Aerosol Delivery Device

Abstract

The present invention relates to an aerosol delivery device. The device includes a first housing and an aerosol generation assembly. The aerosol generation assembly includes a heater assembly configured to receive an aerosol-generating material. The heater assembly includes a susceptor that is heatable by penetration of a varying magnetic field. The aerosol generation assembly also includes a second housing extending around the susceptor and an inductor coil extending around the second housing, the inductor coil configured to generate a varying magnetic field. The second housing includes an arrangement configured to position the aerosol generation assembly on the first housing.

Description

Technical Field

[0001] The present invention relates to an aerosol supply device and an aerosol supply system including the aerosol supply device and an article including an aerosol generating material.

Background Art

[0002] Smoking articles such as cigarettes and cigars generate tobacco smoke by burning tobacco during use. Attempts have been made to provide alternatives to these 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. This 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, there is provided an aerosol supply device including a first housing and an aerosol generating assembly. The aerosol generating assembly includes a second housing and a heater assembly configured to receive an aerosol generating material, the heater assembly including a susceptor that can be heated by the intrusion of a variable magnetic field. The second housing extends around the susceptor, and the aerosol generating assembly also includes an inductor coil extending around the second housing, the inductor coil being configured to generate a variable magnetic field, and the second housing includes an arrangement structure configured to dispose the aerosol generating assembly on the first housing.

[0004] Correspondingly, the first housing may include a cooperation structure configured to cooperate with the arrangement structure to dispose the aerosol generating assembly on the first housing.

[0005] The arrangement structure (and the cooperation structure) may be configured to limit the movement of the aerosol generating assembly relative to the first housing, such as displacement and / or rotation.

[0006] The second housing may be configured to surround the heater assembly.

[0007] The second housing may be configured to dispose the heater assembly on the first housing.

[0008] The second housing may include a coil support configured to support an inductor coil.

[0009] The positioning structure may include a positioning feature or a locating feature at least near one end of the second housing.

[0010] The aerosol supply device may include an end support at one end of the heater assembly, in which case the end support is attached to the second housing.

[0011] The locating mechanism may position the second housing together with the first housing, and the end support may support the pre-aerosol supply device on the first housing.

[0012] The locating mechanism may include a contact portion, and the first housing may include a cooperating surface (referred to as a "cooperating surface"), and the contact portion may contact the cooperating surface to position the aerosol generating assembly on the first housing.

[0013] The second housing may have a longitudinal axis, and the contact portion may be located radially with respect to the cooperating surface.

[0014] The locating mechanism may limit the rotation of the second housing with respect to the first housing.

[0015] The contact portion may be configured such that the aerosol generating assembly is disposed in a specific position and / or orientation with respect to the first housing. Further, the contact portion may be configured to limit the movement of the aerosol generating assembly with respect to the first housing.

[0016] The positioning mechanism may include a pair of abutment surfaces extending in the axial direction. The abutment surfaces may be spaced apart from each other in a direction perpendicular to the longitudinal axis.

[0017] The first housing may include a pair of arms extending in a first direction perpendicular to the longitudinal axis. These arms may be spaced apart from each other in a second direction perpendicular to the longitudinal axis and perpendicular to the first direction. At least one surface of the pair of arms may be a cooperating surface.

[0018] The positioning mechanism may include at least one protrusion.

[0019] The first housing may include at least one socket, and at least one protrusion may be received by at least one socket to dispose the aerosol generating assembly on the first housing. Each protrusion may be configured to engage with a corresponding socket.

[0020] Engagement can be used to dispose the aerosol generating assembly in a specific position and / or orientation relative to the first housing. Also, engagement can be used to restrict movement of the aerosol generating assembly relative to the first housing.

[0021] The second housing may have a longitudinal axis. The longitudinal axis may be a central axis around which the second housing extends. At least one protrusion may extend in the axial direction (e.g., parallel to the longitudinal axis).

[0022] At least one protrusion may include at least two legs protruding axially from one end of the second housing. These legs may be spaced apart from each other in a direction perpendicular to the longitudinal axis.

[0023] The second housing may include a rim, and at least one protrusion may extend from the rim.

[0024] The positioning mechanism may be a first positioning mechanism that is at least near the first end of the second housing, and the second housing may include a second positioning mechanism that is at least near the second end of the second housing.

[0025] The second positioning mechanism may have the characteristics of the positioning mechanism described above.

[0026] The first positioning mechanism may include a contact portion, the first housing may include a cooperation surface, and the contact portion may contact the cooperation surface to position the aerosol generating assembly on the first housing.

[0027] The second positioning mechanism may include at least one protrusion, the first housing may include at least one socket, and the at least one protrusion may be received by the at least one socket to position the aerosol generating assembly on the first housing.

[0028] The second housing including the positioning structure may be integrally formed.

[0029] The device may include an end support at one end of the second housing. Also, the device may include a heater assembly and an air passage through which the aerosol passes. The second housing may include an orientation feature or orientation mechanism configured to limit the rotation of the end support with respect to the second housing.

[0030] A pair of arms may be configured to grip the end support therebetween.

[0031] The second housing may be a tubular member.

[0032] The heater assembly may include a receptacle configured to receive the aerosol generating material. The receptacle may include a susceptor. The air passage may pass through the receptacle. The air passage may pass through the susceptor.

[0033] According to one aspect of the present disclosure, there is provided an aerosol supply device including a first housing and an aerosol generation assembly. The aerosol generation assembly includes a second housing and a heater assembly including a receptacle configured to receive an aerosol generation material. The second housing extends around the receptacle, and the second housing also includes an arrangement structure configured to dispose the aerosol generation assembly on the first housing.

[0034] According to one aspect of the present disclosure, there is provided an aerosol supply device including a receptacle configured to receive an aerosol generation material, the receptacle including a susceptor that can be heated by the intrusion of a variable magnetic field, a coil support extending around the susceptor, an inductor coil extending around the coil support and configured to generate a variable magnetic field, an end support provided at one end of the coil support, and an air passage passing through the receptacle and the end support. The coil support includes an orientation mechanism configured to limit the rotation of the end support with respect to the coil support.

[0035] The end support may include an air inlet of the air passage. During use, air may flow into the air passage from the air inlet.

[0036] The end support may include a stopper configured to cooperate with the orientation mechanism so as to limit the rotation of the end support with respect to the coil support.

[0037] The orientation mechanism may include a slot, and the stopper may include a protrusion engaged with the slot so as to limit the rotation of the end support with respect to the coil support.

[0038] The slot may extend in the axial direction. Correspondingly, the protrusion may also extend in the axial direction.

[0039] The coil support including the orientation mechanism may be integrally formed.

[0040] The device may comprise a housing. The housing may at least partially accommodate the first housing and the aerosol generating assembly. The housing may be connected to the device such that the position of the housing is fixed relative to the first housing. The housing may be rigidly connected to the first housing.

[0041] The device may comprise at least one electronic device module. The at least one electronic device module may be connected to the device such that the position of the at least one electronic device module is fixed relative to the first housing. The at least one electronic device module may be rigidly connected to the first housing.

[0042] The first housing may be a rigid member.

[0043] The device may comprise a flexible battery such as a flexible pouch cell (laminated battery). The first housing may at least partially surround the battery.

[0044] The device may comprise a heat insulating layer extending around the susceptor between the susceptor and the second housing.

[0045] The first housing may comprise a mounting portion for at least one electrical connector. The at least one electrical connector may comprise a charging port such as a USB charging port.

[0046] The coil support comprising the arrangement configuration body and the orientation mechanism may be integrally formed.

[0047] The coil support may be a tubular member.

[0048] The coil support may include an alignment feature or mechanism configured to align the inductor coil on the coil support. The alignment mechanism may include a channel. The inductor coil may be at least partially received within the channel along at least a portion of the length of the channel.

[0049] The inductor coil may be configured to heat the susceptor up to a temperature of about 200°C to about 350°C. In some embodiments, the inductor coil may be configured to heat the susceptor to a temperature of about 350°C.

[0050] According to one aspect of the present disclosure, there is provided an inductor coil support for an aerosol supply device, comprising a housing and at least one placement mechanism configured to place the inductor coil support on the housing.

[0051] The at least one placement mechanism may have the characteristics of the placement mechanism described above.

[0052] According to one aspect of the present disclosure, there is provided an aerosol supply system comprising an aerosol supply device as described above and an article containing an aerosol-generating material, the article being dimensioned to be at least partially received within a heater assembly (a receptacle of the heater assembly).

[0053] The article may be dimensioned to be at least partially received within the susceptor.

[0054] The article may be dimensioned to contact the susceptor when received within the susceptor.

[0055] In a particular configuration, the susceptor may be elongated and may define an axis such as a longitudinal axis. Accordingly, the coil support may be disposed radially outward from the susceptor. For example, the coil support may be coaxial with the susceptor. This radial direction may be defined as being perpendicular to the axis of the susceptor. The inductor coil may be coaxial with the heat insulating member and the susceptor (i.e., the axes of the inductor coil, the heat insulating member, and the susceptor may coincide and be parallel).

[0056] The inductor coil may be substantially helical. The inductor coil may be a helical coil. For example, the inductor coil may be composed of a wire such as a Litz wire wound helically around a coil support. Other wire types such as, for example, a solid wire are also conceivable.

[0057] The "outer surface" of an actual object means the surface disposed farthest from the axis in a direction perpendicular to the axis of the susceptor. Similarly, the "inner surface" of an actual object means the surface disposed closest to the axis in a direction perpendicular to the axis of the susceptor.

[0058] The "thickness" of an actual object means the average distance between the inner surface and the outer surface of the object. The thickness may be measured in a direction perpendicular to the axis of the susceptor.

[0059] The inductor coil, the susceptor, and the second housing may be coaxial.

[0060] 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 apart from the susceptor by an appropriate distance, the temperature of the outer cover can be maintained at a safe level of less than about 60°C, less than about 50°C, less than about 48°C, or less than about 43°C.

[0061] The first housing and / or the second housing may be made of a heat insulating material such as, for example, plastic. In a specific example, the first and second housings are made of polyetheretherketone (PEEK). PEEK has excellent heat insulation properties and is well suited for use in an aerosol supply device.

[0062] In another example, the first housing and / or the second housing may include mica or mica-glass ceramic.

[0063] The first housing and / or the second housing may 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.

[0064] The coil support, the barrier member, the first end support and the second end support may have a melting point of greater than about 320 °C (greater than about 300 °C or greater than about 340 °C). PEEK has a melting point of 343 °C.

[0065] This device may be a tobacco heating device, also known as a non-combustion heating device.

[0066] Other features and advantages of the present invention will become apparent from the following description of the preferred embodiments of the present invention, which is shown by way of example only with reference to the accompanying drawings.

Brief Description of the Drawings

[0067]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13A

Figure 13B

Figure 14A

Figure 14B

Figure 15

Mode for Carrying Out the Invention

[0068] As used herein, the term "aerosol generating material" includes materials that normally provide volatile components upon heating, in the form of an aerosol. The aerosol generating material includes any tobacco-containing material, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Also, other non-tobacco products are included as aerosol generating materials, and depending on the product, they may or may not contain nicotine. The aerosol generating material may be in the form of, for example, a solid, liquid, gel, wax, etc. Also, the aerosol generating material may be a combination or mixture of materials. Also, the aerosol generating material may be known as a "smoking material".

[0069] Devices are known that form an aerosol that can be inhaled, usually without combustion (burn or combust) of the aerosol generating material, by heating the aerosol generating material to volatilize at least one component of the aerosol generating material. Such devices may be described as an "aerosol generating device", "aerosol supply device", "non-combustion heating device", "tobacco heated product device", or "tobacco heating device", 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 a part such as a rod, cartridge, or cassette that can be inserted into the device, or may be provided as a part. The heater that heats and volatilizes the aerosol generating material may be provided as a "permanent" part of the device.

[0070] An aerosol supply device can receive and heat an article containing an aerosol - generating material. In this regard, an "article" is a component that, during use, comprises or contains an aerosol - generating material and is heated to volatilize the aerosol - generating material and optionally other components during use. After a user inserts the article into the aerosol supply device, the aerosol supply device may be heated to generate an aerosol that the user can later inhale. The article may be of a predetermined size, for example, configured to be placed within a heating chamber of a device sized to receive the article, or it may be of a specific size.

[0071] FIG. 1 shows an example of an aerosol supply device 100 that generates an aerosol from an aerosol - generating medium / material. Generally, the device 100 may be used to heat a replaceable article 110 containing an aerosol - generating medium to generate an aerosol or other inhalable medium that can be inhaled by a user of the device 100.

[0072] The device 100 includes a housing 102 that surrounds and houses various components of the device 100 (including an outer cover). The device 100 has an opening 104 at one end through which the article 110 can be inserted and heated by a heater assembly 105 (see FIG. 2). During use, the article 110 may be inserted entirely or partially into the heater assembly 105 and heated by one or more components of the heater assembly 105.

[0073] Also, the device 100 may include a user - operable control element 112, such as a button or a switch, that operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112.

[0074] The device 100 defines a longitudinal axis 101.

[0075] Figure 2 is a schematic exploded view of the device 100 of FIG. 1. The device 100 includes an outer cover 102, a first end member 106, and a second end member 116. The device 100 comprises an aerosol generating assembly 111 including a housing 109, a power source 118, and a heater assembly 105. The device 100 further comprises at least one electronic device module 122.

[0076] The outer cover 102 forms part of the device shell 108. The first end member 106 is disposed at one end of the device 100, and the second end member 116 is disposed at the 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 of the embodiment may include a lid (not shown) that can close the opening 104 by movement relative to the first end member 106 when the article 110 is not in place.

[0077] Also, the device 100 may include an electrical component such as a connector / port 114 that can receive a cable to charge the battery of the device 100. For example, the connector 114 may be a charging port such as a USB charging port. In some examples, the connector 114 may be used for data transfer between the device 100 and another device such as a computer device, additionally or alternatively.

[0078] Device 100 includes a housing 109. This first housing 109 may include a mounting portion for the connector / port 114. The housing 109 is received within an outer cover 102. The housing including the outer cover 102 may be connected to the device 100 in such a manner that the position of the outer cover 102 is fixed relative to the housing 109. For example, the outer cover 102 may be firmly connected to the housing 109. The housing 109 is received by the outer cover 102. The aerosol generation assembly 111 includes a heater assembly 105 into which all or part of an article 110 can be inserted during use, 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 supply 118 are mounted on the housing 109. The housing 109 is an integral (one-piece) component. The housing 109 may be a rigid member. Thus, the housing 109 can provide protection for the components of the device mounted therein, particularly relatively soft components.

[0079] The housing 109 may be formed integrally during manufacture, for example, by an injection molding process. Alternatively, after two or more features of the housing 109 are initially formed separately, an integral component may be formed by integral formation during the manufacturing stage, for example, by a welding process.

[0080] An integral component represents a component of the device 100 that cannot be separated into two or more components after assembly of the device 100. Integral formation relates to two or more features that are formed as an integral component during the manufacturing stage of the component.

[0081] The first and second end members 106, 116 integrally at least partially define an end face of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. Also, an edge of the outer cover 102 may define a part of the end face. The first and second end members 116 close the open end of the outer cover 102. The second end member 116 is at one end of the housing 109.

[0082] The end of the device 100 closest to the opening 104 is closest to the user's mouth during use, and may be known as the proximal end (or the mouth-side end) of the device 100. During use, the user inserts the article 110 into the opening 104, operates the user control 112 to start heating the aerosol-generating material, and utilizes the aerosol generated by the device. Thereby, the aerosol flows through the device 100 toward the proximal end of the device 100 along the flow path.

[0083] The other end of the device farthest from the opening 104 is the end that is farthest from the user's mouth during use, and may be known as the distal end of the device 100. When the user utilizes the aerosol generated by the device, the aerosol flows in a direction toward the proximal end of the device 100. The terms proximal and distal applied to the features of the device 100 will be described by referring to the relative arrangement of such features in the proximal-distal direction along the axis 101.

[0084] The power source 118 is disposed at the distal end of the device 100. The housing 109 houses the power source 118. The housing 109 includes a power source attachment portion 119. The housing 109 partially surrounds the power source 118. The power source 118 may be a battery such as a rechargeable battery or a 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 may be flexible, such as a flexible pouch cell (laminated battery). The first housing 109 (which is relatively harder than that) may at least partially surround the battery so as to protect the battery. The battery is electrically coupled to the aerosol-generating assembly 111, supplies power as needed, and heats the aerosol-generating material under the control of the control device 121. In this example, the battery is connected to the housing 109 that acts as a central support for holding the battery 118 in place.

[0085] The power source 118 and the aerosol generation assembly 111 are arranged as an axial configuration, with the power source 118 disposed at the distal end of the device 100 and the aerosol generation assembly 111 disposed at the proximal end of the device 100. Other configurations are envisioned. The housing 109 includes an aerosol generation assembly mounting portion 113.

[0086] The device 100 further includes at least one electronic device module 122. The electronic device module 122 may include, for example, a printed wiring board (PCB) 123. The PCB 123 may support at least one control device 121, such as a processor, and a memory. Further, the PCB 123 may include one or more electrical tracks that electrically and integrally connect various electronic components of the device 100. For example, a battery terminal may be electrically connected to the PCB 123 so as to enable power distribution throughout the device 100. Also, the connector 114 may be electrically coupled to the battery 118 via an electrical track. The housing 109 includes a PCB mounting portion 117. The at least one electronic device module 122 may be connected to the device 100 such that the position of the at least one electronic device module 122 is fixed relative to the first housing 109. For example, the at least one electronic device module 122 may be fixedly connected to the first housing 109.

[0087] The aerosol generation assembly 111 is an induction heating assembly and includes various components that heat the aerosol generation material of the article 110 by an induction heating process. Induction heating is a process of heating a conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element (for example, one or more inductor coils) and a device that passes a fluctuating current, such as an alternating current, through the induction element. The fluctuating current of the induction element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates into a susceptor suitably arranged with respect to the induction element and generates eddy currents inside the susceptor. Since the susceptor has an electrical resistance to the eddy currents, the susceptor is heated by Joule heating due to the flow of the eddy currents against this resistance. Further, when the susceptor contains a ferromagnetic material such as iron, nickel, or cobalt, heat may also be generated by the magnetic hysteresis loss of the susceptor, that is, the fluctuating orientation of the magnetic dipoles of the magnetic material as a result of alignment with the fluctuating magnetic field. In induction heating, for example, compared with heating by conduction, heat is generated inside the susceptor, so rapid heating is possible. Further, since no physical contact is required between the induction heater and the susceptor, the degrees of freedom in configuration and application increase.

[0088] Figure 3 shows a partially enlarged side sectional view showing a part of the device 100. The outer cover 102 surrounds the aerosol generation assembly 111. The aerosol generation assembly 111 of the device 100 includes 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. Further, the inductor coil assembly 127 includes a second housing having a coil support 200.

[0089] The heater assembly 105 includes a susceptor structure 132 (referred to herein as the "susceptor"). Since the susceptor 132 in this example is hollow, it defines a receptacle 131 for receiving the aerosol - generating material. 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 part of the heater assembly 105. The susceptor 132 has a substantially constant diameter along its axial length. The susceptor 132 has a flare portion 134 at its proximal end 133, which is the first end. The flare portion 134 extends outwardly. The flare portion 134 defines an outward - extending lip 135. That is, the lip 135 has a diameter larger than the outer diameter of the main part of the susceptor 132. The lip 135 acts to minimize contact of the susceptor 132 with other components at the first end 133. This configuration helps to reduce heat transfer, for example, by conduction, when the susceptor 132 is heated.

[0090] The susceptor 132 is formed of a conductive material suitable for heating by electromagnetic induction. The susceptor in this example is formed of carbon steel. It will be understood that other suitable materials (such as ferromagnetic materials like iron, nickel, or cobalt) can also be used.

[0091] In other embodiments, the features that function as a receptacle may not be limited to induction heating. Thus, the features that function as a heating element may be heatable by electrical resistance. For this reason, the heater assembly 105 may include electrical contacts that are electrically connected to a device and pass an electrical energy flow through the heating element to electrically activate the heating element.

[0092] Figure 3 shows a portion of the article 110 received in the receptacle 131 provided by the susceptor 132. The susceptor 132 and the article 110 are dimensioned such that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This helps to ensure that heating is most efficient. The article 110 of this example contains an aerosol generating material. The aerosol generating material is disposed within the susceptor 132. Also, the article 110 may comprise other components such as a filter, a wrapper, and / or a cooling structure.

[0093] Also, the heater assembly 105 includes a funnel portion 140. The funnel portion 140 is at the distal end 136 which is the second end of the susceptor 132. The funnel portion 140 protrudes from the susceptor 132. In an embodiment, the susceptor 132 and the funnel portion 140 are integral components.

[0094] The funnel portion 140 has a simple configuration. The funnel portion 140 is at the distal end 136 which is the second end of the susceptor 132. The funnel portion 140 defines a second part of the heater assembly 105. The funnel portion 140 includes a first part 141 of a first diameter and a second part 142 of a second diameter. An intermediate portion 143 extends between the first and second parts 141, 142. The first part 141 is tubular and extends in the axial direction. The second part 142 is tubular and extends in the axial direction. The funnel portion 140 is hollow. The intermediate portion 143 constitutes a shoulder 145. The shoulder 145 acts as a stopper that limits the insertion of the article 110 into the receptacle. The shoulder 145 extends in a substantially vertical plane towards the longitudinal axis 101.

[0095] The first part 141 has an inner diameter larger than the inner diameter of the second part 142. Thus, the funnel portion 140 flares from the first part 141 to the second part 142. For this reason, the diameter of the funnel portion 140 decreases from the susceptor end 148 to the distal end 149.

[0096] The funnel portion 140 defines an air passage 146 that passes through its interior. The first portion 141 and the susceptor 132 partially overlap each other at one end of the susceptor 132. In one example, this overlap is from about 1 mm to about 3 mm. In a particular example, the overlap is 2 mm. There are also examples where there is no overlap. In such examples, the susceptor 132 and the funnel portion 140 are adjacent. The first portion 141 overlaps the distal end 136, which is the second end of the susceptor 132. The first portion 141 is substantially 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 joint 147 aids in forming a heat transfer path between the susceptor 132 and the funnel portion 140.

[0097] The joint 147 is a fluid-tight joint. The fluid seal is formed between the susceptor 132 and the funnel portion 140. Thus, a fluid-tight fluid path is defined between the opposing ends of the susceptor 132 and the funnel portion 140. Accordingly, the receptacle defined by the susceptor 132 constitutes a fluid-sealed air path with the air passage 146 formed by the funnel portion 140.

[0098] In an embodiment, the fluid seal at the joint 147 is formed by a machining joint (e.g., welding). The fluid seal at the joint 147 is formed by a laser welding process, although it will be understood that other methods such as brazing or adhesion can be used. The funnel portion 140 is formed of a heat transfer material. In an embodiment, the funnel portion 140 is formed of carbon steel. In an embodiment, the funnel portion is formed of the same material as the susceptor 132. The joint is configured to maintain the fluid seal when the susceptor 132 is at its predetermined operating temperature. By such a process, the susceptor 132 and the funnel portion 140 are fabricated as an integral component.

[0099] Accordingly, the sealed fluid path between the susceptor 132 and the funnel portion 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, any fluid flow through the heater assembly 105 is included in the heater assembly 105. A drying zone may be defined outside the heater assembly 105.

[0100] The adjacency of the susceptor 132 and the funnel portion 140 enables heat transfer by conduction from the susceptor 132 to the funnel portion 140. Thus, it is possible to assist the passive heating of the funnel portion 140. By the passive heating of the funnel portion 140, it is possible to limit the accumulation of condensate in the device 100.

[0101] 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. Thus, the direct heating of the funnel portion 140 by the inductor coil assembly 127 is minimal or non-existent. The funnel portion 140 may be adjacent to the inductor coil assembly 127 in the axial direction.

[0102] Referring particularly to FIGS. 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.

[0103] The first end support 220 engages with the proximal end which is the first 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. Referring particularly to FIGS. 7 and 8, the first end support 220 extends away from the first end of the susceptor 132 towards the opening 104. At least a part of a holding structure 221 such as a holding clip for holding adjacent to the article 110 when received within the device 100 is disposed within the first end support 220. The first end support 220 is connected to the end member 106.

[0104] The first end support 220 includes a chamber 222. The chamber 222 is configured to receive the article 110 therein. The holding structure 221 is in the chamber 222. The chamber 222 has an inner diameter larger than the diameter of the article 110. The first end support 220 constitutes the proximal collar which is the first collar of the heater assembly 105. A perforation 223 extends therein. For example, as shown in FIGS. 7 and 8, a distal opposing shoulder 225 is defined on the inner surface of the perforation 223. The distal opposing shoulder 225 is aligned with the lip 135 of the susceptor when the susceptor 132 is received by the first end support 220.

[0105] Referring particularly to FIGS. 4 and 5 here, the first end support 220 forms a seal rim 226 on the distal side of the first end support 220. The distal seal rim 226 extends around the perforation 223. A first attachment flange 227 extends from the proximal end outer surface 228 which is the outer surface of the first end of the first end support 220. The first attachment flange 227 extends circumferentially and is spaced apart from the seal rim 226. The first attachment flange 227 stands upright from the first end outer surface 228 to form a proximal end attachment surface 229 which is the first end attachment surface. The proximal end outer surface 228 which is the first end outer surface and the first end attachment surface 229 define a stepped configuration. The first end attachment surface 229 has a larger diameter than the first end outer surface 228. In an embodiment, the first end outer surface 228 and the first end attachment surface define first and second stepped surfaces.

[0106] Referring particularly to FIGS. 4 - 8, the device 100 further includes a second end support 230 that holds the heater assembly 105 in place by engaging a funnel portion 140 at the distal end which is the second end of the susceptor 132. The second end support 230 forms the distal collar which is the second collar of the heater assembly 105. In an embodiment where the funnel portion is omitted, the second end support 230 engages directly with the susceptor 132. The second end support 230 acts as an air inlet as will be described later. The second end support 230 extends away from the second end of the susceptor 132 towards the distal end of the device 100.

[0107] Referring particularly to FIGS. 4 and 6, the second end support 230 includes a second end perforation 231. 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 internal circumferentially extending surface. The second sealing surface 235 is a circumferentially extending surface extending in a plane substantially perpendicular to the longitudinal axis 101.

[0108] Extending from the distal outer surface 238, which is the second outer surface of the second end support 230, is a second mounting flange 237. The second mounting flange 237 extends circumferentially and is spaced from the proximal end of the second end support 230. The second mounting flange 237 stands upright from the second outer surface 238 to form a distal end mounting surface 239, which is the second end mounting surface. The distal end outer surface 238, which is the second end outer surface, and the distal end mounting surface 239, which is the second end mounting surface, 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.

[0109] 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 as an aid in thermally isolating the heater assembly 105 from other components of the device 100. The barrier member 250 is a hollow tubular member.

[0110] 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 with the first and second end supports 220, 230. In one example, this overlap is from about 2 mm to about 3 mm. In a particular example, the overlap is about 2.2 mm. There are also examples where there is no overlap. The proximal end of the barrier member 250 is adjacent to the first end outer surface 228. The distal end of the barrier member 250 is adjacent to the second end outer surface 238.

[0111] 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 machining joint (e.g., welding) is formed between the barrier member 250 and each of the first and second end supports 220, 230. The fluid seal at the joint of the components is formed by the welding process, but it will be understood that other methods such as brazing or adhesion can be used. In an embodiment, the barrier member 250 and the first and second end supports 220, 230 are formed of the same material. The above joint 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 an integral component.

[0112] In an embodiment, the barrier member 250 is formed of a non-metallic material to assist in limiting interference with magnetic induction. In this particular example, the barrier member 250 is composed of polyetheretherketone (PEEK). The first and second end supports 220, 230 are composed of PEEK. Other suitable materials are possible. Parts formed of such materials help the barrier member 250 maintain rigidity / solidity when the susceptor is heated. The barrier member 250 assists in supporting other components such as the heater assembly 105 and the end supports 220, 230 by being formed of a rigid material. The barrier member 250 may be composed of an insulating material such as plastic, for example. In one example, the thickness of the barrier member 250 is from about 0.1 mm to about 0.5 mm. In this example, the thickness is about 0.3 mm.

[0113] The heater assembly 105, the barrier member 250, and the first and second end supports 220, 230 are coaxial about the central longitudinal axis of the susceptor 132. The barrier member 250 can help insulate the various components of the device 100 from the heat generated in the susceptor 132.

[0114] A radial gap is provided between the susceptor 132 and the first end support 220. The diameter of the perforation 223 is larger than the diameter of the outer surface of the susceptor 132. The radial gap is about 0.2 mm, but may be different. Providing the radial gap helps minimize heat transfer between the susceptor 132 and the first end support 220.

[0115] Here, particularly referring to FIGS. 4 to 6, the first seal member 240 forms a fluid seal between the heating assembly (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 can be used. The first seal member 240 is elastic. This material is configured to stabilize when the heater assembly 105 is at the operating temperature. The first seal member 240 is fixedly mounted on the susceptor 240. The first seal member 240 is attached to the susceptor 132, for example, by overmolding the first seal member 240 onto the outer surface of the susceptor 132. The first seal member 240 is spaced apart from the 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 the first seal member 240 to perform a seal. Such a seal is formed between the first end support 220 and the susceptor 220. The first seal member 240 forms an axial seal.

[0116] The first seal member 240 seals in contact with the barrier member 250. The first seal member 240 stands upright from the susceptor 132. The first seal member 240 is adjacent to the inner surface of the barrier member 250. Accordingly, a seal is formed between the susceptor 132 and the barrier member 250. The first seal member 240 forms a radial seal. The first seal member 240 acts to position and orient the susceptor with respect to the first end support 220 and the barrier member 250.

[0117] The second seal member 245 forms a fluid seal between the heating assembly (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. This material is configured to stabilize when the heater assembly 105 is at the operating temperature. The second seal member 245 is fixedly mounted to the funnel portion 140. In an embodiment, the second seal member is in the susceptor 132, for example, the funnel portion is omitted. The second seal member 245 is attached to the susceptor 132, for example, by overmolding the second seal member 245 onto the outer surface of the funnel portion 140. The second seal member 245 is adjacent to the open end of the funnel portion 140. When the distal end of the heater assembly is received by the second end support 230, the first seal surface 234 of the second end support 230 contacts the second seal member 245 to effect a seal. Such a seal is formed between the second end support 230 and the heater assembly 105. The second seal member 245 forms a radial seal.

[0118] The second seal member 245 contacts the second seal surface 235 of the second end support 230 to effect a seal. The second seal member 245 forms an axial seal. The second seal member 245 stands upright from the heater assembly 105. The second seal member 245 acts to position and orient the heater assembly 105 with respect to the second end support 230 and the barrier member 250.

[0119] In an embodiment, the first seal member 240 is at the first end support 220 and seals together with the heater assembly 105. In an embodiment, the second seal member 245 is at the second end support 230 and seals together with the heater assembly 105. The second seal member 245 is at the second portion 142 of the funnel portion 140. In an embodiment, the second seal member 245 is at the first portion 141 of the funnel portion 140. In such an embodiment, the second seal member 245 seals the proximal rim of the second end support 230.

[0120] The first seal member 240 and the second seal member 250 constitute a sealed air flow path passing 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 constitute 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 disposed away from the outer surface of the susceptor 132, thereby providing a gap between the barrier member 250 and the heater assembly 105. The gap provides insulation from the heat generated at the susceptor 132.

[0121] A fluidly sealed cavity 260 is formed between the heater assembly 105 and the barrier member 250. The fluidly sealed cavity 260 constitutes a chamber. The cavity 260 provides a void. A fluidly sealed enclosure 261 is formed around a portion of the heater assembly 105. The fluidly sealed enclosure is formed by the barrier member 250, 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 fluidly sealed enclosure 261 is formed by the barrier member 250, 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 250 is about 0.8 mm to 1 mm. In an embodiment, the gap is about 0.9 mm.

[0122] 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. Thus, the flow of condensate from the air flow path to the thermocouple 265 is restricted.

[0123] Referring particularly to FIGS. 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 composed of a conductive material. In this example, the first and second inductor coils 124, 126 are composed of Litz wire / cable wound in a spiral to provide helical inductor coils 124, 126. The Litz wire comprises a plurality of individual wires that are individually insulated and form a single wire by an integral twist. The Litz wire is designed to suppress the skin effect loss of the conductor. In the exemplary device 100, the first and second inductor coils 124, 126 are composed of 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 vary. 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.

[0124] The first inductor coil 124 is configured to generate a first alternating 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 alternating 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 two or more separate susceptors. The ends 130 of the first and second inductor coils 124, 126 are connectable to the PCB 123 (see FIG. 2).

[0125] In some examples, it will be apparent that the first and second inductor coils 124, 126 may have at least one characteristic that is different from each other. For example, the first inductor coil 124 may have at least one characteristic that is different from the second inductor coil 126. More specifically, as an example, the first inductor coil 124 may have a value of inductance that is different from the second inductor coil 126. In FIGS. 3 and 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. For this reason, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming that the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 may be composed of a material different from the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially the same.

[0126] 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 adapted to operate at different timings. For example, initially the first inductor coil 124 may be operative to heat a first portion of the article 110, and subsequently the second inductor coil 126 may be operative 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 to suppress the current induced in the non-operative coil when used in conjunction with a particular type of control circuit. In such an example, the first inductor coil 124 may be a right-handed helix, and the second inductor coil 126 may be a left-handed helix. In another embodiment, the first inductor coil 124 may be a left-handed helix, and the second inductor coil 126 may be a right-handed helix.

[0127] It will be understood that the number of inductor coils may be different. In an embodiment, the device 100 includes a single inductor coil.

[0128] The device 100 includes a second housing. The second housing includes a coil support 200 that acts as a support member. The support member may be substantially tubular and may at least partially surround the susceptor 132. The second housing 200 supports the first and second inductor coils 124, 126. In FIG. 4, the second housing 200 is shown in cross section. FIG. 9 is a side view of the second housing 200, showing it with various components of the device 100 omitted. Also, FIG. 10 shows the second housing 200.

[0129] The second housing 200 extends between the first and second end supports 220, 230. The second housing 200, together with the first and second end supports 220, 230, surrounds the heater assembly 105. This serves to assist in the thermal isolation of the heater assembly 105 from other components of the device 100. The coil support 200 is a hollow tubular member.

[0130] In an embodiment, the coil support 200, by being formed of a non-metallic material, assists in limiting interference with magnetic induction. In a particular example, the second housing 200 is composed of polyetheretherketone (PEEK). Other suitable materials are possible. According to the second housing formed of such a material, when the susceptor is heated, it ensures that the assembly maintains rigidity / solidity. The coil support 200, by being formed of a rigid material, assists in supporting other components such as the coils 124, 126. The coil support 200 may be composed of an insulating material such as plastic, for example. In one example, the coil support 200 has a thickness of 1 mm to 1.5 mm. In this example, the thickness is approximately 1.3 mm.

[0131] In particular, as shown in FIGS. 3, 4, and 9, the first and second inductor coils 124, 126 are arranged around the coil support 200 and are adjacent to the coil support 200. The first and second inductor coils 124, 126 are on the radially outer surface 201 of the coil support 200. In an embodiment, the first and second inductor coils are on the radially inner surface 202 of the coil support 200.

[0132] The susceptor 132, the coil support 200, and the first and second inductor coils 124, 126 are coaxial about the central longitudinal axis 101 of the susceptor 132. The coil support 200 can serve to insulate various components of the device 100 from the heat generated in the susceptor 132.

[0133] 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 disposed away from the outer surface 203 of the susceptor 132.

[0134] The second housing 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 to the first end outer surface 228. The distal end of the barrier member 250 is adjacent to the second end outer surface 238. The proximal end of the coil support 220 overlaps the proximal end attachment surface 229, which is the first end attachment surface of the first end support 220. The distal end of the coil support 220 overlaps the distal end attachment surface 229, which is the second end attachment surface of the second end support 230.

[0135] 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 mechanical joining such as welding or adhesion. In an embodiment, the coil support 200 and the first and second end supports 220, 230 are formed of the same material.

[0136] Referring particularly to FIGS. 3, 4, 9, and 10, the first and second inductor coils 124, 126 are aligned by the coil support 200 at 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 the mechanism of the coil support 200. As an example, the alignment mechanism is the channel 205. The channel 205 is formed in the radially outer surface 201 of the coil support 200. The channel 205 is a spiral 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 certain spiral path. The channel 205 is wound multiple times around the coil support 200. The channel 205 acting as an alignment mechanism provides a consistent path for the coils 214, 216, such as a consistent spacing. This helps to maximize the performance of the inductor coil assembly and / or achieve predetermined characteristics of the coils.

[0137] The first and second inductor coils 124, 126 are each aligned in a spiral arrangement at the coil support 200. As an example, one of the inductor coils may be omitted. The first and second inductor coils 124, 126 each follow a spiral path. The windings of the spiral paths of the first and second inductor coils 124, 126 are equally spaced.

[0138] 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 plurality of protrusions. The protrusions may define a helical path along which the support coil is received and held.

[0139] The coil support 200 includes a helical recess 206 between adjacent windings of the channel 205. The helical recess 206 is an elongated groove. As an example, the helical recess 206 includes a plurality of recesses. As an example, the helical recess 206 acts as a void. Providing the helical recess assists in limiting heat transfer. Providing the helical recess may assist in minimizing weight. The helical recess 206 forms a double helix configuration with the channel 205. In an embodiment, the helical recess is omitted. FIGS. 3 and 4 do not show the helical recess.

[0140] The first and second inductor coils 124, 126 are held in the channel 205. Holding mechanisms such as clips, bonding, and overcoats may be used to hold the first and second inductor coils 124, 126 in the channel 205.

[0141] The first and second inductor coils 124, 126 are each fully received in the coil support 200. That is, the first and second inductor coils 124, 126 are each flush with the surface of the coil support 200 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.

[0142] The coil support 200 has a single channel. However, it will be understood that the channel 205 may be separated into two channel portions, one for each of the coils 124, 126. By each channel having one or more different characteristics (e.g., period, width, depth, and length), the alignment between the coils 124, 126 may be different.

[0143] Around the inductor coils 124, 126, a ferrite shield 280 extends. The ferrite shield acts as an electromagnetic shield. Other suitable materials can be used. The ferrite shield 280 is mounted on the coil support 200. Since the ferrite shield 280 is adjacent to the coil support 200, it may be directly attached to the coil support 200, for example, by adhesion. The 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.

[0144] Referring to FIG. 12, on the coil support 200, a sensor 290 such as a thermocouple is disposed. The coil support 200 includes a sensor mounting portion 291. This aids in the accurate placement of the sensor with respect to the coil, enabling accurate measurement. The mounting portion 291 includes a recess. The mounting portion 291 constitutes a placement surface for attaching the thermocouple.

[0145] The alignment mechanism in the above-described embodiment is the channel. However, it will be understood that the channel may be omitted and the alignment mechanism may be different.

[0146] In the above embodiments, a channel 205 for coil alignment and / or other alignment mechanisms are provided on the coil support 200. It will be appreciated that in some embodiments, the channel for coil alignment and / or other alignment mechanisms may be omitted. In such embodiments, the coil may be attached to the surface of the coil support or may be assembled around the coil support with a gap therebetween.

[0147] The heater assembly 105, the barrier member 250, and the coil support 200 are coaxial about the central longitudinal axis of the susceptor 132. The coil support 200 can serve to insulate various components of the device 100 from the heat generated in the susceptor 132.

[0148] The coil support 200 is spaced apart from the susceptor 132. The coil support 200 is spaced apart from the barrier member 250. The barrier member 250 is between the heater assembly 105 and the coil support 200. A heat insulation chamber 270 may be formed between the coil support 200 and the barrier member 250.

[0149] In one example, the distance between the coil support 200 and the barrier member 250 is from 0.5 mm to 1.5 mm. In this example, the thickness is about 0.9 mm. The coil support 200 acts as a second barrier member. Providing a barrier member that acts as a barrier can help provide a separate chamber that aids in the mutual separation of different components of the device in a spaced-apart arrangement.

[0150] The barrier acts as a heat insulating member. Therefore, the barrier forms part of a heat insulating stack that limits heat transfer from the susceptor 132 to the exterior of the aerosol generating assembly 111. The barrier member 250 acts as a first heat insulating member. The coil support 200 acts as a second heat insulating member. A heat insulating layer 271 extends between the barrier member 250 and the coil support 200. The heat insulating layer 271 extends around the barrier member 250. The heat insulating layer 271 is adjacent to the barrier member 250 and the coil support 200.

[0151] In an embodiment, the heat insulating layer 271 is supported by the barrier member 250 and the coil support 200. In some embodiments, the heat insulating layer 271 is supported by the barrier member 250. In such an embodiment, the heat insulating layer 271 may be spaced apart from the coil support 200 by, for example, only a small gap. In some embodiments, the heat insulating layer 271 is supported by the coil support 200. In such an embodiment, the heat insulating layer 271 may be spaced apart from the barrier member 250 by, for example, only a small gap. The heat insulating layer 271 may be attached to one of the barrier member 250 and the coil support 200, or may be attached to both. In an embodiment, the barrier member 250 may be omitted. In an embodiment, the coil support 200 may be integrally formed with the heat insulating layer 271. The heat insulating layer 271 may be omitted. In such an embodiment, a void is formed between the barrier member 250 and the coil support 200. In such a configuration, the void acts as a heat insulator.

[0152] The heat insulation layer 271 acts as a third heat insulation member. In the embodiment, the heat insulation layer 271 is a sheet before assembly. In the embodiment, the heat insulation layer 271 is formed around the inner surface of the coil support 200 in a tubular configuration. The end lip 272 (see FIG. 4) helps to hold the heat insulation layer 271. The heat insulation layer 271 is attached to the coil support 20. By way of example, the heat insulation layer 271 is attached to the barrier member 250. The barrier member 250 separates the heat insulation layer 271 from the susceptor 132. The coil support 200 separates the heat insulation layer 271 away from the inductor coils 124, 126.

[0153] The heat 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 (registered trademark)) (having a thermal conductivity of about 0.03 W / mK to about 0.04 W / mK), (iii) polyetheretherketone (PEEK) (in some examples, may have a thermal conductivity of about 0.25 W / mK), (iv) ceramic cloth (having a specific heat of about 1.13 kJ / kgK), (v) thermal pate. Other suitable materials can be used.

[0154] The heat insulation layer 271 is formed of aerogel. Other suitable materials such as, for example, porous foam materials can also be used. By providing barrier members on both sides of the aerogel, it is possible to provide, for example, a protective barrier for the heat insulation layer 271. One or more barriers help to support the heat insulation layer 271 along its length.

[0155] The combination of the barrier member and the aerogel heat insulation layer assists in restricting heat transfer to the shell of the device 100 in a compact configuration by strengthening the heat insulation structure around the heater assembly 105.

[0156] The heat insulation layer 271 acts as an inner heat insulation layer 273. An outer heat insulation layer 273 extends around the inductor coil assembly 127. The outer heat insulation layer 273 forms a tubular structure. The outer heat insulation layer 273 is supported by the inductor coil assembly 127. The inner and outer heat insulation layers 271, 273 sandwich the inductor coil assembly 127. The outer heat insulation layer 273 is mounted on the ferrite layer 280. The outer heat insulation layer 273 is attached to the ferrite layer 280, although other attachment configurations are also envisioned. By providing the outer heat insulation layer 273, heat insulation of a predetermined thickness can be used while the distance between the coil and the susceptor 132 can be changed. The outer heat insulation layer 273 is formed of an aerogel. Other suitable materials (e.g., porous foam materials) can also be used.

[0157] Referring to FIG. 11, the first end support 220 protrudes from the proximal end of the coil support 200. The second end support 230 protrudes from the 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 attached to the (first) housing 109. The aerosol generation assembly 111 has its proximal and distal ends attached. The aerosol generation assembly attachment portion 113 of the housing 109 holds the aerosol generation assembly 111.

[0158] The device 100 includes an arrangement structure. The first arrangement mechanism 300 of the arrangement structure arranges the aerosol generation assembly 111 at the first proximal end on the housing 109. The second arrangement mechanism 301 of the arrangement structure arranges the aerosol generation assembly 111 on the housing 109 at the second distal end. The housing 109 acts as a first housing, and the coil support 200 acts as a second housing. The second housing 200 includes an arrangement structure.

[0159] FIG. 13A shows an enlarged view of the first proximal end of the coil support 200 including the first placement mechanism 300, and FIG. 13B shows an enlarged view of the second distal end of the coil support 200 including the second placement mechanism 301. The first placement mechanism 300 can place the first proximal end of the coil support (second housing) 200, and thus the aerosol generating assembly 111, on the first housing 109. The second placement mechanism 300 can place the second distal end of the coil support (second housing) 200, and thus the aerosol generating assembly 111, on the first housing 109.

[0160] The illustrated coil support 200 includes the first placement mechanism 300 at the first end of the coil support 200 and the second placement mechanism 301 at the second end of the coil support 200, although in other embodiments, the first or second placement mechanism may be omitted. Further, it is also possible to provide the first placement mechanism at the second distal end of the coil support 200. Similarly, the second placement mechanism may be provided on the first proximal end of the coil support 200. The placement mechanism may be provided at or near one end of the second housing 200.

[0161] As seen in FIG. 13B, the second housing 200 may further include an orientation mechanism 303, which will be described below. In some embodiments, the orientation mechanism 303 may be omitted.

[0162] As will become more apparent below, the placement configuration can help to place the aerosol generating assembly 111 and the heater assembly 105 in an accurate, e.g., unique, position and / or orientation relative to the first housing 109, for example, during and after the assembly of the device 100.

[0163] For example, when the aerosol generation assembly 111 is disposed on the first housing 200 by the arrangement structure of the second housing 109, other components of the aerosol generation assembly 111 may be disposed at desired positions relative to the housing 109. For example, FIG. 11 shows the aerosol generation assembly 111 disposed on the first housing 109 by the first arrangement mechanism 300 and the second arrangement mechanism 301. In this position state, the end of the inductor coil 130 extending from the aerosol generation assembly 111 can be supported on the first housing 109 and connected to the PCB 123.

[0164] Furthermore, the arrangement structure can function as an alignment mechanism to reduce or prevent assembly errors. Therefore, by providing the arrangement structure, the ease and accuracy of assembly can be improved.

[0165] The arrangement structure can limit or prevent the movement of the aerosol generation assembly 111 relative to the first housing 109. This helps to avoid, for example, the inductor coil receiving forces that may undesirably stress or displace the wires of the inductor coil.

[0166] Furthermore, by providing the arrangement mechanism as part of the second housing 200, it becomes possible to manufacture the arrangement mechanism in a simple and direct manner. For example, the arrangement structure may be integrally formed with the coil support 200 in a single manufacturing step, such as by injection molding.

[0167] Referring to FIG. 14A, as described above, the coil support 200 may be a generally tubular member extending along and around the central longitudinal axis 101. The central longitudinal axis 101 can extend in the z direction. FIG. 14A shows the first proximal end of the coil support 200 disposed on the housing 109 by the first arrangement mechanism 300 of the coil support 200, and FIG. 14B shows the second distal end of the coil support 200 disposed on the housing 109 by the second arrangement mechanism 301 of the coil support 200.

[0168] As shown in FIG. 14A, when the coil support 200 is attached to the aerosol generation assembly mount 113 of the housing 109, the aerosol generation assembly attachment portion 113 may be disposed substantially off-axis along the x-direction, for example, perpendicular to the z-direction, with respect to the central longitudinal axis 101 of the coil support 200. The first housing 109 may include a first cooperation mechanism configured to cooperate with the first placement mechanism 300 to place the first proximal end of the aerosol generation assembly 111 on the housing 109, and a second cooperation mechanism configured to cooperate with the second placement mechanism 301 to place the second distal end of the aerosol generation assembly 111 on the housing 109.

[0169] Referring to FIGS. 10, 13A, and 14A, the coil support 200 may include a partial tubular region 300 extending from the first proximal end in the axial direction of the main tubular region of the coil support 200. The partial tubular region 300 may include a pair of surfaces 402A, 402B that can extend in the axial direction (parallel to the longitudinal axis 101 in the z-direction). In this example, the surfaces 402A, 402B generally extend on the same y-z plane. There may also be cases where they are in different planes. The surfaces 402A, 402B may be configured to abut against corresponding cooperation surfaces of the housing 109. These pair of abutting surfaces 402A, 402B may be spaced apart from each other in a direction perpendicular to the longitudinal axis 101, for example, in the y-direction perpendicular to both the z-direction and the x-direction.

[0170] A further abutting surface generally positioned in a plane substantially perpendicular to the longitudinal axis 101 (e.g., the x-y plane) may be defined by a first rim 403 formed at the first proximal end of the main tubular region of the coil support 200.

[0171] As shown explicitly in FIG. 14A, each abutment surface may be configured to abut a corresponding cooperating surface of the housing 109 so as to dispose the first proximal end of the coil support 200, and thus the aerosol generating assembly 111, on the housing 109. Surfaces 402A, 402B may be positioned radially with respect to the cooperating surface. The first rim 403 may be positioned axially with respect to the cooperating surface.

[0172] The first cooperating mechanism of the housing 109 may include a pair of spaced-apart parallel arms 404A, 404B extending substantially perpendicular to the longitudinal axis 101, for example in the x direction. The ends of each arm 404A, 404B may comprise a cooperating surface in a plane substantially parallel to the longitudinal axis 101 (for example, the y-z plane), against which corresponding ones of the pair of abutment surfaces 402A, 402B abut. The sides of each arm may include a cooperating surface in a plane substantially perpendicular to the longitudinal axis 101 (for example, the x-y plane) against which the first rim 403 abuts. As shown in FIG. 14A, the pair of arms 404A, 404B may be further configured to grip the upper end support 220 therebetween.

[0173] These surfaces are configured such that the coil support 200, and thus the aerosol generating assembly 111, is disposed on the housing 109 in a unique position and orientation. This abutment can serve to limit rotation of the second housing 200 relative to the first housing 109. The abutment can also serve to limit axial displacement of the second housing 200 relative to the first housing 109.

[0174] As shown explicitly in FIG. 14B, the coil support 200 may include a second rim 405 at the second distal end in the axial direction. The second placement mechanism 301 may include one or more protrusions that can extend axially (in the z direction, substantially parallel to the longitudinal axis 101) from the second rim 405. In the illustrated embodiment, the second placement mechanism 301 includes a pair of protruding legs 406A, 406B spaced along the second rim 405. There may be more or fewer legs extending from the rim 405.

[0175] Each leg 406A, 406B may be configured to engage corresponding sockets 407A, 407B within the aerosol-generating assembly mounting portion 113 of the housing 109 so as to place the second proximal end of the coil support 200, and thus the aerosol-generating assembly 111, on the housing 109. Accordingly, the second cooperation mechanism of the housing 109 may include a pair of sockets 407A, 407B within the aerosol-generating assembly mount 113.

[0176] As seen in FIG. 14B, each socket 407A, 407B may be defined by a base surface 408 and one or more side wall surfaces 409 extending from the base surface 408. The engagement between the leg and the corresponding socket may be such that the distal end of the leg abuts or is slightly spaced from the base surface 408 of the corresponding socket, and one or more side edges of the leg abut or are slightly spaced from the corresponding side wall surface 409 of the corresponding socket.

[0177] The engagement serves to position the coil support 200, and thus the aerosol-generating assembly 111, on the housing 109 in a unique position and orientation.

[0178] As shown in FIG. 14A, when the coil support 200 is disposed on the first housing 109 by the first and second positioning mechanisms, the ends of the inductor coil 130 are disposed at desired positions with respect to the first housing 109. At this position, the ends of the inductor coil 130 can be connected to, for example, the PCB 123. Similarly, the other end (not shown) of the inductor coil can also be disposed at a desired position with respect to the first housing 109. This enables the ends of the inductor coil 130 to be accurately soldered to the PCB 123.

[0179] As described above, the second housing (coil support) 200 may further include an orientation mechanism 303. Referring to FIG. 14B, the orientation mechanism 303 may include a slot 410 extending in the axial direction. The slot can also extend in another direction. The slot 410 may be defined between a recess extending axially into the second rim 405 and / or a pair of spaced legs 411A, 411B extending axially from the second rim 405. The slot 410 may be disposed between the pair of protruding legs 406A, 407A described above. The slot 410 extends across the entire radial thickness of the coil holder 200. It is also possible for the slot to extend partially through the radial thickness of the coil holder 200.

[0180] Referring to FIG. 15, the slot may be configured to receive and engage a stopper in the form of a protrusion 500 provided on the second end support 230 so as to limit or prevent the movement and / or rotation of the second end support 230 with respect to the coil support 200. In particular, this engagement can be used to limit or prevent the rotation of the second end support 230 about the longitudinal axis 101. In some embodiments, the slot may be provided on the second end support 230, and the corresponding protrusion may be provided on the coil support 200.

[0181] Similarly, by providing an orienting mechanism, assembly can be facilitated and made more accurate. Further, once assembled, the orienting mechanism can limit or prevent unwanted movement of the second end support 230 relative to the coil support 200.

[0182] By providing an orienting mechanism, accurate alignment between the second end support 230 relative to the coil support 200 can be achieved, which can facilitate the provision of a sealed air path through the second end support 230 and the heater assembly 105.

[0183] At least one positioning mechanism and / or orienting mechanism may be integrally formed with the coil support 200, for example, by injection molding. Thus, at least one positioning mechanism and / or orienting mechanism can be formed from the same material as the coil support 200.

[0184] In an embodiment, at least one positioning mechanism and / or orienting mechanism is formed from a non-metallic material to assist in limiting interference with magnetic induction. In this particular example, at least one positioning mechanism and / or orienting mechanism is composed of polyetheretherketone (PEEK). Other suitable materials are possible. Such materials can ensure appropriate rigidity / robustness when the susceptor is heated. At least one positioning mechanism and / or orienting mechanism may be composed of an insulating or heat insulating material such as plastic.

[0185] Similarly, the second end support 230 including the protrusion 500 may be integrally formed from the same material such as PEEK, for example, by injection molding.

[0186] 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 and the outer surface of the susceptor 132 measured in a direction perpendicular to the axis 158.

[0187] In one example, the length of susceptor 132 is from about 30 mm to about 50 mm or from about 30 mm to about 35 mm. In a particular example, susceptor 132 has a length of about 34.8 mm and is capable of receiving article 110 containing the aerosol-generating material. Here, the aerosol-generating material has a length of about 42 mm. The lengths of the aerosol-generating material and susceptor 132 are measured in a direction parallel to axis 101.

[0188] Outer cover 102 protects the internal components of the device and generally comes into contact with the user's hand during use of the device. Outer cover 102 has an inner surface and an outer surface. The inner surface is disposed further away from susceptor 132 than the outer surface. A gap may be provided between the inner surface of outer cover 102 and the aerosol-generating assembly so that the device 100 does not become hot enough to be touched. In this example, the inner surface of outer cover 102 is disposed at a distance of between about 4 mm and about 10 mm from the outer surface of susceptor 132. In this particular example, the distance is about 5.3 mm.

[0189] In some examples, when the inductor coil is used for magnetic field induction, it may itself generate heat, for example, by resistive heating due to the passage of an electric current for magnetic field induction. Providing a heat insulation layer between the inductor coil and the outer cover helps to insulate the heated inductor coil from the outer cover. The ferrite shield helps to insulate the outer cover. It has been found that when the ferrite shield contacts and at least partially surrounds one or more inductor coils, the surface temperature of the outer cover can be reduced by about 3 °C.

[0190] The inner surface of the outer cover may be disposed at a distance of about 2 mm to about 3 mm from the outer surface of the heat insulation member. This separation distance of this size has been found to provide sufficient heat insulation so that the outer cover does not become too hot. Air may be present between the outer surface of the heat insulation member and the outer cover.

[0191] The inner surface of the outer cover may be disposed at a distance of about 0.2 mm to about 1 mm from the outer surface of the inductor coil.

[0192] The inner surface of the inductor coil may be arranged at a distance of about 3 mm to about 4 mm from the outer surface of the susceptor. In a specific example of this case, this distance is about 3.2 mm.

[0193] The outer cover may contain aluminum.

[0194] The outer cover may have a thermal conductivity of about 200 W / mK to about 220 W / mK. For example, the thermal conductivity of aluminum is around 209 W / mK.

[0195] The outer cover may have a thickness of about 0.75 mm to about 2 mm. The outer cover can act as a heat insulation barrier.

[0196] The susceptor 132, the barrier member 250, and the coil support 200 each have a circular cross-section, but the cross-section may be any other shape and, in some examples, may be different from each other.

[0197] The above-described embodiments are to be understood as exemplary examples of the present invention. Other embodiments of the present invention are also conceivable. 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 also in combination with one or more features of any other or any combination thereof of the embodiments. Further, equivalents and improvements not described above as defined in the appended claims can be employed without departing from the scope of the present invention.

Claims

1. a receptacle configured to receive an aerosol-generating material, the receptacle including a susceptor that is heatable by penetration of a varying magnetic field; a coil support extending around the susceptor; an inductor coil extending around the coil support, the inductor coil configured to generate a varying magnetic field; An end support provided at one end of the coil support; an air passage through the receptacle and the end support; 1. An aerosol delivery device comprising: An aerosol delivery device, wherein the coil support comprises an orientation mechanism configured to limit rotation of the end support relative to the coil support.

2. The aerosol delivery device of claim 1 , wherein the end support comprises a stopper configured to cooperate with the orientation mechanism to limit rotation of the end support relative to the coil support.

3. The aerosol delivery device of claim 2 , wherein the orientation mechanism comprises a slot and the stopper comprises a protrusion that engages the slot to limit rotation of the end support relative to the coil support.

Images