How to manufacture a heater

Abstract

A method for manufacturing a heater (300) for an aerosol supply device (100), wherein the heater (300) comprises a free end (304) configured to be inserted into an article so that the heater can heat an aerosol-generating material of the article, and the heater (300) comprises a housing (302) for housing a heating element (350), the method comprising the steps of: preparing a partial housing component (500) having an opening (502) at the free end; inserting the heating element (350) into the partial housing component (500) through the opening (502); and closing the opening (502) to form the housing (302).

Description

Technical Field

[0001] The present invention relates to a method for manufacturing 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] An aerosol supply system including the above-described devices or products is 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, in order to supply different aerosols for inhalation, it is necessary to replace or change the medium used. 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 also known to use an induction heating system as a heater.

Summary of the Invention

[0004] A method for manufacturing a heater for an aerosol supply device, wherein the heater has a free end, and the free end is configured to be inserted into an article so that the heater can heat an aerosol-generating material of the article, and the heater includes a housing that houses a heating element, The method includes preparing a partial housing component having an opening at the free end, inserting a heating element into the partial housing component through the opening, closing the opening to form the housing. A method is provided that includes this.

[0005] The step of closing the opening may include forming a housing tip at the free end.

[0006] The tip of the housing may be roughly conical in shape.

[0007] The step of closing the opening may include attaching the housing tip component to the partial housing component to form the housing tip. The step of closing the opening may include attaching the housing tip component to the partial housing component to form the housing tip by welding. The step of closing the opening may include attaching the housing tip component to the partial housing component to form the housing tip by using an adhesive.

[0008] The step of closing the opening may include forming the housing tip from a liquid material molded onto a partial housing component.

[0009] The step of closing the opening may include deforming a partial housing component to form the housing tip. The step of closing the opening may also include deforming a partial housing component to form the housing tip by crimping.

[0010] The housing may have a base end opposite the free end.

[0011] Before inserting the heating element into the partial housing component through the opening, the partial housing component may be attached to the base component at its base end. The base component may be fixed to the aerosol supply device before inserting the heating element into the partial housing component through the opening.

[0012] This method may include the step of attaching a partial housing component to a base component at its base end.

[0013] The heater may be a resistance heater. The heating element may be configured to generate heat to heat the aerosol-generating material when an electric current flows through it. The heating element may include a first electrical connector that is electrically connected to a first end of the heating element. The heating element may include a second electrical connector that is electrically connected to a second end of the heating element.

[0014] The first and second electrical connectors may extend away from the heating element in a common direction. The common direction may be away from the free end.

[0015] The first and second electrical connectors may extend to the base component.

[0016] The method may include the step of inserting a fastening means into a partial housing component through an opening before closing the opening, the fastening means being configured to maintain the position of the heating element within the housing.

[0017] The fastening means may include an adhesive.

[0018] The heating element may be a coil.

[0019] The heater may be a resistance heater.

[0020] The heating element may also be a resistance heating element.

[0021] The coil may also be a resistance heating coil.

[0022] The heater may be an induction heater.

[0023] The heating element may be an induction heating element.

[0024] The coil may be an induction coil.

[0025] Next, various embodiments will be described by way of example with reference to the accompanying drawings.

Brief Description of the Drawings

[0026] [Figure 1] It is a perspective view showing an aerosol supply system including an aerosol supply device disposed within a charging unit. [Figure 2] It is a schematic cross-sectional view showing a part of the aerosol supply device of FIG. 1. [Figure 3] It is a schematic cross-sectional view showing a part of the aerosol supply device of FIG. 1 and an aerosol generating article of the aerosol supply system. [Figure 4] It is a perspective view showing another aerosol supply device. [Figure 5] It is a schematic cross-sectional view showing the device of FIG. 4. [Figure 6] It is a schematic cross-sectional view showing a heater of the device of FIG. 1 or FIG. 4. [Figure 7] It is a schematic cross-sectional view showing a partial heating component. [Figure 8] It is a schematic cross-sectional view showing a housing tip component. [Figure 9] It is a schematic diagram showing a method of manufacturing a heater.

Modes for Carrying Out the Invention

[0027] According to the present disclosure, a “non-combustion type” aerosol supply system is a system in which the constituent aerosol generating material (or components of the material) of the aerosol supply system is neither burned nor ignited in order to facilitate delivering at least one substance to a user.

[0028] In some embodiments, the delivery system is a non-combustion type aerosol supply system such as an electric non-combustion type aerosol supply system.

[0029] 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.

[0030] 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.

[0031] 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 includes 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.

[0032] 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.

[0033] In some embodiments, the non-combustion 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.

[0034] 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.

[0035] As used herein, the term “aerosol-generating material” refers to a material that can generate an aerosol when energy is supplied, for example, by heating, irradiation, or any other means. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0036] The aerosol-generating material may comprise one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0037] 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.

[0038] 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 filler 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.

[0039] 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.

[0040] 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.

[0041] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of an aerosol-generating material, such as dots, stripes, or lines, which can be supported by a support. In such embodiments, the support may be planar or non-planar.

[0042] The aerosol-generating film may 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 the aerosol-generating film.

[0043] An aerosol supply device can receive an article containing an aerosol-generating material for heating. In this context, “article” is a component that contains or is contained in the 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 the aerosol supply device before it is heated to generate an aerosol, and the user then inhales the aerosol. The article may be of a predetermined or specific size, for example, configured to be placed in or on a heater of a device sized to receive the article.

[0044] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material in order to release one or more volatile substances from the aerosol-generating material to form an aerosol. 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 aerosol-generating material to vibration, pressure boosting, or electrostatic energy.

[0045] Consumables are articles containing or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Consumables may also 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, a material that can be heated by electrical conductivity, or a susceptor.

[0046] A susceptor is a heating material that can be heated by penetration due to a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and as a result, penetration of the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and as a result, penetration of the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and as a result, the susceptor can be heated by both heating mechanisms. An aerosol supply device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0047] A non-combustible aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and interchangeable aerosol products. In some implementations, the non-combustible aerosol supply device may comprise a power supply and a controller (i.e., a control circuit). The power supply 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.

[0048] 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 aerosols from an aerosol product (see Figure 3) that can be inserted into the aerosol supply device 100 when in use. In this embodiment, the article forms part of the aerosol supply system 10.

[0049] The aerosol supply device 100 is an elongated structure extending along its longitudinal axis. Furthermore, the aerosol supply device has a proximal end closest to the user (e.g., the user's mouth) and a distal end furthest from the user during use, for inhaling the aerosol produced by the aerosol supply device 100. The proximal end may also be called the “mouthpiece end.” Thus, the aerosol supply device 100 also defines a proximal direction that is directed toward the user during use. Furthermore, the aerosol supply device 100 also defines a distal direction that is directed away from the user during use. The terms proximal and distal applied to the features of the device 100 are explained by referring to the relative arrangement of such features toward 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.

[0050] The aerosol supply device 100 may be removably inserted into the charging unit 101 for charging. The charging unit 101 includes a cavity (see Figure 2) for receiving the aerosol supply device 100. The aerosol supply device 100 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 by a longitudinal opening provided in the charging unit 101.

[0051] 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 include a curved portion and a straight portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also include a similar curved portion and a straight portion. The straight portion of the cross-sectional profile of the cavity may coincide with a longitudinal opening.

[0052] 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 into the aerosol supply device 100. In other embodiments, the charging unit 101 may have an alternative lid configuration, such as a hinged lid, or may not have a lid at all.

[0053] The charging unit 101 may include a user interface such as a display 108, which can be provided in any suitable position, such as the position shown in Figure 1.

[0054] Figure 2 is a cross-sectional view showing a portion of the aerosol supply device 100. The aerosol supply device 100 comprises a main housing 200. The main housing 200 defines the device body of the device 100. The device 100 defines a heating chamber 201. A receptacle 205 defines the heating chamber 201. An opening 203 is provided to allow 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 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.

[0055] A heating element 301 is provided in 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 may include a base portion 301a that can be positioned in a recess provided in a portion of the main body of the device 100. The heating element 301 is erected within the heating chamber 201. The heating element 301 is upright from its distal end.

[0056] 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 components such as a blade. The heating element 301 may be inserted into the distal end of the aerosol product 50 (see Figure 3) received in the heating chamber 201 to heat the aerosol product internally during use.

[0057] 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 at least partially define the receiving chamber of the aerosol supply device 100 as a volume enclosed within this 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. The receptacle base 205b has an opening 206 through which the heating member 301 protrudes. In the embodiment, the heating member 301 is attached to the receptacle base 205b. The heating member 301 is upright from the receptacle base 205b.

[0058] 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 is omitted in the embodiment. In the embodiment, the housing wall 200a defines at least partially 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. In this embodiment, the removal mechanism 204 may comprise a longitudinal portion such as a tubular peripheral wall portion 207a and a base wall portion 207b. The wall 207a may have a shape other than tubular and may be any shape that encloses (e.g., surrounds) and defines the heating chamber 201 internally.

[0059] 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, for example, the housing side wall 200a and the housing base 200b.

[0060] The base portion 207b has an opening 206 through which the heating member 301 can pass and protrude. In order to hold the removal mechanism 204 in the main housing 200, the removal mechanism 204 is pushed distally, i.e., toward the distal end of the main housing 200, to engage with the main housing 200 until the removal mechanism 204 can no longer move distally. In the following description, when the removal mechanism 204 is "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.

[0061] The circumferential 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 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 may contact 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 received in the article chamber.

[0062] The article chamber may also be called the receiving portion. When the removal mechanism 204 is held in the main housing 200, the article chamber of the removal mechanism 204 is positioned at least partially within the heating chamber 201 during use. The heating member 301 may be positioned to protrude into the article chamber through an opening 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.

[0063] 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.

[0064] In the embodiment, the removal mechanism 204 is completely removable 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.

[0065] The removal mechanism 204 may comprise an internal element ( comprising a tubular portion 207a and a base portion 207b) and an outer cap portion 210, and when held in the main housing 200, the outer cap portion 210 encloses (e.g., covers) at least a portion of the main housing, such as the wall 200a of the main housing 200. The tubular portion 207a, the base portion 207b and the outer cap portion 210 may comprise a single (e.g., a single) component (e.g., formed by molding). Alternatively, the tubular portion 207a and the base portion 207b may comprise a first component, and the outer cap portion 210 may comprise a second separate component. In this case, the first and second components may be fixed to each other.

[0066] 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 the aerosol product 50 contains 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.

[0067] The device 400 comprises a housing 500 that surrounds and houses various components of the device 400. The housing 500 is elongated. The device 400 has an opening 504 at one end into which an article 50 can be inserted for heating by the device 400. The article 50 may be fully or partially inserted into the device 400 for heating by the device 400.

[0068] 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 the switch 406.

[0069] The device 400 defines a longitudinal axis 509, and the article 50 may extend along this axis when inserted into the device 400. The opening 504 is aligned with the longitudinal axis 509.

[0070] Figure 5 is a schematic cross-sectional view of the aerosol supply system 40. Features described with reference to Figure 5 in the embodiment are applicable to the embodiment 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 received.

[0071] The integrated device in Figure 5 shows a power supply 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of the integrated aerosol generation device, the power supply is aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0072] The heating element 301 comprises an elongated heating element in the form of a pin. In embodiments, the heating element 301 comprises other elongated components such as a blade. The heating element 301 is provided within the heating chamber. The heating element 301 described above with reference to Figure 5 and Figures 1 to 3 may each be subject to the details described herein. The heating element 301 extends into or protrudes into the heating chamber 401.

[0073] The heating element 301 may be inserted into the distal end of the aerosol product received in the heating chamber 401 in order to heat the aerosol product internally during use.

[0074] The aerosol supply devices 100 and 400 include a heating component 300. The heating component 300 includes a heater. The heating element 301 acts as a heater. The heater includes a heating element 350 (see Figure 6), such as a resistance heating coil, configured to operate to heat the heating element.

[0075] The heating component 300 is a resistance heating component. The heater is a resistance heating heater. Heating elements such as heating coils, described later, are resistance heating elements. In such a configuration, the heating assembly includes a resistance heating generator which includes components for heating the heating elements through a resistance heating process. In this case, current is applied directly to the resistance heating elements, and the resulting flow of current in the heating elements (acting as heating components) heats the heating elements by Joule heating. The resistance heating elements include a resistance material configured to generate heat when an appropriate current flows through the resistance heating elements, and the heating component includes electrical contacts for supplying current to the resistance material. In the embodiment, the heating elements form at least a portion of the resistance heating member itself. In the embodiment, the resistance heating elements transfer heat to the heating member, for example, by conduction. Providing resistance heating components enables a compact configuration. Resistance heating provides an efficient configuration.

[0076] Figure 6 shows a heating element 301 for use in the aerosol supply device described above. The heating element 301 acts as a heater 300 or forms at least a 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.

[0077] The elongated housing 302 is formed from a thermally conductive material such as aluminum. Other suitable materials such as stainless steel may be used. 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.

[0078] The elongated housing 302 has a base end 303 and a free end 304. The base end 304 is attached to the device body. The mount 305 on the base end 303 attaches the heating element 301. It will be understood that various mounting configurations, such as fastening, molding, and adhesive bonding, may be used. The mount 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0079] The elongated housing 302 comprises a housing body 306, which is cylindrical. The housing body 306 includes a bore 307, which defines a cavity 308 of the heating element 301. The cavity 308 is located inside the housing 302. The cavity 308 extends longitudinally. In the embodiment, the cavity 308 is at least partially filled with, for example, a filler. In the embodiment, the cavity 308 is completely filled with, for example, one or more fillers and / or components. In the embodiment, the cavity 308 defines a void. The inner surface 309 is defined on the inside of the elongated housing 302. An opening 310 to the cavity 308 is provided at the base end 303.

[0080] 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 extend through the free end 304. The housing tip 311 is provided at the free end 304. The housing tip 311 extends to the apex 312. The housing tip 311 is conical. Other shapes and configurations of the housing tip 311 may be provided; for example, the housing tip 311 may define a plane.

[0081] The heating element 350 extends into the heating member 301. The heating element 350 extends longitudinally within the elongated housing 302. The heating element 350 is received within the cavity 308. The heating element 350 extends between the base end 303 and the distal end 304. In the embodiment, the heating element 350 extends partially along the length of the cavity 308. In the embodiment, the heating element 350 extends to or beyond the open end 310.

[0082] In the embodiment, the heating element 350 comprises a heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. In the embodiment, the heating coil 351 comprises an electrically insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302. In the embodiment, the electrically insulating coating is thermally conductive to allow heat transfer from the heating element 350 to the elongated housing 302. In the embodiment, the electrically insulating coating is omitted. In the embodiment, a separate electrically insulating component is provided, such as at least one of an electrically insulating member and an electrically insulating filler. In the embodiment, the electrically insulating member and the electrically insulating filler are thermally conductive to allow heat transfer from the heating element 350 to the elongated housing 302.

[0083] 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 shape. It will be understood that other coil configurations are also possible. In the embodiment, the heating coil 351 has a circular cross-sectional contour. In the embodiment, the heating component 300 includes two or more heating coils.

[0084] The heating element 300 includes 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 connectors overlap over a longitudinal portion of the heating element 350. The 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 such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0085] Figure 7 shows a partial housing component 500. The partial housing component 500 includes all the feature parts of the elongated housing 302, separated from the housing tip 311. For components of the partial housing component 500 that are the same as those of the elongated housing 302, the same reference numbers are used in Figure 7, and repeated descriptions of those components are omitted.

[0086] The partial housing component 500 includes an opening 502. The opening 502 is located at the proximal end of the partial housing component 500. The opening 502 allows access to the cavity 308. The opening 502 is due to the absence of the housing tip 311.

[0087] Figure 8 shows the housing tip component 550. The housing tip component 550 is the same as the housing tip 311 described above, but is separate from the rest of the elongated housing 302. The housing tip component 550 is approximately conical in shape. The housing tip component 550 is made of the same material as the partial housing component 500.

[0088] Figure 9 shows a method 600 for manufacturing a heater 300. Method 600 comprises a first step 602, a second step 604, and a third step 606.

[0089] In the first step 602, the partial housing component 500, the housing tip component 511, and the heating element 350 are prepared.

[0090] In the second step 604, the heating element 350 is inserted into the cavity 308 of the partial housing component 500 through the opening 502.

[0091] In the third step 606, the opening 502 is closed to form the elongated housing 302. The opening 502 is closed by fixing the housing tip component 550 to the partial housing component 500 to form the elongated housing 302. The housing tip component 500 is fixed to the partial housing component 500 by welding. In other examples, the housing tip component 550 is fixed to the partial housing component 500 by adhesive.

[0092] In other examples, the opening 502 is closed by forming a housing tip from a liquid material molded onto a partial housing component. Such material may be, for example, a metal, a metal alloy, or a thermal interface material (TIM) on a liquid dispenser.

[0093] In other examples, the opening 502 is closed by deforming a partial housing component, for example, by crimping a closed partial housing component to form a housing tip.

[0094] The method may further include, before the second and / or third step, the step of fixing the partial housing component 500 via its base end to other components of the aerosol supply device, for example, to the outer frame of the aerosol supply device.

[0095] The method may include, before the third step, the step of inserting a fixing component to hold the heating element 350 in a predetermined position within the cavity 308. The fixing component may be a large amount of material, such as an adhesive.

[0096] In the embodiments described above, the heating element is a resistance heating element. Other types of heating elements, such as induction heating elements, are used in the embodiments. The device configuration is substantially as described above, so a detailed explanation is omitted.

[0097] An induction heating configuration includes 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 (such as a susceptor) by electromagnetic induction. An induction heating configuration may include an induction element, for example, one or more inductor coils, and a device for passing a variable 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) appropriately 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 structure and application.

[0098] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0099] 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.

[0100] 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 and / or exclusive. The advantages, embodiments, examples, functions, features(parts), 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 invention may suitably include, consist of, or essentially consist of, appropriate combinations 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 method for manufacturing a heater for an aerosol supply device, wherein the heater comprises a free end, the free end being configured to be inserted into an article so that the heater can heat an aerosol-generating material of the article, and the heater comprises a housing for housing a heating element. The method described above is The steps include preparing a partial housing component having an opening at the free end, The steps include inserting a heating element into the partial housing component through the opening, The steps include closing the opening to form the housing, Methods that include...

2. The method according to claim 1, wherein the step of closing the opening includes forming a housing tip at the free end.

3. The method according to claim 2, wherein the tip of the housing is substantially conical.

4. The method according to claim 2 or 3, wherein the step of closing the opening includes attaching the housing tip component to the partial housing component to form the housing tip.

5. The method according to claim 2 or 3, wherein the step of closing the opening includes forming the housing tip from a liquid material molded onto the partial housing component.

6. The method according to claim 2 or 3, wherein the step of closing the opening includes deforming the partial housing component to form the housing tip.

7. The method according to claim 6, wherein the deformation of the partial housing component to form the housing tip is performed by crimping.

8. The method according to any one of claims 1 to 7, wherein the housing comprises a base end opposite to the free end.

9. The method according to claim 8, wherein the partial housing component is attached to the base component at its base end before the heating element is inserted into the partial housing component through the opening.

10. The method according to claim 9, further comprising the step of attaching the partial housing component to the base component at its base end before inserting the heating element into the partial housing component through the opening.

11. The method according to any one of claims 1 to 10, wherein the heater is a resistance heater, the heating element is configured to generate heat to heat the aerosol-generating material when an electric current flows through the heating element, and the heating element comprises a first electrical connector electrically communicating with a first end of the heating element and a second electrical connector electrically communicating with a second end of the heating element.

12. The method according to claim 11, wherein the first electrical connector and the second electrical connector extend toward the heating element in a common direction, the common direction being toward the free end.

13. The method according to claim 12, wherein the first electrical connector and the second electrical connector extend to the base component.

14. The method according to any one of claims 1 to 13, comprising the step of inserting a fixing means into the partial housing component through the opening before closing the opening, wherein the fixing means is configured to maintain the position of the heating element within the housing.

15. The method according to claim 14, wherein the fixing means includes an adhesive.

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