Heater for aerosol supply device

Abstract

This application relates to a heater for an aerosol supply device. The device has an elongated housing. A heating coil is located within the housing, defining a longitudinal axis. The heating coil has a diameter that varies along its longitudinal length.

Description

Technical Field

[0001] The present invention relates to a heater for an aerosol supply device, an aerosol supply device, an aerosol supply system, and a method of 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 burning. Examples of such products include so-called "non-combustion heating-type" products that release compounds by heating a material without burning, or tobacco heating devices or products. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] An aerosol supply system covering 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, it is necessary to replace or change the medium used in order to supply different aerosols for inhalation. It is known to use a resistive heating system as a heater for generating an aerosol from a suitable medium. Separately, an induction heating system is known to be used as a heater.

Summary of the Invention

[0004] According to one aspect, an elongated housing, and a heating coil disposed within the housing defining a longitudinal axis, the heating coil having a diameter that varies along the longitudinal length A heater for an aerosol supply device comprising is provided.

[0005] It will be understood that, according to various embodiments, a heating coil that tapers or narrows may be provided. Any gap between the heating coil and the internal cavity of the elongated housing may be filled with a filler material.

[0006] According to various embodiments, the inner cavity may be at least partially filled with a filler material containing an insulating material. The insulating material may include a polymer material. The insulating material may be a potting compound, an adhesive, a thermosetting plastic, or an epoxy resin. According to various embodiments, the potting compound may include an epoxy resin. For example, a two-component epoxy consisting of a polymer resin and a curing agent may be used, which, when mixed together, trigger a chemical reaction that crosslinks the chemical bonds in the polymer chain to produce a tough and rigid compound. Other embodiments may include a potting compound containing polyurethane ("PU"), such as a thermosetting plastic. This may include a two-component compound consisting of a base resin having an isocyanate curing agent. Other embodiments may include a potting compound containing silicone. For example, silicone rubber may be used that contains a synthetic polysiloxane polymer that transitions from a liquid to a solid state using an additive catalyst (such as platinum).

[0007] The filler material may include one or more inorganic materials such as glass, ceramic, magnesium oxide, and aluminum oxide.

[0008] The heating coil may comprise a first section having one or more first turns and a second section having one or more second turns, wherein the one or more first turns may have a larger diameter than the one or more second turns.

[0009] The housing may have a base end and a free end, with the first section located near the base end and the second section located near the free end.

[0010] The heating coil may converge diametrically toward the free end. According to various embodiments, the diameter of the heating coil may narrow, taper, or decrease toward the free end. It will be understood that the diameter of the heating coil may become smaller or decrease when the heating coil is located in the inner cavity of an elongated housing and viewed from the mouthpiece end of the inner cavity toward the distal end of the inner cavity.

[0011] According to various embodiments, the inner cavity of the elongated housing may have a conical or truncated conical profile and may taper or narrow in the direction from the mouthpiece end to the distal end of the inner cavity. The heating coil may have a corresponding or similar profile, i.e., the heating coil may have a diameter that gradually narrows. The heating coil may be positioned to fit relatively tightly within the inner cavity. The outer surface of the heating coil may have an insulator or insulating layer. The insulator or insulating layer may include an electrical insulator. Embodiments are conceivable in which the inner cavity of the heater has a socket or recess and the heating coil has a corresponding plug portion that fits securely into the socket or recess. Further embodiments are conceivable in which at least the end portion of the heating coil may have some degree of flexibility and the inner cavity may have an inner profile such that the cavity tapers in the direction from the mouthpiece end to the distal end of the cavity, contracting to a particular narrowest diameter and then expanding at the distal end. The heating coil may be inserted into the inner cavity, and at least the ends of the heating coil may be compressed as they are inserted through the narrowest diameter portion, and then expanded towards the distal end of the cavity. As a result, the heating coil may be held within the inner cavity of the elongated housing.

[0012] The heating coil may comprise one or more spiral coils.

[0013] The radial dimensions of the heating coil may vary along the longitudinal direction.

[0014] The elongated housing may include an internal cavity. The internal cavity may have a diameter that varies along its longitudinal length.

[0015] The inner cavity may have a mouthpiece end and a distal end. The diameter of the inner cavity may taper or decrease in the direction from the mouthpiece end to the distal end. The heating coil may also have a tapered or decreasing profile to facilitate insertion of the heating coil into the inner cavity. The heating coil may have an outer profile that conforms to the profile of the inner cavity.

[0016] The radial outer dimension of the heating coil at the first end may be greater than the radial outer dimension of the heating coil at the second end.

[0017] The external dimensions of the heating coil may vary substantially uniformly and / or continuously between the first end and the second end of the heating coil, such that the external dimensions of the heating coil gradually decrease from the first end to the second end.

[0018] The external dimensions of the heating coil may vary substantially non-uniformly between the first end and the second end of the heating coil, such that the external dimensions of the heating coil decrease from the first end to the second end.

[0019] The external dimensions of the heating coil may change substantially non-uniformly, discontinuously, or in a stepwise manner between the first end and the second end of the heating coil.

[0020] The external dimensions of the heating coil may vary between a first end and a second end of the heating coil, wherein in at least one longitudinal portion of the heating coil, the external dimensions of the heating coil vary at a first rate of change, and in at least one longitudinal portion of the heating coil, the external dimensions of the heating coil vary at a second rate of change, where the first rate of change is greater than the second rate of change.

[0021] The heating coil may have an outer dimension such that the heating coil has a certain outer contour, and the housing and the heating coil are configured such that the heating coil is positioned between an alpha position and a beta position along the longitudinal range of the inner cavity within the inner cavity, and the surface of the heater that defines the inner cavity between the alpha position and the beta position substantially reflects the outer contour of the heating coil.

[0022] The outer contour of the heating coil may contact at least a part of the surface of the heater that defines the inner cavity between the alpha position and the beta position.

[0023] The housing may extend in the longitudinal direction and may have a first end and a second end, and the inner cavity extends between the first end of the housing and a third position, and the first end of the housing defines a suction port through which the inner cavity can be accessed, the alpha position is proximal to the first end of the housing, and the beta position is proximal to the third position.

[0024] The heating coil may include M turns per unit longitudinal length adjacent to the first end of the heating coil and N turns per unit longitudinal length adjacent to the second end of the heating coil, where N≧M, M≠0, and N≠0.

[0025] The housing may have an outer surface, and the housing may be configured such that the surface of the longitudinal portion of the housing that coincides with the longitudinal position of the inner cavity reflects the longitudinal surface that defines the inner cavity.

[0026] The heater may include a resistance heater.

[0027] The heating coil may include a resistance heating coil.

[0028] According to another aspect, an aerosol supply device configured to heat an article containing an aerosol-generating material is provided, and the device includes the heater described above.

[0029] According to another aspect, a system is provided that includes the aerosol supply device described above and an article containing an aerosol generating material. According to another aspect, the step of providing the aerosol supply device described above, and the step of at least partially inserting an aerosol generating article into a receiving portion of a heating chamber of the aerosol supply device A method of generating an aerosol is provided that includes.

[0030] The method may further include the step of operating the aerosol supply device to generate an aerosol from the aerosol generating article. According to another aspect, the step of providing an elongated housing, and the step of disposing or inserting a heating coil within the housing that defines a longitudinal axis, the heating coil having a diameter that varies along the longitudinal length A method of manufacturing or assembling a heater for an aerosol supply device is provided that includes. According to various other embodiments, the step of providing an elongated housing, the elongated housing having an inner cavity with a suction end and a distal end, the inner cavity tapering from the suction end towards the distal end, and the step of inserting a heating coil into the inner cavity, the heating coil having a diameter that tapers along the longitudinal length, the heating coil being inserted into the inner cavity such that a portion having a diameter D1 of the heating coil is inserted adjacent to the distal end and a portion having a diameter D2 of the heating coil is inserted adjacent to the suction end, where D2 > D1 A method of manufacturing or assembling a heater for an aerosol supply device is provided that includes.

[0031] The method may further include the step of filling the inner cavity with a filling material at least partially before inserting the heating coil into the inner cavity and / or after inserting the heating coil into the inner cavity.

[0032] The heater may be a resistance heater.

[0033] The heating element may also be a resistance heating element.

[0034] The heating element may also be a resistance heating element.

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

[0036] The heater may be an induction heater.

[0037] The heating element may be an induction heating element.

[0038] The coil may also be an induction coil.

[0039] According to one embodiment, an aerosol supply device is provided that is configured to heat an article containing an aerosol-generating material, and the device comprises the heater described above. The aerosol supply device may also comprise a heating chamber provided with the heater.

[0040] The aerosol supply device may comprise a power supply, a controller, and a heating chamber, and the aerosol product is removably received. The power supply may be aligned along the longitudinal axis of the heating chamber. The power supply may also be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0041] The aerosol supply device may be configured for wireless charging.

[0042] According to one embodiment, an aerosol supply system is provided comprising the above-described aerosol supply device and an article containing an aerosol generating material.

[0043] 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.

[0044] In another embodiment, a method for generating an aerosol is provided, comprising the steps of providing an aerosol supply device equipped as described above, and inserting an aerosol product at least partially into a receiving portion of a heating chamber.

[0045] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0046] [Figure 1] This is a perspective view of an aerosol supply system, including an aerosol supply device located within a charging unit. [Figure 2] Figure 1 is a schematic cross-sectional view of a portion of the aerosol supply device. [Figure 3] Figure 1 is a schematic cross-sectional view of a portion of the aerosol supply device and the aerosol products of the aerosol supply system. [Figure 4] This is a perspective view of another aerosol supply device. [Figure 5] Figure 4 is a schematic cross-sectional view of the device. [Figure 6] This is a schematic cross-sectional view of the heater of the device shown in Figure 1 or Figure 4. [Figure 7] These are schematic cross-sectional views of heaters according to various embodiments. [Figure 8] These are schematic cross-sectional views of heaters according to various embodiments. [Figure 9]This figure shows a method for manufacturing or assembling a heater according to various embodiments. [Modes for carrying out the invention]

[0047] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the constituent aerosol-generating materials (or components of those materials) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0048] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0049] 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.

[0050] 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.

[0051] 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 that can be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0052] 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.

[0053] In some embodiments, the non-flammable 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.

[0054] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material transfer component, aerosol generator, aerosol generating area, housing, packaging material, filter, suction nozzle, and / or aerosol modifier.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] An aerosol supply device can receive an article containing an aerosol-generating material for heating. In this context, “article” refers to a component that contains or is contained 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 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.

[0064] 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 provide the aerosol-generating material with one or more of the following: vibration, pressure increase, or electrostatic energy.

[0065] 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 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, an electrically conductive material, or a susceptor.

[0066] A susceptor is a heating material that can be heated by penetration of 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.

[0067] 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 (or control circuit). The power supply may comprise an electrical 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.

[0068] 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 positioned 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.

[0069] 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 when used to inhale 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 directed toward the user when used. Furthermore, the aerosol supply device 100 also similarly defines a distal direction directed 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 toward each other in the proximal-distal direction along the longitudinal axis. The aerosol supply device 100 has an opening at its distal end leading into a heating chamber.

[0070] The aerosol supply device 100 may be removably inserted into a charging unit 101 for charging. The charging unit 101 includes a cavity 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. One or more user-operable control elements, such as a button 106 that can be used to operate the aerosol supply device 100, may be provided on the first side of the aerosol supply device 100. The first side of the aerosol supply device 100 may be received into a longitudinal opening provided in the charging unit 101.

[0071] 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 correspond to a longitudinal opening.

[0072] The charging unit 101 may include a sliding lid 103. When the aerosol supply device 100 is inserted into the charging unit 101 for recharging, the sliding lid 103 may be closed to cover the opening into the aerosol supply device 100. In other embodiments, the charging unit 101 may have an alternative lid configuration, such as a hinged or pivoted lid, or may not have a lid at all.

[0073] 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.

[0074] Figure 2 shows a partial cross-sectional view 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 at the distal end of the receptacle 205. The heating zone 201a is configured as at least a portion of the article for heating.

[0075] The heating element 301 is provided in a part of the main housing 200, and the heating element 301 extends or protrudes into the heating chamber 201. The heating element 301 may have a base 301a which can be positioned in a recess provided in a part of the body of the device 100. The heating element 301 stands upright in the heating chamber 201. The heating element 301 stands upright from its distal end.

[0076] 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 in use at the distal end of the aerosol product 50 (see Figure 3) which is received in the heating chamber 201 to heat the aerosol product 50 internally.

[0077] 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 the wall 200a. The housing base 200b is at the distal end of the housing wall 200a. In the illustrated embodiment, the heating member 301 rises from the housing base 200b. The heating member 301 protrudes through the receptacle base 205b. The receptacle base 205b has an opening 206 from which the heating member 301 protrudes. In the embodiment, the heating member 301 is attached to the receptacle base 205b. The heating member 301 rises from the receptacle base 205b.

[0078] The aerosol supply device 100 further comprises a removal mechanism 204 which can be detachably held in the main housing 200 of the aerosol supply device 100. The removal mechanism 204 in the embodiment is omitted. In the embodiment, the housing wall 200a defines at least partially the receptacle 205. The removal mechanism 204 may be held in the main housing 200, so that at least a portion of the removal mechanism 204 extends into the heating chamber 201. In this embodiment, the removal mechanism 204 may comprise a longitudinal portion such as a tubular peripheral wall portion 207a and a base wall portion 207b. The wall 207a may have a shape other than tubular and may be any shape that encloses (e.g., surrounds) and defines the heating chamber 201 inside.

[0079] 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.

[0080] The base portion 207b has an opening 206 through which the heating member 301 protrudes. In order to hold the removal mechanism 204 in the main housing 200, the removal mechanism 204 is pushed distally, i.e., toward the distal end of the main housing 200, to engage with the main housing 200 until the removal mechanism 204 can no longer move distally. In the following description, when the removal mechanism 204 is referred to as "held in" the main housing 200, this means that the removal mechanism 204 is engaged with the main housing 200 and cannot move distally.

[0081] The circumferential portion 207a and the base portion 207b together may 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 50 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 the longitudinal axis of the aerosol supply device 100 (and optionally aligned in a line) when the article is received in the article chamber.

[0082] 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.

[0083] 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.

[0084] 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 some embodiments, 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.

[0085] The removal mechanism 204 may comprise an internal element (including 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 200, such as the wall 200a of the main housing. The tubular portion 207a, the base portion 207b, and the outer cap portion 210 may comprise an integrated (e.g., 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.

[0086] Figure 4 shows another aerosol supply system 40. System 40 comprises an integrated aerosol supply device 400 for generating aerosols from aerosol-generating material, and an aerosol product 50 containing the aerosol-generating material. Device 400 can be used to heat the aerosol product 50 containing the aerosol-generating material to produce an aerosol or other inhalable material that can be inhaled by the user of device 400.

[0087] 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.

[0088] 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.

[0089] The device 400 defines a longitudinal axis 509 along which the article 50 may extend when it is inserted into the device 400. The opening 504 is aligned on the longitudinal axis 509.

[0090] Figure 5 shows 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 comprises a power supply 410, a controller 420, and a heating chamber 401, and the aerosol product 50 is removably received.

[0091] 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.

[0092] 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 within the heating chamber 401.

[0093] The heating element 301 may be inserted at the distal end of the aerosol product 50, which is received in the heating chamber 401, in order to heat the aerosol product 50 internally.

[0094] The aerosol supply devices 100 and 400 may 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, configured to operate to heat the heating element 301.

[0095] 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 via a resistance heating process. In this case, a current is applied directly to the resistance heating element, and the resulting current flow within the heating element acting as a heating component heats 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 component, and the heating component includes electrical contacts for supplying current to the resistance material. In the embodiment, the heating element forms at least a portion of the resistance heating member itself. In the embodiment, the resistance heating element transfers heat to the heating member, for example, by conduction. Providing a resistance heating component enables a compact configuration. Resistance heating provides an efficient configuration.

[0096] 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.

[0097] 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.

[0098] 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 supports the heating element 301. It will be understood that different mounting configurations, such as fixing, molding, and bonding including adhesive, may be used. The mount 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0099] 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 inner void 308 of the heating member 301. The inner void 308 extends in the longitudinal direction. In the embodiment, the inner void 308 is at least partially filled with, for example, a filler. In the embodiment, the inner void 308 is completely filled with, for example, one or more fillers and / or components. In the embodiment, the inner void 308 defines an air gap. The inner surface 309 is defined on the inside of the elongated housing 302. The base end 303 is provided with an open end 310 toward the inner void 308.

[0100] 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 inner gap 308 does not extend through the free end 304. The tip 311 is provided at the free end 304. 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.

[0101] 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 inner void 308. The heating element 350 extends between the base end 303 and the distal end 304. In the embodiment, the heating element extends partially along the length of the inner void 308. In the embodiment, the heating element 350 extends to or beyond the open end 310.

[0102] 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 electrical insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302. In the embodiment, the electrical insulating coating is thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In the embodiment, the electrical insulating coating is omitted. In the embodiment, a separate electrical insulating component is provided, such as at least one of an electrical insulating member and an electrical insulating filler. In the embodiment, the electrical insulating member and the electrical insulating filler are thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302.

[0103] 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.

[0104] The heating element 300 includes electrical connection paths. The electrical connection paths extend from each end of the heating element 350. The base electrical connection path 352 extends from the distal end of the heating element 350. The return electrical connection path 353 extends from the proximal end of the heating element 350. The return electrical connection path overlaps the longitudinal range of the heating element 350. The electrical connection paths 352, 352 are formed integrally with the heating element 350, for example, as a single wire. In embodiments, a connector connects the electrical connection paths 352, 353 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.

[0105] Figure 7 shows a heating member 301 for an aerosol supply device according to various embodiments. The heating member 301 may be used in an aerosol supply device as described above. The heating member 301 may act as a heater or form at least part of a heater. The heating member 301 comprises an elongated housing 302 and a heating element 350. The elongated housing 302 may include an elongated member defining a longitudinal axis. The longitudinal axis may be parallel to the longitudinal axis of the aerosol supply device. The longitudinal axis may coincide with the longitudinal axis of the aerosol supply device.

[0106] According to various embodiments, heaters for aerosol supply devices are provided. The heater comprises an elongated housing 302 and a heating coil located within the housing that defines a longitudinal axis. The heating coil has a diameter that varies along its longitudinal length.

[0107] According to various embodiments, heating coils having various diameters are provided to facilitate insertion of the heating coil into the inner cavity of the elongated housing 302. The inner cavity may have a mouthpiece end, and the outer contour of the heating coil may be positioned to correspond to the inner contour of the inner cavity. For example, the heating coil may be inserted into the inner cavity and positioned to be relatively fixed within the inner cavity. According to one embodiment, the inner cavity may taper and narrow away from the mouthpiece end of the inner cavity. Similarly, the heating coil may have a corresponding contour.

[0108] It will be understood that, according to various embodiments, a heating coil that tapers or narrows may be provided. A tapered profile of the heating coil is beneficial during the assembly of the heating element. Any gaps between the heating coil and the internal cavity of the elongated housing 302 may be filled with filler material.

[0109] Since the diameter of the heating coil changes along its longitudinal length, heaters can also be provided that have a heating profile that can vary depending on the position to form different heating zones. Alternatively, the change in the diameter of the heating coil may be arranged to compensate for a temperature gradient that would otherwise exist along the length of the heater. Thus, embodiments can be conceivable in which the heater may have a more uniform heating profile along the length of the heater. As a result, aerosol supply devices incorporating heaters can provide an improved user experience and / or more efficient utilization of aerosol-generating materials.

[0110] Heaters in various embodiments offer advantages in terms of ease of assembly and, compared to other configurations, can reduce the amount of filler material required to secure the heating coil within an elongated housing.

[0111] Therefore, it is possible to reduce manufacturing costs and provide more reliable heaters for aerosol supply devices.

[0112] Embodiments are conceivable in which the number of turns of the heating coil may vary depending on its longitudinal position. In particular, when the heating coil is inserted into the inner cavity, it may have more turns per unit length in the region proximal to the distal end of the inner cavity. For example, the heating coil may have fewer turns per unit length toward the inlet end of the inner cavity. This may allow for further adjustment of the heating profile along the length of the device to create different heating zones or to compensate for other existing temperature gradients, thereby providing a more uniform heating profile. This may result in an improved user experience and / or more efficient utilization of aerosol-generating materials.

[0113] The inner cavity may have an inlet end and a distal end. The diameter of the inner cavity may taper or decrease in the direction from the inlet end to the distal end. The heating coil may also have a tapered or decreasing profile to facilitate insertion of the heating coil into the inner cavity. The heating coil may have an outer profile that conforms to the profile of the inner cavity. This helps in heat transfer from the heating coil to the heating zone of the aerosol supply device.

[0114] The external dimensions of the heating coil may vary substantially uniformly and / or continuously between the first and second ends of the heating coil, such that the external dimensions of the heating coil gradually decrease from the first end to the second end. This allows for uniform and / or continuous temperature changes of the aerosol-generating material, potentially providing an improved user experience and / or more efficient utilization of the aerosol-generating material.

[0115] The external dimensions of the heating coil may vary substantially non-uniformly between the first and second ends of the heating coil, such that the external dimensions of the heating coil decrease from the first end to the second end. This may allow for a simpler manufacturing process.

[0116] The heating coil may have external dimensions such that it has a certain outer contour, and the housing and heating coil are configured such that the heating coil is located within the inner cavity between the alpha and beta positions along the longitudinal range of the inner cavity, and the surface of the heater defining the inner cavity between the alpha and beta positions substantially reflects the outer contour of the heating coil. This facilitates heat transfer from the heating coil to the heating zone of the aerosol supply device.

[0117] The outer contour of the heating coil may be in contact with at least a portion of the surface defining the inner cavity between the alpha and beta positions of the heater. This facilitates heat transfer from the heating coil to the heating zone of the aerosol supply device. Furthermore, the housing arrangement and the contour of the heating coil allow for the manufacture of a heater in which the heating coil is firmly held within the housing, reducing the amount of filler material that can be used to fill the inner cavity.

[0118] The elongated housing 302 may be formed from a thermally conductive material such as aluminum. Other suitable materials such as stainless steel may be used. According to another embodiment, the housing 302 may contain ceramic. The elongated housing 302 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.

[0119] The elongated housing 302 has a base end 303 and a free end 304. The base end 304 may be attached to the main body of the aerosol supply device. The mount 305 may be provided on the base end 303 and may be used to attach the heating element 301. It will be understood that different mounting configurations, such as fixing, molding, and bonding including adhesive, may be used. The mount 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0120] The elongated housing 302 comprises a housing body 306. The housing body 306 may be tubular. The housing body 306 may include a bore 307. The bore may have a circular cross-section. Alternatively, the bore may have a different cross-section. The bore 307 may partially define the inner void 308 of the heating member 301. The inner void 308 extends in the longitudinal direction. In the embodiment, the inner void 308 is at least partially filled with, for example, a filler. In the embodiment, the inner void 308 is completely filled with, for example, one or more fillers and / or components.

[0121] According to various embodiments, the inner cavity or inner void 308 may be at least partially filled with a filler material containing an insulating material. The insulating material may be a potting compound, an adhesive, a thermosetting plastic, or an epoxy resin. According to various embodiments, the potting compound may include an epoxy resin. For example, a two-component epoxy consisting of a polymer resin and a curing agent may be used, which, when mixed together, trigger a chemical reaction that crosslinks the chemical bonds in the polymer chain to produce a tough and rigid compound. Other embodiments may include a potting compound containing polyurethane ("PU"), such as a thermosetting plastic. This may include a two-component compound consisting of a base resin having an isocyanate curing agent. Other embodiments may include a potting compound containing silicone. For example, silicone rubber may be used that contains a synthetic polysiloxane polymer that transitions from a liquid to a solid state using an additive catalyst (such as platinum).

[0122] According to various embodiments, the inner void 308 may define an air gap. The inner surface 309 may be defined on the inside of the elongated housing 302. The base end 303 may be provided with an open end 310 toward the inner void 308.

[0123] The inner void 308 may have a diameter that varies along the longitudinal axis. It will be understood that the diameter of the inner void 308 may be the same as the diameter of the bore 307 and the inner surface 309. The diameter of the inner void 308 may vary discontinuously along the longitudinal axis. The inner void 308 may have a first section and a second section. In the first section, the diameter of the inner void 308 may be constant along the longitudinal axis. In the second section, the diameter of the inner void 308 may also be constant along the longitudinal axis. The diameter of the inner void 308 in the first section may be greater than the diameter of the inner void 308 in the second section. In other embodiments, the diameter of the inner void 308 may vary continuously along the longitudinal axis. For example, the inner surface 309 may be substantially conical or frustoconical.

[0124] The free end 304 of the elongated housing 302 may extend toward the proximal end of the heating chamber. The free end 304 of the heating member 301 may be closed. According to various embodiments, the inner void 308 does not extend through the free end 304. A tip 311 is provided at the free end 304. 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. Another embodiment is conceivable in which the inner void 308 extends through the free end 304, but when the heating coil 351 is inserted into the inner void 308, the opening of the free end 304 may be filled with a filler material.

[0125] According to various embodiments, a heating element 350 is provided that extends within a heating member 301. The heating element 350 extends longitudinally within an elongated housing 302. The heating element 350 is received within an inner void 308. The heating element 350 extends between a base end 303 and a distal end 304. In embodiments, the heating element extends partially along the length of the inner void 308. In embodiments, the heating element 350 extends to or beyond an open end 310.

[0126] The heating element 350 may comprise a heating coil 351 or another type of resistance heating element. The heating coil 351 may comprise a resistance member defining the heating coil 351. In embodiments, the heating coil 351 may comprise an electrical insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302. The electrical insulating coating may be thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In embodiments, the electrical insulating coating may be omitted. In embodiments, separate electrical insulating components may be provided, such as at least one of an electrical insulating member and an electrical insulating filler. The electrical insulating member and the electrical insulating filler may be thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302.

[0127] The heating coil 351 may comprise one or more resistance heating coils. One or more heating coils 351 may comprise helical coils. For example, two heating coils of different diameters may be connected in series. The heating coil 351 may comprise wires or electrodes having rectangular, elliptical, circular, or polygonal cross-sectional shapes. It will be understood that other coil configurations are also possible. In embodiments, the heating coil 351 may have a circular cross-sectional contour that varies at different axial positions. In embodiments, the heating structure 300 may comprise two, three, four, or more than four heating coils. The heating coils may be interconnected by wires or electrodes.

[0128] The heating element 300 may have one or more electrical connection paths. The electrical connection paths may extend from each end of the heating element 350. The base electrical connection path 352 may extend from the proximal end of the heating element 350. The return electrical connection path 353 may extend from the distal end of the heating element 350. The return electrical connection path may overlap the longitudinal range of the heating element 350. The electrical connection paths 352, 353 may be formed integrally with the heating element 350, for example, as a single wire or conductor. In embodiments, a connector may be arranged to connect the electrical connection paths 352, 353 to the heating element 350. The heating coil 351 may be 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.

[0129] The external dimensions of the heating coil 351 may vary along its longitudinal direction. The external dimensions may also be radial dimensions. The external dimensions may also be the outer diameter of the heating coil 351. The external dimensions may also be the maximum width of the heating coil 351. Embodiments are described below with reference to the diameter of the heating coil 351 or a portion of the heating coil 351, but it will be understood that embodiments are also conceivable in which the heating coil 351 has a non-circular cross-section and the reference to diameter may be interpreted as including any external dimensions of the heating coil 351.

[0130] The diameter of the heating coil 351 at a first end may be greater than the diameter of the heating coil 351 at a second end. The first end is near the base end 303. The second end is near the free end 304. The heating coil 351 may converge diametrically toward the free end 304. In other words, the diameter of the heating coil 351 may narrow toward the free end 304. The diameter of the heating coil 351 may change substantially non-uniformly between the first end and the second end of the heating coil 351, such that the diameter of the heating coil 351 decreases from the first end to the second end. The diameter of the heating coil 351 may decrease in a stepwise manner toward the base end 303 toward the free end 304. The heating coil 351 may comprise a first section and a second section. The first section may be located near the base end 303, and the second section may be located near the free end 304. The first section may have a plurality of first turns, and the second section may have a plurality of second turns. The first turns have a larger diameter than the second turns.

[0131] The heating coil 351 may comprise a first helical coil and a second helical coil. The first and second helical coils may be provided as a single, integrated component. As used herein, an integrated component means a component that cannot be separated into two or more components after assembly. The first and second helical coils may be integrally formed. Integral formation means two or more features formed on the integrated component during the manufacturing stage of the component. In other embodiments, the first and second helical coils may be separate components. The first helical coil may be positioned toward the base end 303. The second helical coil may be positioned toward the free end 304. The first coil may define a first section. The second coil may define a second section. In embodiments, the heating coil 351 may comprise three or more helical coils. In embodiments, the heating coil may comprise a single helical coil of various diameters.

[0132] In other embodiments, the outer diameter of the heating coil 351 may decrease continuously in the direction from the base end 303 to the free end 304. In embodiments, the heating coil 351 may comprise a single helical coil of varying diameters. In such embodiments, the outer diameter of the heating coil 351 may vary substantially uniformly and / or continuously between the first end and the second end of the heating coil 351, such that the outer diameter of the heating coil 351 decreases progressively from the first end to the second end.

[0133] As shown in Figure 7, the inner cavity 308 and the heating coil 351 may have similar contours. The heating coil 351 may have a contour that can be determined by the outer dimensions of the heating coil 351. The housing 302 and the heating coil 351 may be configured such that the heating coil 351 is located within the inner cavity 308, between an alpha position and a beta position along the longitudinal range of the inner cavity 308. The inner surface 309 between the alpha position and the beta position may substantially reflect the outer contour of the heating coil 351. The outer contour of the heating coil 351 may be in contact with at least a portion of the inner surface 309 between the alpha position and the beta position. The alpha position is proximal to the base end 303 of the housing, and the beta position is proximal to the free end 304.

[0134] In the embodiment, the diameter of the heating coil 351 may vary at a first rate of change in at least one longitudinal portion of the heating coil 351, and the diameter of the heating coil 351 may vary at a second, larger rate of change in at least one longitudinal portion of the heating coil 351. In the embodiment, the heating coil 351 may have M turns per unit longitudinal length adjacent to the first end of the heating coil, and N turns per unit longitudinal length adjacent to the second end of the heating coil, where N≧M, M≠0, and N≠0. Other embodiments are possible where M≧N, M≠0, and N≠0.

[0135] The outer surface of the longitudinal portion of the housing 302 that coincides with the longitudinal position of the inner cavity 308 may be positioned to reflect the inner surface 309.

[0136] Figure 8 shows an alternative embodiment in which the outer diameter of the heating coil 351 increases toward the free end 304 of the heater away from the base end 303. The heating member 301 of Figure 8 may be used in an aerosol supply device as described above. The heating member 301 may act as a heater or form at least part of a heater. The heating member 301 may comprise an elongated housing 302 and a heating element 350. The elongated housing 302 may comprise an elongated member defining a longitudinal axis. The longitudinal axis may be parallel to the longitudinal axis of the aerosol supply device 100. The longitudinal axis may coincide with the longitudinal axis of the aerosol supply device 100.

[0137] The elongated housing 302 may be formed from a thermally conductive material such as aluminum or stainless steel. The elongated housing 302 may have a coating on its outer surface. The elongated housing 302 may be configured to transfer heat from the heating element 350 to the heating zone. 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 of the base end 303 supports the heating member 301. It will be understood that different mounting configurations, such as fixing, molding, and bonding including adhesive, may be used. The mount 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0138] A groove 302a or a region with a reduced cross-sectional diameter may be provided in the elongated housing 302 toward the base end 303 of the elongated housing 302. As will be described in more detail below, the heating coil 351 is positioned within the inner gap 308 of the heating member 301. The groove 302a or region with a reduced cross-sectional diameter may be positioned, for example, along the length of the elongated housing 302 at a longitudinal position intermediate between a first longitudinal position corresponding to the longitudinal position of the end of the heating coil 351 closest to the base end 303 and a second longitudinal position corresponding to the longitudinal position where the base end of the elongated housing 302 is attached to and contacts or otherwise secured to the mount 305.

[0139] It will be understood that the groove 302a or the region with a reduced cross-sectional diameter reduces, limits, or diminishes the effect of heat conduction from the body of the heating member 301 to the base end of the heating member 301 attached to the mount 305. As a result, the flow of heat or thermal energy from the heating member 301 to the mount 305 is reduced. Therefore, the groove 302a or the region with a reduced cross-sectional diameter can be considered to function as an insulating layer that reduces heat bleed from the heating member 301 to the mount 305 or more generally to the mounting point.

[0140] Further embodiments are conceivable in which two or more grooves or regions with reduced cross-sectional diameters may be provided in the elongated housing to act as an insulating layer (not shown). The groove 302a or region with reduced cross-sectional diameter is shown in Figure 6 as including an annular recess, the annular recess having a rectangular cross-sectional profile, but other embodiments are conceivable in which the annular recess may have a different cross-sectional profile, such as a V-notch or a W-notch. Further embodiments are conceivable in which one or more grooves or regions with reduced cross-sectional diameters may be provided on the inner surface of the elongated housing 302.

[0141] The elongated housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body 306 comprises a bore 307. In this embodiment, the bore has a circular cross-section. In other embodiments, the bore may have any other cross-section. The bore 307 defines an inner void 308 of the heating member 301. The inner void 308 extends in the longitudinal direction. In embodiments, the inner void 308 is at least partially filled with, for example, a filler. In embodiments, the inner void 308 is completely filled with, for example, one or more fillers and / or components. In embodiments, the inner void 308 defines an air gap. The inner surface 309 is defined on the inside of the elongated housing 302. The base end 303 is provided with an open end 310 toward the inner void 308. The diameter of the inner void 308 is constant along its longitudinal range.

[0142] 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 inner gap 308 does not extend through the free end 304. The tip 311 is provided at the free end 304. 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.

[0143] 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 inner void 308. The heating element 350 extends between the base end 303 and the distal end 304. In the embodiment, the heating element extends partially along the length of the inner void 308. In the embodiment, the heating element 350 extends to or beyond the open end 310.

[0144] 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 electrical insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302. In the embodiment, the electrical insulating coating is thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In the embodiment, the electrical insulating coating is omitted. In the embodiment, a separate electrical insulating component is provided, such as at least one of an electrical insulating member and an electrical insulating filler. In the embodiment, the electrical insulating member and the electrical insulating filler are thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302.

[0145] The heating coil 351 may comprise a resistance heating coil. The heating coil 351 may comprise a helical coil. The heating coil 351 may have 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.

[0146] The heating element 300 may include electrical connection paths. The electrical connection paths may extend from each end of the heating element 350. The base electrical connection path 352 extends from the proximal end of the heating element 350. The return electrical connection path 353 extends from the distal end of the heating element 350. The return electrical connection path may overlap the longitudinal range of the heating element 350. The electrical connection paths 352 and 353 may be formed integrally with the heating element 350, for example, as a single wire. In embodiments, a connector may connect the electrical connection paths 352 and 353 to the heating element 350. The heating coil 351 may be formed from a resistive material such as copper.

[0147] The external dimensions of the heating coil 351 may vary along its longitudinal direction. The external dimensions are radial dimensions. The external dimensions are the outer diameter of the heating coil 351. In other embodiments, the external dimensions may be the maximum width of the heating coil 351.

[0148] The diameter of the heating coil 351 at the first end may be smaller than the diameter of the heating coil 351 at the second end. The first end is located near the base end 303. The second end is located near the free end 304. The heating coil 351 may diverge diametrically toward the free end 304. The diameter of the heating coil 351 may change substantially non-uniformly between the first end and the second end of the heating coil 351, such that the diameter of the heating coil 351 increases from the first end to the second end. The diameter of the heating coil 351 may increase in a stepwise manner from the base end 303 toward the free end 304. The heating coil 351 comprises a first section and a second section. The first section is located near the base end 303, and the second section is located near the free end 304. The first section has a plurality of first turns, and the second section has a plurality of second turns. The first turns may have a smaller diameter than the second turns.

[0149] The heating coil 351 may comprise a first helical coil and a second helical coil. The first and second helical coils may be provided as a single, integrated component. As used herein, an integrated component means a component that cannot be separated into two or more components after assembly. The first and second helical coils are integrally formed. Integral formation means two or more features that are formed on the integrated component during the manufacturing stage of the component. In other embodiments, the first and second helical coils may be separate components. The first helical coil may be positioned toward the base end 303. The second helical coil may be positioned toward the free end 304. The first coil may define a first section. The second coil may define a second section. In embodiments, the heating coil 351 may comprise three or more helical coils. In embodiments, the heating coil comprises a single helical coil of varying diameters.

[0150] In other embodiments, the outer diameter of the heating coil 351 may increase continuously in the direction from the base end 303 to the free end 304. In embodiments, the heating coil 351 may comprise a single helical coil of varying diameters. In such embodiments, the outer diameter of the heating coil 351 may vary substantially uniformly and / or continuously between the first end and the second end of the heating coil 351, such that the outer diameter of the heating coil 351 increases progressively from the first end to the second end.

[0151] In the embodiment, the diameter of the heating coil 351 may change at a first rate of change in at least one longitudinal portion of the heating coil 351, and the diameter of the heating coil 351 may change at a second, larger rate of change in at least one longitudinal portion of the heating coil 351.

[0152] In the embodiment, the heating coil comprises M turns per unit longitudinal length adjacent to the first end of the heating coil, and N turns per unit longitudinal length adjacent to the second end of the heating coil, where N ≥ M, M ≠ 0, and N ≠ 0. Alternatively, M ≥ N, M ≠ 0, and N ≠ 0. The outer surface of the longitudinal portion of the housing 302 may coincide with the longitudinal position of the inner cavity 308, or it may reflect the inner surface 309.

[0153] Figure 9 shows a method for manufacturing a heater for an aerosol supply device according to various embodiments. The method includes a first step 801 of preparing an elongated housing and a second step 802 of arranging a heating coil within the housing defining a longitudinal axis, the heating coil having a diameter that varies along its longitudinal length. The method may also include an optional third step 803 of inserting a filler material into an inner cavity provided in the housing in order to further secure the heating coil within the inner cavity.

[0154] According to various embodiments, the inner cavity may be at least partially filled with a filler material containing an insulating material. The insulating material may be a potting compound, an adhesive, a thermosetting plastic, or an epoxy resin. According to various embodiments, the potting compound may include an epoxy resin. For example, a two-component epoxy consisting of a polymer resin and a curing agent may be used, which, when mixed together, trigger a chemical reaction that crosslinks the chemical bonds in the polymer chain to produce a tough and rigid compound. Other embodiments may include a potting compound containing polyurethane ("PU"), such as a thermosetting plastic. This may include a two-component compound consisting of a base resin having an isocyanate curing agent. Other embodiments may include a potting compound containing silicone. For example, silicone rubber may be used that contains a synthetic polysiloxane polymer that transitions from a liquid to a solid state using an additive catalyst (such as platinum).

[0155] 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.

[0156] An induction heating configuration 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 configuration may comprise 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 variable current in 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.

[0157] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0158] 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.

[0159] 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, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, 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. The long, slender housing, A heating coil disposed within the housing defining the longitudinal axis, the heating coil having a diameter that changes along the longitudinal length, A heater for an aerosol supply device equipped with the following features.

2. The heater for an aerosol supply device according to claim 1, wherein the heating coil comprises a first section having one or more first turns and a second section having one or more second turns, the one or more first turns having a larger diameter than the one or more second turns.

3. The heater for an aerosol supply device according to claim 2, wherein the housing comprises a base end and a free end, the first section being located near the base end, and the second section being located near the free end.

4. The heater for an aerosol supply device according to claim 3, wherein the heating coil converges in the diametrical direction toward the free end.

5. The heater for an aerosol supply device according to any one of claims 1 to 4, wherein the heating coil comprises one or more helical coils.

6. A heater for an aerosol supply device according to any one of claims 1 to 5, wherein the radial outer dimensions of the heating coil vary along the longitudinal direction.

7. A heater for an aerosol supply device according to any one of claims 1 to 6, wherein the elongated housing comprises an internal cavity.

8. The heater for an aerosol supply device according to claim 7, wherein the inner cavity has a diameter that varies along its longitudinal length.

9. A heater for an aerosol supply device according to any one of claims 1 to 8, wherein the radial outer dimension of the heating coil at the first end of the heating coil is greater than the radial outer dimension of the heating coil at the second end of the heating coil.

10. A heater for an aerosol supply device according to any one of claims 1 to 9, wherein the external dimensions of the heating coil change substantially uniformly and / or continuously between the first end and the second end of the heating coil, such that the external dimensions of the heating coil gradually decrease from the first end to the second end.

11. A heater for an aerosol supply device according to any one of claims 1 to 9, wherein the external dimensions of the heating coil change substantially non-uniformly between the first end and the second end of the heating coil, such that the external dimensions of the heating coil decrease from the first end to the second end.

12. A heater for an aerosol supply device according to any one of claims 1 to 9, wherein the external dimensions of the heating coil vary substantially non-uniformly, discontinuously, or in a stepwise manner from the first end to the second end of the heating coil between the first end and the second end of the heating coil.

13. A heater for an aerosol supply device according to any one of claims 1 to 9, wherein the outer dimensions of the heating coil change between a first end and a second end of the heating coil, the outer dimensions of the heating coil change at a first rate of change in at least one longitudinal portion of the heating coil, the outer dimensions of the heating coil change at a second rate of change in at least one longitudinal portion of the heating coil, and the first rate of change is greater than the second rate of change.

14. A heater for an aerosol supply device according to any one of claims 1 to 13, wherein the heating coil has external dimensions such that the heating coil has a certain external contour, the housing and the heating coil are configured such that the heating coil is located within an internal cavity between an alpha position and a beta position along the longitudinal range of the internal cavity, and the surface of the heater defining the internal cavity between the alpha position and the beta position substantially reflects the external contour of the heating coil.

15. The heater for an aerosol supply device according to claim 14, wherein the outer contour of the heating coil is in contact with at least a portion of the surface of the heater that defines the inner cavity between the alpha position and the beta position.

16. A heater for an aerosol supply device according to claim 14 or 15, wherein the housing extends longitudinally and has a first end and a second end, an inner cavity extends between the first end of the housing and a third position, the first end of the housing defines a suction opening for accessing the inner cavity, the alpha position is proximal to the first end of the housing, and the beta position is proximal to the third position.

17. A heater for an aerosol supply device according to any one of claims 1 to 15, wherein the heating coil comprises M turns per unit longitudinal length adjacent to the first end of the heating coil, and N turns per unit longitudinal length adjacent to the second end of the heating coil, where N ≥ M, M ≠ 0, and N ≠ 0.

18. A heater for an aerosol supply device according to any one of claims 1 to 17, wherein the housing has an outer surface, and the housing is configured such that the surface of a longitudinal portion of the housing that coincides with the longitudinal position of the inner cavity reflects a longitudinal surface that defines the inner cavity.

19. A heater for an aerosol supply device according to any one of claims 1 to 18, comprising a resistance heating heater.

20. The heater for an aerosol supply device according to any one of claims 1 to 19, wherein the heating coil comprises a resistance heating coil.

21. An aerosol supply device configured to heat an article containing an aerosol-generating material, wherein the device comprises a heater according to any one of claims 1 to 20.

22. The aerosol supply device according to claim 21, Articles containing aerosol-generating materials and A system equipped with these features.

23. The steps of providing the aerosol supply device described in claim 21, The steps include: inserting the aerosol product at least partially into the receiving portion of the heating chamber of the aerosol supply device; A method for generating an aerosol containing [a specific substance].

24. A method for generating an aerosol according to claim 23, further comprising the step of operating the aerosol supply device to generate an aerosol from the aerosol product.

25. A step that provides an elongated housing, A step of arranging or inserting a heating coil into the housing that defines a longitudinal axis, wherein the heating coil has a diameter that changes along its longitudinal length. A method for manufacturing or assembling a heater for an aerosol supply device, including the following.

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