Heating element for aerosol supply device

Abstract

A heating element for an aerosol supply device configured to heat at least a portion of an article comprising an aerosol-generating material to provide an aerosol comprises an elongated housing, a heating element extending within the elongated housing, and at least one pre-formed element configured to position and hold the heating element within the elongated housing.

Description

Technical Field

[0001] The present invention relates to a heating member for an aerosol supply device, an aerosol supply device, an aerosol supply system, and a method for generating an aerosol.

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 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, in order to supply different aerosols for inhalation, it is necessary to exchange 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 known that an inductive heating system is used as a heater.

Summary of the Invention

[0004] According to a first embodiment, a heating member is provided for an aerosol supply device configured to heat at least a portion of an article comprising an aerosol-generating material to provide an aerosol, the heating member comprising an elongated housing, a heating element extending within the elongated housing, and at least one pre-formed element configured to position and hold the heating element within the elongated housing. The pre-formed element may be formed in a solid form before being placed in the housing. The pre-formed element may be manufactured to its final shape before being placed in the housing.

[0005] At least one pre-formed element may be configured to position and hold the heating element in a location where it does not come into contact with the housing.

[0006] The heating element may also be a resistive heating element.

[0007] The heating element may be a heating coil. The heating element may be a helical coil. The coil may be a resistance heating coil.

[0008] The heater may be an induction heater. The heating element may be an induction heating element. The heating coil may be an induction coil.

[0009] At least one pre-formed element may be made of an electrical insulating material.

[0010] The elongated housing may define an internal void, and the heating element may be positioned within the internal void.

[0011] At least one pre-formed element may extend substantially along the entire length of the internal void.

[0012] At least one pre-formed element may be positioned to hold the heating element such that its longitudinal axis and the elongated housing are substantially coaxial.

[0013] The housing may have a substantially cylindrical shape. The housing may be pointed at its free end. The housing may be flat at its free end.

[0014] The housing may have a substantially elongated shape.

[0015] The housing may be shaped like a blade.

[0016] The housing may be in the shape of a rectangular parallelepiped.

[0017] The housing may have a pointed end.

[0018] The inner surface of the housing may define a cylindrical void.

[0019] At least one pre-formed element may be shaped to fit between the elongated housing and the heating element.

[0020] At least a portion of at least one pre-formed element may be positioned between the heating element and the inner surface of the elongated housing.

[0021] At least one pre-formed element may be configured to apply a radially inward force to the radially outer surface of the heating element, thereby preventing the heating element from moving in the axial direction.

[0022] The radial inner surface of at least one pre-formed element may be shaped to coincide with or complement the radial outer surface of the heating element. The radial outer surface of the heating element may be at least partially in contact with the radial inner surface of at least one pre-formed element. The at least one pre-formed element may be shaped to complement the inner surface of the elongated housing. The at least one pre-formed element may have a cylindrical shape. The at least one pre-formed element may comprise a cylindrical element. The radial outer surface of at least one pre-formed element complements the inner surface of the elongated housing and is at least partially in contact with the inner surface of the elongated housing. The radial inner surface of at least one pre-formed element defines a central void in which the heating element is positioned.

[0023] At least one pre-formed element, at least a portion of it, may be formed from an elastic material.

[0024] At least a portion of at least one pre-formed element may be compressed between the heating element and the inner surface of the housing to maintain the heating element in place relative to the elongated housing.

[0025] At least one pre-formed element may use friction to hold the heating element in place so that the heating element can be removed from the elongated housing.

[0026] At least one pre-formed element may be made from an electrical insulating material. At least one pre-formed element may be made from an elastomer material. At least one pre-formed element may be made from rubber. At least one pre-formed element may be made from plastic or ceramic.

[0027] At least one pre-formed element may be made from a thermally conductive material.

[0028] At least the pre-formed elements may extend along the heating element.

[0029] At least one preformed element may abut against the radial outer surface of the heating element.

[0030] At least one preformed element may be attached to at least a part of the inner surface of the housing. At least one preformed element may be attached to at least a part of the radial outer surface of the heating element.

[0031] At least one preformed element may extend along most of the length of the heating element. At least one preformed element may extend along 75% of the length of the heating element. At least one preformed element may extend along 90% of the length of the heating element. At least one preformed element may extend along the entire length of the heating element.

[0032] At least the preformed element may include at least two preformed elements surrounding the heating element. At least one preformed element may include at least three preformed elements surrounding the heating element. At least two elements may be shaped to complement the shape of the elongated housing.

[0033] At least one preformed element may include a helical surface for supporting the heating coil.

[0034] The heating coil may have a variable pitch along the length of the heating coil. The pitch of the heating coil may be greater at the central portion of the heating coil than at the two end portions of the heating coil.

[0035] The heating element may be formed from a continuous length of heating material that may have various cross-sectional profiles. The continuous length of heating material may have a constant cross-sectional profile. The continuous length of heating material may have a circular cross-sectional profile. The continuous length of heating material may have a rectangular cross-sectional profile. The continuous length of heating material may have a flat cross-sectional profile. At least one pre-formed element may include a portion positioned between the free end of the heating coil and the housing.

[0036] The internal void of the elongated housing may be at least partially filled with a filler material. The filler material may be located inside the heater element. If the heating element is a coil, the filler material may be located inside the coil windings.

[0037] In another embodiment, a method is provided for manufacturing a heating element for an aerosol supply device configured to heat at least a portion of an article comprising an aerosol-generating material to provide an aerosol, the method comprising: providing an elongated housing having a longitudinal axis; forming at least one element; and, after forming at least one element, placing at least one pre-formed element within the housing to hold and position the heating element within the housing.

[0038] The method may include placing at least a portion of at least one element between the housing and the heating element.

[0039] Forming at least one element may include using a mold to form the shape of at least one element.

[0040] Forming at least one element may include forming the shape of at least one element using additive manufacturing.

[0041] Forming at least one element may include cutting the material to form the final shape of at least one element.

[0042] The method may include fixing at least one element within the elongated housing before placing the heating coil inside the housing. The method may further include fixing at least one element within the elongated housing using an adhesive.

[0043] The method may include fixing at least one pre-formed element to the heating element before inserting the heating element and elements into the housing.

[0044] The method may include using an adhesive before inserting the heating element and components into the housing.

[0045] The method may further include inserting a filler material into the housing. The filler material may be provided inside the heating element.

[0046] The method may further include providing a filling material inside the heating element before inserting the heating element and elements into the housing.

[0047] 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 the heating member described above. The aerosol supply device may also comprise a heating chamber provided with a heater.

[0048] The aerosol supply device may include 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 be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0049] The aerosol supply device may be configured for wireless charging.

[0050] According to one embodiment, an aerosol supply system is provided, comprising the above-described aerosol supply device and an article comprising an aerosol generating material.

[0051] 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.

[0052] In another embodiment, a method for generating an aerosol is provided, comprising providing an aerosol supply device including the aerosol supply device described above, and inserting the aerosol product at least partially into a receiving portion of a heating chamber.

[0053] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0054] [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 heating element for the device. [Figure 7]A schematic cross-sectional view of another heating element for the device shown in Figure 1 or Figure 4 is shown. [Figure 8] A flowchart of the method for manufacturing the heating element according to the present invention is shown. [Modes for carrying out the invention]

[0055] 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.

[0056] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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 an aerosol from an aerosol product (see Figure 3) that can be inserted into the aerosol supply device 100 when in use. In the embodiment, the article forms part of the aerosol supply system 10.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] Figure 2 shows a cross-sectional view of a portion of the aerosol supply device 100. The aerosol supply device 100 comprises a main housing 200. The main housing 200 defines the device body of the device 100. The device 100 defines a heating chamber 201. A receptacle 205 defines the heating chamber 201. An opening 203 is provided to provide access to the heating chamber 201. The receptacle 205 comprises a wall 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.

[0083] 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 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.

[0084] 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.

[0085] 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.

[0086] 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 may be held in the main housing 200, and as a result, 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. The removal mechanism 204 in the embodiment is omitted. In the embodiment, the housing wall 200a defines the receptacle 205 at least partially. The heating member 301 is attached to the receptacle base and the heating member 301 stands upright from the receptacle base. 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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., unit-type) 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] Figure 5 is a schematic cross-sectional view of the aerosol generation system 40. Features described with reference to Figure 5 in the embodiment are applicable to the embodiment described above. The aerosol generation device 400 comprises a power source 410, a controller 420, and a heating chamber 401 in which the aerosol product 50 is removably received.

[0098] 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.

[0099] 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 of 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] The 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.

[0105] 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. It will be understood that different mounting configurations, such as bonding including fixing, molding, and adhesive, may be used. The mounting base 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0106] The elongated housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body 306 comprises a bore 307. The bore 307 defines an internal void 308 of the heating element 301. The internal void 308 extends in the longitudinal direction. The inner surface 309 is defined on the inside of the elongated housing 302. The base end 303 is provided with an opening end 310 to the internal void 308.

[0107] 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 internal void 308 does not extend through the free end 304. The free end 304 is provided with a tip 311. The tip 311 extends to the apex 312. Other shapes and configurations of the tip 311 may be provided; for example, the tip 311 may define a plane.

[0108] The heating element 350 extends within the heating member 301. The heating element 350 extends longitudinally within the elongated housing 302. The heating element 350 is received within the internal void 308. The heating element 350 extends between the base end 303 and the free end 304. In the embodiment, the heating element extends partially along the length of the internal void 308. In the embodiment, the heating element 350 extends to or beyond the open end 310.

[0109] In one embodiment, the heating element 350 includes a heating coil 351. The heating coil 351 includes a resistive member that defines the heating coil 351. In other embodiments, the heating element 350 is not a heating coil and has a different shape.

[0110] An element 313 is provided within the internal void 308. The element 313 is configured to position and hold the heating coil 351 within the elongated housing 302. The element 313 may be at least partially positioned between the heating coil 351 and the inner surface 309 of the elongated housing 302, thereby separating the heating coil 351 from the inner surface 309 of the elongated housing 302 and preventing direct contact between the heating coil 351 and the elongated housing 302.

[0111] Element 313 can also provide electrical insulation between the heating element 350 and the elongated housing 302, thereby preventing current from flowing between the heating element 350 and the elongated housing 302. This is achieved by element 313 being formed from an electrically insulating material and being at least partially positioned between the heating element 350 and the elongated housing 302, thereby preventing the heating element 350 and the elongated housing 302 from directly contacting each other. Element 313 may be formed from any suitable electrically insulating material, such as rubber, plastic, or ceramic.

[0112] Element 313 may be thermally conductive to enable effective heat transfer from the heating element 350 to the elongated housing 302, in order to allow the elongated housing 302 to effectively and efficiently heat an article containing an aerosol-generating material.

[0113] Element 313 is molded to fit between the elongated housing 302 and the heating coil 351. In this embodiment, element 313 is molded to complement the shape of the internal void 308 of the elongated housing 302, thereby fitting snugly or tightly within the internal void 308. In this embodiment, element 313 has a cylindrical shape to complement the cylindrical shape of the inner surface 309 of the elongated housing 302. In other embodiments, it will be understood that other shapes of element 313 may be provided depending on the shape of the inner surface 309 of the elongated housing 302. The radial outer surface 315 of element 313 complements and contacts the inner surface 309 of the elongated housing 302.

[0114] The radial inner surface 317 of element 313 defines a central void 319 for receiving the heating coil 351. The radial inner surface 317 of element 313 is shaped to coincide with or complement the radial outer surface 321 of the heating coil 351, thereby allowing the heating coil 351 to fit snugly into the central void 319 of element 313. In this embodiment, the radial inner surface 317 of element 313 is cylindrical to coincide with the outer surface of the helical heating coil 351, which has a cylindrical envelope. The radial outer surface 321 of the heating coil 351 is in contact with the radial inner surface 317 of element 313.

[0115] The element 313 shown in Figure 6 provides a simple and robust means for reliably holding the heating coil 351 in a position such that the central longitudinal axis of the heating coil and the longitudinal axis extending along the center of the internal gap 308 are substantially aligned. This helps to provide uniform heating along the length of the heating member 301. More uniform and consistent heating along the length of the heating member 301 results in more consistent heating of the aerosol-generating material in the aerosol product, providing consumers with an improved sensory experience.

[0116] In one embodiment, element 313 may extend along the entire length of the internal void 308. This helps to provide uniform heating along the entire length of the internal void 308. In other embodiments, element 313 extends along only a portion of the entire length of the internal void 308, for example, the central portion, the upper portion, or the lower portion.

[0117] Element 313 serves to hold and support the heating element 350 within the internal gap 308 of the elongated housing 302, and thus element 313 is fixed in place within the elongated housing 302. In this embodiment, the friction between the radial outer surface 315 of element 313 and the inner surface 309 of the elongated housing 302 is sufficient to prevent element 313 from moving relative to the elongated housing 302. Similarly, the friction between the radial outer surface 321 of the heating coil 351 and the radial inner surface 317 of element 313 prevents the heating coil 351 from moving relative to element 313. The friction means that, during use, the heating coil 351 does not move or rotate axially within element 313, and the heating element 313 does not move or rotate axially within the internal gap 308 of the elongated housing 302.

[0118] In some embodiments, an adhesive can be applied between at least a portion of the outer surface 315 of element 313 and a portion of the inner surface 309 of the elongated housing, and / or between at least a portion of the radial outer surface 321 of the heating coil 351 and at least a portion of the radial inner surface 317 of element 313 to provide a particularly robust configuration.

[0119] Element 313 may be formed from an elastomer material. This allows element 313 to be compressed between the heating coil 351 and the elongated housing 302, thereby more securely holding the heating coil 351 in place. The compression of element 313 causes element 313 to exert a radial force on the inner surface 309 of the elongated housing 302, thereby increasing the coefficient of friction between element 313 and the elongated housing 302, and more securely holding element 313 in place. This may also allow the heating coil 351 to compress the radial inner surface 317 of element 313, thereby increasing the coefficient of friction between the heating coil 351 and element 313. In other embodiments, element 313 is formed from an inelastic material.

[0120] Element 313 is pre-formed to be inserted into the internal void 308. The pre-formed element 313 can serve a dual purpose: to provide electrical insulation between the heating coil 351 and the elongated housing 302, and to support the heating coil 351 within the internal void 308. The pre-formed element 313, as shown in Figure 6, also helps provide a consistent, reliable, and robust means of holding the heating element 351 in an optimal central location within the internal void 308. The heating member 301 can also be assembled more easily using the pre-formed element 313. The pre-formed element 313 can also allow for disassembly of the components of the heating member 301, for example, for maintenance or cleaning, or to replace expired parts, or to recycle parts.

[0121] In the embodiment, the heating coil 351 may be provided with an electrically insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302. The electrically insulating coating in the embodiment is thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. If there is an electrically insulating coating, the element 313 can be formed from a non-electrically insulating material. In such an example, the element 313 is an element that provides support for the heating coil 351.

[0122] 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.

[0123] The heating element 300 includes electrical connection paths. The electrical connection paths extend from each end of the heating element 350. A base electrical connection path 352 extends from the distal end of the heating element 350. A return electrical connection path 353 extends from the free 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.

[0124] Figure 7 shows another embodiment of the heating element 550. The configuration of the heating element 550 in Figure 7 is substantially the same as that described above with reference to Figure 6, and therefore a detailed description is omitted. In Figure 7, the configuration of element 513 differs from the configuration shown in Figure 6 in that element 513 is helical instead of cylindrical. The heating element 551 may be a coil heater 551, which may be wound on element 513 such that the coil heater 551 is firmly maintained in a central location within the internal gap 508, and thus the winding surface of element 513 supports the winding of the coil heater 551. In this embodiment, the inner surfaces 559 of the heating element 551 and / or the housing 502 may be coated with an electrically insulating material so that the heating elements 551 are in direct contact with each other. This embodiment may help to provide more effective heat transfer from the heating element 551 to the housing 559, while still providing a robust means for maintaining the heating element 551 in a fixed central location within the internal gap 508.

[0125] It will be understood that pre-formed elements may still be provided, having shapes and configurations other than those shown in Figure 6 or Figure 7.

[0126] In all of the embodiments described above, the internal void of the elongated housing may be at least partially filled with a filler material, which is located inside the heater element. If the heating element is a coil, the filler material may be located inside the coil winding.

[0127] Next, a method for manufacturing the heating element 350 will be described with reference to Figure 8. The elongated housing 302 and the heating element 351 are manufactured using any preferred method. Element 313 is also manufactured to its final shape using any preferred method, for example, by mold or additive manufacturing or by cutting material to form the final shape, or by forming separate parts and then assembling those parts together to form the final shape. In some embodiments, element 313 is formed into multiple parts, for example, multiple rings, or as two longitudinal halves that are assembled together. In another embodiment, the upper and lower parts may be formed and then assembled together. In yet another embodiment, three or more parts are formed and assembled together to form an element.

[0128] The advantage of partially forming element 313 is that it can be more easily assembled around the heating element 351.

[0129] Element 313 is manufactured before being assembled into the internal void 308 and is therefore a pre-formed element. If the element is formed of multiple parts, it will be understood that each of these parts is a pre-formed element. The elongated housing 302, element 313, and heating element 351 are then assembled together. The heating element 351 may be fixed or assembled inside element 313 before element 313 is assembled into the internal void 308, or vice versa. If adhesive is used, it is applied between the relevant surfaces of the heating element 351 and element 313, and to the inner surface 309 of the elongated housing 302 before they are assembled together. The method may include press-fitting element 313 into the bore 307 and / or press-fitting the heating element 351 into element 313. In other embodiments, a filler material may be provided within the elongated housing, and the filler material is positioned centrally within the heating element.

[0130] Although the above method is explained in relation to Figure 6, it can also be similarly applied to the embodiment of the heating element shown in Figure 7 and described above.

[0131] 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 generally as described above, so a detailed explanation is omitted.

[0132] 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.

[0133] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0134] 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.

[0135] 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 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 heating member for an aerosol supply device configured to provide an aerosol by heating at least a portion of an article comprising an aerosol generating material, wherein the heating member is The long, slender housing, A heating element extending within the aforementioned elongated housing, At least one pre-formed element configured to position and hold the heating element within the elongated housing, A heating element comprising:

2. The heating member according to claim 1, wherein the at least one pre-formed element is configured to position and hold the heating element in a position where the heating element does not come into contact with the housing.

3. The heating member according to claim 1 or 2, wherein the heating element is a resistance heating element.

4. The heating member according to any one of claims 1 to 3, wherein the at least one pre-formed element is made of an electrical insulating material.

5. The heating member according to any one of claims 1 to 4, wherein the elongated housing defines an internal void, and the heating element is positioned within the internal void.

6. The heating member according to claim 5, wherein the at least one pre-formed element extends substantially along the entire length of the internal void.

7. The heating member according to any one of claims 1 to 6, wherein the at least one pre-formed element maintains the heating element in a position such that the longitudinal axis of the heating element and the elongated housing are substantially coaxial.

8. The heating member according to any one of claims 1 to 7, wherein at least a portion of the at least one pre-formed element is positioned between the heating element and the inner surface of the elongated housing.

9. The heating member according to any one of claims 1 to 8, wherein the at least one pre-formed element is configured to apply a radially inward force to the radially outer surface of the heating element to prevent the heating element from moving in the axial direction.

10. The heating member according to any one of claims 1 to 9, wherein at least a portion of the at least one pre-formed element is formed of an elastic material and is compressed between the heating element and the inner surface of the housing to maintain the heating element in a fixed position relative to the elongated housing.

11. The heating member according to any one of claims 1 to 10, wherein the at least one pre-formed element is shaped to complement the inner surface of the elongated housing.

12. The heating member according to any one of claims 1 to 11, wherein the at least one pre-formed element comprises a cylindrical element.

13. The heating member according to any one of claims 1 to 12, wherein at least one of the elements comprises a helical surface for supporting the heating element.

14. An aerosol supply device configured to heat an article comprising an aerosol generating material, wherein the device comprises a heating member according to any one of claims 1 to 13.

15. A system comprising a device having a heating element according to any one of claims 1 to 13, and an article having an aerosol generating material.

16. A method for manufacturing a heating element for an aerosol supply device configured to provide an aerosol by heating at least a portion of an article comprising an aerosol generating material, wherein the method is: A step of providing an elongated housing having a longitudinal axis, The steps include providing a heating element and A step of forming at least one element, After the step of forming the at least one element, the step of placing the at least one pre-formed element in the elongated housing to hold and position the heating element within the housing, Methods that include...

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