Method for manufacturing or assembling an aerosol generator

Abstract

A method of manufacturing or assembling an aerosol generator for an aerosol delivery device (100) is disclosed, the method including providing a tubular housing (104) including a plurality of separated ring electrodes (101) embedded in a matrix; inserting a susceptor element (103), a plug element (105) and a cleaning tube (106) into the tubular housing (104); securing the plug element (105) to the tubular housing (104) and contacting the plug element (105) with the susceptor element (103) to secure the susceptor element (103) within the tubular housing (104); and securing the cleaning tube (106) to the tubular housing (104) and contacting the cleaning tube (106) with the susceptor element (103).

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing or assembling an aerosol generator, a method for manufacturing or assembling an aerosol delivery device, an aerosol generator, an aerosol delivery device and an aerosol generation system, and a method for generating an aerosol. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to produce alternatives to these articles by creating products that release compounds without combustion. Examples of such products include so-called "heat-no-burn" products, or tobacco heating devices and products, which release compounds by heating, but not burning, a material. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] Aerosol delivery systems are known that cover the above-mentioned devices and products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by a user. Often, the medium used must be replaced or changed to provide a different aerosol for inhalation. It is known to use an induction heating system as a heater for generating an aerosol from a suitable medium. An induction heating system generally consists of a magnetic field generating device that generates a varying magnetic field and a heatable susceptor or heating material that is permeated with the varying magnetic field and heats the suitable medium.

[0004] Induction coils are known magnetic field generating devices. Induction coils can be formed in a shape suitable for achieving the desired heating of a material. This can be achieved by winding a suitable material, such as Litz wire (RTM), into the desired coil shape. However, the coil shape (e.g., pitch) can be unintentionally changed during device assembly, which can result in the desired heating of the material not being achieved.

[0005] It would be desirable to provide an improved aerosol delivery device. Summary of the Invention

[0006] According to one aspect, there is provided a method of manufacturing or assembling an aerosol generator for an aerosol delivery device, the method comprising: providing a tubular housing comprising a plurality of separated ring electrodes embedded within a matrix; inserting the susceptor element, the plug element, and the cleaning tube into the tubular housing; securing the susceptor element within the tubular housing by securing a plug element to the tubular housing and contacting the plug element with the susceptor element, and by securing a cleaning tube to the tubular housing and contacting the cleaning tube with the susceptor element; Includes.

[0007] According to various embodiments, a method for assembling an aerosol generator is disclosed that allows the various components to be easily assembled without the need for fasteners, adhesives, or specialized tools. For example, a tubular housing can be provided that includes a plurality of ring electrodes embedded in a matrix and formed by an injection molding process. A susceptor element can be secured to the tubular housing between a plug element and a cleaning tube. According to one embodiment, the susceptor element can be held in compression between the plug element and the cleaning tube. Both the plug element and the cleaning tube can be attached to the tubular housing and the susceptor element without the use of fasteners, adhesives, or specialized tools; i.e., the components can be snap-fit ​​or compression-fit together.

[0008] Optionally, the plurality of separated ring electrodes embedded within the matrix comprise inductors.

[0009] Optionally, the susceptor element may be secured within the tubular housing by being placed or held in compression between the plug element and the clearing tube.

[0010] Optionally, the step of securing the plug element to the tubular housing comprises inserting the plug element into the tubular housing and providing a snap fit or interference fit with the tubular housing and / or the susceptor element.

[0011] Optionally, the step of securing the cleaning tube to the tubular housing comprises inserting the cleaning tube into the tubular housing and providing a snap fit or interference fit with the tubular housing and / or the susceptor element.

[0012] Optionally, the step of providing a tubular housing comprises injection molding a matrix around the ring electrodes. Optionally, the injection molding comprises: placing a plurality of ring electrodes within the mold; Injecting a matrix into a mold; curing the matrix around the plurality of ring electrodes to form a tubular housing; Includes.

[0013] Optionally, the matrix or the tubular housing comprises a thermoplastic material.

[0014] Optionally, the matrix or tubular housing comprises polyetheretherketone ("PEEK").

[0015] Optionally, the method further comprises arranging a portion of the ring electrode to extend beyond the tubular housing to form an electrical connection.

[0016] Optionally, the method further comprises mounting, fastening or soldering electrical connections to the first substrate.

[0017] Optionally, the first substrate comprises a first printed circuit board ("PCB"). Optionally, the first substrate comprises one or more electrical connectors or pads, and the method further comprises: Electrically connecting the one or more electrical connectors or pads to one or more electrical connectors or pads provided on the second substrate.

[0018] Optionally, the second substrate comprises a second printed circuit board ("PCB").

[0019] Optionally, the plurality of separated ring electrodes comprises 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more than 20 ring electrodes.

[0020] Optionally, the plurality of ring electrodes are coaxially arranged within the tubular housing.

[0021] Optionally, the plurality of ring electrodes are equally spaced axially.

[0022] Optionally, the plurality of ring electrodes are grouped into at least a first group of ring electrodes and a second group of ring electrodes.

[0023] Optionally, the method further comprises securing one or more thermocouple wires to the susceptor element.

[0024] Optionally, the method further comprises passing one or more thermocouple wires through openings or notches in the tubular housing.

[0025] Optionally, the method further comprises inserting a seal into an opening or notch in the tubular housing to form a seal with the tubular housing around the one or more thermocouple wires.

[0026] Optionally, the method further comprises passing one or more thermocouple wires through openings or notches provided in the first substrate.

[0027] Optionally, the method further comprises applying a ferrite shielding layer to the tubular housing.

[0028] Optionally, applying the ferrite shield layer to the tubular housing comprises adhering the ferrite shield to the tubular housing using a self-adhesive.

[0029] According to another aspect, there is provided a method of manufacturing or assembling an aerosol generator for an aerosol delivery device, the method comprising: providing a tubular housing comprising a plurality of separated ring electrodes embedded in a matrix and comprising an integral plug element; inserting a susceptor element into the tubular housing so that it contacts the integral plug element; Inserting a cleaning tube into the tubular housing; securing a cleaning tube to the tubular housing and contacting the susceptor element with the cleaning tube to secure the susceptor element within the tubular housing; Includes.

[0030] According to another aspect, there is provided a method of manufacturing or assembling an aerosol generator for an aerosol delivery device, the method comprising: providing a tubular housing having a plurality of separated ring electrodes embedded in a matrix and having an integral clearing tube; inserting the susceptor element into the tubular housing so that it contacts the integral cleaning tube; Inserting a plug element into the tubular housing; securing a plug element to the tubular housing and contacting the susceptor element with the plug element to secure the susceptor element within the tubular housing; Includes.

[0031] According to another aspect, there is provided a method of manufacturing or assembling an aerosol delivery device comprising a method as disclosed above.

[0032] According to another aspect, a tubular housing having a plurality of separated ring electrodes embedded in a matrix; A plug element; Cleaning pipe and a susceptor element; Equipped with a plug element secured to the tubular housing and in contact with the susceptor element, and a cleaning tube secured to the tubular housing and in contact with the susceptor element, for securing the susceptor element within the tubular housing; An aerosol generator is provided.

[0033] According to another aspect, a tubular housing comprising a plurality of separated ring electrodes embedded in a matrix and further comprising an integral plug element; Cleaning pipe and a susceptor element; Equipped with a plug element contacting the susceptor element to secure the susceptor element within the tubular housing, and a cleaning tube secured to the tubular housing and contacting the susceptor element; An aerosol generator is provided.

[0034] According to another aspect, a tubular housing comprising a plurality of separated ring electrodes embedded in a matrix and further comprising an integral cleaning tube; A plug element; a susceptor element; Equipped with a plug element secured to the tubular housing and contacting the susceptor element to secure the susceptor element within the tubular housing, and a cleaning tube contacting the susceptor element; An aerosol generator is provided.

[0035] Optionally, the susceptor element is secured within the tubular housing by being placed or held in compression between the plug element and the cleaning tube.

[0036] According to another aspect, The above-mentioned aerosol generator An aerosol delivery device is provided, comprising:

[0037] According to another aspect, the aerosol delivery device described above; an aerosol-producing article; An aerosol generating system is provided, comprising:

[0038] According to another aspect, Providing an aerosol delivery device as described above; inserting an aerosol production article into an aerosol delivery device; energizing the ring electrode, thereby heating the susceptor element and the aerosol product; A method for generating an aerosol is provided, comprising:

[0039] According to another aspect, placing a plurality of separated ring electrodes in the mold; Injecting the matrix into a mold; cooling or hardening the matrix to form a tubular housing having a plurality of ring electrodes embedded therein; A method of manufacturing an aerosol generator is provided, comprising:

[0040] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0041] [Figure 1] FIG. 1 illustrates an aerosol delivery device according to one embodiment, the aerosol delivery device comprising an inductor formed from a plurality of separated ring electrodes mounted on a first substrate comprising a printed circuit board. [Figure 2] FIG. 1 illustrates an inductor according to one embodiment comprising a plurality of ring electrodes mounted on a first substrate comprising a printed circuit board. [Figure 3]1 shows a cross-sectional view of an aerosol generator according to one embodiment. [Figure 4] FIG. 1 shows a side view of an aerosol generator according to one embodiment. [Figure 5] FIG. 1 shows a side view of an aerosol generator according to one embodiment. [Figure 6] 1 shows a cross-sectional view of an aerosol generator according to one embodiment. [Figure 7] 1A-1D illustrate a method of assembling an aerosol generator for an aerosol delivery device according to one embodiment of the present disclosure. [Figure 8] 10A-10C illustrate a method of inserting a susceptor element into a tubular housing according to one embodiment. [Figure 9A] 10A-10C illustrate how a seal can be inserted into an opening or notch in the tubular housing to form a seal around one or more thermocouple wires. [Figure 9B] 10A-10C illustrate how the electrical connections of the ring electrodes may be attached, mounted, fastened, or soldered to the first substrate. [Figure 10A] FIG. 1 illustrates an assembled aerosol generator according to one embodiment. [Figure 10B] 1A-1D show different views of an assembled aerosol generator according to one embodiment. [Figure 10C] FIG. 1 shows an end view of the assembled aerosol generator. [Figure 11] 10A-10C illustrate steps for applying a ferrite shielding layer to a tubular housing according to one embodiment. [Figure 12] 10A-10C illustrate how a plug element may be inserted into a tubular housing according to one embodiment after a ferrite shield has been applied to the tubular housing. [Figure 13A] 1 shows a diagram of the aerosol generator after it has been assembled. [Figure 13B] 1 shows another view of the aerosol generator after it has been assembled. DETAILED DESCRIPTION OF THE INVENTION

[0042] Aspects and features of particular examples and embodiments are discussed or described herein. Some aspects and features of particular examples and embodiments may be conventionally implemented and, for the sake of brevity, will not be discussed or described in detail. Thus, it will be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented in accordance with conventional techniques for implementing such aspects and features.

[0043] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0044] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0045] In some embodiments, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0046] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0047] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, include tobacco or a non-tobacco product.

[0048] Generally, a non-combustible aerosol delivery system may include a non-combustible aerosol delivery device and a consumable item for use with the non-combustible aerosol delivery device.

[0049] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol-forming materials and are configured for use with non-combustible aerosol delivery devices.

[0050] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat transfer material proximate the heat generating power source.

[0051] In some embodiments, the non-combustible aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0052] In some embodiments, consumables for use with non-combustible aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage areas, aerosol-generating material delivery components, aerosol generators, aerosol-generating areas, housings, packaging, filters, mouthpieces, and / or aerosol modifiers.

[0053] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-forming material may be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavoring materials.

[0054] The aerosol-forming material may include a binder and an aerosol-forming agent. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-forming material may or may not be soluble in the solvent. In some embodiments, the aerosol-forming material is substantially free of plant material. In particular, in some embodiments, the aerosol-forming material is substantially free of tobacco.

[0055] In some embodiments, the aerosol-generating material may include or be an "amorphous solid." An amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may contain, for example, from about 50%, 60%, or 70% amorphous solid by weight, up to about 90%, 95%, or 100% amorphous solid by weight.

[0056] The aerosol-generating material may include or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with one or more other components, such as a solvent, such as water, an aerosol-forming agent, and an active agent, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film. Heating the slurry may remove at least about 60%, 70%, 80%, 85%, or 90% of the solvent by weight. The aerosol-generating film may be continuous or discontinuous, such as an arrangement of discontinuous portions of the film on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0057] The aerosol-generating film may comprise or be a sheet, optionally chopped to form chopped sheets.

[0058] The aerosol-forming material may include one or more active agents and / or flavors, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0059] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, elevated pressure, or electrostatic energy.

[0060] A consumable is an article that includes or is composed of an aerosol-generating material, some or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that generates heat to generate an aerosol in the aerosol-generating material during use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0061] The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. An aerosol delivery device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0062] The non-combustible aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some embodiments, the non-combustible aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may comprise a power source, such as, for example, a battery or a rechargeable battery. In some embodiments, the non-combustible aerosol delivery device may also include an aerosol generating component. However, in other embodiments, the aerosol product article may partially or entirely include the aerosol generating component.

[0063] Induction heating is a process in which a conductive object, called a susceptor, is heated by immersing it in a varying magnetic field. This process is explained by Faraday's law of induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another so that the varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current, and when such eddy currents are generated within the object, their flow against the object's electrical resistance causes the object to heat. This process is called Joule heating, ohmic heating, or resistive heating.

[0064] Magnetic hysteresis heating is the process of heating an object made of a magnetic material by immersing it in a varying magnetic field. Magnetic materials can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align along the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes in response to the applied varying magnetic field. This reorientation of the magnetic dipoles generates heat within the magnetic material.

[0065] When an object is both conductive and magnetic, permeating it with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating. Furthermore, the use of magnetic materials can strengthen the magnetic field, thereby enhancing Joule heating.

[0066] Various embodiments will now be described in more detail.

[0067] 1 shows an aerosol delivery device 100 according to one embodiment. The aerosol delivery device 100 comprises an outer housing 130 and an inductor or induction heating element comprising a plurality of ring electrodes 101 arranged around a tubular heating chamber housing 104.

[0068] As described in more detail below, the plurality of ring electrodes 101 may be embedded in a matrix to form a tubular heat chamber housing 104. In particular, the tubular heat chamber housing 104 may be formed by an injection molding process, which is described in more detail below.

[0069] A susceptor 103 is provided within the heating chamber housing 104, forming a heating chamber within the susceptor 103. The entrance to the heating chamber is provided with a lid or slidable cover 107. An aerosol product may be inserted into the heating chamber through the lid or slidable cover 107 and may be surrounded by at least a portion of the susceptor 103.

[0070] It will be appreciated that the susceptor 103 is heated to a high temperature by interacting with the magnetic field emitted from the inductor or induction heating element comprising the multiple ring electrodes 101. As a result, the aerosol product article disposed within the susceptor 103 is heated.

[0071] The inductor or induction heating element comprises a plurality of ring electrodes 101 mounted on a first substrate 102. The first substrate 102 may comprise a printed circuit board ("PCB"). According to various embodiments, the inductor or induction heating element may comprise 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more than 20 ring electrodes 101.

[0072] The susceptor 103 may be disposed within the heat chamber housing 104 and may be mounted or held in compression between the top 105 of the heat chamber housing 104 and the sweep tube 106. It should be understood that the term held in compression refers to the position of the susceptor 103 rather than the susceptor 103 being subjected to a high compressive force.

[0073] The top 105 of the heat chamber housing 104 may comprise a separate component, which may be referred to as a plug element. Alternatively, the top 105 of the heat chamber housing 104 may be integral with the body of the heat chamber housing 104. According to this embodiment, the plug element may be integral with the body of the heat chamber housing 104, and the susceptor 103 and cleaning tube 106 may be inserted through a lower opening in the heat chamber housing 104.

[0074] Various different methods of assembling or manufacturing the disclosed arrangement are contemplated. According to one embodiment, the susceptor 103 may be inserted into the heat chamber housing 104 through the lower opening and attached to (or contacted with) the top portion 105 of the heat chamber housing 104. The cleaning tube 106 may then be inserted into and secured to both the heat chamber housing 104 and the susceptor 103. Embodiments are contemplated in which the susceptor 103 is held in compression between the top portion 105 of the heat chamber housing 104 and the cleaning tube 106.

[0075] Embodiments are also contemplated in which the cleaning tube 106 may be integral with the heat chamber housing 104. According to this embodiment, the susceptor 103 and plug element may be inserted into the heat chamber housing 104 via an upper opening in the heat chamber housing 104.

[0076] According to one embodiment, a method of manufacturing or assembling an aerosol generator for an aerosol delivery device is disclosed, the method including providing a tubular housing 104 including a plurality of separated ring electrodes 101 embedded in a matrix, the tubular housing 104 including an integral plug element. The method may include inserting a susceptor element 103 into the tubular housing 104, contacting the susceptor element 103 with the integral plug element, inserting a cleaning tube 106 into the tubular housing 104, securing the cleaning tube 106 to the tubular housing 104, and contacting the susceptor element 103 with the cleaning tube 106 to secure the susceptor element 103 within the tubular housing 104.

[0077] According to another method, a tubular housing 104 may be provided that includes a plurality of separated ring electrodes 101 embedded in a matrix. The tubular housing 104 may include an integral cleaning tube 106. The method may further include inserting a susceptor element 103 into the tubular housing 104 and securing the susceptor element 103 to (or contacting) the integral cleaning tube 106. The method may further include inserting a plug element into the housing 104, securing the plug element to the tubular housing 104, and contacting the susceptor element 103 to secure it within the tubular housing 104.

[0078] The susceptor 103 comprises a heating material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor 103 may comprise a conductive material, such that penetration of the conductive material by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor 103 may be both conductive and magnetic, such that the susceptor 103 can be heated by both heating mechanisms. The susceptor 103 may include a ferroelectric material and / or a ferromagnetic material.

[0079] The aerosol product article may be inserted through an inlet into the heating chamber formed by the susceptor 103. The aerosol product article may be received within the heating chamber such that the aerosol product article is in thermal communication with the susceptor 103. Thus, when the susceptor 103 is inductively heated, the susceptor 103 conducts heat to the aerosol product article, thereby enabling the generation of an aerosol from the aerosol-generating material comprising the aerosol product article.

[0080] The control device 109 may be provided on a second substrate 150 (which may comprise a printed circuit board) and may be connected to the first substrate 109 via one or more electrical connections. The control device 109 may be arranged to apply an AC or RF voltage to the ring electrode 101 to generate a time-varying magnetic field. The time-varying magnetic field heats the heating material of the susceptor 103.

[0081] According to one embodiment, the control device 109 may be configured to apply an AC or RF voltage independently to each ring electrode 101. Alternatively, the control device 109 may be configured to apply an AC or RF voltage to a group of ring electrodes 101.

[0082] It will be appreciated that passing an alternating current through each of the ring electrodes 101 generates an alternating magnetic field, which heats the corresponding region of the susceptor 103 .

[0083] 1, the control device 109 may be provided on a second substrate 150 that is separate from the first substrate 102 on which the ring electrodes 101 are disposed. However, other embodiments are contemplated in which all or some of the components of the control device 109 may be located on the same first substrate 102 on which the ring electrodes 101 are disposed.

[0084] According to various embodiments, the first substrate 102 and the second substrate 150 may comprise printed circuit boards (PCBs). The first substrate 102 or the printed circuit board may include one or more connectors or pads on a rear surface of the first substrate 102 that may be positioned to electrically connect with corresponding connectors or pads on a front surface of the second substrate 150 or the printed circuit board.

[0085] Embodiments are contemplated in which the control device 109 may be located on a substrate 150 different from the first substrate 102 on which the ring electrode 101 is arranged, and in which a wireless connection may be made between the first substrate 102 and the other substrate 150.

[0086] Figure 2 shows in more detail an inductor or induction heating element according to one embodiment, which comprises a plurality of separated ring electrodes 101 mounted on a first substrate 102. According to the particular embodiment shown in Figure 2, twelve ring electrodes 101 are mounted on the first substrate 102. However, it will be appreciated that according to other embodiments, a different number of ring electrodes 101 may be mounted on the first substrate 102.

[0087] Various embodiments of inductors or induction heating elements that include multiple separated ring electrodes 101 can allow different desired inductor geometries to be easily configured. For example, the number of ring electrodes 101 can be varied and / or the separation distance between the ring electrodes 101 can be varied, thereby achieving different heating profiles.

[0088] According to various embodiments, the ring electrodes 101 may be embedded within a matrix.

[0089] According to various embodiments, the ring electrode 101 may comprise a rigid electrode embedded in a matrix, which may result in a robust inductor or induction heating element when the ring electrode 101 is provided on or secured to the first substrate 102. It will therefore be appreciated that various embodiments may provide a particularly robust and robust aerosol delivery device.

[0090] Each separate ring electrode 101 may be provided as a discrete element mounted on a first substrate 102, with each ring electrode 101 spaced apart from one another.

[0091] Each ring electrode 101 may comprise a ring section or ring portion having an electrical connection at each end. The ends of the ring electrodes 101 may comprise electrical connections that may be attached or otherwise fixed to the first substrate 102. Each ring electrode 101 may be electrically connected to and supported by the first substrate 102 via the electrical connections.

[0092] According to various embodiments, each ring electrode 101 may include two electrical connections that allow the ring electrode 101 to be positioned on the first substrate 102 independently of the other ring electrodes 101 while allowing for proper electrical connection to the first substrate 102. Each ring electrode 101 may have its own electrical connection to the first substrate 102, independent of the electrical connections of at least some of the other electrodes 101 to the first substrate 102, to allow for independent control of the particular electrode 102.

[0093] The ring electrode 101 may be attached to the first substrate 102 in any suitable manner. In one embodiment, the electrical connection portion and / or the first substrate 102 may be configured and adapted to connect to one another. For example, the electrical connection portion of the ring electrode 101 and the first substrate 102 may be configured such that the electrical connection portion is inserted into a corresponding hole or slot in the first substrate 102. Other embodiments are contemplated in which the electrical connection portion comprises a hole or slot configured to attach to a corresponding electrode in the first substrate 102. Attachment means such as screws may be used.

[0094] According to one embodiment, the ring electrodes 101 may be soldered to the first substrate 102. To facilitate this, the electrical connections may be configured to be soldered to corresponding slots in the first substrate 102, which may comprise a printed circuit board. The electrical connections may be coated with a material (e.g., gold) to facilitate solder connection to the first substrate 102.

[0095] According to various embodiments, insertion of the electrical connection portion into a corresponding slot in the first substrate 102 may be sufficient to secure the ring electrode 101 to the first substrate 102 and form an electrical connection between the first substrate 102 and the ring electrode 101. For example, according to various embodiments, the ring electrode 101 may be connected to the first substrate 102 by an interference fit or a snap fit.

[0096] According to various embodiments, a method of manufacturing or assembling an aerosol generator is disclosed that includes positioning a portion of the ring electrode 101 to extend beyond the tubular housing 104 to form an electrical connection. The method may further include mounting, fastening, or soldering the electrical connection to a first substrate 102, which may comprise a first printed circuit board ("PCB"). The first substrate 102 may include one or more electrical connectors or pads, and the method may further include electrically connecting the one or more electrical connectors or pads to one or more electrical connectors or pads provided on a second substrate 150. The second substrate 150 may comprise a second printed circuit board ("PCB").

[0097] An alternating current is arranged to pass through the ring portion of the electrode 101 via an electrical connection, thereby generating a varying magnetic field. It will be appreciated that the varying magnetic field heats a susceptor 103 located radially inside the ring electrode 101. The susceptor 103 may be disposed within a volume defined by the inner diameter of the ring portion of the ring electrode 101. One end of the susceptor 103 may be fixed to a portion of the heating chamber housing 104. The other end of the susceptor 103 may be fixed to a cleaning tube 106.

[0098] The ring electrodes 101 may be arranged coaxially with one another. Each of the ring electrodes 101, or at least a ring portion thereof, may be substantially planar, i.e., flat. The ring electrodes 101 may be substantially planar in a plane perpendicular to the axis of the ring electrode 101 or the longitudinal axis of the inductor or induction heating element. The ring electrodes 101 may be aligned with one another when attached to the first substrate 102 so that the flat surfaces of the ring electrodes 101 are in parallel planes. Providing flat ring electrodes 101 allows for localized heating of a relatively small portion of the susceptor 103 by each ring electrode 101, thereby enabling precise control of the temperature distribution along the length of the susceptor 103.

[0099] In other embodiments, it is contemplated that the ring electrodes 101 may be non-planar, e.g., helical, to heat a relatively long susceptor 103 with fewer electrodes. The ring electrodes 101 may have a rectangular, circular, or polygonal cross-sectional shape. The ring portions may comprise a conductive material, e.g., copper or gold. It is also contemplated that each ring electrode 101 may have conductive tracks on one or both planes, or that the ring portions themselves may be (entirely) constructed from a conductive material (e.g., copper). The ring electrodes 101 may be constructed, for example, by cutting from a flat sheet material or by bending a strip of material into the required shape. The ring electrodes 101 are shown mounted in a heating chamber housing 104 connected to a cleaning tube 106.

[0100] 3 shows a cross-sectional view of an aerosol generator according to various embodiments. The aerosol generator comprises an inductor or induction heating element including a plurality of separated ring electrodes 101 mounted on a first substrate 102, which may comprise a printed circuit board. The ring electrodes 101 are embedded within a heating chamber housing 104. The aerosol generator further comprises a susceptor 103 disposed within the heating chamber housing 104.

[0101] According to one embodiment, the susceptor 103 may be disposed between the top 105 of the heating chamber housing 104 and the cleaning tube 106. The heating chamber housing 104 may be disposed within the ring portion of the ring electrode 101, and the susceptor 103 may be disposed within the heating chamber housing 104.

[0102] The electrical connection portions of the ring electrodes 101 may extend beyond the heating chamber housing 104 to allow connection to the first substrate 102. A plurality of spacers 111 formed of an electrically insulating material (e.g., a thermoplastic such as polyetheretherketone (PEEK)) may be disposed between the ring electrodes 101. The spacers 111 may have a cross-sectional shape that substantially corresponds to the ring portions of the electrodes 101.

[0103] However, it should be understood that the spacers 111 are optional, and the ring electrodes 101 and / or the heating chamber housing 104 may be sufficiently rigid so that it is not necessary to provide the spacers 111 between the ring electrodes 101. For example, the heating chamber housing 104 may form a spacer portion between each of the ring electrodes in place of the spacers 111.

[0104] According to various embodiments, the ring electrodes 101 may be embedded in a matrix to form a tubular housing 104 that forms the heating chamber housing 104. It will be appreciated that the ring electrodes 101 may be embedded in the matrix during an injection molding process, and the tubular housing 104 with the embedded ring electrodes 101 may be particularly strong. Thus, spacers 111 may not be utilized.

[0105] According to various embodiments, a temperature sensor 113 such as a thermocouple may be attached to the susceptor 103 to sense the temperature of the susceptor 103 .

[0106] FIG. 4 shows a side view of the ring electrode 101, spacer 111, heating chamber housing 104, upper portion 105 of the heating chamber housing, cleaning tube 106, and first substrate 102 mounted on the electrical connection portion of ring electrode 101.

[0107] According to various embodiments, the ring electrode 101 may be embedded within the heating chamber housing 104 .

[0108] 5 shows a side view of an aerosol generator according to various embodiments. The aerosol generator comprises an inductor or induction heating element including a plurality of separated ring electrodes 101 mounted on a first substrate 102 (e.g., a PCB). The aerosol generator further comprises a susceptor (not shown), a heating chamber housing 104, an upper housing 105, and a cleaning tube 106.

[0109] The ring electrode 101 may be embedded in a matrix to form the heating chamber housing 104. According to one embodiment, the matrix may be injection molded around the ring electrode 101 to form the heating chamber housing 104. The matrix or heating chamber housing 104 may comprise a thermoplastic material such as polyetheretherketone (PEEK).

[0110] The first substrate 102 (e.g., a PCB) may be connected to the ring electrode 101 before or after the heat chamber housing 104 is formed around the ring electrode 101. One end of the heat chamber housing 104 may be configured to be attached to the upper housing 105, and the other end of the heat chamber housing 104 may be configured to be attached to the cleaning tube 106. A susceptor element may be disposed within the heat chamber housing 104 between the cleaning tube 106 and the upper housing 105. According to various embodiments, the susceptor may be held in compression between the upper housing 105 and the cleaning tube 106.

[0111] Shielding 117 may be provided around the outside of ring electrode 101 to prevent the magnetic field generated by ring electrode 101 from being transmitted radially outward and thus towards the user. A thermocouple 113 may be attached to the susceptor to measure the temperature of the susceptor element.

[0112] 6 shows a cross-sectional view of an aerosol generator according to one embodiment. According to one embodiment, a first seal 114a may be provided between the upper housing 105 and the heating chamber housing 104. A second seal 114b may be provided between the heating chamber housing 104 and the cleaning tube 106.

[0113] The heating chamber housing 104 may be formed with a single piece or a continuous upper portion instead of a separate, distinct upper housing 105. The upper housing 105 may comprise a thermoplastic material such as polyetheretherketone (PEEK). The heating chamber housing 104 may be formed with a hole or slot into which a thermocouple 113 may be inserted. The thermocouple 113 may be positioned to sense the temperature of the susceptor 103. A seal 115a may be provided to secure the thermocouple 113 within the hole or slot provided in the heating chamber housing 104. The seal 115a may abut against the surface of the first substrate 102 on which the multiple ring electrodes 101 are attached.

[0114] Shielding material 117 may be provided around the outside of ring electrode 101 to attenuate the magnetic field generated by ring electrode 101 in a radial direction toward the outer housing of the aerosol delivery device. According to various embodiments, shielding material 117 may be provided as an adhesive wrap. Shielding material 117 may include a magnetic material such as ferrite.

[0115] The susceptor 103 may be secured within the heat chamber housing 104 by being attached to (or contacting) the cleaning tube 106 at one end and attached to (or contacting) the top of the upper housing 105 and / or the heat chamber housing 104 at the other end. For example, if the heat chamber housing 104 includes an integral upper portion 105, the susceptor 103 may be inserted into the heat chamber housing 104 from the end opposite the upper portion 105. Once the susceptor 103 is inserted, the cleaning tube 106 may then be configured to be attached to (or contact) the end of the susceptor 103. According to one embodiment, the cleaning tube 106 may have a snap-fit ​​connection with the susceptor 103 to secure the susceptor 103 between the upper portion 105 and the cleaning tube 106. Other embodiments are contemplated in which the susceptor 103 is held in compression between the upper portion 105 and the cleaning tube 106.

[0116] According to one embodiment, the cleaning tube 106 may be configured to be attached to the susceptor 103 such that the cleaning tube 106 is first attached to the susceptor 103, and then both the susceptor 103 and the attached cleaning tube 106 are inserted together into the heating chamber housing 104 and secured to the top of the heating chamber housing 104.

[0117] If a separate upper housing 105 is provided, the susceptor 103 may be inserted into the heat chamber housing 104 through the bottom of the heat chamber housing 104, as described above. Alternatively, the susceptor 103 may be inserted through the top end of the heat chamber housing 104, and then the upper housing 105 may be secured to (or contact) the susceptor 103. The upper housing 105 may be configured to attach to the heat chamber housing 104, for example, using a compression fit.

[0118] According to various embodiments, the multiple ring electrodes 101 may be arranged in one or more electrode groups. For example, the aerosol generator may be configured to heat different regions of the susceptor 103 (and therefore different regions of the aerosol product) to different temperatures. For example, each group of electrodes 101 may be arranged to maintain a corresponding portion of the susceptor 103 at a different temperature during use.

[0119] According to the embodiment shown in Figure 6, the ring electrodes 101 may be arranged in a first group of ring electrodes 101a and a second group of ring electrodes 101b. In the particular embodiment shown in Figure 6, the first group of ring electrodes 101a comprises seven ring electrodes 101 and the second group of ring electrodes 101b comprises five ring electrodes 101. However, it will be understood that both the first group of ring electrodes 101a and the second group of ring electrodes 101b may comprise a different number of ring electrodes 101.

[0120] It is contemplated that different regions of the susceptor 103 may be maintained at different temperatures during use, which may be achieved by applying a different voltage to the first group of ring electrodes 101a than to the second group of ring electrodes 101b.

[0121] Other embodiments are contemplated in which the axial separation (pitch) between electrodes 101 in different groups and / or the number of electrodes 101 in different groups may vary. For example, a first group of ring electrodes 101a may have a first axial spacing S1 between the electrodes, and a second group of ring electrodes 101b may have a second, different axial spacing S2 between the electrodes. According to one embodiment, the first axial spacing S1 may be <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm, or >10 mm. Similarly, according to one embodiment, the second axial spacing S2 may be <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm, or >10 mm.

[0122] It is contemplated that different temperatures may additionally or alternatively be achieved by the aerosol delivery device being configured to supply different voltages and / or currents to different groups of electrodes 101. The aerosol delivery device may include a control device 109 (as shown and described above in connection with FIG. 1 ) that may be configured to independently apply either one or more AC or RF voltages to the groups of ring electrodes 101. This allows different voltages to be independently applied to different groups of ring electrodes 101.

[0123] For example, the control device 109 may be configured to simultaneously apply different non-zero voltages to different groups of ring electrodes 101, and / or to apply a voltage to one or more groups of ring electrodes 101 while applying substantially no voltage to one or more other groups of ring electrodes 101. The control device 109 may be arranged to independently apply either one or more AC or RF voltages to individual ring electrodes 101 of the same or different groups.

[0124] According to one embodiment, the control device 109 may be arranged to supply a first voltage V1 to the first group of first ring electrodes 101a and a second voltage V2 to the second group of ring electrodes 101b. According to various embodiments, the ratio V1 / V2 may be in the range <0.5, 0.5-0.6, 0.6-0.7, 0.7-0.8, 0.8-0.9, 0.9-1.0, 1.0-1.1, 1.1-1.2, 1.2-1.3, 1.3-1.4, 1.4-1.5, or >1.5.

[0125] According to one embodiment, the frequency f1 of the first voltage V1 and the frequency f2 of the second voltage V2 may be different. According to various embodiments, the ratio f1 / f2 may be in the range of <0.5, 0.5-0.6, 0.6-0.7, 0.7-0.8, 0.8-0.9, 0.9-1.0, 1.0-1.1, 1.1-1.2, 1.2-1.3, 1.3-1.4, 1.4-1.5, or >1.5.

[0126] According to other embodiments, the aerosol generator may comprise a single group of ring electrodes 101, and the control device 109 may be arranged to apply one or more AC or RF voltages independently to each of the individual ring electrodes 101.

[0127] By maintaining different regions of the susceptor 103 at different temperatures, it is possible to selectively heat different portions of an aerosol product article inserted into the aerosol generator while not heating other specific portions of the aerosol product article. For example, the control device 109 may be configured to apply one or more voltages to the first group 101a of ring electrodes 101 to heat a first portion of the aerosol product article at a first time t1, while not heating a second portion of the aerosol product article at the same first time t1.

[0128] At a second time t2, the control device 109 may be configured to apply one or more voltages to the second group 101b of ring electrodes so as to heat a second portion of the aerosol product while not heating the first portion of the aerosol product at the same second time t2.

[0129] Additionally or alternatively, the control device 109 may be configured to apply specific voltages to specific groups of electrodes to heat a portion of the aerosol product to a certain temperature, and simultaneously apply different voltages to different groups of electrodes to heat different portions of the aerosol product to different temperatures.

[0130] The control device 109 may comprise or consist of circuits or circuit elements. The circuits / circuit elements may be programmable or configured by software. According to various embodiments, the control device 109 may be disposed on the first substrate 102 on which the plurality of ring electrodes 101 are mounted, or the control device 109 may be disposed on a separate substrate, such as on another printed circuit board that may be connected to the first substrate 102.

[0131] Each group of ring electrodes 101 may be axially spaced apart from one another. The ring electrodes 101 may be arranged such that the flat surfaces of the ring electrodes 101 of different groups are in parallel planes. Each group of electrodes 101 may comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more than 20 ring electrodes 101.

[0132] Embodiments are contemplated in which the ring electrodes 101 may be grouped into 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 groups of electrodes 101. Each group may include the same or a different number of ring electrodes 101. Each group of ring electrodes 101 may include at least 2, 3, 4, 5, or more than 5 ring electrodes 101. For example, according to one embodiment, the ring electrodes 101 may be arranged in two to five groups of ring electrodes 101, with each group of ring electrodes 101 including at least three ring electrodes 101. The ring electrodes 101 of different groups may all be disposed on the same first substrate 102, or alternatively, the electrodes 101 of different groups may be disposed on different substrates.

[0133] According to various embodiments, an aerosol generator is disclosed that includes multiple ring electrodes 101 arranged to form multiple independently controllable heating zones. A control device 109 may be configured to independently energize the ring electrodes 101 such that a heating profile translates along at least a portion of the length of the aerosol generator during use. For example, the control device may be configured to apply AC or RF voltages to individual ring electrodes 101 and / or to groups of ring electrodes 101, either sequentially or according to a predetermined sequence. The aerosol delivery device may include an opening for receiving an aerosol product, with a first heating zone disposed proximal to the opening and a second heating zone disposed distal to the opening. The control device 109 may be configured (i) such that a heating profile translates from the first heating zone to the second heating zone during use, and / or (ii) such that a heating profile translates from the second heating zone to the first heating zone during use.

[0134] Embodiments are contemplated in which the aerosol generator comprises 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 independently controllable heating zones, and the heating profile may be translated between or along the different heating zones.

[0135] Figure 7 illustrates a method 700 for assembling an aerosol generator for an aerosol delivery device in accordance with one embodiment of the present disclosure. According to various embodiments, method 700 illustrates the steps involved in assembling or manufacturing an aerosol generator such as those disclosed in Figures 3 through 6. According to one embodiment, this method can be used to provide an aerosol delivery device such as that shown in Figure 1.

[0136] The method 700 includes providing a tubular housing 104 comprising a plurality of separated ring electrodes 101 (step 701). The separated ring electrodes 101 are embedded in a matrix. Providing the tubular housing 104 may include injection molding the matrix around the ring electrodes 101. In one embodiment, the injection molding includes placing the plurality of ring electrodes 101 in a mold, injecting a matrix into the mold, and allowing the matrix to harden around the plurality of ring electrodes 101 to form the tubular housing 104. In various embodiments, the matrix or the tubular housing 104 comprises a thermoplastic material such as polyetheretherketone ("PEEK").

[0137] The method 700 further includes inserting the susceptor element 103 into the tubular housing 104 (step 702). This step is described in more detail below with reference to FIG. 8. According to various embodiments, the susceptor element 103 may be part of a subassembly that includes a temperature sensor. According to various embodiments, the susceptor element 103 may be attached to either a plug element or a cleanout tube 106.

[0138] According to one embodiment, the plug element may be inserted into the tubular housing 104, then the susceptor element 103 may be inserted into and secured to the plug element, after which the cleaning tube 106 may be attached to both the tubular housing 104 and the susceptor element 103.

[0139] The method 700 includes securing the susceptor within the tubular housing 104 (step 703). While various fittings may be used, advantageous embodiments are contemplated in which the various components, i.e., the susceptor element 103, the plug element, and the cleanout tube 106, can be inserted and secured to one another and to the tubular housing 104 without the need to use adhesives, screws, or the like.

[0140] The method 700 may further include establishing an electrical connection from the exterior of the tubular housing 104 to a temperature sensor, such as a thermocouple, attached to the susceptor element 103. The temperature sensor may be provided by fastening one or more thermocouple wires 113 to the susceptor element 103, such as by using welding. In one embodiment, the method includes threading the one or more thermocouple wires 113 through openings or notches provided in the tubular housing 104 (see FIG. 6 ). For example, the one or more thermocouple wires 113 may be attached to the susceptor element 103 before the susceptor element 103 is inserted into the tubular housing 104. After the susceptor element 103 is inserted into the tubular housing 104, the one or more thermocouple wires 113 can be threaded through the openings or notches. Alternatively, one or more thermocouple wires 113 may be secured to the susceptor element 103 through openings or notches after the susceptor element 103 is inserted into the tubular housing 104 .

[0141] In one embodiment, the method includes inserting a seal 115a into an opening or notch in the tubular housing 104 to form a seal with the tubular housing 104 around the one or more thermocouple wires 113. This is shown in both Figures 6 and 9A.

[0142] The method 700 may further include attaching, mounting, fastening, or soldering an electrical connection to the first substrate 102 (step 705). The method may include arranging a portion of the ring electrode 101 to extend beyond the tubular housing 104 to form an electrical connection for attaching, mounting, fastening, or soldering the first substrate 102 to the ring electrode 101. Figure 9B shows how this step may be performed. The first substrate 102 may include a first PCB.

[0143] In one embodiment, step 705 may be performed after step 702, step 703, and / or step 704. However, in other embodiments, step 705 may be performed as part of step 701. For example, the separated ring electrodes 101 may be attached, mounted, fastened, or soldered to the first substrate 102 before the matrix is ​​injection molded around the ring electrodes 101 to form the tubular housing 104.

[0144] In one embodiment, the first substrate 102 includes one or more electrical connectors or pads, and the method further includes electrically connecting the one or more electrical connectors or pads to one or more electrical connectors or pads provided on a second substrate 150, such as a second PCB 150.

[0145] 10A-10C show the aerosol generator after steps 701-706 have been performed. Method 700 may include applying a ferrite shield layer 117 to the tubular housing 104 (step 706), as shown in FIG. 11 . Applying the ferrite shield layer 117 to the tubular housing may include adhering the ferrite shield 117 to the tubular housing using a self-adhesive. FIG. 12 shows how a plug element 105, which may have a seal 114a, may be inserted into the tubular housing 104 after the ferrite shield 117 has been applied to the tubular housing. FIGS. 13A-13B show the aerosol generator once assembled according to the disclosed method 700.

[0146] It will be apparent that, according to various embodiments, a method of assembling an aerosol generator is disclosed that allows the various components to be easily assembled without the need for fasteners, adhesives, or specialized tools. For example, a tubular housing 104 may be provided with a plurality of ring electrodes 101 embedded in a matrix by an injection molding process. A susceptor element 103 may be secured to the tubular housing 104 between a plug element 105 and a clearing tube 106. Both the plug element 105 and the clearing tube 106 may be attached to the tubular housing 104 and the susceptor element 103 without the use of fasteners, adhesives, or specialized tools; i.e., the components may be snap-fit ​​or compression-fit together.

[0147] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. 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 it should be understood that other embodiments may be utilized and changes may be made without departing from the scope of the claimed invention. Various embodiments of the 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. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A method of manufacturing or assembling an aerosol generator for an aerosol delivery device, comprising: providing a tubular housing comprising a plurality of separated ring electrodes embedded within a matrix; inserting a susceptor element into the tubular housing; contacting the susceptor element with a plug element and contacting the susceptor element with a cleaning tube to secure the susceptor element within the tubular housing; Including, (i) the method includes inserting the plug element and the cleaning tube into the tubular housing and securing the plug element and the cleaning tube to the tubular housing to secure the susceptor element within the tubular housing; or (ii) the plug element is an integral part of the tubular housing, and the susceptor element is inserted into the tubular housing so as to contact the plug element, and the method includes the steps of inserting the cleaning tube into the tubular housing and securing the cleaning tube to the tubular housing to secure the susceptor element within the tubular housing; or (iii) the cleaning tube is an integral part of the tubular housing, and the susceptor element is inserted into the tubular housing so as to contact the cleaning tube, the method including the step of inserting the plug element into the tubular housing and securing the plug element to the tubular housing to secure the susceptor element within the tubular housing.

2. The method of claim 1 , wherein the plurality of isolated ring electrodes embedded within the matrix comprise inductors.

3. The method of claim 1 , wherein the susceptor element is secured within the tubular housing by being placed or held in compression between the plug element and the cleaning tube.

4. The method of claim 1 , wherein the method includes inserting the plug element into the tubular housing and providing a snap fit or interference fit with the tubular housing and / or the susceptor element.

5. The method of claim 1 , wherein the method includes inserting the cleaning tube into the tubular housing and providing a snap or interference fit with the tubular housing and / or the susceptor element.

6. The method of claim 1 , wherein the step of providing the tubular housing comprises injection molding the matrix around the ring electrode.

7. The method of claim 1 , wherein the matrix or the tubular housing comprises a thermoplastic material.

8. The method of claim 1 , further comprising the step of positioning a portion of the ring electrode to extend beyond the tubular housing to form an electrical connection.

9. The method of claim 8 further comprising the step of mounting, fastening, or soldering the electrical connection to a first substrate.

10. the first substrate includes one or more electrical connectors or pads; 10. The method of claim 9, further comprising electrically connecting the one or more electrical connectors or pads to one or more electrical connectors or pads provided on a second substrate.

11. The method of claim 1 , wherein the plurality of ring electrodes are coaxially disposed within the tubular housing.

12. The method of claim 1 , wherein the plurality of ring electrodes are equally spaced axially.

13. The method of claim 1 further comprising the step of securing one or more thermocouple wires to the susceptor element.

14. The method of claim 13 further comprising threading the one or more thermocouple wires through an opening or notch in the tubular housing.

15. 15. The method of claim 14, further comprising inserting a seal into the opening or notch in the tubular housing to form a seal with the tubular housing around the one or more thermocouple wires.

16. The method of claim 1 further comprising applying a ferrite shielding layer to the tubular housing.

17. The method of claim 16 , wherein the step of applying the ferrite shield layer to the tubular housing includes adhering the ferrite shield to the tubular housing using a self-adhesive.

18. a tubular housing having a plurality of separated ring electrodes embedded in a matrix; A plug element; Cleaning pipe and a susceptor element; Equipped with the plug element and the cleaning tube contact the susceptor element to secure the susceptor element within the tubular housing; (i) the plug element and the cleaning tube are secured to the tubular housing to secure the susceptor element within the tubular housing; or (ii) the plug element is an integral part of the tubular housing and the cleaning tube is secured to the tubular housing to secure the susceptor element within the tubular housing; or (iii) The aerosol generator, wherein the cleaning tube is an integral part of the tubular housing, and the plug element is secured to the tubular housing to secure the susceptor element within the tubular housing.

19. 19. The aerosol generator of claim 18, wherein the susceptor element is secured to the tubular housing by being placed or held in compression between the plug element and the clearing tube.

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