pre-formed element, on which the overmolded portion is formed. Thus, the pre-formed element and the overmolded portion can form a single component. The overmolded portion may extend from the base toward the free end.

[0134] In the embodiment, a portion of the base end 303, such as the base 305, is formed from a pre-formed element, and an overmolded portion is formed thereon. Thus, the pre-formed element and the overmolded portion can form a single component. The overmolded portion may extend from the base toward the free end. In the embodiment, both the tip and the base are pre-formed elements or parts of a single pre-formed element. The overmolded portion may extend between the tip and the base. One or both of the tip and the base may define a shoulder from which the overmolded portion extends.

[0135] In the embodiment, the support member 316 defines at least one of the tip portion and the base. In the embodiment, the overmolded portion supports at least one of the pre-formed tip portion and the base.

[0136] In the embodiment, the elongated housing is sintered on the heating element. The elongated housing may comprise a sintered portion, which functions as a formed part. The arrangement of the sintered configuration described herein generally corresponds to the arrangement of the overmolded configuration described above, and the features and descriptions described above with respect to the overmolded configuration are applicable to the sintered configuration described herein. Therefore, further detailed descriptions are omitted. The figures used above in describing the overmolded portion may be referenced.

[0137] The heating element is embedded in a sintered portion of an elongated housing. In embodiments, at least a portion of the heating element is embedded. The heating element is positioned within a suitable sintered material, such as ceramic. In embodiments, the ceramic sintered material includes aluminum nitride, but other suitable sintered materials may be used. The sintered material is sintered to form a sintered portion. The heating element is embedded in the sintered portion. The sintered portion encloses the heating element. The sintered material may include powders that become a solid sintered portion when heat or pressure is applied. The sintered material is compressed to its liquefaction point without melting the material, forming a solid. The sintered material may include at least one of glass, ceramic, or plastic. While the heating element is within the sintered material, its sintered portion can be sintered onto it.

[0138] The heating components 300, 600 are provided with electrical connection paths. The electrical connection paths extend from each end of the heating element 350. The base electrical connection path 352 extends from the distal end of the heating element 350. The 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 coil 351 is formed from a resistive material such as a nickel / chromium alloy such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0139] In the embodiments described above, the heating element is a resistance heating element. In the embodiments, other types of heating elements, such as induction heating, are used. In such embodiments, low-resistance or non-resistive materials may be used. The device configuration is generally as described above, so a detailed description is omitted.

[0140] An induction heating system comprises various components for heating the aerosol-generating material of an article by 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 system may comprise an induction element, for example, one or more inductor 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 generates 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 generates heat inside the susceptor, enabling rapid heating. Furthermore, it does not require any physical contact between the induction element and the susceptor, increasing the freedom of construction and application.

[0141] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0142] In the embodiment, the heating element of the aerosol supply system is not part of the aerosol supply device but 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 may allow current to flow through the resistive heating element.

[0143] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive or 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 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 present invention may suitably include, consist of, or essentially consist of, disclosed elements, components, features, 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 article containing an aerosol generating material, wherein the heater is The long, slender housing, The heating element in the elongated housing and Equipped with, The elongated housing includes an overmolded portion that is overmolded on the heating element. heater.

2. The heater according to claim 1, wherein the overmolded portion is overmolded onto the heating element.

3. The heater according to claim 1 or 2, wherein the elongated housing comprises a base, and the overmolded portion extends from the base toward the free end of the heater.

4. The heater according to any one of claims 1 to 3, wherein the elongated housing has a tip portion, and the overmolded portion extends from the tip portion toward the base end of the heater.

5. The heater according to claim 1 or 2, wherein the elongated housing defines a longitudinal axis, and the overmolded portion defines the longitudinal range of the elongated housing.

6. The heater according to any one of claims 1 to 5, wherein the overmolded portion extends between at least two portions of the heating element.

7. The heater according to any one of claims 1 to 6, wherein the heating element comprises a coil.

8. The heater according to any one of claims 1 to 7, wherein the coil is a resistance heating coil.

9. The heater according to claim 7 or 8, wherein the overmolded portion extends between at least two turns of the coil.

10. The heater according to any one of claims 1 to 9, wherein the heating element defines at least a portion of the void, and the overmolded portion extends into the void.

11. The heater according to any one of claims 1 to 10, wherein the overmolded portion is electrically insulating.

12. The heater according to any one of claims 1 to 11, wherein the overmolded portion is thermally conductive and configured to conduct heat from the heating element to the outer surface of the overmolded portion.

13. The heater according to any one of claims 1 to 12, wherein the overmolded portion is formed of an overmolding composition comprising a matrix and a fine particle material.

14. The heater according to any one of claims 1 to 13, wherein the overmolded portion is configured to support the heating element.

15. A heater according to any one of claims 1 to 14, comprising a support, wherein the heater element is supported on the support, and the overmolded portion extends over the heater element and the support.

16. The heater according to any one of claims 1 to 15, wherein the overmolded portion defines at least a portion of the outer surface of the housing.

17. The heater according to any one of claims 1 to 16, wherein the heater is a resistance heating heater.

18. A heater for an aerosol supply device configured to heat an article containing an aerosol generating material, wherein the heater is The long, slender housing, The system comprises a heating element located within the elongated housing, The elongated housing comprises a sintered portion, and at least a portion of the heating element is embedded in the sintered portion. heater.

19. an aerosol supply device configured to heat an article containing an aerosol generating material, A receptacle configured to receive at least a portion of an article containing an aerosol-generating material, A heater protruding into the receptacle, Housing and The heating element in the housing and A heater equipped with Equipped with, The housing comprises an overmolded portion above at least a portion of the heating element that protrudes into the receptacle. Aerosol supply device.

20. A system comprising one of the heaters described in any one of claims 1 to 18 or the aerosol supply device described in claim 19, and an article comprising an aerosol generating material.

21. A method for forming a heater for an aerosol supply device configured to heat an article containing an aerosol generating material, wherein the method is The steps include providing an elongated heating element, The steps include: overmolding an overmolding material onto at least a portion of the heating element to form an elongated housing; Methods that include...

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