Aerosol Delivery Device

Abstract

The present invention relates to an aerosol delivery device. The device includes a heater assembly configured to receive an aerosol-generating material. The heater assembly has a susceptor that is heatable by penetration of a varying magnetic field. A fluidically sealed enclosure extends around at least a portion of the heater assembly and defines a fluidically sealed cavity between the enclosure and the susceptor. An inductor coil also extends at least partially around the enclosure. The inductor coil is configured to generate a varying magnetic field.

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device and an aerosol delivery system that includes an aerosol delivery device and an article that includes an aerosol-generating material. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion. An example of such a product is a heating device that releases compounds by heating a material without burning it. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Summary of the Invention

[0003] According to one aspect of the present disclosure, an aerosol delivery device is provided that includes a heater assembly configured to receive an aerosol-generating material, the heater assembly including a susceptor that is heatable by penetration of a varying magnetic field, a fluidically sealed enclosure extending around at least a portion of the heater assembly, the enclosure defining a fluidically sealed cavity between the enclosure and the susceptor, and an inductor coil extending at least partially around the enclosure, the inductor coil configured to generate a varying magnetic field.

[0004] The heater assembly may define a heater chamber configured to receive the aerosol-generating material. The aerosol delivery device may include a sensor within the fluidly sealed cavity. The sensor may be a thermocouple.

[0005] The thermocouple may be on the susceptor.

[0006] The sensor may include a communication cable. The fluidly sealed enclosure may include a communication cable passage through which the communication cable extends through the enclosure. The enclosure may also include a sealing element in the communication cable passage to seal the communication cable passage.

[0007] The fluidly sealed enclosure may include an end support at one end of the susceptor, and the communication cable passage may be formed within the end support.

[0008] The aerosol delivery device may include a fluid seal between the fluidly sealed enclosure and the heater assembly.

[0009] The fluid seal may be a circumferentially extending member.

[0010] The fluid seal may be formed on the exterior of the heater assembly.

[0011] The fluid seal may be overmolded onto the outside of the heater assembly.

[0012] The fluid seal may be an O-ring, a compression gasket and / or a grommet.

[0013] The aerosol delivery device may include a tubular member extending around the heater assembly. The fluidly sealed enclosure may include the tubular member.

[0014] A fluid seal may extend between the heater assembly and the tubular member.

[0015] The aerosol delivery device may include an end support at one end of the heater assembly, and the tubular member may rest on the end support.

[0016] A fluid seal may be formed in one of the heater assembly and the end support.

[0017] The fluid seal may be configured to abut a rim of the end support.

[0018] The end support may define an air inlet at an open end of the heater assembly.

[0019] The fluid seal may position the heater assembly axially or may position the heater assembly radially.

[0020] The fluidly sealed enclosure may include end supports, and the fluid seal may fluidly seal between the end supports and the heater assembly.

[0021] The end support may be a first end support at a first end of the heater assembly and the fluid seal may be a first fluid seal. The fluidly sealed enclosure may include a second end support at a second end of the heater assembly and a second fluid seal between the second end support and the heater assembly.

[0022] The or each end support and the tubular member may be fabricated as a unitary component.

[0023] The fluidly sealed enclosure may define a cavity.

[0024] According to one aspect of the present disclosure, an aerosol delivery device is provided that includes a heater assembly having a receptacle configured to receive an aerosol generating material, the heater assembly including a heating element, and a fluidly sealed enclosure extending around at least a portion of the heater assembly, the enclosure defining a fluidly sealed cavity between the enclosure and the receptacle.

[0025] The heating element may form a receptacle.

[0026] According to one aspect of the present disclosure, an aerosol supply device is provided that includes a heater assembly configured to receive an aerosol generating material, the heater assembly including a susceptor that is heatable by the penetration of a varying magnetic field, an insulating member extending around the susceptor, a first barrier between the insulating member and the susceptor, an inductor coil extending around the insulating member, the inductor coil configured to generate a varying magnetic field, and a second barrier between the inductor coil and the insulating member.

[0027] The first barrier may define a heater assembly chamber.

[0028] The first barrier may be spaced apart from the heater assembly. The aerosol delivery device may include a gap between the first barrier and the heater assembly.

[0029] The first barrier and the second barrier may define an insulating member chamber between the first barrier and the second barrier.

[0030] The insulation member chamber may be isolated from the heater assembly.

[0031] The aerosol delivery device may include a device shell around the inductor coil, the second barrier and the device shell may define an inductor coil chamber between the device shell and the second barrier.

[0032] The second barrier may comprise a coil support for the inductor coil.At least one of the first barrier and the second barrier may comprise a tubular member.

[0033] According to one aspect of the disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device as described in any of the above paragraphs and an article containing an aerosol-generating material, the article being dimensioned to be at least partially received within the heater assembly.

[0034] In use, the inductor coil may be configured to heat the susceptor to a temperature of about 200° C. to about 300° C. In use, the inductor coil may be configured to heat the susceptor to a temperature of about 350° C.

[0035] The inductor coil may be substantially helical. The inductor coil may be a helical coil. For example, the inductor coil may comprise a wire, such as a Litz wire, helically wound on a coil support. The wire may be a solid wire.

[0036] By "outer surface" of the actual object is meant the surface disposed furthest from the axis of the susceptor in a direction perpendicular to the axis, and similarly, by "inner surface" of the actual object is meant the surface disposed closest to the axis of the susceptor in a direction perpendicular to the axis.

[0037] By "thickness" of a real article is meant the average distance between the inner surface of the article and the outer surface of the article. Thickness may be measured in a direction perpendicular to the axis of the susceptor.

[0038] The inductor coil, the susceptor and the fluidly sealed enclosure may be coaxial.

[0039] In some examples, during use, the inductor coil is configured to heat the susceptor to a temperature of about 200° C. to about 350° C. (such as about 240° C. to about 300° C. or about 250° C. to about 280° C.) When the outer cover is spaced at least this distance from the susceptor, the temperature of the outer cover is maintained at a safe level, such as less than about 60° C., less than about 50° C., less than about 48° C., or less than about 43° C.

[0040] The fluidly sealed enclosure may be made from an insulating material such as plastic. In one particular example, the fluidly sealed enclosure is constructed from polyetheretherketone (PEEK), which has excellent thermal insulation properties and is well suited for use in aerosol delivery devices.

[0041] In another example, the fluidly sealed enclosure may include mica or a mica-glass ceramic.

[0042] The fluidly sealed enclosure may also have a thermal conductivity of less than about 0.5 W / mK or less than about 0.4 W / mK. For example, the thermal conductivity may be about 0.3 W / mK. PEEK has a thermal conductivity of about 0.32 W / mK.

[0043] The fluidly sealed enclosure may have a melting point greater than about 320° C. (greater than about 300° C. or greater than about 340° C.). PEEK has a melting point of 343° C.

[0044] The device may be a tobacco heating device, also known as a non-combustion heating device.

[0045] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only and with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0046] [Figure 1] FIG. 1 is a front view of an example of an aerosol delivery device. [Diagram 2] 2 is a partially exploded side view of the aerosol delivery device of FIG. 1 showing the housing, end member, power source, aerosol generation assembly, replaceable article, and outer cover. [Diagram 3] 2 is an enlarged cross-sectional side view of a portion of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 3 is an enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. [Diagram 5] FIG. 3 is another enlarged cross-sectional view showing the proximal portion of the aerosol generation assembly of FIG. 2. [Figure 6] FIG. 3 is another enlarged cross-sectional view showing the distal portion of the aerosol generation assembly of FIG. 2. [Figure 7]FIG. 3 is another enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. [Figure 8] FIG. 3 is another enlarged cross-sectional view of a portion of the aerosol generation assembly of FIG. 2. [Figure 9] FIG. 3 is a side view of the aerosol generation assembly of FIG. 2 including an inductor coil and a coil support. [Figure 10] FIG. 10 is a side view of the coil support of FIG. [Figure 11] FIG. 3 is a side view of the housing and aerosol generation assembly of FIG. 2. [Figure 12] FIG. 5 is an enlarged side view of a portion of the coil support of FIG. 4 showing the thermocouple attachment. [Figure 13] A partial enlarged perspective view of the aerosol generation assembly of Figure 2, including a sensor communication cable and a communication cable channel. [Figure 14] FIG. 3 is a perspective view of a sealing element configured to seal a communication cable channel of the aerosol generation assembly of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] As used herein, the term "aerosol generating material" includes materials that provide volatilization upon heating, usually in the form of an aerosol. Aerosol generating materials include any tobacco-containing material, such as one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol generating materials also include other non-tobacco products, which may or may not contain nicotine. Aerosol generating materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol generating materials may also be a combination or mixture of materials. Aerosol generating materials may also be known as "smoking materials."

[0048] Devices are known that heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, thereby forming an inhalable aerosol, usually without burning or combusting the aerosol-generating material. Such devices may be described as "aerosol-generating devices", "aerosol delivery devices", "non-combustion heating devices", "tobacco heating product devices", "tobacco heating devices", etc. Similarly, there are so-called e-cigarette devices that vaporize an aerosol-generating material, usually in liquid form, which may or may not contain nicotine. The aerosol-generating material may be in the form of, or may be provided as, a part, such as a rod, cartridge, or cassette that can be inserted into the device. A heater that heats and volatilizes the aerosol-generating material may be provided as a "permanent" part of the device.

[0049] The aerosol delivery device can receive and heat an article that includes an aerosol-generating material. In this context, an "article" is a component that comprises or contains an aerosol-generating material during use and is heated to volatilize the aerosol-generating material and optionally other components during use. A user may insert the article into the aerosol delivery device, which may then be heated to generate an aerosol that is subsequently inhaled by the user. The article may be of a predetermined size or may be of a particular size, for example, configured to be placed in a heating chamber of a device sized to receive the article.

[0050] 1 shows an example of an aerosol delivery device 100 that generates an aerosol from an aerosol-generating medium / material. In general, device 100 may be used to heat a replaceable item 110 that contains an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0051] The device 100 comprises a housing 102 (including an outer cover) that encloses and contains various components of the device 100. The device 100 has an opening 104 at one end through which an article 110 can be inserted and heated by a heater assembly 105 (see FIG. 2). In use, the article 110 may be fully or partially inserted into the heater assembly 105 and heated by one or more components of the heater assembly 105.

[0052] Device 100 may also include user-operable controls 112, such as buttons or switches, that, when pressed, cause device 100 to operate. For example, a user may turn device 100 on by operating switch 112.

[0053] The device 100 defines a longitudinal axis 101 .

[0054] Figure 2 is a schematic exploded view of the device 100 of Figure 1. The device 100 comprises an outer cover 102, a first end member 106, and a second end member 116. The device 100 comprises an aerosol generation assembly 111 including a housing 109, a power source 118, and a heater assembly 105. The device 100 further comprises at least one electronics module 122.

[0055] The outer cover 102 forms part of a device shell 108. A first end member 106 is disposed at one end of the device 100 and a second end member 116 is disposed at an opposite end of the device 100. The first and second end members 106, 116 close the outer cover 102. The first and second end members 106, 116 form part of the shell 108. The device 100 in accordance with an embodiment includes a lid (not shown) that can be moved relative to the first end member 106 to close the opening 104 when the article 110 is not in place.

[0056] Device 100 may also include electrical components, such as a connector / port 114, capable of accepting a cable to charge a battery of device 100. For example, connector 114 may be a charging port, such as a USB charging port. In some examples, connector 114 may additionally or alternatively be adapted to transfer data between device 100 and another device, such as a computing device.

[0057] The device 100 comprises a housing 109. The housing 109 is received by the outer cover 102. The aerosol generation assembly 111 comprises a heater assembly 105 into which, in use, all or part of the article 110 may be inserted, and the article 110 may be adapted to be heated by one or more components of the heater assembly 105. The aerosol generation assembly 111 and the power source 118 are mounted in the housing 109. The housing 109 is a one-piece component.

[0058] Housing 109 may be integrally formed at the time of manufacture, for example by an injection molding process, or two or more features of housing 109 may be first formed separately and then integrally formed at the manufacturing stage, for example by a welding process, to form a one-piece component.

[0059] An integral component refers to a component of device 100 that cannot be separated into two or more components after assembly of device 100. Integral formation refers to two or more features that are formed as a unitary component during the fabrication stage of the component.

[0060] The first and second end members 106, 116 together at least partially define an end surface of the device 100. For example, a bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. The first and second end members 116 close an open end of the outer cover 102. The second end member 116 is at one end of the housing 109.

[0061] The end of device 100 closest to opening 104 may be known as the proximal end (or mouth end) of device 100, as it is closest to a user's mouth during use. In use, a user inserts item 110 into opening 104 and operates user controls 112 to initiate heating of the aerosol-generating material and utilize the aerosol generated by the device, which causes the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0062] The other end of the device, furthest from the opening 104, may be known as the distal end of the device 100, as this is the end that will be furthest from a user's mouth when in use. When a user utilizes the aerosol generated by the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 will be explained by reference to the relative orientation of such features to one another in the proximal-distal direction along the axis 101.

[0063] The power source 118 is disposed at the distal end of the device 100. The housing 109 carries the power source 118. The housing 109 includes a power supply mount 119. The housing 109 partially encloses the power source 118. The power source 118 may be a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the aerosol generation assembly 111 to provide power as required and heat the aerosol-generating material under the control of the controller 121. In this example, the battery is connected to the housing 109, which acts as a central support to hold the battery 118 in place.

[0064] The power source 118 and the aerosol generation assembly 111 are disposed in an axial configuration, with the power source 118 at a distal end of the device 100 and the aerosol generation assembly 111 at a proximal end of the device 100. Other configurations are envisioned. The housing 109 includes an aerosol generation assembly mounting portion 113.

[0065] The device 100 further comprises at least one electronics module 122. The electronics module 122 may comprise, for example, a printed circuit board (PCB) 123. The PCB 123 may support at least one controller 121, such as a processor, and a memory. The PCB 123 may also comprise one or more electrical tracks that electrically connect together various electronic components of the device 100. For example, a battery terminal may be electrically connected to the PCB 123 so that power can be distributed throughout the device 100. The connector 114 may also be electrically coupled to the battery 118 via the electrical tracks. The housing 109 comprises a PCB mounting portion 117.

[0066] The aerosol generating assembly 111 is an induction heating assembly, which includes various components that heat the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element (e.g., one or more inductor coils) and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned relative to the induction element and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, so that the flow of eddy currents against this resistance heats the susceptor by Joule heating. Also, if the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e., the varying orientation of the magnetic dipoles of the magnetic material as a result of alignment with the varying magnetic field. Inductive heating allows for rapid heating as heat is generated inside the susceptor, as compared to, for example, heating by conduction, and furthermore does not require any physical contact between the induction heater and the susceptor, allowing greater freedom of design and application.

[0067] 3 shows an enlarged side view, partially in cross section, of a portion of the device 100. The outer cover 102 surrounds the aerosol generation assembly 111. The aerosol generation assembly 111 of the device 100 comprises a heater assembly 105 and an inductor coil assembly 127. The inductor coil assembly 127 extends around the heater assembly 105. The inductor coil assembly 127 includes a first inductor coil 124 and a second inductor coil 126. The inductor coil assembly 127 also comprises a coil support 200.

[0068] The heater assembly 105 includes a susceptor structure 132 (referred to herein as a "susceptor"). The susceptor 132 in this example is hollow and thus defines a receptacle 131 in which an aerosol-generating material is received. For example, an article 110 can be inserted into the susceptor 132. In this example, the susceptor 132 is tubular with a circular cross section. The susceptor 132 defines a first portion of the heater assembly 105. The susceptor 132 has a generally constant diameter along its axial length. The susceptor 132 has a flared portion 134 at a first, proximal end 133. The flared portion 134 flares outwardly. The flared portion 134 defines an outwardly extending lip 135. That is, the lip 135 has a diameter greater than the outer diameter of the main portion of the susceptor 132. The lip 135 acts to minimize contact with other components of the susceptor 132 at the first end 133. This configuration helps reduce heat transfer, for example by conduction, when the susceptor 132 is heated.

[0069] The susceptor 132 is made of a conductive material suitable for heating by electromagnetic induction. In this example, the susceptor is made of carbon steel. It will be appreciated that other suitable materials (e.g., ferromagnetic materials such as iron, nickel, or cobalt) may also be used.

[0070] In other embodiments, the feature functioning as a receptacle may not be limited to induction heating. Thus, the feature functioning as a heating element may be heatable by electrical resistance. To this end, the heater assembly 105 may include electrical contacts in electrical communication with the device to pass a flow of electrical energy through the heating element to electrically activate the heating element.

[0071] 3 shows a portion of an article 110 received in a receptacle 131 provided by a susceptor 132. The susceptor 132 and article 110 are sized so that the article 110 is received by the susceptor 132, which helps ensure that heating is most efficient. The article 110 in this example includes an aerosol-generating material. The aerosol-generating material is disposed within the susceptor 132. The article 110 may also include other components, such as filters, packaging, and / or cooling structures.

[0072] The heater assembly 105 also includes a funnel 140. The funnel 140 is at a second, distal end 136 of the susceptor 132. The funnel 140 protrudes from the susceptor 132. In an embodiment, the susceptor 132 and the funnel 140 are an integral component.

[0073] The funnel portion 140 has a thimble configuration. The funnel portion 140 is at the second end, distal end 136, of the susceptor 132. The funnel portion 140 defines a second portion of the heater assembly 105. The funnel portion 140 includes a first portion 141 of a first diameter and a second portion 142 of a second diameter. An intermediate portion 143 extends between the first and second portions 141, 142. The first portion 141 is tubular and extends axially. The second portion 142 is tubular and extends axially. The funnel portion 140 is hollow. The intermediate portion 143 defines a shoulder 145. The shoulder 145 acts as a stop to limit the insertion of the article 110 into the receptacle. The shoulder 145 extends in a substantially vertical plane to the longitudinal axis 101.

[0074] First portion 141 has an inner diameter that is larger than the inner diameter of second portion 142. Thus, funnel 140 widens from first portion 141 to second portion 142. Thus, funnel 140 narrows in diameter from susceptor end 148 to distal end 149.

[0075] The funnel portion 140 defines an air passage 146 therethrough. The first portion 141 and the susceptor 132 overlap one another at one end of the susceptor 132. In one example, the overlap is about 1 mm to about 3 mm. In this particular example, the overlap is 2 mm. In some cases, there is no overlap. In such an example, the susceptor 132 and the funnel portion 140 are adjacent. The first portion 141 overlaps the second end, the distal end 136, of the susceptor 132. The first portion 141 is generally cylindrical and has an inner diameter that substantially corresponds to the outer diameter of the susceptor 132. The first portion 141 is adjacent to the susceptor 132. A joint 147 is formed between the first portion 141 of the funnel portion 140 and the susceptor 132. The interface 147 helps to provide a thermal path between the susceptor 132 and the funnel 140 .

[0076] Junction 147 is a fluidly sealed junction. A fluid seal is formed between susceptor 132 and funnel 140. Thus, a fluidly sealed fluid path is defined between the opposing ends of susceptor 132 and funnel 140. The receptacle defined by susceptor 132 thus constitutes a fluid sealed air passage with air passage 146 formed by funnel 140.

[0077] In an embodiment, the fluid seal at the joint 147 is formed by a mechanically machined bond (e.g., welding). The fluid seal at the joint 147 is formed by a laser welding process, although it will be appreciated that other methods, such as adhesive bonding, may be used. The funnel 140 is formed of a heat conductive material. In an embodiment, the funnel 140 is formed of carbon steel. In an embodiment, the funnel is formed of the same material as the susceptor 132. The joint is configured to maintain a fluid seal when the susceptor 132 is at its predetermined operating temperature. With such a process, the susceptor 132 and the funnel 140 are made as a unitary component.

[0078] Thus, a sealed fluid path between the susceptor 132 and the funnel 140 extends from one open end of the heater assembly 105 through the heater assembly 105 to the other open end of the heater assembly 105. Thus, the heater assembly 105 contains any fluid flow through the heater assembly 105. A dry zone may be defined outside the heater assembly 105.

[0079] The proximity of the susceptor 132 and the funnel 140 allows for conductive heat transfer from the susceptor 132 to the funnel 140, thereby assisting in passive heating of the funnel 140. Passive heating of the funnel 140 can limit the rate of condensation build-up in the device 100.

[0080] The funnel portion 140 is axially spaced from the inductor coil assembly 127. In particular, the second portion 142 of the funnel portion 140 is axially spaced from the inductor coil assembly 127. This minimizes or eliminates direct heating of the funnel portion 140 by the inductor coil assembly 127. The funnel portion 140 may be axially adjacent to the inductor coil assembly 127.

[0081] 4-8, the device 100 includes a first end support 220 and a second end support 230. The heater assembly 105 extends between the first and second end supports 230. A barrier member 250 extends between the first end support 220 and the second end support 230. The barrier member 250 acts as a support member.

[0082] The first end support 220 engages a first end, proximal end, of the heater assembly 105 to hold the susceptor 132 in place. The first end support 220 acts as an expansion chamber, as described below. With particular reference to Figures 7 and 8, the first end support 220 extends away from the first end of the susceptor 132 toward the opening 104. Located within the first end support 220 is at least a portion of a retention arrangement 221, such as a retention clip, that holds the article 110 adjacent to it when received within the device 100. The first end support 220 is connected to the end member 106.

[0083] The first end support 220 includes an insertion chamber 222. The insertion chamber 222 is configured to receive the article 110 therein. The retaining structure 221 is in the insertion chamber 222. The insertion chamber 222 has an inner diameter larger than the diameter of the article 110. The first end support 220 defines a proximal collar, which is a first collar of the heater assembly 105. A bore 223 extends therethrough. An inner surface of the bore 223 defines a distally facing shoulder 225, as shown, for example, in FIGS. 7 and 8. The distally facing shoulder 225 is aligned with the lip 135 of the susceptor 132 when the susceptor 132 is received by the first end support 220.

[0084] 4 and 5, the first end support 220 defines a seal rim 226 distally therefrom. The distal seal rim 226 extends around the bore 223. A first mounting flange 227 extends from a first end outer surface, a proximal end outer surface 228, of the first end support 220. The first mounting flange 227 extends circumferentially and is spaced apart from the seal rim 226. The first mounting flange 227 upstands from the first end outer surface 228 to define a first end mounting surface, a proximal end mounting surface 229. The first end outer surface, the proximal end outer surface 228, and the first end mounting surface 229 define a stepped configuration. The first end mounting surface 229 has a larger diameter than the first end outer surface 228. In an embodiment, the first end exterior surface 228 and the first end mounting surface define first and second step surfaces.

[0085] 4-8, the device 100 further comprises a second end support 230 which holds the heater assembly 105 in place by engaging the funnel 140 at the second end, distal end, of the susceptor 132. The second end support 230 constitutes a second collar, distal collar, of the heater assembly 105. In embodiments in which the funnel is omitted, the second end support 230 directly engages the susceptor 132. The second end support 230 acts as an air inlet, as described below. The second end support 230 extends away from the second end of the susceptor 132 towards the distal end of the device 100.

[0086] 4 and 6 in particular, the second end support 230 includes a second end perforation 231. The second end perforation 231 acts as an air inlet. The air inlet defines a flow path through the second end support 230. The air inlet communicates with the exterior of the aerosol generation assembly 111 to provide an air passage to the exterior of the device 100. The second end support 230 is configured to at least partially receive the funnel portion 140. The inner surface of the second end support 230 is stepped. The inner surface includes a first stepped region 232 with a first step and a second stepped region 233 with a second step. The first stepped region 232 receives the first portion 141 of the funnel portion 140. The second stepped region 233 receives the second portion 142 of the funnel portion 140. The second stepped region 233 includes a first sealing surface 234. The second stepped region 233 includes a second sealing surface 235. The first sealing surface 234 is an inner, circumferentially extending surface. The second sealing surface 235 is a circumferentially extending surface that extends in a plane substantially perpendicular to the longitudinal axis 101.

[0087] A second mounting flange 237 extends from a second outer surface, a distal outer surface 238, of the second end support 230. The second mounting flange 237 extends circumferentially and is spaced from a proximal end of the second end support 230. The second mounting flange 237 upstands from the second end outer surface 238 to define a second end mounting surface, a distal end mounting surface 239. The second end outer surface, a distal end outer surface 238, and the second end mounting surface, a distal end mounting surface 239, define a stepped configuration. The second end mounting surface 239 has a larger diameter than the second end outer surface 238. In an embodiment, the second end outer surface 238 and the second end mounting surface 239 define first and second stepped surfaces.

[0088] The barrier member 250 extends between the first end support 220 and the second end support 230. The barrier member 250 extends between the first and second end supports 220, 230. The barrier member 250, together with the first and second end supports 220, 230, surrounds the heater assembly 105. This acts to aid in thermal isolation of the heater assembly 105 from the other components of the device 100. The barrier member 250 is a hollow tubular member.

[0089] The barrier member 250 is fixedly attached to the first and second end supports 220, 230. The first and second end supports 220, 230 are received at the ends of the barrier member 250. The first end support 220 closes the proximal end of the barrier member 250. The second end support 230 closes the distal end of the barrier member 250. The barrier member 250 partially overlaps the first and second end supports 220, 230. In one example, the overlap is about 2 mm to about 3 mm. In this particular example, the overlap is about 2.2 mm. In some cases, there is no overlap. The proximal end of the barrier member 250 is adjacent the first end outer surface 228. The distal end of the barrier member 250 is adjacent the second end outer surface 238.

[0090] The barrier member 250 is fixedly attached to the first and second end supports 220, 230. The barrier member 250 forms a fluid seal with the first and second end supports 220, 230. In an embodiment, a mechanically worked bond (e.g., welded) is formed between the barrier member 250 and the first and second end supports 220, 230, respectively. The fluid seal at the joint of the parts is formed by a welding process, although it will be understood that other methods such as brazing or adhesives can be used. In an embodiment, the barrier member 250 and the first and second end supports 220, 230 are formed from the same material. The bond is configured to maintain the fluid seal when the susceptor 132 is at its predetermined operating temperature. By such a process, the barrier member 250 and the first and second end supports 220, 230 are formed as a unitary component.

[0091] In an embodiment, the barrier member 250 is made of a non-metallic material to help limit interference with magnetic induction. In this particular example, the barrier member 250 is made of polyetheretherketone (PEEK). The first and second end supports 220, 230 are made of PEEK. Other suitable materials are possible. Components made of such materials help the barrier member 250 maintain its rigidity / solidity when the susceptor is heated. The barrier member 250 is made of a rigid material to help support other components such as the heater assembly 105 and the end supports 220, 230. The barrier member 250 may be made of an insulating material such as plastic. In one example, the barrier member 250 has a thickness of about 0.1 mm to about 0.5 mm. In this example, the thickness is about 0.3 mm.

[0092] The heater assembly 105, the barrier member 250, and the first and second end supports 220, 230 are coaxial about a central longitudinal axis of the susceptor 132. The barrier member 250 may help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0093] A radial gap is provided between the susceptor 132 and the first end support 220. The diameter of the perforations 223 is greater than the diameter of the outer surface of the susceptor 132. The radial gap is approximately 0.2 mm, but may vary. Providing a radial gap helps minimize heat transfer between the susceptor 132 and the first end support 220.

[0094] 4-6, the first seal member 240 provides a fluid seal between the heater assembly 105 and the first end support 220. The first seal member 240 is a circumferentially extending member. The first seal member 240 includes a silicone rubber seal. Other suitable materials may be used. The first seal member 240 is elastomeric. The material is configured to stabilize when the heater assembly 105 is at operating temperature. The first seal member 240 is fixedly mounted to the susceptor 132. The first seal member 240 is attached to the susceptor 132, for example, by overmolding the first seal member 240 onto an outer surface of the susceptor 132. The first seal member 240 is spaced from a proximal end of the susceptor 132. When the proximal end of the susceptor 132 is received by the first end support 220, the seal rim 226 of the first end support 220 contacts and seals with the first seal member 240. Such a seal is formed between the first end support 220 and the susceptor 220. The first seal member 240 provides an axial seal.

[0095] The first seal member 240 seals against the barrier member 250. The first seal member 240 upstands from the susceptor 132. The first seal member 240 abuts the inner surface of the barrier member 250. Thus, a seal is formed between the susceptor 132 and the barrier member 250. The first seal member 240 provides a radial seal. The first seal member 240 acts to position and orient the susceptor relative to the first end support 220 and the barrier member 250.

[0096] The second seal member 245 provides a fluid seal between the heater assembly 105 and the second end support 230. The second seal member 245 is a circumferentially extending member. The second seal member 245 includes a silicone rubber seal. Other suitable materials can be used. The second seal member 245 is elastic. The material is configured to stabilize the heater assembly 105 when at operating temperature. The second seal member 245 is fixedly mounted to the funnel 140. In an embodiment, the second seal member is on the susceptor 132, e.g., the funnel is omitted. The second seal member 245 is attached to the susceptor 132, e.g., by overmolding the second seal member 245 onto the outer surface of the funnel 140. The second seal member 245 is adjacent to the open end of the funnel 140. When the distal end of the heater assembly is received by the second end support 230, the first sealing surface 234 of the second end support 230 contacts and seals with the second seal member 245. Such a seal is formed between the second end support 230 and the heater assembly 105. The second seal member 245 provides a radial seal.

[0097] The second seal member 245 seals against the second seal surface 235 of the second end support 230. The second seal member 245 provides an axial seal. The second seal member 245 upstands from the heater assembly 105. The second seal member 245 acts to position and orient the heater assembly 105 relative to the second end support 230 and the barrier member 250.

[0098] In embodiments, the first seal member 240 is at the first end support 220 and seals with the heater assembly 105. In embodiments, the second seal member 245 is at the second end support 230 and seals with the heater assembly 105. The second seal member 245 is at the second portion 142 of the funnel 140. In embodiments, the second seal member 245 is at the first portion 141 of the funnel 140. In such embodiments, the second seal member 245 seals with the proximal rim of the second end support 230.

[0099] The first seal member 240 and the second seal member 250 define a sealed air flow path through the second seal member 250, the heater assembly 105, and the first seal member 240. The barrier member 250 and the first and second end supports 220, 230 define a continuously sealed enclosure for the heater assembly 105. The barrier member 250 is spaced apart from the susceptor 132. The inner surface of the barrier member 250 is spaced apart from the outer surface of the susceptor 132 to provide a gap between the barrier member 250 and the heater assembly 105. The gap provides thermal insulation from heat generated in the susceptor 132.

[0100] A fluidically sealed cavity 260 is formed between the heater assembly 105 and the barrier member 105. The fluidically sealed cavity 260 constitutes a chamber. The cavity 260 provides an air gap. The cavity 260, in some embodiments, contains other gaseous or solid elements. A fluidically sealed enclosure 261 is formed around a portion of the heater assembly 105. The fluidically sealed enclosure 261 forms an airtight seal. The fluidically sealed enclosure is formed by the barrier member 105, the first and second seal members 240, 245, the heater assembly 105, and the second end support 230. In some embodiments, the first end support 220 constitutes a part of the enclosure 261. In some embodiments, the fluidically sealed enclosure 261 is formed by the barrier member 105, the heater assembly 105, and the first and second seal members 240, 245. In an embodiment, the gap between the heater assembly 105 and the barrier member 105 is about 0.8 mm to 1 mm. In an embodiment, the gap is about 0.9 mm.

[0101] A sensor, such as a thermocouple 265, is disposed in the fluidly sealed cavity 260. The thermocouple 265 is mounted on the susceptor 132. The thermocouple 265 is configured to determine the temperature of the susceptor 132. The thermocouple 265 directly detects the temperature of the susceptor 132. The device 100 may include two or more thermocouples 132 configured to determine the temperature of the susceptor 132. Providing the fluidly sealed cavity 260 helps to isolate the thermocouple 265 from the atmosphere outside the fluidly sealed cavity 260. Providing the fluidly sealed cavity 260 helps to isolate the thermocouple 265 from the air flow path through the device 100. This limits the flow of condensate from the air flow path to the thermocouple 265.

[0102] 13, one or more communication cables 266 extend from the thermocouple 265, which acts as a sensor. Although three cables are shown in FIG. 13, the number of cables may vary. One or more cables 266 may be associated with a single thermocouple 265. The communication cables 266 extend within the fluidly sealed cavity 260. The communication cables 266 extend through an opening 267 in the fluidly sealed enclosure. The opening defines a communication cable passage. The opening is formed by a cable channel 268 in the second end support 230. The cable channel 268 is formed on the second distal outer surface 238 of the second end support 230. The cable channel 268 extends through the second mounting flange 237. In this embodiment, the cable channel 268 is an open channel. In some embodiments, the cable channel 268 is a closed channel forming a hole. The barrier member 250 overlaps a portion of the cable channel to close the open side of the cable channel. Thus, the communication cable 266 passes between the second end support 230 and the barrier member 250. A sealing element seals the cable channel. The sealing element has been omitted from Figure 13 for clarity.

[0103] The sealing element may be, for example, a hardenable resin, such as an epoxy resin, and / or an elastomeric insert. The sealing element forms a fluidic seal with the communication cable 266 and the surrounding channel surfaces. The cable channel 268 is formed in the second end support 230, although it will be appreciated that in some embodiments, the cable channel 268 acting as the sealable cable opening 267 is formed in the barrier member 250 or the first end member 220. The communication cable 266 is configured to transmit and / or receive at least one of electrical power and communication signals. A peripheral wall 269 extends around the distal end of the channel 268. The peripheral wall 269 aids in sealing and positioning of the sealing element during assembly.

[0104] According to one embodiment, the sealing element is a curable thermal potting.

[0105] 13 , cable channel 268 is formed by a partial cut in second end support 230 and second mounting flange 237. Cable channel 268 is provided by an opening defined by second end support 230 and barrier member 250 through which communication cable 266 extends. In other embodiments, the opening is defined in one of barrier member 250 and second end support 230. A sealing element acts to seal the opening defined by barrier member 250 and / or second end support 230.

[0106] The opening of the cable channel 268 as shown in Figure 13 is axially elongated. It will be understood that alternative shapes and dimensions are possible. Figure 14 shows a sealing element 310. Although the sealing element 310 of Figure 14 is configured to seal a radially elongated opening of the cable channel, it will be understood that the sealing element 310 may be modified in shape to seal another configuration of opening, such as an axially elongated opening.

[0107] The sealing element 310 is an elastic member. Such a sealing element 310 is known as a grommet. The sealing element 310 is received in the opening to seal the cable channel 268. The peripheral sides of the sealing element 310 seal with the barrier member 250 and / or the second end support 230. The communication cable 266 extends through the cable channel 268. The sealing element 310 seals with the communication cable 266 extending therethrough. Thus, a fluidic seal can be easily obtained.

[0108] The seal element 310 has an inner body end 311a and an outer body end 311b. A neck portion 312 extends between the inner body end 311a and the outer body end 311b. The inner body end 311a and the outer body end 311b include flanges. The neck portion 312 extends through an opening where the inner body end 311a and the outer body end 311b are on either side of a rim of the opening. Three cable passages 313a, 313b, 313c extend through the seal element 310. Each cable passage extends between the inside and outside of the seal element 310. Each of the cable passages 313a, 313b, 313c receives a corresponding cable, although it will be understood that a different number of cable passages may be used, for example a single cable passage for a single cable. A notch 314 in the inner body end 311a provides a guide path for the cable 266 from a first end of the cable passage 313. A second end (not shown) of the cable passage may be provided with a notch similar to notch 314. Such a notch minimizes the space required for the sealing element 310 and provides a path for the cable.

[0109] 9 and 10, the inductor coil assembly 127 includes a first inductor coil 124 and a second inductor coil 126. The first and second inductor coils 124, 126 are constructed from a conductive material. In this example, the first and second inductor coils 124, 126 are constructed from a Litz wire / cable that is helically wound to provide the helical inductor coils 124, 126. The Litz wire comprises a number of individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect losses of electrical conductors. In the exemplary device 100, the first and second inductor coils 124, 126 are constructed from copper Litz wire having a circular cross section. In other examples, the Litz wire may have a cross section of other shapes, such as rectangular. The number of inductor coils may be different. For example, in an embodiment, the inductor coil assembly 127 may include a single inductor coil. The first or second inductor coil may be omitted.

[0110] The first inductor coil 124 is configured to generate a first varying magnetic field that heats a first portion of the susceptor 132 (see FIG. 4), and the second inductor coil 126 is configured to generate a second varying magnetic field that heats a second portion of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along the longitudinal axis 101 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap). The susceptor structure 132 may comprise a single susceptor or may comprise two or more separate susceptors. Ends 130 of the first and second inductor coils 124, 126 are connectable to the PCB 123 (see FIG. 2).

[0111] It will be apparent that in some examples, the first and second inductor coils 124, 126 may have at least one characteristic different from each other. For example, the first inductor coil 124 may have at least one characteristic different from the second inductor coil 126. More specifically, as an example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 3 and FIG. 4, the first and second inductor coils 124, 126 have different lengths such that the portion of the first inductor coil 124 wound around the susceptor 132 is smaller than the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0112] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in the same direction. The inductor coils may be activated at different times. For example, the first inductor coil 124 may be activated first to heat a first portion of the article 110, and the second inductor coil 126 may be activated later to heat a second portion of the article 110. In an embodiment, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. Winding the coils in opposite directions helps reduce current induced in non-activated coils when used in conjunction with certain types of control circuits. In such an example, the first inductor coil 124 may be a right-handed spiral and the second inductor coil 126 may be a left-handed spiral. In another embodiment, the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0113] It will be appreciated that the number of inductor coils may vary, in an embodiment, device 100 includes a single inductor coil.

[0114] The device 100 includes a coil support 200 that acts as a support member. The support member may be generally tubular and at least partially surround the susceptor 132. The support member 200 supports the first and second inductor coils 124, 126. The coil support 200 is shown in cross section in Figure 4. Figure 9 is a side view of the coil support 200 with various components of the device 100 omitted. The coil support 200 is also shown in Figure 10.

[0115] The coil support 200 extends between the first and second end supports 220, 230. The coil support 200, together with the first and second end supports 220, 230, surrounds the heater assembly 105. This helps to thermally isolate the heater assembly 105 from the other components of the device 100. The coil support 200 is a hollow tubular member.

[0116] In an embodiment, the coil support 200 is made of a non-metallic material to help limit interference with magnetic induction. In this particular example, the coil support 200 is made of polyetheretherketone (PEEK). Other suitable materials are possible. Having the coil support made of such a material ensures that the assembly remains rigid / solid when the susceptor is heated. The coil support 200 is made of a rigid material to help support the other components, such as the coils 124, 126. The coil support 200 may be made of an insulating material, such as plastic. In one example, the coil support 200 is 1 mm to 1.5 mm thick. In this example, the thickness is about 1.3 mm.

[0117] As shown particularly in Figures 3, 4 and 9, the first and second inductor coils 124, 126 are disposed about and adjacent to the coil support 200. The first and second inductor coils 124, 126 are on a radially outer surface 201 of the coil support 200. In an embodiment, the first and second inductor coils are on a radially inner surface 202 of the coil support 200.

[0118] The susceptor 132, the coil support 200, and the first and second inductor coils 124, 126 are coaxial about a central longitudinal axis 101 of the susceptor 132. The coil support 200 may help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0119] The coil support 200 has an outer surface 203. The outer surface 203 is spaced from the outer cover 102. The coil support 200 is spaced from the heater assembly 105. The coil support 200 has an inner surface that is spaced from the outer surface 203 of the susceptor 132.

[0120] The coil support 200 is fixedly attached to the first and second end supports 220, 230. The first and second end supports 220, 230 are received at the ends of the coil support 200. The first end support 220 closes the proximal end of the coil support 200. The second end support 230 closes the distal end of the coil support 200. The coil support 200 partially overlaps the first and second end supports 220, 230. The proximal end of the barrier member 250 is adjacent the first end outer surface 228. The distal end of the barrier member 250 is adjacent the second end outer surface 238. The proximal end of the coil support 200 overlaps the first end mounting surface, the proximal end mounting surface 229, of the first end support 220. The distal end of the coil support 220 overlaps a second end mounting surface, distal end mounting surface 229 , of the second end support 230 .

[0121] The coil support 200 is fixedly attached to the first and second end supports 220, 230. The coil support 200 is held between the first and second end supports 220, 230. In an embodiment, the coil support 200 is fixed in place by a mechanically engineered bond, such as a weld or adhesive. In an embodiment, the coil support 200 and the first and second end supports 220, 230 are formed from the same material.

[0122] 3, 4, 9, and 10, the first and second inductor coils 124, 126 are aligned on the coil support 200 by the coil support 200. That is, the first and second inductor coils 124, 126 are held in a specific arrangement relative to the coil support 200 by features of the coil support 200. By way of example, the alignment feature is a channel 205. The channel 205 is formed on the radially outer surface 201 of the coil support 200. The channel 205 is a helical channel 205. The channel 205 receives the first and second inductor coils 124, 126. The first and second inductor coils 124, 126 are held by the channel 205. The channel 205 follows a constant helical path. The channel 205 has multiple turns around the coil support 200. The channel 205 acting as an alignment feature provides a consistent path, e.g., consistent spacing, for the coils 214, 216. This helps maximize the performance of the inductor coil assembly and / or achieve predetermined characteristics of the coils.

[0123] The first and second inductor coils 124, 126, respectively, are aligned in a helical arrangement on the coil support 200. By way of example, one of the inductor coils may be omitted. The first and second inductor coils 124, 126, respectively, follow a helical path. The turns of the helical path of each of the first and second inductor coils 124, 126 are equally spaced.

[0124] In an embodiment, the helical channel 205 is formed by a groove in the outer surface 203 of the support coil 200. In an embodiment, the helical channel 205 is formed by a pair of adjacent ridges extending in a helical arrangement. The ridges may be discontinuous and formed by a number of protrusions. The protrusions may define a helical path in which the support coil is received and retained.

[0125] The coil support 200 includes a helical recess 206 between adjacent turns of the channel 205. The helical recess 206 is an elongated groove. By way of example, the helical recess 206 includes multiple recesses. By way of example, the helical recess 206 acts as an air gap. The provision of the helical recess helps to limit heat transfer. The provision of the helical recess can help to minimize weight. The helical recess 206 is in a double helix configuration with the channel 205. In an embodiment, the helical recess is omitted. The helical recess is not shown in Figures 3 and 4.

[0126] The first and second inductor coils 124, 126 are held in the channel 205. The first and second inductor coils 124, 126 may be held in the channel 205 using a retention mechanism such as clips, bonding, an overlayer, or the like.

[0127] The first and second inductor coils 124, 126, respectively, are fully received in the coil support 200. That is, the first and second inductor coils 124, 126, respectively, are flush with or recessed from the surface of the coil support 200. In an embodiment, the first and second inductor coils 124, 126 protrude partially from the channel 205.

[0128] The coil support 200 comprises a single channel, although it will be appreciated that the channel 205 may be separated into two channel portions, one for each of the coils 124, 126. Each channel may have one or more different characteristics (e.g., period, width, depth, and length) to allow for different alignment between the coils 124, 126.

[0129] A ferrite shield 280 extends around the inductor coils 124, 126. The ferrite shield acts as an electromagnetic shield. Other suitable materials may be used. The ferrite shield 280 is mounted to the coil support 200. The ferrite shield 280 is adjacent to the coil support 200 and may be attached directly to the coil support 200, for example by gluing. A channel 205 recesses the coils 124, 126 into the coil support 200. The inductor coils 124, 126 are surrounded by the coil support 200 and the ferrite shield 280.

[0130] 12, a sensor 290, such as a thermocouple, is disposed on the coil support 200. The coil support 200 includes a sensor mounting portion 291. This aids in accurate positioning of the sensor relative to the coil, thereby enabling accurate measurements. The mounting portion 291 includes a recess. The mounting portion 291 provides a positioning surface for mounting a thermocouple.

[0131] The alignment feature in the above embodiment is a channel, although it will be appreciated that the channel may be omitted and the alignment feature may be different.

[0132] In the above-described embodiments, the coil support 200 includes a channel 205 and / or other alignment features for aligning the coil. It will be appreciated that in some embodiments, the channel and / or other alignment features for aligning the coil may be omitted. In such embodiments, the coil may be attached to a surface of the coil support or may be assembled around the coil support with a gap therebetween.

[0133] The heater assembly 105, the barrier member 250, and the coil support 200 are coaxial about a central longitudinal axis of the susceptor 132. The coil support 200 may help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0134] The coil support 200 is spaced apart from the susceptor 132. The coil support 200 is spaced apart from a barrier member 250. The barrier member 250 is between the heater assembly 105 and the coil support 200. An insulating chamber 270 may be formed between the coil support 200 and the barrier member 250.

[0135] In one example, the spacing between the coil support 200 and the barrier member 250 is 0.5mm to 1.5mm. In this example, the thickness is about 0.9mm. The coil support 200 acts as a second barrier member. Providing a barrier member that acts as a barrier can help provide separate chambers that help isolate different components of the device from each other in a stand-off configuration.

[0136] The barrier acts as an insulating member. Thus, the barrier forms part of an insulating stack that limits heat transfer from the susceptor 132 to the exterior of the aerosol generation assembly 111. The barrier member 250 acts as a first insulating member. The coil support 200 acts as a second insulating member. An insulating layer 271 extends between the barrier member 250 and the coil support 200. The insulating layer 271 extends around the barrier member 250. The insulating layer 271 is adjacent to the barrier member 250 and the coil support 200.

[0137] In embodiments, the insulating layer 271 is supported by the barrier member 250 and the coil support 200. In some embodiments, the insulating layer 271 is supported by the barrier member 250. In such embodiments, the insulating layer 271 may be separated from the coil support 200, for example by a small gap. In some embodiments, the insulating layer 271 is supported by the coil support 200. In such embodiments, the insulating layer 271 may be separated from the barrier member 250, for example by a small gap. The insulating layer 271 may be attached to one or both of the barrier member 250 and the coil support 200. In embodiments, the barrier member 250 may be omitted. In embodiments, the coil support 200 may be integrally formed with the insulating layer 271. The insulating layer 271 may be omitted. In such embodiments, an air gap is formed between the barrier member 250 and the coil support 200. In such configurations, the air gap acts as an insulator.

[0138] The insulating layer 271 acts as a third insulating member. In an embodiment, the insulating layer 271 is a sheet prior to assembly. In an embodiment, the insulating layer 271 is formed around the inside surface of the coil support 200 in a tubular configuration. End lips 272 (see FIG. 4) help retain the insulating layer 271. The insulating layer 271 is attached to the coil support 20. By way of example, the insulating layer 271 is attached to a barrier member 250. The barrier member 250 spaces the insulating layer 271 from the susceptor 132. The coil support 200 spaces the insulating layer 271 away from the inductor coils 124, 126.

[0139] The insulation stack may be provided by a combination of two or more of the following materials: (i) air (having a thermal conductivity of about 0.02 W / mK); (ii) aerogel (e.g., AeroZero®) (having a thermal conductivity of about 0.03 W / mK to about 0.04 W / mK); (iii) polyetheretherketone (PEEK) (which in some instances may have a thermal conductivity of about 0.25 W / mK); (iv) ceramic cloth (having a specific heat of about 1.13 kJ / kgK); and (v) thermal putty. Other suitable materials may be used.

[0140] The insulating layer 271 is formed from an aerogel. Other suitable materials may be used, such as, for example, a porous foam material. For example, a barrier member may be provided on either side of the aerogel to provide a protective barrier for the insulating layer 271. The barrier or barriers may help support the insulating layer 271 along its length.

[0141] The combination of the barrier member and the aerogel insulation layer aids in limiting heat transfer to the shell of the device 100 in a compact configuration by providing an enhanced insulation configuration around the heater assembly 105 .

[0142] The insulation layer 271 acts as an inner insulation layer 273. An outer insulation layer 273 extends around the inductor coil assembly 127. The outer insulation layer 273 is of a tubular configuration. The outer insulation layer 273 is supported by the inductor coil assembly 127. The inner and outer insulation layers 271, 273 sandwich the inductor coil assembly 127. The outer insulation layer 273 is mounted to the ferrite layer 280. The outer insulation layer 273 is attached to the ferrite layer 280, although other mounting configurations are envisioned. The provision of the outer insulation layer 273 allows for a predetermined thickness of insulation to be used while allowing for varying distances between the coil and the susceptor 132. The outer insulation layer 273 is formed of aerogel. Other suitable materials (e.g., porous foam materials) may also be used.

[0143] 11, the first end support 220 protrudes from a proximal end of the coil support 200. The second end support 230 protrudes from a distal end of the coil support 200. The first end support 220 is axially aligned. The second end support 230 is axially aligned. The aerosol generation assembly 111 is mounted to the housing 109. The aerosol generation assembly 111 is mounted at its proximal and distal ends. The aerosol generation assembly mounting portion 113 of the housing 109 holds the aerosol generation assembly 111. The first positioning mechanism 300 positions the aerosol generation assembly 111 at a first end, the proximal end, in the housing 109. The second positioning mechanism 301 positions the aerosol generation assembly 111 at a second end, the distal end, in the housing 109.

[0144] The inductor coil end 130 extends from the aerosol generation assembly 111. The inductor coil end 130 is supported by the housing 109. The inductor coil end 130 is connected to the PCB 123.

[0145] In the above example, the susceptor 132 has a thickness 154 of about 0.08 mm. The thickness of the susceptor 132 is the average distance between the inner surface of the susceptor 132 and the outer surface of the susceptor 132, measured in a direction perpendicular to the axis 158.

[0146] In one example, the length of the susceptor 132 is between about 30 mm and about 50 mm, or between about 30 mm and about 35 mm. In this particular example, the susceptor 132 has a length of about 34.8 mm and is capable of receiving the article 110 including the aerosol-forming material. The lengths of the aerosol-forming material and the susceptor 132 are measured in a direction parallel to the axis 101.

[0147] The outer cover 102 protects the internal components of the device and is typically in contact with a user's hands when the device is in use. The outer cover 102 has an inner surface and an outer surface.

[0148] In some instances, the inductor coil may itself heat up when used to induce a magnetic field, for example, by resistive heating due to the passage of electrical current to induce the magnetic field. Providing an insulating layer between the inductor coil and the outer cover helps insulate the heated inductor coil from the outer cover. A ferrite shield helps insulate the outer cover. It has been found that a ferrite shield can reduce the surface temperature of the outer cover by approximately 3° C. when in contact with and at least partially surrounding one or more inductor coils.

[0149] The inner surface of the outer cover may be spaced from the outer surface of the insulating member by a distance of about 2 mm to about 3 mm. A separation distance of this size has been found to provide sufficient insulation so that the outer cover does not become too hot. Air may be present between the outer surface of the insulating member and the outer cover.

[0150] The inner surface of the outer cover may be spaced apart from the outer surface of the inductor coil by a distance of about 0.2 mm to about 1 mm.

[0151] The inner surface of the inductor coil may be spaced from the outer surface of the susceptor by a distance of about 3 mm to about 4 mm, in this particular example, this distance is about 3.2 mm.

[0152] The outer cover may comprise aluminum.

[0153] The outer cover may have a thermal conductivity of about 140 W / mK to about 220 W / mK. For example, the thermal conductivity of aluminum is around 209 W / mK.

[0154] The outer cover may have a thickness of from about 0.4 mm to about 2 mm. The outer cover may act as a thermal insulating barrier.

[0155] The susceptor 132, barrier member 250, and coil support 200 each have a circular cross-section, although the cross-sections may be any other shape and, in some instances, may be different from one another.

[0156] The above-described embodiments are to be understood as illustrative examples of the present invention. Other embodiments of the present invention are also contemplated. It is to be understood that any feature described with respect to any one embodiment can be used alone or in combination with other described features, and can also be used in combination with one or more features of any other embodiment or any combination thereof. Moreover, equivalents and modifications not described above can be employed without departing from the scope of the present invention as defined in the appended claims.

Claims

1. a heater assembly configured to receive an aerosol-generating material, the heater assembly including a susceptor that is heatable by penetration of a varying magnetic field; a fluidly sealed enclosure extending around at least a portion of the heater assembly, the enclosure defining a fluidly sealed cavity between the enclosure and the susceptor; an inductor coil extending at least partially around the enclosure, the inductor coil configured to generate a varying magnetic field; 1. An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , further comprising a sensor disposed within the fluidly sealed cavity.

3. The aerosol delivery device of claim 2 , wherein the sensor is a thermocouple.

4. The aerosol delivery device of claim 3 , wherein the thermocouple is on the susceptor.

5. The aerosol delivery device of any one of claims 2 to 4, wherein the sensor includes a communication cable, and the fluidically sealed enclosure comprises a communication cable passage, the communication cable extending through the enclosure through the communication cable passage, and a sealing element within the communication cable passage to seal the communication cable passage.

6. 6. The aerosol delivery device of claim 5, wherein the fluidly sealed enclosure comprises an end support at one end of the susceptor, the communication cable passage being formed within the end support.

7. The aerosol delivery device of any one of claims 1 to 6, comprising a fluid seal between the fluidly sealed enclosure and the heater assembly.

8. The aerosol delivery device of claim 7 , wherein the fluid seal is a circumferentially extending member.

9. 9. The aerosol delivery device of claim 7 or 8, wherein the aerosol delivery device comprises a tubular member extending around the heater assembly, the fluidly sealed enclosure comprising the tubular member.

10. The aerosol delivery device of claim 9 , wherein the fluid seal extends between the heater assembly and the tubular member.

11. 11. The aerosol delivery device of claim 9 or 10, comprising an end support at one end of the heater assembly, the tubular member being on the end support, the fluidically sealed enclosure comprising the end support, and the fluid seal fluidly sealing between the end support and the heater assembly.

12. 12. The aerosol delivery device of claim 11, wherein the end support is a first end support at a first end of the heater assembly, the fluid seal is a first fluid seal, and the fluidically sealed enclosure comprises a second end support at a second end of the heater assembly and a second fluid seal between the second end support and the heater assembly.

13. The aerosol delivery device of any one of claims 1 to 12, wherein the fluidly sealed enclosure defines a cavity.

14. An aerosol delivery device according to any one of claims 1 to 13; an article including an aerosol-forming material, the article being dimensioned to be at least partially received within the heater assembly; An aerosol delivery system comprising:

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