Fabrication of aerosol generating device heater elements

Abstract

To provide a novel method of manufacturing an aerosol generation system heater element.SOLUTION: The aerosol generation system heater element comprises a seamless hollow tube. The method according to the present invention comprises deforming a wall of a hollow tube to form the seamless hollow tube, where the seamless hollow tube has a deformed wall, where the deformed wall of the seamless hollow tube is thinner than the wall of the hollow tube.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to aerosol generating systems and the manufacture of aerosol generating system heater elements. [Background technology]

[0002]

[0002] Smoking articles such as cigarettes, cigars, and the like burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion.

[0003]

[0003] An example of such an article is a heating device that releases a compound by heating the material without burning it. The material can be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Heating the tobacco or non-tobacco product can volatilize at least one component of the tobacco or non-tobacco product to form an aerosol that can typically be inhaled, without burning or combusting the tobacco or non-tobacco product.

[0004] Heating devices that heat tobacco or non-tobacco products are sometimes referred to as "non-combustion heating" devices or "tobacco heating products" (THPs) or "tobacco heating devices." Various configurations have been attempted to volatilize at least one component of the tobacco or non-tobacco product. Summary of the Invention

[0005]

[0005] A first aspect of the present invention provides a method for manufacturing an aerosol generation system heater element comprising a seamless hollow tube, the method comprising a step of deforming a wall of the hollow tube to form a seamless hollow tube, the seamless hollow tube having a deformed wall, the deformed wall of the seamless hollow tube being thinner than the wall of the hollow tube.

[0006]

[0006] In one embodiment, the wall of the hollow tube has a first cross-sectional internal perimeter and the deformed wall of the seamless hollow tube has a second cross-sectional internal perimeter that is at least as long as the first cross-sectional internal perimeter.

[0007] In one embodiment, the deformed wall of the seamless hollow tube has a second inner cross-sectional circumference that is longer than the first inner cross-sectional circumference.

[0008] In one embodiment, the seamless hollow tube has a substantially circular cross section.

[0009] In one embodiment, the step of deforming the wall of the hollow tube includes hydroforming the hollow tube to expand the first cross-sectional inner circumference of the hollow tube.

[0010] In one embodiment, the step of deforming the wall of the hollow tube includes swaging the hollow tube over a mandrel.

[0011] In one embodiment, the step of deforming the wall of the hollow tube includes swaging the hollow tube by drawing the hollow tube through a mold.

[0012] In one embodiment, the step of deforming the wall of the hollow tube includes rotary swaging the hollow tube.

[0013] In one embodiment, the step of deforming the wall of the hollow tube includes ironing the wall of the hollow tube through at least one ironing die.

[0014] In one embodiment, the hollow tube is formed by deep drawing a blank of sheet material.

[0015] In one embodiment, the hollow tube comprises a metallic material.

[0016]

[0016] In one embodiment, the metal material is selected from at least one of iron, iron alloy, stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloy, gold, copper, cupronickel alloy, iron-chromium-aluminum alloy, nickel aluminide alloy.

[0017] A second aspect of the present invention provides a method of manufacturing an aerosol generating system heater element comprising a seamless hollow tube, the method comprising the step of coating an inner surface of a hollow tubular substrate with a metal layer.

[0018] In one embodiment, the method includes extruding a hollow tubular substrate.

[0019] In one embodiment, the hollow tubular substrate comprises a ceramic material.

[0020] In one embodiment, the hollow tubular substrate includes air channels between the inner surface of the hollow tubular substrate and the outer surface of the hollow tubular substrate.

[0021] In one embodiment, the hollow tubular substrate is a cylindrical tube and has a circular cross section.

[0022] In one embodiment, the coating step includes electroplating a metal layer onto the interior surface of the hollow tubular substrate.

[0023] In one embodiment, the coating step includes physical vapor deposition of a metal layer on the interior surface of the hollow tubular substrate.

[0024] In one embodiment, the coating step includes chemical vapor deposition of a metal layer on the interior surface of the hollow tubular substrate.

[0025] In one embodiment, the coating step includes thermally spraying a metal layer onto the inner surface of the hollow tubular substrate.

[0026]

[0026] In one embodiment, the metal layer comprises a metal material selected from at least one of iron, iron alloy, stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloy, gold, copper, cupronickel alloy, iron-chromium-aluminum alloy, and nickel aluminide alloy.

[0027] A third aspect of the present invention provides an aerosol generation system heater element manufactured by a method according to the first aspect of the present invention or manufactured by a method according to the second aspect of the present invention.

[0028]

[0028] A fourth aspect of the present invention provides an aerosol generation system heater element comprising a seamless hollow tube, the seamless hollow tube having a wall thickness of about 100 μm or less.

[0029]

[0029] In one embodiment, the seamless hollow tube comprises a metallic material selected from at least one of iron, iron alloy, stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloy, gold, copper, cupronickel alloy, iron-chromium-aluminum alloy, and nickel aluminide alloy.

[0030]

[0030] A fifth aspect of the present invention provides an aerosol generation system heater element comprising a seamless hollow tube, the seamless hollow tube comprising a metal layer coated on the inner surface of a hollow tubular substrate.

[0031] In one embodiment, the metal layer has a thickness of about 100 μm or less.

[0032]

[0032] In one embodiment, the metal layer comprises a metal material selected from at least one of iron, iron alloy, stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloy, gold, copper, cupronickel alloy, iron-chromium-aluminum alloy, and nickel aluminide alloy.

[0033]

[0033] A sixth aspect of the present invention provides an aerosol generation device comprising an aerosol generation system heater element according to the third, fourth or fifth aspect of the present invention, wherein the aerosol generation system heater element at least partially defines a receiving portion for receiving an aerosol-forming consumable.

[0034] In one embodiment, the aerosol generating device comprises a system for causing heating of the aerosol generating system heater element.

[0035]

[0035] A seventh aspect of the present invention provides an aerosol generation system comprising an aerosol generation device according to the sixth aspect of the present invention and at least one aerosol-forming consumable, wherein the at least one aerosol-forming consumable is shaped and dimensioned to be receivable within the receiving portion.

[0036]

[0036] An eighth aspect of the present invention provides an aerosol-forming consumable comprising an aerosolizable material and an aerosol generation system heater element according to the third, fourth or fifth aspect of the present invention.

[0037] In one embodiment, the aerosol generating system heater element at least partially supports the aerosolizable material.

[0038]

[0038] A ninth aspect of the present invention provides an aerosol generating device comprising a receiving portion configured to receive an aerosol forming consumable according to the eighth aspect of the present invention, and the aerosol generating device comprising a system for causing heating of an aerosol generating system heater element of the aerosol forming consumable.

[0039]

[0039] A tenth aspect of the present invention provides an aerosol generation system comprising an aerosol generation device according to the ninth aspect of the present invention and at least one aerosol-forming consumable according to the eighth aspect of the present invention.

[0040]

[0040] An eleventh aspect of the present invention provides an aerosol generation system comprising an aerosol-forming consumable, an aerosol generation system heater element according to the third, fourth or fifth aspect of the present invention, and an aerosol generation device comprising a receiving portion configured to receive the aerosol-forming consumable and a system for causing heating of the aerosol generation system heater element.

[0041]

[0041] Additional features and advantages will become apparent from the following detailed description of specific examples that proceed with reference to the accompanying drawings.

[0042]

[0042] Specific examples will now be described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0043] [Figure 1] FIG. 1 is a schematic diagram of an example aerosol generation system. [Figure 2] 1 is a schematic diagram of an example of an aerosol generation system heater element and an aerosol-forming consumable of an aerosol generating device. FIG. [Figure 3] 1 is a schematic diagram of an example of an aerosol-forming consumable comprising an aerosol generation system heater element and an aerosolizable material. FIG. [Figure 4] FIG. 1 is a schematic diagram of an example aerosol generation system. [Figure 5] FIG. 1 is a schematic diagram of an example aerosol generation system. [Figure 6] FIG. 1 is a schematic diagram of an example aerosol generation system. [Figure 7A] FIG. 1 is a schematic diagram of a hollow tube. [Figure 7B] FIG. 1 is a schematic diagram of an example of an aerosol generation system heater element comprising a seamless hollow tube. [Figure 8] FIG. 1 is a schematic diagram of a hollow tube in the process of being drawn through a die. [Figure 9] 1 is a schematic diagram of the rotary swaging process of a hollow tube. [Figure 10] FIG. 1 is a schematic diagram of a hollow tube undergoing hydroforming. [Figure 11] 1 is a schematic diagram of a hollow tube being stamped through an ironing die. [Figure 12] FIG. 1 is a schematic diagram of an example of an aerosol generation system heater element. DETAILED DESCRIPTION OF THE INVENTION

[0044]

[0055] The tobacco and / or non-tobacco product from which at least one component is to be volatilized may be referred to as an aerosolizable material. An "aerosolizable material" is any suitable material capable of generating an aerosol. In certain instances, the aerosol generated from the aerosolizable material may be generated by applying heat to the aerosolizable material.

[0045]

[0056] In certain instances, the aerosolizable material may be a solid. In certain instances, the aerosolizable material may include a foam. In certain instances, the aerosolizable material may include a gel.

[0046]

[0057] In certain examples, the aerosolizable material may be a tobacco material. In certain examples, the aerosolizable material may include a nicotine source or may not include a tobacco material. In certain examples, the aerosolizable material may include a tobacco material and a separate nicotine source. In certain examples, the aerosolizable material may not include a nicotine source. In certain examples, the aerosolizable material may include a flavoring.

[0047]

[0058] In examples where the aerosolizable material includes a gel, the gel may include a nicotine source. In some examples, the gel may include a tobacco material. In some cases, the gel may include a tobacco material and a separate nicotine source. For example, the gel may additionally include powdered tobacco and / or nicotine and / or tobacco extract.

[0048]

[0059] In certain instances where the aerosolizable material comprises a gel, the gel may comprise a gelling agent. The gelling agent may comprise a hydrocolloid. In certain instances where the aerosolizable material comprises a gel, the gel may comprise a hydrogel. The gel may additionally comprise a solvent.

[0049]

[0060] In certain examples, when the aerosol is generated from heating an aerosolizable material, the aerosolizable material may be heated to a temperature of from about 50°C to about 250°C or 300°C.

[0050]

[0061] It should be noted that, in general, a vapor is a substance that is in the gas phase at a temperature below its critical temperature, meaning that the vapor can be condensed into a liquid, for example, by increasing the pressure without reducing the temperature. On the other hand, in general, an aerosol is a colloid of fine solid particles or liquid droplets in air or another gas. A colloid is a substance in which microscopically dispersed insoluble particles are suspended throughout another substance.

[0051]

[0062] For convenience, the term "aerosol" as used herein should be taken to mean an aerosol, a vapor, or a combination of an aerosol and a vapor.

[0052]

[0063] As used herein, the term "aerosolizable material" may, in certain instances, include an "aerosol-generating agent," which refers to an agent that facilitates the generation of an aerosol. For example, if the aerosolizable material includes a gel, the gel may include an aerosol-generating agent. The aerosol-generating agent may facilitate the generation of an aerosol by promoting the initial evaporation and / or condensation of a gas into an inhalable solid and / or liquid aerosol.

[0053]

[0064] Suitable aerosol generating agents include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol; monohydric alcohols; high-boiling hydrocarbons; acids such as lactic acid; glycerol derivatives; diacetin, triacetin, triethylene glycol diacetate; triethyl citrate; or myristates, including ethyl myristate and isopropyl myristate; and non-polyols such as esters, such as aliphatic carboxylic acid esters, including methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. The aerosol generating agent may suitably have a composition that does not dissolve menthol. The aerosol generating agent may suitably comprise, consist essentially of, or consist of glycerol.

[0054]

[0065] As used herein, the term "aerosolizable material" may, in certain instances, include "flavoring," which is a material that imparts flavor to the aerosol generated. As used herein, the term "flavoring" may be used to produce a desired flavor or scent in products intended for adult consumers, where local regulations permit.

[0055]

[0066] The term "flavoring" includes extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, peppermint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cinnamon bark, caraway, cognac, jasmine, jasmine, jasmine, jasmine) and other aromatic compounds (e.g., jasmine, jasmine, jasmine)). The additives may include other additives such as mint oils (mint, ylang-ylang, sage, fennel, bell pepper, ginger, anise, coriander, coffee, or mint oil derived from any species of mint), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame K, aspartame, saccharin, cyclamate, lactose, saccharose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. These additives may be simulated, synthetic, or natural ingredients, or mixtures thereof. These additives may be in any suitable form, such as, for example, an oil, liquid, or powder. The flavoring may suitably include one or more mint flavorings and may suitably include mint oil derived from any species of mint. The flavoring may suitably include, consist essentially of, or consist of menthol.

[0056]

[0067] As used herein, the term "tobacco material" therefore refers to any material containing tobacco or a tobacco derivative. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract.

[0057]

[0068] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental. The tobacco material may also be other processed stem materials, such as tobacco particle "fines" or powder, expanded stems, and cut and rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may include tobacco fiber and may be formed by casting, a Fourdrinier process with post-addition of tobacco extract, or extrusion.

[0058]

[0069] An aerosolizable material including any or any combination of the above-described features and characteristics may be provided as a consumable. The consumable may be referred to as an aerosol-forming consumable that includes an aerosolizable material capable of generating an aerosol. In some examples, the aerosol-forming consumable may include other materials and components in addition to the aerosolizable material. For example, the aerosol-forming consumable may include a substrate on which the aerosolizable material is supported. For example, the aerosol-forming consumable may include a handling feature that allows a user to handle the aerosol-forming consumable without touching the aerosolizable material of the aerosol-forming consumable.

[0059]

[0070] Figure 1 schematically illustrates an exemplary aerosol generation system 1 for generating an aerosol from an aerosol-forming consumable 100. The aerosol-forming consumable may be receivable by an aerosol-generating device 10 of the aerosol generation system 1. Figure 1 may be considered a cross section through the aerosol generation system 1. The aerosol-forming consumable 100 may be an example of an aerosol-forming consumable that includes an aerosolizable material as described above.

[0060]

[0071] The aerosol generating device 10 may include a housing 12 for supporting and holding various components of the device 10. In certain examples, the aerosol generating device 10 may include a mouthpiece 20 through which a user of the device 10 can inhale the aerosol generated by the device 10. In certain examples, the aerosol generating device 10 may include an intake port 30 through which air is drawn when a user inhales the aerosol generated by the device 10. In the example shown in FIG. 1 , when a user inhales, air may be drawn in the direction of arrow A, and the user may inhale the aerosol in the direction of arrow B. In other examples, the aerosol generating device 10 may not include a mouthpiece. For example, a user of the device 10 may inhale the aerosol generated by the device 10 from the aerosol-forming consumable 100 itself.

[0061]

[0072] The aerosol generating device 10 may include a receptacle 40. The receptacle 40 may be configured to receive, during use, an aerosol-forming consumable 100, such as the examples described above. The receptacle 40 may include an opening for receiving the aerosol-forming consumable 100. The aerosol-forming consumable 100 may be shaped to fit into the receptacle 40. In certain examples, the aerosol-forming consumable 100 may be a rod, stick, or pod that corresponds to the interior shape of the receptacle 40. The receptacle 40 may be configured to allow air to pass from the inlet 30 through the receptacle 40 and out to the mouthpiece 20 when a user inhales. The air passing through the receptacle 40 may capture any aerosol being generated from the aerosol-forming consumable 100 before it enters the user's mouth as the user inhales.

[0062]

[0073] The aerosol generation system 1 may include an aerosol generation system heater element 200. The aerosol generation device system 1 may include a plurality of aerosol generation system heater elements 200.

[0063]

[0074] In certain examples, the aerosol generation device 10 can include an aerosol generation system heater element 200. In some examples, the aerosol generation system heater element 200 can define at least a portion of a receptacle 40 within the device 10 in which the consumable 100 is received. For example, the aerosol generation system heater element 200 can define a portion of the wall of the receptacle 40 in which the consumable 100 is received. In some examples, the aerosol generation system heater element 200 can form a larger portion of the wall of the receptacle 40. In certain examples, when the aerosol generation system 1 includes multiple aerosol generation system heater elements 200, the receptacle 40 can be defined, at least in part, by the multiple aerosol generation system heater elements 200. In certain examples, when the aerosol generation system 1 includes multiple aerosol generation system heater elements 200, multiple receptacles 40 can be provided.

[0064]

[0075] FIG. 2 shows an example of an aerosol-generation system heater element 200 within the device 10, which defines at least a portion of the receptacle 40 within which the consumable 100 is received. In this case, the aerosol-generation system heater element 40 at least partially defines a heating chamber 50 within which the aerosol-forming consumable 100 is received. The heating chamber therefore at least partially surrounds the aerosol-forming material contained within the aerosol-forming consumable 100, such that, during use, the aerosol-forming material is heated by the aerosol-generation system heater element 200. The aerosol-forming consumable 100 can be inserted into the heating chamber 50 in the direction of arrow C. In the example shown in FIG. 2, the aerosol-forming consumable 100 takes the form of an elongated cylinder, which may also be referred to as a rod. As mentioned above, the aerosol-forming consumable 100 may take any suitable form.

[0065]

[0076] In examples where the aerosol generation system heater element 200 is part of the aerosol generation device 10 and at least partially defines the receptacle 40, the heating chamber 50 and the receptacle 40 may be, at least in part, common features of the aerosol generation device 10. In other words, the heating chamber 50 may define a portion of the receptacle 40 within the device 10 in which the aerosol-forming consumable 100 is received.

[0066]

[0077] In certain examples, the aerosol-forming consumable 100 may include an aerosol-generation system heater element 200. In certain examples, the aerosol-generation system heater element 200 may support the aerosol-forming material of the aerosol-forming consumable 100. In certain examples, the aerosol-generation system heater element 200 may be a substrate, such as the substrates mentioned above, on which the aerosol-forming material is supported. In certain examples, the aerosol-generation system heater element 200 may partially support the aerosol-forming material. In certain examples, the aerosol-forming consumable 100 may include at least one other or additional substrate that supports the aerosol-forming material. In certain examples, the aerosol-generation system heater element 200 may at least partially encase or surround the aerosol-forming material of the aerosol-forming consumable 100. For example, the aerosol-forming consumable 100 may include tobacco inserted into the aerosol-generation system heater element 200 to form a rod- or stick-shaped aerosol-forming consumable 100.

[0067]

[0078] In some examples, the aerosol-generating system heater element 200 can assist a user in handling the aerosol-forming consumable 100 without touching the aerosol-forming consumable material of the aerosol-forming consumable 100. In some examples, the aerosol-generating system heater element 200 can form at least a portion of the outer covering, wall, or casing of the aerosol-forming consumable 100. In some examples, the aerosol-generating system heater element 200 can surround at least a portion of the aerosol-forming material of the aerosol-forming consumable 100 and can be wrapped by another covering. For example, the aerosol-generating system heater element 200 can be wrapped in a paper wrapper or the like. The paper wrapper can be marked to indicate characteristics of the aerosol-forming consumable 100, such as, for example, a particular flavor or heating profile characteristic of the consumable.

[0068]

[0079] An example of an aerosol-forming consumable 100 comprising an aerosol-generation system heater element 200 and an aerosolizable material 101 is shown in FIG. 3. In this case, the aerosol-generation system heater element 200 partially encases the aerosolizable material 101. The aerosolizable material 101 may be referred to, for example, as a cigarette, as described above. In this case, the aerosol-forming consumable 100 takes the form of an elongated cylinder, which may also be referred to, for example, as a rod. As mentioned above, the aerosol-forming consumable 100 may take any suitable form.

[0069]

[0080] In certain examples, when the aerosol generation system 1 includes multiple aerosol generation system heater elements 200, the aerosol-forming consumable 100 can include multiple aerosol generation system heater elements 200. In such examples, the multiple aerosol generation system heater elements 200 can be arranged in any suitable configuration. In some examples, the multiple aerosol generation system heater elements 200 can define multiple substrates supporting aerosolizable material or individual segments of aerosolizable material. For example, the multiple aerosol generation system heater elements 200 can be arranged in a concentric pattern. In other examples, the multiple aerosol generation system heater elements 200 can be arranged consecutively along the length of the aerosol-forming consumable 100.

[0070]

[0081] One or more aerosol generation system heater elements 200 can comprise seamless hollow tubes, as described further below. In Figure 1, the aerosol generation system heater element 200 is shown schematically in cross section through the hollow tube shape of the aerosol generation system heater element 200 shown.

[0071]

[0082] The one or more aerosol generation system heater elements 200 can be configured to heat at least a portion of the aerosol-forming consumable 100 aerosol when the aerosol generation system 1 is in use. Heating at least a portion of the aerosol-forming consumable 100 can heat the aerosol-forming material contained therein, thereby generating an aerosol from the aerosol-forming material. Activation of the aerosol generation system heater elements 200 can be activated by a user drawing air through the device 10 or by another means, such as a switch.

[0072]

[0083] In certain examples, the receptacle 40 can include a lid 60. The lid 60 can be a closable lid. When closed, the lid 60 can seal the aerosol-forming consumable 100 within the device 10. When closed, the lid 60 can seal the receptacle 40 to form an enclosed passageway through which air can be drawn by a user from the air inlet 30 into the mouthpiece 20. When closed, the lid 60 can be configured to allow aerosol generated from the aerosol-forming consumable 100 to escape and be drawn through the mouthpiece 20.

[0073]

[0084] The device 10 may include other components not shown in FIG. 1 . The aerosol generation device 10 may include a system for causing heating of the aerosol generation system heater element 200. In certain examples, the device 10 may have a power unit that holds a power source, which may be, for example, a battery, for providing electrical energy to the device 10. The device 10 may have an electrical circuit connected to the power source for conducting electrical energy to other components within the device 10. In certain examples, the circuit may connect the power source to the system for causing heating of the aerosol generation system heater element 200.

[0074]

[0085] The aerosol-generation system heater element 200 can be configured to heat the aerosolizable material of the aerosol-forming consumable 100 without burning it. In certain examples, the aerosol-generation system heater element 200 can heat the aerosolizable material of the aerosol-forming consumable 100 by conducting heat to the aerosolizable material. In certain examples, the aerosol-generation system heater element 200 can heat the aerosolizable material of the aerosol-forming consumable 100 by radiating heat to the aerosolizable material. In certain examples, the aerosol-generation system heater element 200 can heat the aerosolizable material of the aerosol-forming consumable 100 by convecting heat to the aerosolizable material.

[0075]

[0086] In certain examples, the aerosol generation system heater element 200 may include a metallic material. For example, the aerosol generation system heater element may include a metal material, an intermetallic material, or a semi-metal (metalloid). In certain examples, the aerosol generation system heater element 200 may include a ceramic material. In some examples, the aerosol generation system heater element 200 may be made from a mixture of a metallic material and a non-metallic material. For example, the aerosol generation system heater element 200 may be made from a mixture of a metallic material and a ceramic material.

[0076]

[0087] In examples where the aerosol generation system heater element 200 includes a metallic material, the metallic material may be any suitable metallic material, such as, but not limited to, at least one of iron, iron alloys such as stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloys, gold, copper, cupronickel alloys, iron-chromium-aluminum alloys, and nickel aluminide alloys.

[0077]

[0088] In examples where the aerosol generation system heater element 200 includes a ceramic material, the ceramic material may be any suitable ceramic material, such as, but not limited to, at least one of alumina, zirconia, yttria, calcium carbide, and calcium sulfate.

[0078]

[0089] In use, the system for causing heating of the aerosol generation system heater element 200 can cause the aerosol generation system heater element 200 to heat up, i.e., increase in temperature. Heating of the aerosol generation system heater element 200 may be performed by any suitable heating arrangement.

[0079]

[0090] In certain examples, the system for causing heating of the aerosol generation system heater element 200 can include heat- ing the aerosol generation system heater element 200 by conduction. For example, a heat source can be placed in contact with the aerosol generation system heater element 200 and activated when the device 10 is in use.

[0080]

[0091] In certain examples, the system for causing heating of the aerosol generation system heater element 200 can include an induction heating system for heating the aerosol generation system heater element 200 .

[0081]

[0092] Induction heating is the process of heating a conductive object by electromagnetic induction. When the conductive object is subsequently used to heat another element or item, the conductive object may be referred to as a “susceptor.” The susceptor material may be formed from any suitable susceptor material, such as, for example, at least one of the metallic materials identified above in connection with the aerosol-generating system heater element 200. Thus, in certain examples, as used herein, the aerosol-generating system heater element 200 may be a “susceptor” in that it is heated by induction heating so as to subsequently heat the aerosolizable material of the aerosol-forming consumable 100. Heating of the aerosolizable material of the aerosol-forming consumable 100 may then be primarily by conduction or radiation of heat, for example, from the aerosol-generating system heater element 200 to the aerosolizable material of the aerosol-forming consumable 100.

[0082]

[0093] Configuring the aerosol generation system heater element 200 as a susceptor can allow for effective heating of the aerosolizable material of the aerosol-forming consumable 100, which may be substantially non-conductive in certain instances. Additionally, configuring the aerosol generation system heater element 200 as a susceptor can allow for the thermal pattern of heat directed at the aerosolizable material of the aerosol-forming consumable 100 to be controlled.

[0083]

[0094] An induction heating system can include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. The varying current in the electromagnet generates a varying magnetic field. The varying magnetic field penetrates an aerosol generation system heater element 200 appropriately positioned relative to the electromagnet, generating eddy currents within the aerosol generation system heater element 200. The aerosol generation system heater element 200 has an electrical resistance to the eddy currents, and therefore, by causing eddy currents to flow across this resistance, the aerosol generation system heater element 200 heats by Joule heating. If the aerosol generation system heater element 200 includes a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis loss within the aerosol generation system heater element 200, i.e., by the magnetic dipoles of the magnetic material aligning with the varying magnetic field, resulting in a change in the orientation of the magnetic dipoles.

[0084]

[0095] Because heat is generated inside the aerosol generation system heater element 200 (susceptor), induction heating can enable faster heating of the aerosol generation system heater element 200 compared to, for example, heating by conduction. Furthermore, no physical contact is required between the induction heating system and the aerosol generation system heater element 200, which can improve the configuration, flexibility of application, and reliability of the aerosol generation system 1.

[0085]

[0096] An example of an aerosol generation system 1 in which the system for causing heating of the aerosol generation system heater element 200 includes an induction heating system 70 for heating the aerosol generation system heater element 200 is shown in Figure 4. Another example of an aerosol generation system 1 in which the system for causing heating of the aerosol generation system heater element 200 includes an induction heating system 70 for heating the aerosol generation system heater element 200 is shown in Figure 5.

[0086]

[0097] 4 and 5 show a particular example of a system for causing heating of the aerosol generation system heater element 200. For convenience and clarity, the system for causing heating of the aerosol generation system heater element 200 is not shown in any of the other figures.

[0087]

[0098] 4 and 5 includes a mouthpiece 20 and an air inlet 30. The air inlet 30 may also act as a lid 60 that covers the receptacle 40 to prevent user access, allowing the user to insert the aerosol-forming consumable 100 into the aerosol generation device 10. In certain examples, the air inlet / lid may not be present in the device 10, and air may be drawn in through the open end of the device 10.

[0088]

[0099] 4, and as described above, the aerosol generation device 10 includes an aerosol generation system heater element 200. In the example of FIG. 4, a heating chamber 50 is defined by the aerosol generation system heater element 200 that is open at one end to allow an aerosol-forming consumable 100 to be inserted into the heating chamber 50.

[0089]

[0100] 5, and as described above, the aerosol-forming consumable 100 includes an aerosol-generation system heater element 200. The aerosol-generation system heater element 200 is inserted into the receptacle 40 of the device 10 by the aerosol-forming consumable 100 through an access point in the receptacle during use.

[0090]

[0101] Similar to the aerosol generation system 1 shown in FIG. 1, the aerosol generation system heater element 200 shown in FIGS. 4 and 5 may comprise a seamless hollow tube, as further described below.

[0091]

[0102] In Figure 4, it can be seen that the induction heating system 70 includes an induction coil wrapped around the aerosol generation system heater element 200. In Figure 5, the induction heating system 70 includes an induction coil wrapped around the aerosol generation system heater element 200 upon receipt of the aerosol-forming consumable 100 in the receiving portion 40 of the aerosol generation device 10.

[0092]

[0103] The induction coil is shown schematically in Figures 4 and 5 as a cross section through the major axis, i.e., the helical axis, of the coil, which also passes through the hollow tubular shape of the aerosol generation system heater element 200 shown.

[0093]

[0104] When the induction coil is induced with an alternating current, the resulting varying magnetic field heats the aerosol generation system heater element 200, thereby heating the aerosolizable material of the aerosol-forming consumable 100 inserted into the receptacle 40.

[0094]

[0105] In a particular example, a system for causing heating of an aerosol generation system heater element 200 can include an aerosol generation system heater element 200 configured as an electrical resistance heater. Accordingly, the system for causing heating of an aerosol generation system heater element 200 can include circuitry for connecting the aerosol generation system heater element 200 to a power source. During use, current from the power source can pass through the aerosol generation system heater element 200 to cause Joule heating of the aerosol generation system heater element 200. The aerosol generation system heater element 200 can be any suitable material that forms an electrical conductor, such as, for example, a metallic material as described herein above. In one example, the system for causing heating of an aerosol generation system heater element 200 can include a controller that can control the current passing through the aerosol generation system heater element 200 by conduction, and therefore the amount of heat generated by the aerosol generation system heater element 200.

[0095]

[0106] In certain examples, the system for causing heating of the aerosol generation system heater element 200 can include a radiant heating system. In one example, the radiant heating system can include a heat lamp that radiates thermal energy to the aerosol generation system heater element 200. For example, the radiant heating system can include an infrared light source directed at the aerosol generation system heater element 200. For example, the radiant heating system can include a radiant heat source such as an LED or a laser.

[0096]

[0107] In certain examples, the system for causing heating of the aerosol generation system heater element 200 may include a chemical heat heating system. For example, the system for causing heating of the aerosol generation system heater element 200 may include a chemical heat source that undergoes an exothermic reaction in use to generate heat.

[0097]

[0108] When the aerosol generation system 1 includes multiple aerosol generation system heater elements 200, in certain examples, each aerosol generation system heater element 200 may be provided with a respective system for causing heating of the aerosol generation system heater element 200. In other examples, the system for causing heating of the aerosol generation system heater element 200 may heat more than one aerosol generation system heater element 200. For example, as described herein, when multiple heater elements 200 are arranged, for example, linearly or concentrically, a single system for causing heating of the heater elements 200 may be provided, such as, for example, an induction heating coil that surrounds all of the aerosol generation system heater elements 200 when heated.

[0098]

[0109] As already briefly mentioned above, the aerosol generation system heater element 200 can comprise a seamless hollow tube. A seamless hollow tube is a hollow tube without seams; these seams are marks and / or distortions in the material forming the hollow tube and may result from the particular manufacturing technique used to manufacture the hollow tube. Such seams may extend lengthwise along the hollow tube, for example. Such seams may be undesirable due to physical distortion of the hollow tube. The physical distortion may reduce the effectiveness of the aerosol generation system heater element 200 in delivering heat to the aerosolizable material. The seams may also cause a non-uniform heat profile pattern throughout the aerosol generation system heater element 200, thereby causing uneven and / or insufficient heating of the aerosolizable material. The aerosol generation system heater element 200 can be manufactured according to the exemplary method described below.

[0099]

[0110] 2 and 3, referenced above, show examples of aerosol generation system heater elements 200 that include seamless hollow tubes. In the particular examples shown in Figures 2 and 3, the seamless hollow tube has a substantially circular cross-section, such that the seamless hollow tube is substantially cylindrical along its length. In other examples of aerosol generation system heater elements 200, the cross-section of the seamless hollow tube may be substantially square, rectangular, conical, or elliptical, or any suitable shape, for example, to form an elongated hollow tube of any suitable shape.

[0100]

[0111] 2 , the heating chamber 50 is defined by the interior volume of a seamless hollow tube 200. In this case, due to the circular cross-section of the seamless hollow tube, the heating chamber 50 is substantially cylindrical and is therefore capable of receiving therein an appropriately sized, substantially cylindrical aerosol-forming consumable 100. As mentioned above, the aerosol-forming consumable 100 can be inserted into the heating chamber 50 in the direction of arrow C. In other examples of the aerosol generation system heater element 200, if the cross-section of the seamless hollow tube takes on another appropriate shape, the heating chamber 50 defined by the seamless hollow tube will be capable of receiving therein an appropriately sized and shaped aerosol-forming consumable 100.

[0101]

[0112] If the aerosol generation system heater element 200 is a component of an aerosol generation device 10, such as that in Figure 2, a gap may be provided between the aerosol generation system heater element 200 and the aerosol-forming consumable 100 when initially inserted into the heating chamber 50. This may allow a user of the aerosol generation device 10 to easily insert and withdraw the aerosol-forming consumable 100.

[0102]

[0113] After the aerosol-forming consumable 100 is received in the receptacle 40, and during operation of the aerosol-generation system 1, a system can be activated to cause heating of the aerosol-generation system heater element 200 such that the aerosol-forming system heater element 200 heats the aerosolizable material of the aerosol-forming consumable 100. A user can then inhale the aerosol generated in the receptacle 40.

[0103]

[0114] When the temperature of the aerosolizable material of the aerosol-forming consumable 100 reaches a predetermined initial temperature, the system for causing the heating of the aerosol generation system heater element 200 can be deactivated. In certain examples, the system for causing the heating of the aerosol generation system heater element 200 can be activated and deactivated as needed to generate an aerosol while maintaining the aerosolizable material of the aerosol-forming consumable 100 at a predetermined operating temperature. In other examples, the power level of the system for causing the heating of the heater element 200 can be varied as needed to generate an aerosol while maintaining the aerosolizable material of the aerosol-forming consumable 100 at a predetermined operating temperature. The predetermined operating temperature may be the same as or different from the predetermined initial temperature, for example. In certain examples, the predetermined operating temperature may change as the user inhales the aerosol. For example, the predetermined operating temperature may change throughout a single inhalation of the aerosol or may change over multiple inhalations. In certain cases, the predetermined operating temperature may change as the aerosol-forming consumable is consumed.

[0104]

[0115] A temperature and / or heat transfer sensor may be provided in the aerosol generation device 10 to monitor the temperature of the aerosolizable material of the aerosol-forming consumable and / or the heat transferred to the aerosol-forming consumable 100. For example, a temperature sensor monitor may be located inside the receptacle 40.

[0105]

[0116] As mentioned above, in certain examples, the aerosol generation system heater element 200 can be one of multiple aerosol generation system heater elements 200. Figure 6 shows an exemplary aerosol generation device 10 provided with two aerosol generation system heater elements 200. In other examples, any suitable number of heater elements 200 may be provided.

[0106]

[0117] 6, the aerosol generation system heater elements 200 are arranged in series within the aerosol generation device 10 such that an elongated aerosol-forming consumable 100 can be received within a receptacle 40 defined at least in part by each heater element 200. It should be understood that multiple heater elements, such as those in the examples described herein, may be arranged in other manners within an aerosol generation device. For example, multiple heater elements may be arranged in a radial array and configured to receive a corresponding plurality of aerosol-forming consumables.

[0107]

[0118] 6 , the heater elements 200 can be operated independently of one another, such that different portions of the aerosol-forming consumable 100 can be temperature-controlled independently. For example, one portion of the aerosol-forming consumable 100 can be heated before another portion of the aerosol-forming consumable 100, such that the first portion is consumed by the user before the second portion. In another example, the aerosol-forming consumable 100 can be maintained at a predetermined temperature profile over time as it is heated and consumed by a user of the device 10. For example, one portion of the aerosol-forming consumable 100 can be maintained at a higher temperature than another portion of the aerosol-forming consumable 100. This can allow, for example, a flavoring aerosol to be emitted from one portion of the aerosol-forming consumable 100 while a nicotine-bearing aerosol is emitted from another portion of the aerosol-forming consumable 100.

[0108]

[0119] 6 shows an example in which the heater element 200 is a component of the aerosol generating device 10. However, in other examples, the heater element 200 may be a component of the aerosol-forming consumable 100, as described above, and may be operated in the same manner as described herein in connection with FIG.

[0109]

[0120] A specific exemplary method for manufacturing an aerosol generation system heater element comprising a seamless hollow tube will now be described, which method can be utilized, for example, to manufacture any of the examples of aerosol generation system heater element 200 described above.

[0110]

[0121] Applicant has found that, in certain instances, seamless hollow tubes having wall thicknesses of less than about 100 μm can be formed using the methods described herein. Applicant has also found that, in certain instances, seamless hollow tubes having metal layers less than about 100 μm thick coated on the inner surface of a hollow tubular substrate can be formed using the methods described herein. In certain instances, Applicant has found that thin walls or layers of the above thicknesses provide excellent heating performance. For example, induction heating using the above thin walls or layers has been found to be highly efficient and have fast heating and / or heat dissipation response times. Applicant has found that walls or layers of the above thicknesses made from aluminum or aluminum alloys provided excellent heating performance.

[0111]

[0122] In certain examples, the aerosol generation system heater element can comprise a seamless hollow tube having a wall thickness of about 100 μm or less. In some examples, the seamless hollow tube can comprise a metallic material and have a wall thickness of less than about 100 μm. The aerosol generation system heater element can be formed from the hollow tube according to one or more of the methods described below.

[0112]

[0123] Thus, an aerosol generation system heater element can be provided that includes a seamless hollow tube, the seamless hollow tube having a wall thickness of less than about 100 μm. In certain examples, the wall thickness may be less than 100 μm. In certain examples, the seamless hollow tube may include a metallic material. The metallic material may be selected from at least one of iron, iron alloy, stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloy, gold, copper, cupronickel alloy, iron-chromium-aluminum alloy, and nickel aluminide alloy.

[0113]

[0124] In certain examples, the aerosol generation system heater element can include a seamless hollow tube comprising a hollow tubular substrate, with a metal layer coated on the inner surface of the hollow tubular substrate. In certain examples, the metal layer can have a thickness of about 100 μm or less. The aerosol generation system heater element can be formed by coating the hollow tubular substrate with a metal layer according to at least one of the methods described below.

[0114]

[0125] Thus, an aerosol generation system heater element can be provided that includes a seamless hollow tube, the seamless hollow tube including a metal layer coated on the inner surface of a hollow tubular substrate. In certain examples, the metal layer may have a thickness of less than about 100 μm. In certain examples, the metal layer may include a metallic material. The metallic material may be selected from at least one of iron, iron alloy, stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloy, gold, copper, cupronickel alloy, iron-chromium-aluminum alloy, and nickel aluminide alloy.

[0115]

[0126] An aerosol generation system may be provided that includes an aerosol generation system heater element according to at least one method described herein and / or manufactured according to at least one exemplary method described herein. The aerosol generation system may include an aerosol generation device. The aerosol generation device may include a receiver configured to receive an aerosol-forming consumable. The aerosol generation device may include a system for causing heating of the aerosol generation system heater element. The aerosol generation system may include at least one aerosol-forming consumable.

[0116]

[0127] The aerosol generating device may be according to at least one example described herein. The aerosol-forming consumable may be according to at least one example described herein. The aerosol generating system may be provided as a kit of parts comprising an aerosol generating system heater element, an aerosol generating device, and one or more aerosol-forming consumables.

[0117]

[0128] An aerosol generation device may be provided that includes an aerosol generation system heater element according to at least one example described herein and / or manufactured according to at least one exemplary method described herein. In some examples, the aerosol generation system heater element of such an aerosol generation device may at least partially define a receptacle for receiving an aerosol-forming consumable. In other examples, the aerosol generation system heater element of such an aerosol generation device may not define a receptacle or a portion of a receptacle for receiving an aerosol-forming consumable. The aerosol generation device may include a system for causing heating of the aerosol generation system heater element. The aerosol generation device may be provided according to any of the examples described herein and may therefore include, in addition to the aerosol generation system heater element and the system for causing heating of the aerosol generation system heater element, other components necessary for the function of the aerosol generation device.

[0118]

[0129] The aerosol generating device may be provided to a user as an aerosol generating system including at least one aerosol-forming consumable for use with the aerosol generating device. The aerosol generating system may be provided as a kit of parts comprising the aerosol generating device and one or more similar aerosol-forming consumables for use with the aerosol generating device. The at least one aerosol-forming consumable may be shaped and dimensioned to be receivable within a receptacle of the aerosol generating device. The aerosol-forming consumable may be according to at least one example described herein.

[0119]

[0130] An aerosol-forming consumable may be provided that includes an aerosol-generation system heater element according to at least one example described herein and / or manufactured according to at least one exemplary method described herein. The aerosol-forming consumable may include an aerosol-generating material. The aerosol-generating system heater element 200 of such an aerosol-forming consumable may at least partially support the aerosol-generating material of the aerosol-forming consumable 100. The aerosol-forming consumable may be according to at least one example described herein.

[0120]

[0131] An aerosol generation device can be provided that includes a receptacle configured to receive an aerosol-forming consumable. The aerosol generation device can include a system for causing heating of an aerosol generation system heater element. The aerosol generation device can be provided according to any of the examples described herein and can therefore include, in addition to a system for causing heating of an aerosol generation system heater element, other components necessary for the functioning of the aerosol generation device.

[0121]

[0132] The aerosol-forming consumables and the aerosol generation device may be provided to a user as an aerosol generation system. The aerosol generation system may be provided as a kit of parts comprising a plurality of similar aerosol-forming consumables for use with the aerosol generation device. At least one aerosol-forming consumable may be shaped and dimensioned to be receivable within a receptacle of the aerosol generation device.

[0122]

[0133] A method of manufacturing an aerosol generation system heater element can include deforming a wall of a hollow tube to form an aerosol generation system heater element comprising a seamless hollow tube, the deformed wall of the seamless hollow tube being thinner than the wall of the hollow tube.

[0123]

[0134] In certain instances, the hollow tube may include a metallic material, such as those described herein above. For example, the metallic layer may include a metal material, an intermetallic material, or a semi-metal.

[0124]

[0135] The step of deforming the wall of the hollow tube to form a thinner deformed wall of the seamless hollow tube may involve reducing a cross-sectional area of ​​the wall as deformed. The deforming step may include plastically deforming the wall to form the seamless hollow tube.

[0125]

[0136] By providing a relatively thin-walled hollow tube, less energy is required to heat the aerosol generation system heater element compared to a thicker-walled hollow tube. Therefore, less time is required to bring the aerosol generation system heater element to a predetermined operating temperature. Furthermore, because there is less mass to heat, the aerosol generation system heater element is also more responsive to changes in the required operating temperature.

[0126]

[0137] A relatively thin-walled hollow tube aerosol generation system heater element can be formed that is seamless to the hollow tube by deforming the wall of a relatively thick-walled tube that is already hollow. The seamless hollow tube itself can be seamless before its wall is deformed.

[0127]

[0138] Other methods for forming thin-walled tubes rely on, for example, joining two adjacent edges of a rolled-up sheet to form the tube. For example, two adjacent edges may be welded together to form the joint. However, because the sheet of material forming the tube must also be relatively thin, the joining process results in distortion of the material near the joint, and thus the thin-walled tubes formed as described above are irregular in shape. Because the hollow tube has a distorted shape, any aerosol-forming consumable received within the hollow tube may have irregular contact with the inner surface of the hollow tube. Variations in the distance between the aerosol-forming consumable and the inner surface of the hollow tube result in uneven heating distribution across the aerosolizable material of the aerosol-forming consumable. Therefore, the process of heating the aerosol-forming consumable becomes inefficient, thereby reducing the operating efficiency of the aerosol generating device.

[0128]

[0139] For example, when attempting to produce a cylindrically shaped, thin-walled hollow tube by an edge-joining process, the resulting tube will not be perfectly circular in cross section due to local distortions near the joined edges of the thin sheet of material used to produce the hollow tube. Thus, the cylindrically shaped portion of the aerosolizable material forming the consumable will make irregular contact with the distorted cylindrical wall of such hollow tube, causing any heating of the aerosolizable material to be uneven.

[0129]

[0140] Because the deformed wall of the seamless hollow tube has no seams, it is possible to produce a seamless hollow tube of the desired shape without any of the distortions mentioned above.

[0130]

[0141] Thin-walled seamless hollow tubes have thinner walls compared to thick-walled hollow tubes. Purely by way of example, the walls of the hollow tube can be 1 to 3 times thicker than the walls of seamless hollow tubes. In some instances, the walls of the hollow tube can be 1 to 1.3 times thicker than the walls of seamless hollow tubes.

[0131]

[0142] Relatively thick-walled hollow tubes can be quickly, cheaply, and simply manufactured. For example, they can be manufactured by drilling or punching holes in a bar of any suitable shape, such as, for example, a round bar. Relatively thick-walled hollow tubes can also be manufactured by, for example, an extrusion process.

[0132]

[0143] In certain instances, the cross-sectional inner circumference of the wall of the hollow tube can be maintained as the wall of the hollow tube is deformed. Because the cross-sectional inner circumference of the wall is maintained during the wall deformation process, the resulting deformed wall of the seamless hollow tube can have the same cross-sectional inner circumference as the wall of the hollow tube. As discussed further below, in other exemplary methods, the cross-sectional inner circumference of the wall of the hollow tube may be lengthened as the wall of the hollow tube is deformed.

[0133]

[0144] Thus, in manufacturing an aerosol generation system heater element comprising a seamless hollow tube, the wall of the hollow tube can have a first cross-sectional inner circumference, and the deformed wall of the seamless hollow tube can have a second cross-sectional inner circumference that is at least as long as the first cross-sectional inner circumference.

[0134]

[0145] 7A and 7B show an example of an aerosol generation system heater element 200 comprising a seamless hollow tube 202, the deformed wall of which has the same cross-sectional inner circumference as the wall of the hollow tube 300 from which the seamless hollow tube 202 was manufactured.

[0135]

[0146] Figure 7A shows a cross section through hollow tube 300 before the wall of hollow tube 300 is deformed. Hollow tube 300 has a wall with a thickness t1 and a first inner cross-sectional circumference L1. Figure 7B shows a cross section through an aerosol generation system heater element 200 comprising a seamless hollow tube 202 fabricated from hollow tube 300. Seamless hollow tube 202 has a deformed wall with a thickness t2 and a second inner cross-sectional circumference L2. In the example shown in Figures 7A and 7B, second inner cross-sectional circumference L2 is the same length as first inner cross-sectional circumference L1.

[0136]

[0147] 7B also shows an exemplary aerosol generation system heater element 200 in which the seamless hollow tube 202 has a substantially circular cross-section, such that the seamless hollow tube 202 is substantially cylindrical along the length of the seamless hollow tube 202. In certain examples, the seamless hollow tube 202 can be fabricated from a hollow tube 300 that has a substantially circular cross-section, such that the hollow tube 300 is substantially cylindrical along the length of the hollow tube 300, such as the example shown in FIG. 7A. In other examples, the seamless hollow tube 202 may be fabricated from a hollow tube that does not have a substantially circular cross-section.

[0137]

[0148] Thus, in instances where the hollow tube and seamless hollow tube have substantially circular cross sections, the deformed walls of the resulting seamless hollow tube can have the same cross-sectional inner circumference as the walls of the hollow tube, because the walls can maintain their cross-sectional inner circumference as they are deformed. As a result, the inner diameter of the resulting seamless hollow tube can have the same inner diameter as the hollow tube. As noted above, the deformed walls of the seamless hollow tube maintain the circular cross section of the hollow tube while providing the benefits of a thinner-walled seamless hollow tube, as discussed above.

[0138]

[0149] Thus, in manufacturing an aerosol generation system heater element comprising a seamless hollow tube, the wall of the hollow tube can have a first cross-sectional inner circumference, and the deformed wall of the seamless hollow tube can have a second cross-sectional inner circumference that is at least as long as the first cross-sectional inner circumference.

[0139]

[0150] For the example shown in Figures 7A and 7B, because the cross sections of hollow tube 300 and seamless hollow tube 202 are circular, and because the cross-sectional inner circumference L2 is the same length as the cross-sectional inner circumference L1, the deformed wall of seamless hollow tube 202 has a second cross-sectional inner circumference that is the same length as the first cross-sectional inner circumference of hollow tube 300.

[0140]

[0151] In certain examples, the step of deforming the wall of the hollow tube can include swaging the hollow tube to form a seamless hollow tube. Swaging the hollow tube can include hot or cold forming the hollow tube.

[0141]

[0152] In certain examples, the step of deforming the wall of the hollow tube can include swaging the hollow tube over a mandrel. Swaging the hollow tube over a mandrel can stretch the wall of the hollow tube as the hollow tube is urged over and / or against the mandrel. Swaging the hollow tube over a mandrel can reduce a cross-sectional area of ​​the wall as the wall is deformed. The mandrel can be positioned inside the hollow tube before deforming the wall. The hollow tube can be slid over the mandrel before deforming the wall.

[0142]

[0153] In certain examples, the step of deforming the wall of the hollow tube can include swaging the hollow tube by squeezing the hollow tube through a mold. Squeezing can include pushing or pulling the hollow tube through the mold. For example, a mandrel can be placed inside the hollow tube, and the hollow tube can then be squeezed over the mandrel through the mold, such that the mandrel defines the interior dimensions of the seamless hollow tube and the mold defines the exterior dimensions of the seamless hollow tube.

[0143]

[0154] For example, if the seamless hollow tube has a circular cross section as described above, the mandrel can define the inner cross-sectional circumference of the seamless hollow tube, and the mold can define the outer cross-sectional circumference of the seamless hollow tube.

[0144]

[0155] An example of a hollow tube in the process of being drawn over a mandrel through a die is shown in Figure 8. A mandrel 400 is positioned inside the hollow tube 300. The mandrel can define the interior dimensions of the seamless hollow tube 202. A die 450 surrounds the hollow tube 300 and has a throat 452 through which the hollow tube 300 passes as it is drawn through the die 450. The hollow tube 300 is drawn through the die 450 in the direction of arrow F. Together with the mandrel 300, the throat 452 defines the wall thickness of the seamless hollow tube 202.

[0145]

[0156] In certain examples, the step of deforming the wall of the hollow tube can include swaging the hollow tube by rotary swaging the hollow tube. In such examples, the hollow tube can be mounted on a mandrel or slid over the mandrel. A swaging tool can then be propelled against the outer surface of the hollow tube, drawing the wall of the hollow tube against the mandrel and thereby thinning the wall of the hollow tube to form a seamless hollow tube. In certain examples, the mandrel and / or the swaging tool can rotate, such that the hollow tube rotates relative to the swaging tool during the swaging process. The swaging tool can be, for example, a shaped die that moves radially inward and outward relative to the mandrel to apply pressure to the hollow tube on the mandrel to produce a seamless hollow tube.

[0146]

[0157] FIG. 9 illustrates an example of a rotary swaging process in which a hollow tube 300 is rotary swaged. The hollow tube 300 is attached to a mandrel 500. During the swaging process, the mandrel can rotate, as indicated by arrow R. The mandrel can rotate in any direction. Four shaping dies (referred to as "dies") 550 are disposed around the mandrel 500. During the swaging process, the dies can move radially inward and outward to apply pressure to the surface of the hollow tube 300, thereby deforming and thinning the wall of the hollow tube 300 to form a seamless hollow tube. For example, the dies 550 can move as indicated by arrow F. In other examples, the dies 550 can rotate relative to the hollow tube 300. Any suitable number of dies 550 can be provided, such as two or four dies 550 configured to rotate the hollow tube.

[0147]

[0158] As briefly mentioned above, in certain instances, the cross-sectional inner circumference of the wall of a hollow tube can increase when the wall of the hollow tube is deformed. Thus, in manufacturing an aerosol generation system heater element comprising a seamless hollow tube, the deformed wall of the seamless hollow tube can have a second cross-sectional inner circumference that is longer than the first cross-sectional inner circumference of the wall of the hollow tube.

[0148]

[0159] In instances where the hollow tube and the seamless hollow tube both have substantially circular cross-sections, the deformed wall of the seamless hollow tube can have a second inner cross-sectional circumference that is longer than the first inner cross-sectional circumference of the wall of the hollow tube.

[0149]

[0160] In certain examples, the step of deforming the wall of the hollow tube can include internally swaging the hollow tube to form a seamless hollow tube. Internally swaging the hollow tube can include hot or cold forming the hollow tube. Internally swaging can include using a tool that expands or rotates inside the hollow tube to deform the wall of the hollow tube. In other examples, the step of internally swaging can include using a flexible tool that expands the hollow tube, thereby deforming the wall of the hollow tube. For example, the wall of the hollow tube can be expanded using an inflatable tool. In certain examples, the step of deforming the wall of the hollow tube can include hydroforming the hollow tube to expand a first internal cross-sectional circumference of the hollow tube wall to create a longer second internal cross-sectional circumference of the deformed wall of the seamless hollow tube. The hydroforming stretches the wall of the hollow tube, thereby lengthening the wall and forming a longer, thinner deformed wall of the seamless hollow tube. The hydroforming step also increases or expands the interior volume of the hollow tube as the walls deform and thin to create a seamless hollow tube. It should be understood that hydroforming a hollow tube to deform its walls can be used with any suitable shape hollow tube.

[0150]

[0161] FIG. 10 schematically illustrates a cross section of a hollow tube 300 undergoing hydroforming. In a particular example, the hollow tube 300 can be placed in a mold that defines the desired exterior dimensions of the seamless hollow tube. The open end of the hollow tube 300 can be sealed with a bung. A hydraulic fluid can then be pumped into the interior of the hollow tube 300 to apply pressure, causing the walls of the hollow tube to expand against the mold. The hydraulic fluid can be, for example, an aqueous fluid. The aqueous fluid can include, for example, a lubricant.

[0151]

[0162] The walls of the hollow tube plastically deform under the pressure of the pressurized hydraulic fluid and expand to the desired final dimensions as set by the surrounding mold. In Figure 10, arrow F indicates the direction of pressure exerted on the walls of hollow tube 300 as they expand to form a seamless hollow tube. As hollow tube 300 expands under the pressure of the hydraulic fluid, the inner circumference of a first cross-section of the wall of hollow tube 300 lengthens in the direction of arrow F in Figure 10.

[0152]

[0163] In certain examples, the step of deforming the wall of the hollow tube can include ironing the wall of the hollow tube through at least one ironing die. Ironing the wall of the hollow tube can uniformly thin the wall of the hollow tube to form the deformed wall of the seamless hollow tube. As the hollow tube passes through the ironing die, the length of the hollow tube is extended as the wall thins to form the deformed wall of the seamless hollow tube.

[0153]

[0164] 11 illustrates an example in which the wall of hollow tube 300 is ironed through an ironing die 650. The hollow tube is forced in the direction of arrow F by a punch 600, which forces the hollow tube through an opening 652 in the ironing die 650. The opening 652 in the ironing die 650 includes a surface 654 that corresponds to the desired outer shape of the seamless hollow tube 202. The opening 652 can have an internal dimension that is smaller than the external dimension of the hollow tube 300 prior to processing. The internal dimensions of the opening 652 and the external dimensions of the punch 600 can be configured such that the wall of the hollow tube 300 is squeezed as it is forced through the opening 652 in the ironing die 650, thereby thinning the wall and lengthening the hollow tube to form the seamless hollow tube 202.

[0154]

[0165] In certain examples, if the seamless hollow tube 300, as described above, has a substantially circular cross-section such that the hollow tube 300 is substantially cylindrical along the length of the hollow tube 300, the opening 652 of the ironing die 650 can have a correspondingly circular cross-section. In other examples, if the hollow tube 300 and the seamless hollow tube 202 have another suitable shape, the opening 652 of the ironing die 650 can have a shape corresponding to that suitable shape.

[0155]

[0166] In certain examples, such as the example shown in Figure 11, the hollow tube 300 can include a closed end 302 that assists the punch 600 in applying an ironing force to the hollow tube 300. Thus, in some instances, the hollow tube 300 can take the form of a cup, as shown in Figure 11.

[0156]

[0167] In certain examples, hollow tube 300 can be ironed sequentially through multiple ironing dies, with each successive ironing die progressively thinning the wall of hollow tube 300 and lengthening hollow tube 300. Progressively ironing hollow tube 300 through multiple ironing dies can allow the metal material to be stretched while reducing the risk that the wall of hollow tube 300 will tear or otherwise be damaged during processing.

[0157]

[0168] In some instances, it may be necessary to remove excess material from the resulting seamless hollow tube 202 after the ironing process. For example, the ends of the seamless hollow tube 202 may be trimmed to fit the desired final dimensions of the seamless hollow tube 202. In certain instances, if the hollow tube 300 includes a closed end 302 as shown in FIG. 11 , the closed end 302 may be removed from the resulting seamless hollow tube 202 after the hollow tube 300 is ironed.

[0158]

[0169] In certain instances, a hollow tube 300, such as the example shown in Figure 11, may be formed by deep drawing a blank of sheet material. For example, a flat blank may be stamped from a sheet of metal and then deep drawn to form a cup.

[0159]

[0170] A method of manufacturing an aerosol generation system heater element can include coating an inner surface of a hollow tubular substrate with a metal layer to form an aerosol generation system heater element comprising a seamless hollow tube.

[0160]

[0171] The metal layer may comprise a metallic material as described herein above. For example, the metal layer may comprise a metal material, an intermetallic material, or a semi-metal.

[0161]

[0172] The use of a hollow tubular substrate provides structural stability and rigidity to the seamless hollow tube while allowing the thickness of the metal layer to be precisely controlled. The structural stability provided by the hollow tubular substrate allows for thin metal layers to be formed.

[0162]

[0173] By providing a metal layer on the inner surface of a hollow tubular substrate, the energy required to heat the aerosol generation system heater element can be reduced because the metal layer can be thinly deposited on the hollow tubular substrate. Therefore, less time is required to bring the aerosol generation system heater element to a predetermined operating temperature compared to heater elements made from relatively thick-walled tubes, such as tubes made by drilling holes in round bar stock. Furthermore, because there is less mass to heat, the aerosol generation system heater element will also be more responsive to changes in the required operating temperature.

[0163]

[0174] Because the metal layer is coated onto a tubular substrate, an aerosol generation system heater element can be formed having a tubular metal layer, where the tubular metal layer has no seams. As mentioned above, other methods of forming thin-walled tubular shapes that can be used as heater elements rely on joining sheets of material, and the joining process results in distortion of the material near the joint. Because the tubular metal layer has no seams, a seamless hollow tube of the desired shape can be produced without any of the distortion mentioned above.

[0164]

[0175] FIG. 12 shows an example of an aerosol generation system heater element 200 manufactured by the described coating method. The aerosol generation system heater element 200 comprises a seamless hollow tube 202. The seamless hollow tube 202 includes a metal layer 250 deposited on an inner surface 262 of a hollow tubular substrate 260. In the example shown in FIG. 9, the hollow tubular substrate 260 has a circular cross-section, such that the hollow tubular substrate 260 is substantially cylindrical along its length. Accordingly, the metal layer 250 and the seamless hollow tube 202 also have a circular cross-section and are substantially cylindrical along its length. In other aerosol generation system heater element examples, the cross-section of the hollow tubular substrate may be, for example, substantially square, rectangular, or oval, or any other suitable shape to form any suitable seamless hollow tube.

[0165]

[0176] The hollow tubular substrate may be any suitable material capable of supporting the required metal layer coating and remaining structurally sound at the required operating temperatures.

[0166]

[0177] In certain examples, the hollow tubular substrate may be formed from a ceramic material, which may include any of the ceramic materials described herein above. For example, the hollow tubular substrate may be formed from at least one of alumina, zirconia, yttria, calcium carbide, and calcium sulfate.

[0167]

[0178] In certain examples, hollow tubular substrates may be manufactured using a ceramic slurry. The ceramic slurry may be formed into a desired shape and then allowed to solidify and dry. The ceramic slurry may be formed into a desired shape by casting or molding the ceramic slurry. The ceramic slurry may then be fired to harden and rigidify the ceramic, thereby forming a hollow tubular substrate comprising the ceramic material.

[0168]

[0179] In certain instances, the hollow tubular substrate may be made by sintering, by applying pressure, or by any other technique for forming a porous ceramic. For example, the hollow tubular substrate may be manufactured through isostatic pressing, plastic forming (e.g., wheel casting, extrusion, or injection molding), or by casting.

[0169]

[0180] In some examples, the hollow tubular substrate may be made by sintering a ceramic powder, which may be pressed or molded into the final shape of the hollow tubular substrate, after which the powder is sintered.

[0170]

[0181] In certain examples, a method of manufacturing an aerosol generation system heater element can include extruding a hollow tubular substrate. The hollow tubular substrate can be extruded from any suitable material.

[0171]

[0182] In certain instances, the hollow tubular substrate can be extruded from any of the ceramic materials described hereinabove. For example, the hollow tubular substrate can be formed by extruding a ceramic slurry into a tubular shape. The extruded ceramic slurry can then be fired to harden and rigidify the ceramic into the desired shape of the hollow tubular substrate.

[0172]

[0183] In certain examples, the hollow tubular substrate can be provided with air channels between the inner surface of the hollow tubular substrate and the outer surface of the hollow tubular substrate, which can insulate the metal layer of the seamless hollow tube and reduce heat energy lost through the hollow tubular substrate during operation, thereby increasing the efficiency of the aerosol generating system heater element.

[0173]

[0184] In instances where the hollow tubular substrate is formed from a ceramic material, the ceramic material may be porous, resulting in the formation of air channels between the inner surface of the hollow tubular substrate and the outer surface of the hollow tubular substrate. The necessary porosity of the ceramic material may be provided by sintering a ceramic powder to form the hollow tubular substrate.

[0174]

[0185] The metal layer can be coated onto the hollow tubular substrate by any suitable coating method that results in the metal layer being attached to the hollow tubular substrate.

[0175]

[0186] In certain examples, coating the hollow tubular substrate may include, for example, atom-by-atom or molecule-by-molecule coating of the metal layer. In certain examples, the metal layer can be coated onto the hollow tubular substrate by depositing the metal material of the metal layer onto the hollow tubular substrate.

[0176]

[0187] In certain examples, depositing the metal layer can include electroplating the metal layer onto the interior surface of the hollow tubular substrate.

[0177]

[0188] In certain examples, depositing the metal layer can include physical vapor deposition of the metal layer on the interior surface of the hollow tubular substrate.

[0178]

[0189] In certain examples, depositing the metal layer can include chemical vapor deposition of the metal layer on the interior surface of the hollow tubular substrate.

[0179]

[0190] In certain examples, depositing the metal layer can include thermally spraying the metal layer onto the surface of the hollow tubular substrate.

[0180]

[0191] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. The embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. It is understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention, as defined by the claims, or limitations on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure may include other concepts not claimed herein but which may be claimed in the future.

Claims

1. 1. A method of manufacturing an aerosol generating system heater element comprising a seamless hollow tube, the method comprising: deforming a wall of a hollow tube to form the seamless hollow tube, the seamless hollow tube having a deformed wall, the deformed wall of the seamless hollow tube being thinner than the wall of the hollow tube; The seamless hollow tube has a substantially uniform cross section and thickness along its length. method.

2. 2. The method of claim 1, wherein the wall of the hollow tube has a first inner cross-sectional circumference and the deformed wall of the seamless hollow tube has a second inner cross-sectional circumference that is at least as long as the first inner cross-sectional circumference.

3. The method of claim 2 , wherein the deformed wall of the seamless hollow tube has a second inner cross-sectional circumference that is longer than the first inner cross-sectional circumference.

4. The method according to any one of claims 1 to 3, wherein the seamless hollow tube has a substantially circular cross section.

5. 4. The method of claim 2 or claim 3, wherein the step of deforming the wall of the hollow tube comprises hydroforming the hollow tube to expand the first cross-sectional inner circumference of the hollow tube.

6. The method of any one of claims 1 to 4, wherein the step of deforming the wall of the hollow tube comprises swaging the hollow tube over a mandrel.

7. 7. The method of claim 6, wherein the step of deforming the wall of the hollow tube comprises swaging the hollow tube by squeezing the hollow tube through a mold.

8. The method of claim 6 , wherein the step of deforming the wall of the hollow tube comprises rotary swaging the hollow tube.

9. The method of any one of claims 1 to 4, wherein the step of deforming the wall of the hollow tube comprises ironing the wall of the hollow tube through at least one ironing die.

10. 10. The method of claim 9, wherein the hollow tube is formed by deep drawing a blank of sheet material.

11. The method of any one of claims 1 to 10, wherein the hollow tube comprises a metallic material.

12. 12. The method of claim 11, wherein the metallic material is selected from at least one of iron, iron alloys, stainless steel, mild steel, molybdenum, silicon carbide, aluminum, aluminum alloys, gold, copper, cupronickel alloys, iron-chromium-aluminum alloys, and nickel aluminide alloys.