HEATER ELEMENT, METHODS OF FORMING HEATER ELEMENTS AND AEROSOL DELIVERY DEVICES - Patent application

Abstract

To provide a novel heater element for an aerosol delivery device. A heater element (34, 36) according to the present invention comprises a support (36) and a heating material (34) heatable by the incidence of a varying magnetic field, the heating material (34) being electrolessly plated onto the support (36). The support (36) may be made of a non-conductive material, and may be made of a polymer, for example a polyimide such as Zytel® High Temperature Nylon (HTN) or Kapton®.

Description

[Technical field]

[0001] The present invention relates to a heater element, a method of forming a heater element, an aerosol delivery device, and an aerosol delivery system. [Background technology]

[0002] Smoking articles such as cigarettes, cigars, and the like, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide an alternative to these tobacco-burning smoking 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 substance without combustion. The substance may be, for example, tobacco or other non-tobacco products, and the products may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of the present disclosure, there is provided a heater element for an aerosol delivery device comprising a support and a heating material heatable by the incidence of a varying magnetic field, the heating material being electrolessly plated onto the support.

[0004] The support may be made of a non-conductive material. The support may be made of a polymer, for example a polyimide such as Zytel® high temperature nylon (HTN) or Kapton®.

[0005] The support may be made of a material having a melting point above 300° C. The support may include polyetheretherketone (PEEK).

[0006] The heatable material may include at least one of nickel and cobalt.

[0007] The heating material may have a thickness perpendicular to the surface of the support of 100 microns or less. The heating material may have a thickness perpendicular to the surface of the support of 50 microns or less, 20 microns or less, or 10 microns or less. The heating material may have a thickness of about 15 microns when the liner comprises nickel and about 10 microns when the heating material comprises cobalt.

[0008] The support may include a tubular support, for example, the support may be hollow and may have open longitudinal ends to allow for insertion of the consumable.

[0009] The heating material may be disposed on a radially inwardly facing surface of the support.

[0010] The heater element may comprise a further heating material attached to the heating material, the further heating material comprising a material different from the heating material, the further heating material being disposed between the further heating material and the support.

[0011] Further heating materials may be heatable by the incidence of a varying magnetic field and may include any of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze, or any combination of these materials.

[0012] The heater element may comprise a plurality of regions of heating material, the plurality of regions being spaced apart on the support. The plurality of regions may be uniformly spaced apart on the support.

[0013] The heater element, when disposed within the aerosol delivery device, can form a chamber that receives a consumable containing an aerosol generating material.

[0014] The heater element may include a heater element for use in an aerosol delivery device comprising a chamber and a heating assembly that applies heat to a consumable containing an aerosol generating substance when the consumable is placed in the chamber to generate an aerosol from the aerosol generating substance, the heater element being for selective insertion into the chamber to at least partially cover the inside of the chamber.

[0015] The heater element may be formable into a first shape wound by a first diameter and into a second shape wound by a second diameter larger than the first diameter, and transitionable from the first shape to the second shape when inserted into the chamber such that it at least partially covers the inside of the chamber.

[0016] The outer surface of the heater element can form a substantially cylindrical shape in a first configuration, e.g., having a first diameter. The outer surface of the heater element can form a substantially cylindrical shape in a second configuration, e.g., having a second diameter.

[0017] The first diameter may comprise the maximum distance between two opposing points on an outwardly facing surface, e.g., a radially outwardly facing surface, of the heater element in the first configuration. The second diameter may comprise the maximum distance between two opposing points on an outwardly facing surface, e.g., a radially outwardly facing surface, of the liner in the second configuration.

[0018] The heater element may have first and second free ends, with one of the first and second free ends being wound towards the other of the first and second free ends in a first shape, and in a second shape, one of the first and second free ends being at least partially wound towards the other of the first and second free ends.

[0019] In the first shape, the first free end and the second free end can overlap. In the first shape, the heater element may have an outwardly facing surface and an inwardly facing surface, e.g., a radially outwardly facing surface and a radially inwardly facing surface, the outwardly facing surface and the inwardly facing surface extending between the first free end and the second free end, and in the first shape, the first free end and the second free end can overlap, such that in the first shape, the outwardly facing surface and the inwardly facing surface overlap. In the first shape, the outwardly facing surface can contact the inwardly facing surface.

[0020] The first free end and the second free end can be substantially joined or overlapped in the second shape, for example such that the heater element is inserted into the chamber and covers the entire inside circumferential extent of the chamber when in the second shape. The heater element can have an outwardly facing surface and an inwardly facing surface in the second shape, the outwardly facing surface and the inwardly facing surface extending between the first free end and the second free end, and the first free end and the second free end can overlap in the second shape, such that the outwardly facing surface and the inwardly facing surface overlap in the second shape. In the second shape, the outwardly facing surface can contact the inwardly facing surface.

[0021] The first free end and the second free end can be spaced apart in the second shape, for example such that the heater element is inserted into the chamber and partially covers an inside circumferential extent of the chamber when in the second shape. The first free end and the second free end can be spaced apart in the second shape, such that the outwardly facing surface and the inwardly facing surface do not overlap in the second shape.

[0022] In the first shape, the heater element may have a spiral shape when viewed along the longitudinal axis of the liner. In the second shape, the heater element may have a spiral or circular shape when viewed along the longitudinal axis of the liner. The heater element may be elongated in the first and second shapes, e.g., having an overall length greater than its diameter in the first and second shapes.

[0023] The second diameter may be in the range of 5.0 to 6.0 mm, for example in the range of 5.3 to 5.7 mm. The second diameter may be in the range of 6.5 to 7.5 mm, for example in the range of 6.7 to 7.3 mm. The second diameter may be substantially equal to the diameter of the chamber.

[0024] The heater element may be expandable by at least partially unwinding to transition from a first shape to a second shape when inserted into the chamber.

[0025] In the first and second configurations, the heater element may have open longitudinal ends.

[0026] The heater element may be elastically deformable.

[0027] According to a second aspect of the present disclosure, there is provided an aerosol delivery device comprising a heater element for applying heat to a consumable containing an aerosol generating substance to generate an aerosol from the aerosol generating substance, the heater element comprising a support and a heating substance heatable by the incidence of a varying magnetic field, the heating substance comprising electroless plating on the support, and the heater element at least partially forming a chamber into which the consumable can be inserted for heating by the heating substance.

[0028] The heater element may be tubular in shape, for example the support comprises a tubular support.

[0029] The heating material can be disposed on a radially inwardly facing surface of the heater element, e.g., whereby the heating material at least partially defines the chamber.The heating material can be disposed on a radially inwardly facing surface of the support.

[0030] According to a third aspect of the present disclosure, there is provided an aerosol delivery system comprising a chamber, a heating assembly for applying heat to a consumable containing an aerosol generating material when the consumable is placed in the chamber to generate an aerosol from the aerosol generating material, and a heater element according to the first aspect of the present disclosure.

[0031] According to a fourth aspect of the present disclosure, there is provided a method for forming a heater element for an aerosol delivery device, the method comprising the steps of providing a support and electrolessly plating a heating material onto the support, the heating material being heatable by the incidence of a varying magnetic field.

[0032] The support may be made of a non-conductive material.

[0033] The method may include electrolessly plating a heating substance onto a radially inwardly facing surface of the support.

[0034] The method may include attaching a further heating substance to the heating substance, the further heating substance comprising a material different from the first heating substance, the first heating substance being disposed between the further heating substance and the support.

[0035] The method may include the step of masking (covering) a portion of the support prior to electroless plating.

[0036] Further characteristics 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 made with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0037] [Figure 1] 1 is a schematic diagram of an aerosol delivery device according to an example. [Figure 2a] 2 is a schematic cross-sectional view of a portion of the aerosol delivery device of FIG. 1. [Figure 2b] 2 is a schematic cross-sectional view showing a heater element of the aerosol delivery device of FIG. 1. [Diagram 3] 2 is a flow diagram illustrating steps in a method of forming a heater element of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 2 is a schematic diagram illustrating a heater element according to an example. [Diagram 5] 5 is a flow diagram illustrating method steps for forming the heater element of FIG. 4. [Figure 6] 1 is a schematic cross-sectional view of a heater element according to an example; [Figure 7] 7 is a flow diagram illustrating method steps for forming the heater element of FIG. 6. [Figure 8a] 2 is a schematic diagram of a liner for use with the aerosol delivery device of FIG. 1. [Figure 8b] FIG. 8b is a schematic diagram of the liner of FIG. 8a in a first shape. [Figure 8c] FIG. 8b is a schematic diagram of the liner of FIG. 8a in a second configuration. [Figure 8d] FIG. 8b is a schematic diagram of the liner of FIG. 8a in a second alternative configuration. [Figure 9a] FIG. 8b is a schematic diagram of a first retention member for use with the liner of FIG. 8a. [Figure 9b] FIG. 8b is a schematic diagram of a second retention member for use with the liner of FIG. 8a. [Figure 10] 1 is a schematic diagram of a liner according to an example. [Figure 11] 1 is a schematic diagram of a liner according to an example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] An aerosol delivery device according to one example of the present disclosure is shown generally at 12 in FIG.

[0039] The aerosol delivery device 12 comprises a housing 16, a power supply 18, a heating assembly 20, a chamber 22, a processor 24, a computer readable memory 25, and user operable controls 26.

[0040] Housing 16 forms the outer covering of aerosol delivery device 12 and surrounds and contains the various components of aerosol delivery device 12 .

[0041] The power supply 18 provides power to the various components of the aerosol delivery device 12, including, for example, the heating assembly 20. In the embodiment of Figure 1, the power supply 18 comprises a battery 28 and a DC-AC converter 30 to provide AC current to the heating assembly 20. It should be understood that in alternative embodiments, the heating assembly 20 may require DC current, such that the DC-AC converter 30 may be omitted or replaced with a DC-DC converter, such as a step-down or step-up converter, as appropriate.

[0042] Aerosol delivery device 12 may further include electrical components, such as a socket / port (not shown) that can accept a cable for charging battery 28. For example, the socket may include a charging port, such as a USB charging port. In some examples, the socket may additionally or alternatively be used to transmit data between aerosol delivery device 12 and another device, such as a computing device. The socket may further be electrically coupled to battery 28 through an electrical circuit.

[0043] The processor 24 is in data communication with the computer-readable memory 25. The processor 24 is configured to control various aspects of the operation of the aerosol delivery device 12. The processor 24 controls the various aspects by executing instructions stored in the computer-readable memory 25. For example, the processor 24 can control the operation of the heating assembly 20. For example, the processor can control the delivery of power from the power source 18 to the heating assembly 20 by controlling various electrical components such as switches (not shown in FIG. 1 ).

[0044] User-operable control element 26 is, for example, a button or a switch that, when pressed, activates aerosol delivery device 12. For example, a user can activate aerosol delivery device 12 by manipulating user-operable control element 26, or can change a setting of heating assembly 20 by manipulating user-operable control element 26.

[0045] 1 is an induction heating assembly and includes a plurality of heating coils 32 that are individually controllable and spaced along the chamber 22 and configured to interact with a susceptor 34, which is described below.

[0046] A susceptor is a material that can be heated by the incidence of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that the incidence of a varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material, such that the incidence of a varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the susceptor can be heated by both heating mechanisms.

[0047] To heat the chamber 22, and thereby the consumables contained therein, a DC-AC converter 30 passes an AC current through a number of heating coils 32, which in turn generate a varying magnetic field that interacts with the susceptor 34, inducing an eddy current in the susceptor 34, which in turn causes the susceptor 34 to heat.

[0048] The chamber 22 is defined by a generally hollow tubular member 36, as seen in cross section in FIG. 2a. The tubular member 36 comprises an elongated hollow body. An inner wall of the tubular member 36 defines the chamber 22, which has a proximal end 40 and a distal end 42. The extent of the chamber 22 between the proximal end 40 and the distal end 42 may be referred to as the main portion 23 of the chamber 22. The distal end 42 comprises a tapered wall 44, which tapers towards a central axis AA of the chamber 22. An opening 46 in the tapered wall 44 is in fluid communication with an air inlet 47 of the aerosol delivery device 12.

[0049] The proximal end 40 of the chamber 22 includes an opening 48 through which a consumable (not shown in FIG. 2 a ) is insertable into the chamber 22 .

[0050] To prevent deformation of the tubular member 36 due to heat during use, the tubular member 36 is formed from a material having a melting point above 300° C., and in the example of FIG. 2a is formed from PEEK. The material of the tubular member 36 is also non-conductive to prevent generation of eddy currents within the tubular member due to interaction with the magnetic fields generated by the plurality of coils 32, thereby preventing heating of the tubular member 36 due to induction heating during use.

[0051] In use, the chamber 22 is configured to house consumables containing an aerosol generating material, one at a time, and the heating assembly 20 is used to generate an aerosol from the aerosol generating material, which is inhaled by a user. The chamber 22 may therefore be considered a heating chamber.

[0052] An aerosol generating material is a material capable of generating an aerosol when, for example, heated, irradiated, or otherwise activated. The aerosol generating material may be in the form of, for example, a solid, liquid, or gel, which may or may not contain actives and / or flavorings. In some embodiments, the aerosol generating material may include an "amorphous material," which may otherwise be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous material may be a dry gel. An amorphous material is a solid material that may contain some fluid, such as a liquid. In some embodiments, the aerosol generating material may include, for example, about 50%, 60%, or 70% amorphous material by weight up to about 90%, 95%, or 100% amorphous material by weight.

[0053] The aerosol generating material may include one or more active agents and / or fragrances, one or more aerosol forming substances, or optionally one or more other functional substances.

[0054] A consumable is an article that includes or is composed of an aerosol generating material that is adapted to be consumed in part or in whole during use by a user. A consumable may include 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, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may further include an aerosol generating portion that radiates heat to cause the aerosol generating material to generate an aerosol upon use, such as a heater. The heater may include, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor. Such consumables are typically elongated and generally cylindrical in shape.

[0055] Since the consumables are adapted for insertion into the chamber 22 for use, and the chamber 22 is adapted for use as a heating chamber, it is desirable to locate the susceptor 34 near the chamber 22 .

[0056] In the embodiment of Figures 2a and 2b, the susceptor 34 is provided as a layer of heating material plated on the inner wall of the tubular member 36 by electroless plating. Heating material refers to a material that can be heated by the incidence of a varying magnetic field, i.e., as part of an induction heating process. The heating material in the examples of Figures 2a and 2b is either nickel or cobalt. Collectively, the combination of the susceptor 34 and the tubular member 36 can be considered as a heater element for the aerosol delivery device 12. In such an example, the susceptor 34 can also be considered as a wall of the chamber 22.

[0057] Electroless plating is a chemical process that deposits a uniform layer of a metallic material on the surface of a solid substrate, such as a metal or plastic. In nickel phosphorus electroless plating, the process involves immersing the substrate in an aqueous solution containing a nickel salt and a phosphorus-containing reducing agent, usually a hypophosphite. Generally, electroless plating processes do not require the application of an electric current to the bath and substrate, and the reduction of the metal cations in the solution to metal is accomplished by purely chemical means through an autocatalytic reaction. Thus, electroless plating can produce a uniform layer of metal regardless of the surface topography and can be applied to non-conductive surfaces.

[0058] Electroless plating, as disclosed herein, can provide a uniform layer of heating material on the inside of the tubular member 36, which can form a susceptor 34 of substantially constant thickness. This can improve heating characteristics during use, for example, by providing more uniform heating within the chamber 22 along the length of the susceptor 34. Electroless plating can also allow the metal susceptor 34 to be positioned on the plastic tubular member 36 without the need for adhesives, for example, that would otherwise increase the distance from the susceptor 34 to the multiple coils 32, thereby adversely affecting heating during use.

[0059] An electrically conductive (and magnetizable) medium such as a heating material has a characteristic depth (skin depth) into which an electromagnetic field can penetrate. Thus, the thickness of the heating material forming the susceptor 34 is at least some useful portion of the skin depth for that heating material at the operating frequency of the induction system. For example, a thickness corresponding to one or more skin depths should help ensure that a majority of the useful energy is introduced into the heating material forming the susceptor 34. In some examples, the heating material has a thickness of 100 microns or less, 50 microns or less, or 20 microns or less, measured in a direction perpendicular to the plastic tubular member 36. If the heating material includes nickel, the thickness of the heating material may be about 15 microns. If the heating material includes cobalt, the thickness of the heating material may be about 10 microns.

[0060] A method 300 of forming a heater element for the aerosol delivery device 12 is shown in the flow diagram of Figure 3. The method 300 includes providing 302 a support in the form of a tubular member 36 and electrolessly plating 304 a heating material in the form of a susceptor 34 onto the tubular member 36.

[0061] As shown in FIGS. 2a and 2b, the susceptor 34 is formed by electroless plating along substantially the entire length of the chamber 22 and along the entire circumference of the chamber 22. As shown in FIG.

[0062] 4, the susceptor 34 is provided by electrolessly plating nickel or cobalt onto multiple regions of the interior of the tubular member 36, the regions being spaced apart about the circumference of the tubular member 36. Again, the susceptor 34 and tubular member 36 together form a heater element 400. The regions not including the susceptor 34 are masked with wax during the plating process. By providing multiple regions, the susceptor 34 is provided only where needed, thereby providing better heating characteristics compared to, for example, a configuration in which the susceptor 34 extends the entire circumference of the tubular member 36.

[0063] A method 500 for forming the heater element 400 of Figure 4 is shown in the flow diagram of Figure 5. The method 500 includes the steps of providing 502 a support in the form of a tubular member 36 and masking 504 portions of the tubular member 36. The method 500 includes the step of electrolessly plating 506 a heating material in the form of a susceptor 34 onto the tubular member 36 in the unmasked areas.

[0064] Another form of heater element 600 is shown diagrammatically in cross section in Figure 6. In this case, the heater element comprises a tubular member 36 as a support, a first layer of heating material 602, and a second layer of heating material 604. Collectively, the first layer of heating material 602 and the second layer of heating material 604 form the susceptor 34.

[0065] The first layer of heating material 602 includes one of nickel or cobalt, and the second layer of heating material 604 includes one or more materials from the following list: aluminum, gold, iron, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze. The first layer of heating material 602 is electrolessly plated onto the tubular member 36 as previously described. The second layer of heating material 604 may have better induction heating properties compared to the first layer of heating material 602 and may be attached to the first layer of heating material 602 by any suitable bonding method.

[0066] A method 700 of forming the heater element 600 of Figure 6 is shown in the flow diagram of Figure 7. The method 700 includes the step 702 of providing a support in the form of a tubular member 36, and the step 704 of electrolessly plating a first layer 602 of heating material onto the tubular member 36. The method 700 includes the step 706 of bonding a second layer 604 of heating material to the tubular member 36.

[0067] As previously mentioned, the combination of the tubular member 36 and the susceptor 34 form the heater element, and the tubular member 36 and the susceptor form the chamber 22 which, in use, contains the consumables. In an alternative embodiment, the tubular member 36 may still form the chamber 22, but the heater element may be provided as a removable liner 800 that is selectively inserted into the chamber 22, as shown generally in Figures 8a-d.

[0068] Liner 800 includes a support layer 802, which is a rectangular sheet of a high temperature resistant polymer, such as, for example, a polyimide such as Zytel® High Temperature Nylon (HTN) or Kapton®. Such materials can be considered non-conductive and can prevent the formation of eddy currents. Liner 800 includes a layer 804 of heating material, either nickel or cobalt, which is electrolessly plated onto support layer 802 as previously described.

[0069] The liner 800 is elastically deformable and comprises a first free end 806 and a second free end 808. The rectangular shape of the liner 800 shown in Figure 8a may be considered the free shape of the liner 800 in some examples.

[0070] The liner 800 is formable into a first shape shown in Figure 8b and a second shape shown in Figure 8c. The interface between the support layer 802 and the layer of heating material 804 is not shown in Figures 8b and 8c for clarity. The thickness or material of the layers 802, 804 can be selected to allow the liner 800 to be formed into either the first shape of Figure 8b and the second shape of Figures 8c and 8d. The layer of heating material 804 is arranged to form an inwardly facing surface of the liner 800 in the first and second shapes.

[0071] In the first shape of Fig. 8b, the first free end 806 is rolled towards the second free end 808, such that the liner 800 is formed, e.g., rolled, into a spiral shape as seen in Fig. 8b, which is a view parallel to the longitudinal direction of the first free end 806 and the second free end 808. The liner 800 in the first shape has a generally cylindrical shape with a first diameter A. The first diameter A is the maximum distance between two opposing points of the support layer 802 of the liner 800 in the first shape. In the first shape of Fig. 8b, the support layer 802 of the liner 800 overlaps the layer 804 of the heating material of the liner 800 to exhibit a spiral shape.

[0072] In the second shape of Fig. 8c, the first free end 806 has been unwound relative to the first shape of Fig. 3b, with the liner 800 retaining the spiral shape of Fig. 8b but wound more loosely. Thus, the first shape can be considered to be partially unwound to achieve the second shape. The liner 800 in the second shape has a generally cylindrical shape with a second diameter B, which is greater than the first diameter A. The second diameter B is the maximum distance between two opposing points of the support layer 802 of the liner 800 in the second shape. In the second shape of Fig. 8c, the support layer 802 of the liner 800 overlaps the layer 804 of the heating material of the liner 800 to retain the spiral shape.

[0073] In use, the liner 800 is first rolled into the first shape of Fig. 8b and then inserted into the chamber 22. When the user releases the liner 800, the elastic deformation properties of the liner 800 cause the liner 800 to partially unroll from the first shape to assume the second shape of Fig. 8c. A second diameter B of the second shape of the liner 800 is substantially equal to the diameter of the chamber 22, and the spiral shape of the shape of Fig. 8c causes the liner 800 to line the entire circumferential extent of the chamber 22. Both open longitudinal ends of the liner 800 allow for the insertion of consumables into the liner 800 and thus into the chamber 22 through the opening 48.

[0074] When inserted in chamber 22 in this manner, liner 800 can prevent buildup of deposits on the walls of chamber 22 caused by side flows from heated consumables, and liner 800 can be removable and replaceable as required. This provides a convenient means of protecting the walls of chamber 22 while at the same time making the aerosol delivery device 12 itself easier for the user to use and requiring less maintenance. The overlap of liner 800 in the second configuration of FIG. 8c can ensure protection of the entire circumferential extent of the walls of chamber 22, and may even go so far as to form a labyrinth seal that prevents side flows from exiting liner 800.

[0075] Those skilled in the art will appreciate that the extent to which the liner 800 can be unrolled from a first shape to a second shape can depend on many factors, including, but not limited to, the initial dimensions of the liner 800, the material of the liner 800, and the dimensions of the chamber 22, such as the diameter of the chamber 22. In some instances, these factors can result in a different second shape for the liner 800.

[0076] One such alternative second configuration for the liner 800 is shown in Figure 8d. In the configuration of Figure 8d, the liner 800 is unrolled until the first free end 806 and the second free end 808 are substantially joined. In such an embodiment, the support layer 802 and the layer of heating material 804 do not overlap. In this case, the liner 800 has a generally cylindrical shape with a substantially circular cross-sectional shape, which may still be considered rolled when viewed from the relative positions of the first free end 806 and the second free end 808.

[0077] Although liner 800 is shown in FIG. 8a as initially having the form of a rectangular sheet, liner 800 may be supplied to a consumer, i.e., user, of aerosol delivery device 12 in a pre-rolled form, such as the first form of FIG. 8b or the second form of FIG. 8c.

[0078] In some examples, the material of the liner 800 can be selected to enable the liner 800 to retain the liner in a rolled shape, such as the second shape of Figure 8c. In this case, the liner 800 can be formed into the first shape of Figure 8b by tightly rolling it before insertion into the chamber 22, and then allowed to unroll and assume the second shape of Figure 8c upon insertion into the chamber 22 and release by the user.

[0079] In another example, the liner 800 may include a retaining member to hold the liner 800 in the first configuration. One such retaining member 900 shown in Figure 9a is a simple annular ring of a relatively rigid material having an inner diameter that substantially corresponds to the diameter A of the liner 800 in the first configuration of Figure 8b. The retaining member 900 of Figure 9a can be simply removed from the liner 800 during insertion into the chamber 22 to allow the liner 800 to unroll from the first configuration of Figure 8b to either of the second configurations of Figures 8c and 8d.

[0080] A second embodiment of a retention member 902 is shown in Figure 9b. In this case, the retention member 902 comprises a strip 904 and a clamp 906 capable of selectively holding the strip 904 in an annular configuration of variable diameter. Such a retention member 902 may be similar to a Jubilee clip, for example. The engagement of the clamp 906 with the strip 904 may be varied to allow the liner to transition between a first shape of Figure 8b and a second shape of either of Figures 8c and 8d as desired.

[0081] An alternative embodiment 1000 of a liner is shown diagrammatically in FIG. 10. The liner 1000 comprises a first layer 1002 of high temperature resistant polymer, a second layer 1004 of heating material, and a third layer 1006 of heating material. The second layer 1004 of heating material includes one of nickel or cobalt, and the third layer 1006 of heating material includes one or more materials from the following list: aluminum, gold, iron, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze. The second layer 1004 of heating material is electrolessly plated onto the first layer 1002 of high temperature resistant polymer, as previously described. The third layer 1006 of heating material may have better induction heating properties compared to the second layer 1004 of heating material, and may be attached to the second layer 1006 of heating material by any suitable bonding method.

[0082] The liner 1000 of Figure 10 may be moldable into the shapes of Figures 8a-d, as previously described.

[0083] Yet another alternative embodiment of a liner 1100 is shown diagrammatically in FIG. 11. The liner 1100 comprises a support layer 1102 that is a rectangular sheet of a high temperature resistant polymer, such as, for example, a polyimide such as Zytel® High Temperature Nylon (HTN) or Kapton®. Such materials may be considered non-conductive and may prevent the formation of eddy currents within the material. The liner 1100 comprises a plurality of regions 1104 of heating material, either nickel or cobalt, that are electrolessly plated onto the support layer 1102 as previously described. Regions intermediate the plurality of regions 1104 of heating material are masked by wax during the electroless plating process. The use of the plurality of regions 1104 may aid in the deformability of the liner 1100 and facilitate the transition between the first and second shapes previously described.

[0084] The various embodiments described herein are presented merely to aid in the understanding and teaching of the features recited in the claims. These embodiments are presented merely 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 as limiting the scope of the invention as defined by the claims or the equivalents of the claims, and it is understood that other embodiments can be used and changes can be made without departing from the scope of the invention as defined in the claims. The various embodiments of the invention can include, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future. [Item of invention] [Item 1] 1. A heater element for an aerosol delivery device, comprising: A support and a heating material that can be heated by application of a varying magnetic field, The heater element, wherein the heating material comprises electroless plating on the support. [Item 2] Item 2. The heater element of item 1, wherein the support is made of a non-conductive material. [Item 3] 3. The heater element according to item 1 or 2, wherein the support is made of a material having a melting point higher than 300°C. [Item 4] 4. The heater element of any one of items 1 to 3, wherein the heating material comprises at least one of nickel and cobalt. [Item 5] 5. The heater element of any one of claims 1 to 4, wherein the heating material has a thickness in a direction perpendicular to a surface of the support of less than 100 microns. [Item 6] 6. The heater element of any one of claims 1 to 5, wherein the support comprises a tubular support. [Item 7] 7. The heater element of any one of items 1 to 6, wherein the heating material is disposed on a radially inwardly facing surface of the support. [Item 8] a further heating material attached to the heating material; 8. The heater element of any one of claims 1 to 7, wherein the further heating material comprises a material different from the heating material, and the heating material is disposed between the further heating material and the support. [Item 9] 9. The heater element of claim 8, wherein the additional heating material comprises any one of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze, or any combination thereof. [Item 10] a plurality of regions of the heating material; 10. The heater element according to any one of items 1 to 9, wherein the plurality of regions are spaced apart on the support. [Item 11] 11. The heater element of any one of claims 1 to 10, wherein when disposed within the aerosol delivery device, the heater element defines a chamber for receiving a consumable containing an aerosol generating material. [Item 12] 11. The heater element of any one of items 1 to 10, wherein the heater element is for use in an aerosol delivery device comprising a chamber and a heating assembly that applies heat to a consumable containing an aerosol generating material when the consumable is placed in the chamber to generate an aerosol from the aerosol generating material, the heater element being for selective insertion into the chamber to at least partially line the inside of the chamber. [Item 13] Item 13. The heater element of item 12, wherein the heater element is formable into a first shape wound by a first diameter and into a second shape wound by a second diameter larger than the first diameter, and wherein the heater element is transitionable from the first shape to the second shape when inserted into the chamber such that the heater element at least partially covers an inside of the chamber. [Item 14] Item 14. The heater element of item 13, wherein the heater element is expandable by at least partial unwinding to transition from the first shape to the second shape when inserted into the chamber. [Item 15] 15. The heater element of claim 13 or 14, in the first shape and in the second shape, with both longitudinal ends that are open. [Item 16] 16. The heater element according to any one of items 12 to 15, which is elastically deformable. [Item 17] 1. An aerosol delivery device comprising a heater element for applying heat to a consumable containing an aerosol generating material to generate an aerosol from the aerosol generating material, the heater element comprising: An aerosol delivery device, wherein the heater element comprises a support and a heating material heatable by the incidence of a varying magnetic field, the heating material being electrolessly plated onto the support, and the heater element at least partially forms a chamber into which a consumable can be inserted for heating by the heating material. [Item 18] 17. An aerosol delivery system comprising: a chamber; a heating assembly for applying heat to a consumable containing an aerosol generating material when the consumable is placed in the chamber to generate an aerosol from the aerosol generating material; and a heater element according to any one of items 12 to 16. [Item 19] 1. A method of forming a heater element for an aerosol delivery device, comprising: providing support; electrolessly plating a heating substance onto the support, the heating substance being heatable by the incidence of a fluctuating magnetic field; The method includes: [Item 20] 20. The method of claim 19, wherein the support is made of a non-conductive material. [Item 21] 21. The method of claim 19 or 20, wherein the heating material comprises at least one of nickel and cobalt. [Item 22] 22. The method according to any one of claims 19 to 21, wherein the heating material has a thickness in a direction perpendicular to the surface of the support of 100 microns or less. [Item 23] 23. The method according to any one of claims 19 to 22, wherein the support comprises a tubular support. [Item 24] 24. The method of any one of claims 19 to 23, comprising electrolessly plating the heating material onto a radially inwardly facing surface of the support. [Item 25] 25. The method according to any one of items 19 to 24, comprising a step of attaching a further heating substance to the heating substance (hereinafter referred to as the "first heating substance"), the further heating substance comprising a material different from the first heating substance, and the first heating substance being disposed between the further heating substance and the support. [Item 26] 26. The method of claim 25, wherein the additional heating material comprises any one of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze, or any combination thereof. [Item 27] 27. The method of any one of claims 19 to 26, wherein the heater element comprises a plurality of regions of the heating material, the plurality of regions being spaced apart on the support. [Item 28] 28. The method according to any one of items 19 to 27, comprising a step of masking a portion of the support prior to the electroless plating.

Claims

1. 1. A heater element for an aerosol delivery device, comprising: A support and a heating material that can be heated by application of a varying magnetic field, the heating material is electrolessly plated onto the support; the heater element comprises a further heating material attached to the heating material; The heater element, wherein the further heating material comprises a material different from the heating material, the heating material being disposed between the further heating material and the support.

2. The heater element of claim 1 , wherein the support is made of a non-conductive material.

3. 3. A heater element as claimed in claim 1 or 2, wherein the support is made of a material having a melting point above 300°C.

4. The heater element of any one of claims 1 to 3, wherein the heating material comprises at least one of nickel and cobalt.

5. A heater element according to any preceding claim, wherein the heating material has a thickness, in a direction perpendicular to the surface of the support, of no more than 100 microns.

6. A heater element according to any preceding claim, wherein the support comprises a tubular support.

7. A heater element according to any preceding claim, wherein the heating material is disposed on a radially inwardly facing surface of the support.

8. A heater element as described in any one of claims 1 to 7, wherein the further heating material is heatable by the incidence of a fluctuating magnetic field.

9. 9. The heater element of claim 8, wherein the additional heating material comprises any one or any combination of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze.

10. a plurality of regions of the heating material; A heater element according to any preceding claim, wherein the plurality of regions are spaced apart on the support.

11. A heater element according to any preceding claim, which when positioned within the aerosol delivery device defines a chamber for receiving a consumable containing an aerosol generating substance.

12. The heater element of any one of claims 1 to 10, for use in an aerosol delivery device comprising a chamber and a heating assembly that applies heat to a consumable containing an aerosol generating substance when the consumable is placed in the chamber to generate an aerosol from the aerosol generating substance, the heater element being for selective insertion into the chamber so as to at least partially cover the inside of the chamber.

13. 13. The heater element of claim 12, wherein the heater element is formable into a first shape wound by a first diameter and into a second shape wound by a second diameter larger than the first diameter, and wherein the heater element is transitionable from the first shape to the second shape when inserted into the chamber such that the heater element at least partially covers an interior of the chamber.

14. The heater element of claim 13 , wherein the heater element is expandable by at least partial unwinding to transition from the first shape to the second shape when inserted into the chamber.

15. 15. A heater element as claimed in claim 13 or 14, comprising opposite open longitudinal ends in said first and second shapes.

16. A heater element according to any one of claims 12 to 15, which is elastically deformable.

17. 1. An aerosol delivery device comprising a heater element for applying heat to a consumable containing an aerosol generating material to generate an aerosol from the aerosol generating material, the heater element comprising: the heater element comprises a support and a heating material heatable by the incidence of a varying magnetic field, the heating material being electrolessly plated onto the support, the heater element at least partially defining a chamber into which a consumable can be inserted for heating by the heating material; the heater element comprises a further heating material attached to the heating material; The aerosol delivery device, wherein the further heating substance comprises a substance different from the heating substance, the heating substance being disposed between the further heating substance and the support.

18. 17. An aerosol delivery system comprising a chamber, a heating assembly for applying heat to a consumable containing an aerosol generating material when the consumable is placed in the chamber to generate an aerosol from the aerosol generating material, and a heater element according to any one of claims 12 to 16.

19. 1. A method of forming a heater element for an aerosol delivery device, comprising: providing support; electrolessly plating a heating substance onto the support, the heating substance being heatable by the incidence of a fluctuating magnetic field; attaching a further heating substance to the heating substance (hereinafter referred to as the "first heating substance"), the further heating substance comprising a material different from the first heating substance, the first heating substance being disposed between the further heating substance and the support; The method includes:

20. 20. The method of claim 19, comprising electrolessly plating the heating material onto a radially inwardly facing surface of the support.

21. 21. The method of claim 19 or 20, comprising masking a portion of the support prior to the electroless plating.

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