Aerosol generating device having an overmolded button

Abstract

The present invention relates to a method for assembling an aerosol generating device. The method includes providing a shell (10) for the aerosol generating device. The shell is configured to receive a frame assembly (16) therein. The frame assembly includes a push-activated switch. The method includes providing a through hole on a wall of the shell. The method includes securing a button (12) onto the shell to cover the through hole. The method includes inserting the frame assembly into the shell such that the button (12) is overlaid on the push-activated switch. The present invention further relates to an aerosol generating device.

Description

Technical Field

[0001] The present disclosure relates to a method for assembling an aerosol generating device. The present disclosure further relates to an aerosol generating device.

Background Art

[0002] It is known to provide an aerosol generating device for generating an inhalable vapor. Such a device may heat an aerosol-forming substrate contained in an aerosol-generating article without burning it. The aerosol-generating article may have a suitable shape for insertion into the heating chamber of the aerosol generating device. For example, the aerosol-generating article may have a rod shape. The heating element may be disposed in or around the heating chamber to heat the aerosol-forming substrate when the aerosol-generating article is inserted into the heating chamber of the aerosol generating device.

[0003] It is known to provide an aerosol generating device comprising an outer shell surrounding internal components housed within a shell. The internal components are, for example, components of a printed circuit board (PCB) comprising a heater assembly, a battery, and a push-start switch for operating the device.

[0004] It is known to provide a button that enables a user to operate a switch located within the outer shell. For example, the button may be fixed to the switch or may protrude outside the outer shell through a hole in the outer shell. Thus, when the user presses the button, the button presses the push-start switch.

Summary of the Invention

Problems to be Solved by the Invention

[0005] In some devices, the device architecture is such that the internal components are mounted on a frame assembly. The outer shell is arranged to enclose the inner frame assembly.

[0006] In an aerosol generating device comprising a frame assembly and an outer shell, it may sometimes be desirable for the wall of the outer shell to be very thin. A thin-walled shell may, for example, reduce material costs or may help to provide a lightweight and compact device.

[0007] To enable a compact architecture for the aerosol generating device, the design may be such that the inner frame fits very closely into the outer shell. Therefore, when the frame assembly is slid into the outer shell, there may be very little space between the frame assembly and the outer shell.

[0008] The assembly of an aerosol generating device comprising an inner frame assembly and an outer shell may include the step of inserting the frame assembly into the outer shell. Buttons may then be installed later in an additional step. For example, the buttons may be fixed to the frame assembly and may project through through-holes in the outer shell.

[0009] It is desirable to provide an aerosol generating device comprising a button for a user to operate a switch that can be assembled by inserting an inner frame into an outer shell. It is desirable to provide an aerosol generating device that is easy to assemble. It is desirable to provide an aerosol generating device that is a reproducible mechanical assembly.

[0010] It is desirable to provide an aerosol generating device that avoids or reduces the gap between a button and the wall of the outer shell adjacent to the button. It is desirable to provide an aerosol generating device with a watertight seal.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6A

Figure 6B

Figure 7

Mode for Carrying Out the Invention

[0012] According to an embodiment of the present invention, a method for assembling an aerosol generating device is provided. The method may include the step of providing an outer shell for the aerosol generating device. The outer shell may be configured to receive a frame assembly therein. The frame assembly may include a push - start switch. The method may include the step of providing a through - hole in the wall of the outer shell. The method may include the step of fixing a button on the outer shell to cover the through - hole. The method may include the step of inserting the frame assembly into the outer shell, whereby the button is superimposed on the push - start switch.

[0013] According to an embodiment of the present invention, a method for assembling an aerosol generating device is provided. The method includes the step of providing an outer shell for the aerosol generating device. The outer shell is configured to internally receive a frame assembly. The frame assembly includes a push - start switch. The method includes the step of providing a through - hole in the wall of the outer shell. The method includes the step of fixing a button on the outer shell to cover the through - hole. The method includes the step of inserting the frame assembly into the outer shell, whereby the button is superimposed on the push - start switch.

[0014] The button may be directly fixed on the outer shell. The step of fixing the button on the outer shell may be performed before the step of inserting the frame assembly into the outer shell. The frame assembly may be slidably inserted into the outer shell.

[0015] By fixing a button on the outer shell, the aerosol generating device can be assembled by inserting an inner frame into the outer shell. After installing the shell and the inner frame assembly, an additional step of fixing the button to the device is avoided. Thereby, a method may be provided that may enable easy assembly of the aerosol generating device. A method may be provided that may enable reproducible assembly of the aerosol generating device by a machine. By fixing a button on the outer shell of the button, the gap between the button and the wall of the outer shell adjacent to the button may be reduced or avoided. By reducing the gap, a watertight seal may be provided. By reducing the gap, a more optically appealing device may be provided.

[0016] The button may be fixed on the outer shell to cover the through hole so as to provide a watertight seal between the button and the outer shell. The seal may be watertight according to IPX7.

[0017] The outer shell may comprise a wall. The wall of the outer shell may comprise an outer surface and an opposite inner surface. The outer surface of the wall of the outer shell faces towards the outside of the aerosol generating device, and the inner surface of the wall of the outer shell faces towards the inside of the aerosol generating device. In the assembled state, the inner surface of the wall of the outer shell faces towards the frame assembly.

[0018] The wall of the outer shell may surround a hollow inner shape so as to receive the frame assembly. The wall of the inner shell may generally form a hollow cylindrical shape. At least one end face of the hollow cylinder formed by the wall of the outer shell may be at least partially open, whereby the frame assembly may be slidably inserted into the outer shell along the open end face.

[0019] The outer shell may comprise a hollow cylindrical shape. The frame assembly may comprise a cylindrical shape. The frame assembly may comprise a shape configured to closely fit within the outer shell.

[0020] The wall of the outer shell may be thin. The thickness of the wall of the outer shell may be 1 millimeter or less than 1 millimeter, for example, about 0.8 millimeters. A thin-walled shell may be provided, for example, to save material costs or to provide a lightweight and compact device.

[0021] The through hole may be a hole in the wall of the outer shell. The through hole may have a rounded shape.

[0022] The button may include a flexible material. For example, the button may include an elastomeric plastic material. The button may be deformable. For example, the button may be deformed when the user presses a finger thereon. The button may be deformed to activate in contact with a push-start switch.

[0023] The button may include an outer surface and an opposite inner surface. When the button is fixed on the outer shell, the outer surface of the button faces outward of the aerosol generating device, and the inner surface of the button faces inward of the aerosol generating device. The outer surface of the button may include protrusions or ridges to enable tactile feedback to the user. Therefore, the user may feel when the user's finger is in the correct position to press the button. More comfortable operation of the device may be possible.

[0024] The button may be permanently fixed on the outer shell. The button may be irreversibly fixed on the outer shell. A permanently or irreversibly fixed button may not be configured to be removed or reattached by the user.

[0025] The button may be directly fixed on the outer shell. Therefore, the button may be directly and permanently fixed to the outer shell.

[0026] The button may be fixed on the outer shell by a molding process.

[0027] By molding onto the outer shell of the button, the button may be fixed to the thin wall of the outer shell. By molding the button onto the outer shell, additional fixing means that may project in the direction towards the inside of the outer shell may be avoided. Thereby, it may be possible to insert the frame assembly into the outer shell, such that even when the design of the aerosol generating device is such that the inner frame fits very closely into the outer shell, the button may be superimposed on the push - activation switch.

[0028] The molding process may be an over - molding process. The molding process may be an injection over - molding process. The molding process may be a plastic injection over - molding process.

[0029] The molding process may include the step of positioning the outer mold 36 over the through - hole 20 from the outer side surface of the outer shell. The molding process may include the step of positioning the inner mold under the through - hole from the inner side of the outer shell. The molding process may include the step of injecting molten material into the cavity formed between the outer mold and the inner mold to form the button. The molten material may be injected through channels within the inner mold. Alternatively or additionally, the molten material may be injected through channels within the outer mold.

[0030] The method may include the step of providing a groove on the outer shell. The wall thickness of the outer shell may be reduced at the location of the groove. For example, the wall thickness of the outer shell may be reduced by about 10 percent to about 90 percent at the location of the groove. The wall thickness of the outer shell may be reduced by about 10 percent to about 30 percent at the location of the groove. The wall thickness of the outer shell may be reduced by about 70 percent to about 90 percent at the location of the groove. The wall thickness of the outer shell may be reduced by about 30 percent to about 70 percent, preferably about 40 percent to about 60 percent at the location of the groove.

[0031] The thickness of the outer shell wall may be 0.2 millimeters to 0.7 millimeters, preferably 0.3 millimeters to 0.5 millimeters, at the position of the groove.

[0032] The groove may be provided on the inside of the outer shell wall. The groove may be provided on the outside of the outer shell. The groove may be provided on the outer side surface of the outer shell wall. The groove may be provided around the periphery of the through hole. The button may be fixed on the groove of the outer shell.

[0033] The groove may be provided by machining.

[0034] The method may include a step of providing a corrugated holding structure on the groove before fixing the button on the groove. The corrugated surface structure may be a roughened portion of the surface of the outer shell wall at the position of the groove.

[0035] The corrugated holding structure may comprise a pitch pattern.

[0036] The pitch pattern may have a grid shape with a square pitch. The side length of the square pitch may be 0.1 millimeter to 0.4 millimeters, preferably about 0.2 millimeters. The grid grooves between the pitches may have a depth of at least 0.03 millimeters, for example, 0.03 millimeters to 0.10 millimeters. The pitch pattern may have a grid shape with a square pitch of about 0.2 millimeter side length separated by grid grooves with a depth of at least 0.03 millimeters.

[0037] The corrugated holding structure may be provided by a laser engraving process.

[0038] The method may include a step of applying an adhesive on the surface of the groove before fixing the button on the groove. The method may include a step of applying an adhesive on the corrugated holding structure before fixing the button on the groove.

[0039] The adhesive may be applied by a spray process.

[0040] The adhesive may be a one - coat adhesive composed of a mixture of a polymer, a curing agent, and a pigment dissolved in an organic solvent system.

[0041] The adhesive may contain about 50% - 55% methyl ethyl ketone, about 20% - 25% epoxy resin, about 11% - 20% ester solvent, about 10% - 15% xylene, about 1% - 5% ethylbenzene, and about 0.1% - 0.9% silane monomer.

[0042] The adhesive may be Chemlok® 213 adhesive available from LORD Corporation.

[0043] The outer shell and the button may include different materials. The outer shell may be made of a rigid material, and the button may be made of a flexible material. The outer shell may include metal, preferably aluminum. The button may include a plastic material, preferably a thermoplastic material, more preferably thermoplastic polyurethane. The outer shell may be made of metal, and the button may be made of plastic. The outer shell may be made of aluminum, and the button may be made of thermoplastic polyurethane.

[0044] For example, the button may be fixed on the outer shell by a molding process, the outer shell may include metal, and the button may include a plastic material. For example, the button may be fixed on the outer shell by a molding process, the outer shell may be made of metal, and the button may be made of a plastic material.

[0045] As described herein, fixing a button on a groove of an outer shell, preferably by molding, may additionally improve the connection durability of a plastic button fixed to a metal outer shell. As described herein, providing a corrugated retaining structure on a groove of an outer shell may additionally improve the connection durability of a plastic button fixed to a metal outer shell. As described herein, providing an adhesive on a corrugated retaining structure on a groove of an outer shell may additionally improve the connection durability of a plastic button fixed to a metal outer shell.

[0046] The button may be disposed on the same plane as the inner surface of the wall of the outer shell. The inner surface of the button may be disposed on the same plane as the inner surface of the wall of the outer shell. This may facilitate the smooth insertion of the frame assembly into the outer shell.

[0047] The button may be disposed on the same plane as the outer surface of the wall of the outer shell. The outer surface of the button may be disposed on the same plane as the outer surface of the wall of the outer shell.

[0048] As used herein, the term "on the same plane" means that the button is at the same height as the wall of the outer shell. Therefore, the button may fill a through hole in the wall of the outer shell without further protruding towards one or both of the inside and outside of the outer shell.

[0049] The button may be disposed on the same plane as the wall of the outer shell, apart from a central protrusion of the button on the outer surface of the outer shell. The protrusion may function to provide tactile feedback that can be sensed tactilely by the user.

[0050] Using a molding process as described herein may be particularly advantageous for achieving the disposition of the button and the wall of the outer shell on the same plane.

[0051] The method may include a step of firmly attaching the frame assembly inside the outer shell after the step of inserting the frame assembly into the outer shell. The frame assembly may be firmly attached inside the outer shell by screwing a retaining element to the insertion end of the outer shell.

[0052] The aerosol generating device preferably comprises control electronics for controlling the operation of the aerosol generating device. The control electronics may be provided on a printed circuit board (PCB). The control electronics may be connected to a push - start switch. The control electronics may be configured to change the operating state of the aerosol generating device based on a signal received from the push - start switch.

[0053] The frame assembly may comprise the control electronics of the aerosol generating device.

[0054] For example, the push - start switch may be a toggle switch, a press switch, or may utilize a capacitance sensor.

[0055] The aerosol generating device preferably comprises a heater assembly for heating the aerosol - forming substrate. The heater assembly may be an electric heater assembly. The electric heater assembly may comprise a resistive heating element. The electric heater assembly may utilize induction heating and may also comprise an induction coil and a susceptor.

[0056] The frame assembly may comprise at least a part of the heater assembly of the aerosol generating device. The frame assembly may comprise a resistive heating element. The frame assembly may comprise an induction coil and a susceptor. The frame assembly may comprise an induction coil, and the susceptor may be part of an aerosol - forming article used with the aerosol generating device.

[0057] The aerosol generating device preferably comprises a power source configured to supply power to the heater. The power source preferably comprises a power supply. The power supply is preferably a battery such as a lithium-ion battery. Alternatively, the power supply may be another form of charge storage device such as a capacitor. The power supply may need to be recharged. For example, the power supply may have a capacity sufficient to enable continuous generation of aerosol for approximately one-sixth, or a multiple of one-sixth, of a period. In another embodiment, the power supply may have a capacity sufficient to enable a predetermined number of smoking sessions, or discontinuous activation of the heater assembly.

[0058] The power supply may comprise control electronics. The control electronics may comprise a microcontroller. The microcontroller is preferably a programmable microcontroller. The electrical circuit may further comprise additional electronic components. The electrical circuit may be configured to regulate the supply of power to the heater assembly. The power may be supplied continuously to the heater assembly after activation of the system, or intermittently (such as for each smoking session). The power may be supplied to the heater assembly in the form of pulses of current.

[0059] The frame assembly may comprise the power source of the aerosol generating device.

[0060] A method for assembling an aerosol generating device may comprise the following steps in the following order. First, provide an outer shell for the aerosol generating device. Second, provide a through hole in the wall of the outer shell. Third, provide a groove on the outside of the outer shell around the periphery of the through hole, and optionally, provide a corrugated retaining structure on the surface of the groove, and optionally, provide glue on the corrugated retaining structure. Fourth, fix a button over the through hole on top of the groove of the outer shell. The button is preferably fixed on top of the groove by a molding process. Fifth, insert the frame assembly into the outer shell, whereby the button is superimposed on the push activation switch of the frame assembly.

[0061] According to an embodiment of the present invention, an aerosol generating device can be obtained by the method as described in this specification.

[0062] According to an embodiment of the present invention, an aerosol generating device comprising an outer shell and a frame assembly is provided. The outer shell comprises a button extending across a through-hole of the outer shell. The button is directly fixed on the outer shell. The frame assembly comprises a push start switch. The frame assembly is slidably inserted into the outer shell, whereby the button is superimposed on the push start switch.

[0063] The outside of the outer shell may comprise a groove around the periphery of the through-hole. The groove may comprise a laser engraving pattern. Adhesive may be applied on the laser engraving pattern. The button may be molded on the groove.

[0064] As used herein, the term "aerosol-forming substrate" refers to a substrate having the ability to release a volatile compound capable of forming an aerosol. The volatile compound may be released by heating or burning the aerosol-forming substrate. As an alternative to heating or burning, in some cases, the volatile compound may be released by a chemical reaction or by a mechanical stimulus such as ultrasonic waves. The aerosol-forming substrate may be solid or liquid, or may comprise both solid and liquid components. The aerosol-forming substrate may be part of an aerosol-generating article.

[0065] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate having the ability to release a volatile compound capable of forming an aerosol. The aerosol-generating article may be disposable. An aerosol-generating article comprising an aerosol-forming substrate containing tobacco may be referred to herein as a tobacco stick in some cases.

[0066] As used herein, the term "aerosol generating device" refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol generating device may interact with one or both of an aerosol generating article comprising an aerosol-forming substrate and a cartridge comprising an aerosol-forming substrate. In some embodiments, the aerosol generating device may heat the aerosol-forming substrate to facilitate the release of volatile compounds from the substrate. An electrically-operated aerosol generating device may comprise an atomizer, such as an electric heater, for heating the aerosol-forming substrate to form an aerosol.

[0067] As used herein, the term "aerosol generating system" refers to a combination of an aerosol generating device and its aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol generating article, the aerosol generating system refers to the combination of the aerosol generating device and the aerosol generating article. In an aerosol generating system, the aerosol-forming substrate and the aerosol generating device cooperate to generate an aerosol.

[0068] The following is a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more of the features of another example, embodiment, or aspect described herein.

[0069] [Example A] A method of assembling an aerosol generating device, comprising: providing a housing for the aerosol generating device, the housing being configured to receive therein a frame assembly comprising a push-start switch; providing a through-hole in the wall of the housing; fixing a button on the housing to cover the through-hole; inserting the frame assembly into the housing such that the button overlays the push-start switch.

[0070] [Example B] The method of Example A, wherein the step of fixing the button onto the outer shell is before the step of inserting the frame assembly into the outer shell.

[0071] [Example C] The method of Example A or Example B, wherein the button is fixed onto the outer shell by a molding process.

[0072] [Example D] The method of Example C, wherein the molding process is an injection overmolding process, preferably a plastic injection overmolding process.

[0073] [Example E] The molding process is a step of positioning an outer mold over the through hole from the outer side surface of the outer shell, and a step of positioning an inner mold under the through hole from the inner side of the outer shell, and a step of injecting molten material through a channel in the inner mold into a cavity formed between the outer mold and the inner mold to form the button, the method of Example D.

[0074] [Example F] including a step of providing a groove on the outside of the outer shell around the periphery of the through hole, The method of any of the preceding examples, wherein the button is fixed over the groove of the outer shell.

[0075] [Example G] The method of Example F, wherein the groove is provided by machining.

[0076] [Example H] The method of Example F or Example G, including a step of providing a corrugated retaining structure over the groove before fixing the button over the groove.

[0077] [Example I] The method of Example H, wherein the corrugated retaining structure includes a pitch pattern.

[0078] [Example J] The method of Example I, wherein the pitch pattern comprises a grid pattern of square pitches with a side length of about 0.2 millimeters separated by grooves with a depth of at least 0.03 millimeters.

[0079] [Example K] The method according to any one of Examples H to J, wherein the holding structure of the waveform is provided by a laser engraving process.

[0080] [Example L] The method according to any one of Examples H to K, including the step of applying an adhesive onto the holding structure of the waveform before fixing the button over the groove.

[0081] [Example M] The method according to Example L, wherein the adhesive is applied by a spray process.

[0082] [Example N] The method according to Example L or Example M, wherein the adhesive is a one - coat adhesive composed of a mixture of a polymer dissolved in an organic solvent system, a curing agent, and a pigment.

[0083] [Example O] The method according to Example N, wherein the adhesive contains about 50% - 55% methyl ethyl ketone, about 20% - 25% epoxy resin, about 11% - 20% ester solvent, about 10% - 15% xylene, about 1% - 5% ethyl benzene, and about 0.1% - 0.9% silane monomer.

[0084] [Example P] The method according to any of the preceding examples, wherein the outer shell and the button contain different materials, preferably one or both of the outer shells contain metal, preferably aluminum, and the button contains plastic, preferably thermoplastic polyurethane.

[0085] [Example Q] The method according to any of the preceding examples, wherein the button is arranged on the same plane as the inner surface of the wall of the outer shell to facilitate smooth insertion of the button into the outer shell of the frame assembly.

[0086] [Example R] The method of Example Q, wherein the button is disposed on the same plane as the wall of the outer shell, except for a central ridge on the outer surface of the outer shell that enables tactile feedback perceivable by touch.

[0087] [Example S] A method according to any of the preceding examples, wherein the outer shell has a hollow cylindrical shape and the frame assembly includes a cylindrical shape.

[0088] [Example T] A method according to any of the preceding examples, wherein the wall thickness of the outer shell is less than about 1 millimeter.

[0089] [Example U] A method according to any of the preceding examples, including the step of firmly attaching the frame assembly within the outer shell, preferably by screwing a retaining element to the insertion end of the outer shell, after the step of inserting the frame assembly into the outer shell.

[0090] [Example V] A method according to any of the preceding examples, wherein the button is fixed on the outer shell to cover the through hole so as to provide an IPX7-compliant watertight seal between the button and the outer shell.

[0091] [Example W] An aerosol generating device obtainable by the method of any of the preceding examples.

[0092] [Example X] An aerosol generating device, an outer shell comprising a button extending across a through hole of the outer shell, the button being directly fixed on the outer shell, and a frame assembly comprising a push-activation switch, the frame assembly being slidably inserted into the outer shell, thereby overlaying the button on the push-activation switch.

[0093] [Embodiment Y] An aerosol generating device according to Example X, wherein the outside of the outer shell has a groove around the periphery of the through hole, the groove has a laser engraving pattern, glue is applied on the laser engraving pattern, and a button is molded on the groove.

[0094] Features described with respect to one embodiment may equally apply to other embodiments of the present invention.

[0095] The present invention will be further described with reference to the accompanying drawings, by way of illustration only.

[0096] FIG. 1 shows a part of the outer shell 10 of the aerosol generating device. The button 12 is fixed on the wall 14 of the outer shell 10. The button 12 has a central protrusion on the outer surface of the outer shell 10. The central protrusion provides tactile feedback that can be sensed tactilely for the user.

[0097] FIG. 2 schematically shows a frame assembly 16 inserted into the outer shell 10. The arrow indicates the slidable insertion of the frame assembly 16 into the outer shell 10. The frame assembly 16 generally has a cylindrical shape. The outer shell 10 has a corresponding shape of a hollow cylinder with an open end that allows the frame assembly 16 to be slidably inserted into the outer shell 10. In particular, the battery component 18 may be a component of the frame assembly 16 with strict location requirements. To enable a compact architecture of the aerosol generating device, the battery component 18 of the frame assembly 16 fits very closely into the outer shell 10. Therefore, when the frame assembly 16 is slid into the outer shell 10, there is very little space between the frame assembly 16 and the outer shell 10. The button 12 fixed to the outer shell 10 is disposed in the same plane as the inner surface of the wall 14 of the outer shell 10. Thereby, smooth insertion of the frame assembly 16 into the outer shell 10 is enabled.

[0098] Figure 3 shows the through-hole 20 of the outer shell 10. A groove 22 is provided on the outside of the outer shell 10. The groove 22 is provided on the outer side surface of the wall 14 of the outer shell 10. The groove 22 is provided around the periphery of the through-hole 20. A button (not shown) may be fixed on the groove of the outer shell 10.

[0099] Figure 4 shows a part of an aerosol generator in which a frame assembly is inserted into the outer shell. The groove 22 on the outer wall 14 of the outer shell is provided around the through-hole. For illustrative purposes, the button is not shown. The printed circuit board 24 is part of the inserted frame assembly and is also visible through the open through-hole. The printed circuit board 24 includes a push-start switch 26.

[0100] Figure 5 shows a part of the frame assembly 16 including a push-start switch 26 and a movable plunger 28. The plunger 28 includes a button contact area 30 for contacting a button (not shown) of the outer shell when the frame assembly 16 is inserted into the outer shell. The plunger 28 further includes a switch contact area 32 for contacting the push-start switch 26 when the movable plunger 28 is pushed downward when the user presses on the button fixed on the outer shell. The plunger 28 includes two legs 34. The plunger 28 is mounted on the frame assembly 16 having two legs 34 to create a spring force to automatically return the plunger 28 and thus the button after being pushed down by the user.

[0101] Figure 6A schematically shows the setup of an injection molding process. The molding process includes positioning an outer mold 36 over a through hole 20 from the outer side surface of the outer shell 10. The molding process includes positioning an inner mold 38 under the through hole 20 from the inside of the outer shell 10. The through hole 20 and the groove 22 in the wall 14 of the outer shell 10 are located between the outer mold 36 and the inner mold 38. The arrow indicates the injection path of the molten material through a channel in the inner mold 36. Alternatively or additionally, the channel for injecting the molten material may be in the outer mold 38. Therefore, the molding button 12 will be fixed over the groove 22 as shown in Figure 6B.

[0102] Using the setup of Figure 6A, the molding button 12 shown in Figure 6B is disposed on the same plane as the inner surface of the wall 14 of the outer shell 10 to facilitate smooth insertion of the button 12 into the outer shell 10 of a frame assembly (not shown). Also, the groove 22 may further enable improving the durable connection between the button 12 and the outer shell 10.

[0103] The outer mold 38 of Figure 6A additionally includes a recess 40. Thereby, as shown in Figure 6B, a central bulge 42 of the button 12 on the outer surface of the wall 14 of the outer shell 10 is provided. The central bulge 42 may enable tactile feedback that can be sensed tactilely.

[0104] Figure 7 shows a portion of the outer shell 10 with a corrugated retaining structure provided over the groove 22 before fixing a button over the groove 22.

[0105] The corrugated retaining structure includes a laser engraved pitch pattern. The pitch pattern includes a grid shape of square pitches with a side length of about 0.2 millimeters separated by grooves with a depth of at least 0.03 millimeters.

[0106] The waveform holding structure may additionally improve the durability of the connection between the button (not shown) and the outer shell 10 when the button is fixed to the groove 22 by the molding process. Optionally, the durability of the connection between the button and the outer shell 10 may be further improved by spraying an adhesive onto the laser engraved pitch pattern before molding the button over the groove 22.

Claims

1. A method of assembling an aerosol generating device, comprising: providing an outer shell for the aerosol generating device, the outer shell being configured to receive therein a frame assembly having a push activation switch; providing a through hole in a wall of the outer shell; providing a groove on an outer side of the outer shell around a periphery of the through hole; fixing a button on the outer shell to cover the through hole; inserting the frame assembly into the outer shell, whereby the button is superimposed on the push activation switch; wherein the button is fixed on the groove of the outer shell.

2. The method according to claim 1, wherein the button is fixed on the outer shell by a molding process, preferably an injection overmolding process, more preferably a plastic injection overmolding process.

3. The method according to claim 1 or claim 2, wherein the step of fixing the button on the outer shell is performed before the step of inserting the frame assembly into the outer shell.

4. The molding process comprises: positioning an outer mold on the through hole from an outer side surface of the outer shell; positioning an inner mold under the through hole from an inner side of the outer shell; injecting molten material through a channel in the inner mold into a cavity formed between the outer mold and the inner mold to form the button, the method according to claim 3, which depends on claim 2.

5. The method according to claim 1, comprising providing a corrugated retaining structure on the groove before fixing the button on the groove.

6. The method according to claim 5, wherein the holding structure of the waveform has a pitch pattern, and the pitch pattern includes a grid shape of a square pitch with a side length of about 0.2 millimeters separated by grooves having a depth of at least 0.03 millimeters.

7. The method according to claim 5 or 6, wherein the holding structure of the waveform is provided by a laser engraving process.

8. The method according to claim 5 or 6, including the step of applying an adhesive onto the holding structure of the waveform before fixing the button onto the groove.

9. The method according to claim 1, wherein the outer shell and the button include different materials, preferably, one or both of the outer shells include metal, preferably aluminum, and the button includes plastic, preferably thermoplastic polyurethane.

10. The method according to claim 1, wherein the button is disposed on the same plane as the inner surface of the wall of the outer shell to facilitate smooth insertion of the button into the outer shell of the frame assembly.

11. The method according to claim 10, wherein the button is disposed on the same plane as the wall of the outer shell, apart from a central ridge on the outer surface of the outer shell for enabling tactile feedback that can be sensed tactilely.

12. The method according to claim 1, wherein the button is fixed onto the outer shell to cover the through hole so as to provide a watertight seal conforming to IPX7 between the button and the outer shell.

13. An aerosol generating device, The outer shell having a button extending across a through hole of the outer shell, wherein the button is directly fixed onto the outer shell, and the outer shell, A frame assembly having a push-start switch, wherein the frame assembly is slidably inserted into the outer shell, thereby overlaying the button on the push-start switch, and a frame assembly. An aerosol generator, wherein an outer side of the outer shell has a groove around a periphery of the through hole, and the button is fixed on the groove of the outer shell.

14. The aerosol generator according to claim 13, wherein the groove has a laser engraving pattern, glue is applied on the laser engraving pattern, and the button is formed on the groove.

Images