Inductor coil for aerosol delivery device

Abstract

To provide a method for forming an inductor coil for aerosol supply device, and a bearing member for the same.SOLUTION: A bearing member 800 is for forming an inductor coil of an aerosol supply device and defines an axis around which a multi-strand wire of the inductor coil can be wound. An outer surface of the bearing member 800 is provided with a channel for receiving a wire 810. A method includes steps of: preparing a multi-strand wire provided with a plurality of wire strands, in which at least one of the plurality of wire strands is provided with at least one adhesive coating; winding the multi-strand wire around the bearing member 800; activating the adhesive coating so that the multi-strand wire substantially maintains a shape determined by the bearing member; and decreasing a cross-sectional width of the bearing member in a direction perpendicular to the axis.SELECTED DRAWING: Figure 16B

Description

[Technical Field]

[0001] The present invention relates to an inductor coil for an aerosol delivery device, a support member, a system for manufacturing an inductor coil for an aerosol delivery device, an inductor coil, and a method for forming the system. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion. An example of such a product is a heating device that releases compounds by heating a material without burning it. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of the present disclosure, there is provided a method of forming an inductor coil for an aerosol delivery device, comprising: providing a multi-strand wire comprising a plurality of wire strands, at least one of the plurality of wire strands comprising an adhesive coating; wrapping the multi-strand wire around a support member such that the multi-strand wire is received in a channel formed in an outer surface of the support member; activating the adhesive coating such that the multi-strand wire substantially maintains the shape determined by the channels; removing the multi-strand wire from the support member; A method is provided that includes:

[0004] According to a second aspect of the present disclosure, there is provided a support member for forming an inductor coil of an aerosol delivery device, the support member defining an axis about which a multi-strand wire of the inductor coil can be wound, and an outer surface of the support member including a channel for receiving the multi-strand wire.

[0005] According to a third aspect of the present disclosure, there is provided a system for manufacturing an inductor coil for an aerosol delivery device, comprising: a support member according to the second aspect; a drive assembly configured to rotate the support member about its axis such that, in use, the multi-strand wire is wound onto the support member; and A system for manufacturing an inductor coil for an aerosol delivery device is provided, comprising:

[0006] According to a fourth aspect of the present disclosure, there is provided an inductor coil for an aerosol delivery device, the inductor coil being formed according to a method including the method of the first aspect.

[0007] According to a fifth aspect of the present disclosure, there is provided an inductor coil for an aerosol delivery device, the inductor coil defining an axis and comprising a multi-strand wire wound around the axis, the multi-strand wire having a cross-section with a maximum lateral dimension greater than a maximum longitudinal dimension, the maximum lateral dimension measured in a direction perpendicular to the axis, and the maximum longitudinal dimension measured in a direction perpendicular to the maximum lateral dimension.

[0008] According to a sixth aspect of the present disclosure, a receptacle for receiving at least a portion of an article comprising an aerosolizable material; a heating assembly for heating the article while the article is disposed in the receptacle; An aerosol delivery device is provided, comprising: a heating assembly comprising at least one inductor coil of any of the fourth, fifth and tenth aspects for generating a varying magnetic field to penetrate the susceptor and thereby heat the susceptor.

[0009] According to a seventh aspect of the present disclosure, there is provided a support member for use in forming an inductor coil of an aerosol delivery device, the support member defining an axis about which a wire of the inductor coil can be wound, the support member being movable between a first configuration in which the wire can be wound onto the support member and a second configuration in which the cross-sectional width of the support member perpendicular to the axis is smaller than when the support member is in the first configuration, thereby facilitating removal of the wire from the support member.

[0010] According to an eighth aspect of the present disclosure, a support member according to the seventh aspect; a device configured to move the support member between the first configuration and the second configuration; A system is provided comprising:

[0011] According to a ninth aspect of the present disclosure, there is provided a method of forming an inductor coil for an aerosol delivery device, comprising: providing a multi-strand wire comprising a plurality of wire strands, at least one of the plurality of wire strands comprising an adhesive coating; winding a multi-strand wire around a support member defining an axis; activating the adhesive coating so that the multi-strand wire substantially maintains the shape determined by the support member; reducing a cross-sectional width of the support member in a direction perpendicular to the axis; removing the multi-strand wire from the support member; A method is provided that includes:

[0012] According to a tenth aspect, there is provided an inductor coil for an aerosol delivery device, the inductor coil being formed according to a method including the method of the ninth aspect.

[0013] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, made with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a front view of an example aerosol delivery device. [Figure 2] FIG. 2 is a front view of the aerosol delivery device of FIG. 1 with the outer cover removed. [Figure 3] 2 is a cross-sectional view of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 3 is an exploded view of the aerosol delivery device of FIG. 2. [Figure 5] FIG. 5A is a cross-sectional view of a heating assembly within an aerosol delivery device, and FIG. 5B is an enlarged view of a portion of the heating assembly of FIG. 5A. [Figure 6] FIG. 2 is a perspective view of first and second inductor coils wound around an insulating member. [Figure 7] 1 is a flow diagram of an exemplary method for forming an inductor coil. [Figure 8] FIG. 1 is a perspective view of manufacturing equipment used to form the inductor coil. [Figure 9A] FIG. 1 is a perspective view of a formed inductor coil. [Figure 9B] FIG. 1 is a perspective view of a formed inductor coil. [Figure 10] FIG. 10A is a schematic diagram of a support member according to a first example, and FIG. 10B is an enlarged view of a portion of the support member of FIG. 10A. [Figure 10C] 10B is an enlarged view of a portion of the support member of FIG. 10A of FIG. 10. [Figure 11] FIG. 10 is a schematic diagram of a support member according to a second example. [Figure 12] FIG. 10 is a schematic diagram of a support member according to a third example. [Figure 13] FIG. 10 is a schematic diagram of a support member according to a fourth example. [Figure 14] FIG. 10 is a schematic diagram of a support member according to a fifth example. [Figure 15] FIG. 10 is a schematic diagram of a support member according to a sixth example. [Figure 16A] 10 is a schematic diagram of a support member according to a seventh example, in which the support member is arranged in a first configuration. FIG. [Figure 16B] FIG. 16B shows the support member of FIG. 16A surrounded by a wire. [Figure 16C] FIG. 16B is a cross-sectional view of the support member of FIG. 16A. [Figure 16D] FIG. 16C is a cross-sectional view of the support member of FIG. 16B. [Figure 17A] FIG. 16B shows the support member of FIG. 16A arranged in a second configuration. [Figure 17B] FIG. 17B shows the support member of FIG. 17A surrounded by a wire. [Figure 17C] FIG. 17B is a cross-sectional view of the support member of FIG. 17A. [Figure 17D] FIG. 17C is a cross-sectional view of the support member of FIG. 17B. [Figure 18A] FIG. 16B is an end view of the support member of FIG. 16A. [Figure 18B] FIG. 17B is an end view of the support member of FIG. 17A. [Figure 19A] FIG. 1 is a cross-sectional block diagram of a device inserted into a hollow cavity of an exemplary support member. [Figure 19B] FIG. 1 is a cross-sectional block diagram of a device partially removed from a hollow cavity of an exemplary support member. [Figure 20] 10 is a flow chart of a second exemplary method for forming an inductor coil. DETAILED DESCRIPTION OF THE INVENTION

[0015] As used herein, the term "aerosol-forming material" includes materials that, upon heating, provide volatile components, typically in the form of an aerosol. Aerosol-forming materials include any tobacco-containing material, and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials may also include other non-tobacco products, and may or may not contain nicotine, depending on the product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-forming materials may also be, for example, a combination or blend of materials. Aerosol-forming materials are sometimes referred to as "smoking materials."

[0016] Devices are known that heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, typically forming an inhalable aerosol without burning or combusting the aerosol-generating material. Such devices are sometimes referred to as "aerosol-generating devices," "aerosol delivery devices," "non-combustion heated tobacco devices," "tobacco heating product devices," or "tobacco heating devices." Similarly, there are so-called e-cigarette devices, which typically vaporize aerosol-generating material in liquid form, which may or may not contain nicotine. The aerosol-generating material may be in the form of, or provided as part of, a rod, cartridge, or cassette that can be inserted into the device. A heater for heating and volatilizing the aerosol-generating material may be provided as a "permanent" part of the device.

[0017] The aerosol delivery device can accept an article that includes an aerosol-generating material for heating. An "article" in this context is a component that includes or contains the aerosol-generating material during use, and is heated during use to volatilize the aerosol-generating material and optionally other components. A user can insert the article into the aerosol delivery device, which then heats to generate an aerosol, which the user then inhales. The article can be of a predetermined or specific size, for example, configured to be placed within a heating chamber of the device sized to accept the article.

[0018] A first aspect of the present disclosure defines a method for forming an inductor coil for use in an aerosol delivery device. The method begins with a multi-strand wire, such as a Litz wire. Multi-strand wire is a wire comprising multiple wire strands and is used to transmit alternating current. Multi-strand wire, which may be used to reduce skin effect losses in a conductor, comprises multiple individually insulated wires twisted or interwoven together. The result of this winding is an equal ratio of the total length of each strand outside the conductor. This has the effect of evenly distributing the alternating current among the wire strands and reducing the resistance of the wire. In some examples, the multi-strand wire comprises several bundles of wire strands, with the wire strands in each bundle twisted together. The wire bundles are twisted / woven together in a similar manner.

[0019] After the multi-strand wire is provided, the method includes winding the multi-strand wire around a support member such that the multi-strand wire is received in a channel formed around an outer surface of the support member. The support member serves as a support for forming the inductor coil. The support member may be, for example, tubular or cylindrical, and the multi-strand wire may be helically wound / wrapped around the support member.

[0020] In the present disclosure, the support member has a channel extending around the outer surface of the support member. The channel receives the multi-strand wire as it is wound onto the support member. The spacing between adjacent turns within the channel can set the spacing between adjacent turns of the resulting inductor coil. The inductor coil therefore takes on the shape provided by the channel. The channel allows for better control over the shape and dimensions of the inductor coil during manufacturing. The channel can be used to maintain the multi-strand wire in a fixed position relative to the support member while the inductor coil is being formed.

[0021] The channel may be helical in some examples. The helical channel may have a constant or varying pitch along the axis of the support member. The channel may also be referred to as a concave guideway or groove. The support member may also be referred to as a forming jig or mandrel.

[0022] At least one of the multiple wire strands includes an adhesive coating. The adhesive coating surrounds the wire strand and can be activated (e.g., by heating) to bond the wire strand to one or more adjacent strands in the multi-strand wire. The adhesive coating allows the multi-strand wire to be formed into the shape of the inductor coil of the support member, and the inductor coil maintains that shape after the adhesive coating is activated. Thus, the adhesive coating "sets" the shape of the inductor coil. In some examples, the adhesive coating is an electrically insulating layer surrounding the conductive core. However, the adhesive coating and the insulator can be separate layers, with the adhesive coating surrounding the insulating layer. In one example, the conductive core of the multi-strand wire includes copper. The adhesive coating may include enamel.

[0023] With the multi-strand wire disposed within the channel, the method may further include activating the adhesive coating such that the multi-strand wire substantially maintains the shape determined by the channel, and the multi-strand wire (now in the shape of an inductor coil) may be removed from the support member without losing its shape.

[0024] The above method can be implemented to form an inductor coil for use in an aerosol delivery device. In some examples, the device may include two or more inductor coils. Each inductor coil is positioned to generate a varying magnetic field that penetrates a susceptor. As discussed in more detail herein, the susceptor is an electrically conductive object that can be heated by the penetration of the varying magnetic field. An article containing an aerosol-generating material can be received within the susceptor or placed near or in contact with the susceptor. When heated, the susceptor transfers heat to the aerosol-generating material and emits an aerosol.

[0025] The steps of winding the multi-strand wire and activating the adhesive coating may include altering the cross-sectional shape of at least a portion of the multi-strand wire. Thus, the cross-sectional shape of the multi-strand wire may change when the multi-strand wire is received in the channel. Thus, the channel may not only set the dimensions of the coil (such as the spacing between individual turns), but may also provide a means for controlling or altering the cross-sectional shape of the multi-strand wire.

[0026] The channel can have a predetermined cross-sectional shape, and the step of altering the cross-sectional shape can include imparting the predetermined cross-sectional shape to the multi-strand wire. The use of a channel provides a simple and effective way to manufacture a multi-strand wire having a specific cross-sectional shape. Thus, the dimensions of the channel can act as a mold to shape the multi-strand wire as needed. This is particularly useful because specific cross-sectional shapes can provide different heating effects.

[0027] The combined effect of introducing the multi-strand wire into the channel and activating the adhesive coating can modify the cross section of the multi-strand wire.

[0028] In some examples, the support member defines an axis, and the winding step includes winding the multi-strand wire around the axis. In some examples, the support member is elongated, and the axis is a longitudinal axis. Altering the cross-sectional shape of the multi-strand wire can include modifying a cross-section of the multi-strand wire such that the cross-section has a maximum longitudinal dimension that is different from a maximum transverse dimension, where the maximum longitudinal dimension is measured in a direction parallel to the axis and the maximum transverse dimension is measured in a direction perpendicular to the maximum longitudinal dimension. Thus, the support member and the channel can be used to form an inductor coil in which the multi-strand wire has a non-circular or non-square cross-section. For example, the width of the multi-strand wire can be smaller or larger than its depth. As previously discussed, this can provide a desirable heating effect.

[0029] In certain examples, the step of altering the cross-sectional shape may include modifying the cross-section of the multi-strand wire so that the cross-section of the multi-strand wire has a maximum longitudinal dimension that is greater than its maximum transverse dimension. Thus, the multi-strand wire has a cross-section in which the longitudinal extension (in a direction parallel to the magnetic axis of the inductor coil) is greater than the transverse extension (in a direction perpendicular to the magnetic axis). Thus, the multi-strand wire may have a flat or rectangular cross-section, with the individual wires within the multi-strand wire extending more along the axis than perpendicular to the axis. Other shapes may also have these dimensions. Such cross-sections have been found to reduce energy losses in the inductor coil.

[0030] In an alternative example, altering the cross-sectional shape may include modifying the cross-section of the multi-strand wire so that the cross-section has a maximum longitudinal dimension that is smaller than its maximum transverse dimension. Thus, the multi-strand wire may have a flat or rectangular cross-section, with the individual wires within the multi-strand wire extending less along the axis than perpendicular to the axis. Such a configuration may allow the inductor coil to have more turns along its length or to reduce heating effects, if necessary. For example, it may be useful to reduce heating effects in specific regions along a susceptor.

[0031] References to the maximum longitudinal dimension refer to the longest longitudinally extending area of ​​the cross-section that can be measured in a direction parallel to the (longitudinal) axis. The cross-section may have an irregular shape, and therefore the longitudinally extending area of ​​the cross-section may vary at various points along the wire. Similarly, references to the maximum transverse dimension refer to the longest transversely extending area of ​​the cross-section that can be measured in a direction perpendicular to the (longitudinal) axis. Again, the cross-section may have an irregular shape, and therefore the longitudinally extending area of ​​the cross-section may vary at various points along the axis. In some instances, the maximum longitudinal dimension may be referred to as the largest first dimension, and the maximum transverse dimension may be referred to as the largest second dimension.

[0032] The step of modifying the cross-sectional shape of the multi-strand wire may include compressing the multi-strand wire in a direction parallel to the axis to increase the density of the wire strands. For example, the channel may have a width dimension that decreases with distance toward the bottom of the channel, and the reduced width may cause the individual wires of the multi-strand wire to be compressed more tightly in the longitudinal dimension. This compression may mean reducing the longitudinal extension area of ​​the multi-strand wire and increasing the lateral extension area of ​​the multi-strand wire.

[0033] The step of activating the adhesive coating may include heating the support member such that the adhesive coating is heated. For example, after the multi-strand wire is wound around the support member, heating the multi-strand wire allows the adhesive coating on the wire strands to self-adhere and the inductor coil to undergo thermal curing. Heating the support member allows heat to be uniformly conducted to the multi-strand wire.

[0034] The method may include simultaneously heating the support member and winding the multi-strand wire around the support member. Thus, the heating is performed simultaneously with the winding step. Heating the multi-strand wire while winding it around the support member may reduce manufacturing time. In other examples, heating may occur after or before the multi-strand wire is wound around the support member.

[0035] Heating the support member may include heating the support member to a temperature in the range of about 150° C. to 350° C., such as in the range of about 150° C. to 250° C., or in the range of about 180° C. to 200° C. Thus, the adhesive coating may be activated at a temperature within this range.

[0036] In another example, the adhesive coating may be solvent activated.

[0037] The step of activating the adhesive coating may further include cooling the multi-strand wire after heating the adhesive coating, thereby cooling the adhesive coating and thereby setting the shape of the inductor coil. Cooling the multi-strand wire may include passing air over the multi-strand wire. For example, an air gun or fan may blow air onto the multi-strand wire. Use of the air gun or fan may speed up the cooling process.

[0038] In one example, the wire strands are Thermobond STP18 wires available from Elektrisola Inc. (New Hampshire, USA). These wires have been found to be well suited for use in aerosol delivery devices. For example, these wires have a relatively high bonding temperature so that the adhesive coating is not re-softened by the heated susceptor within the device.

[0039] The method may further include rotating the support member about its axis to thereby wind the multi-strand wire around the support member. Thus, the support member may be rotated such that the multi-strand wire is pulled by the support member. This rotation facilitates fabrication of the inductor coil. For example, it may eliminate the need to move the wire around a stationary support member.

[0040] The method may further include moving the support member in a direction parallel to the axis (while simultaneously rotating the support member) to receive the multi-strand wire into the helical channel. In certain examples, the ends of the multi-strand wire are secured at or near the ends of the support member to prevent the multi-strand wire from unwinding.

[0041] According to a second aspect, there is provided a support member for forming an inductor coil of an aerosol delivery device. The support member defines an axis, such as a longitudinal axis, about which a multi-strand wire of the inductor coil can be wound. An outer surface of the support member includes a channel for receiving the multi-strand wire. The channel can be, for example, a helical channel.

[0042] In some examples, the channel has a maximum depth dimension measured perpendicular to the axis and a maximum width dimension measured perpendicular to the maximum depth dimension, the maximum depth dimension being different from the maximum width dimension. In some examples, the maximum depth dimension is greater than the maximum width dimension. Thus, the channel may be deeper than it is wide. Such a channel can securely hold the multi-strand wire in place when it is wound around the support member. A channel that is deeper than it is wide can help prevent the multi-strand wire from unintentionally exiting the channel before the shape of the multi-strand wire can be fixed by activating the adhesive coating. In some examples, the ratio of the maximum depth dimension to the maximum width dimension is within a range of about 1.1 to 2 (i.e., within a range of about 1.1:1 to about 2:1).

[0043] In some instances, the maximum depth dimension is less than the maximum width dimension, and thus the channel may be wider than it is deep.

[0044] The channel may include a tapered mouth portion leading to the wire-receiving portion. The wire-receiving portion is configured to receive a multi-strand wire. The wire-receiving portion may have a maximum depth measured in a direction perpendicular to the axis and a maximum width measured in a direction perpendicular to the maximum depth, where the maximum depth is different from the maximum width. In some examples, the maximum depth is greater than the maximum width. This allows for the formation of an inductor coil having a maximum longitudinal extension area / dimension that is smaller than the maximum lateral extension area / dimension.

[0045] In an alternative example, the maximum width may be greater than the maximum depth, thereby forming an inductor coil having a maximum longitudinal dimension greater than its maximum lateral dimension.

[0046] The wire-receiving portion is the portion of the channel that holds or abuts the multi-strand wire after it is fully received in the channel. Therefore, the wire-receiving portion is located toward the bottom / floor of the channel. In instances where the channel imparts a predetermined shape to the multi-strand wire, the wire-receiving portion is the portion of the channel that imparts the predetermined shape. The tapered mouth portion defines a guide for guiding the multi-strand wire into the wire-receiving portion of the channel. For example, the tapered mouth portion has a width dimension (measured parallel to the axis of the support member) that decreases toward the bottom of the channel. Therefore, the tapered mouth portion allows the multi-strand wire to be received into the channel with better alignment. The tapered mouth portion is located farther from the axis than the wire-receiving portion. The tapered mouth portion may be provided by a beveled or chamfered edge.

[0047] References to maximum width dimension or maximum width refer to the widest portion of a channel that can be measured in a direction parallel to the (longitudinal) axis. A channel may have a variable width, and therefore the width of a channel may vary at various points. Similarly, references to maximum depth dimension or maximum depth refer to the deepest portion of a channel that can be measured in a direction perpendicular to the (longitudinal) axis. A channel may have a variable depth, and therefore the depth of a channel may vary at various points.

[0048] In particular examples, the ratio of the maximum depth dimension to the maximum width dimension is within the range of about 1.1 to 2 (i.e., within the range of about 1.1:1 to about 2:1). A ratio within this range has been found to allow for controlled heating effects of the inductor coil while ensuring that the multi-strand wire within the inductor coil remains properly oriented. Optionally, the ratio is within the range of about 1.1 to about 1.5. The ratio may be within the range of about 1.1 to about 1.2.

[0049] In one example, the maximum width is in the range of about 1.2 mm to about 1.5 mm. In one example, the maximum depth is in the range of about 1.6 mm to about 1.7 mm. Inductor coils formed in wire-receiving portions having these dimensions have been found to be particularly suitable for heating in aerosol delivery devices.

[0050] In some instances, the channel is a spiral channel.

[0051] The surface of the tapered mouth portion may have a first surface slope, and the surface of the wire-receiving portion adjacent to the tapered mouth portion may have a second surface slope greater than the first surface slope. The first and second surface slopes are defined relative to the axis. Thus, the tapered mouth portion has a shallower slope than the slope of the wire-receiving portion disposed adjacent to the tapered mouth portion. The shallower slope allows for a smooth transition into the channel without unintentionally altering the cross-sectional shape of the multi-strand wire before it is received in the wire-receiving portion. In one example, the surface of the wire-receiving portion disposed adjacent to the tapered mouth portion is substantially vertically oriented (i.e., oriented perpendicular to the axis). This vertical orientation can provide a means for receiving and securing the multi-strand wire within the channel.

[0052] In certain instances, the floor of the channel is substantially flat or rounded, i.e., the bottom of the channel is flat or rounded, which allows for easy and simple removal of the multi-strand wire from the channel.

[0053] The channel may have a width dimension that decreases with distance toward the floor / bottom of the channel. Thus, the channel is tapered, having an inclined surface, which allows the multi-strand wire to contract / compress more uniformly as it is received in the channel. The bottom of the channel is the portion of the channel located furthest from the outer surface of the support member.

[0054] The support member may be heat resistant to temperatures greater than 150°C, allowing the support member to be heated to a temperature of at least 150°C, thereby activating the adhesive coating of the multi-strand wire. The support member may be made of, for example, a metal that is a good thermal conductor and has a high melting point. For example, the support member may include steel, stainless steel, or aluminum. The support member may have a melting point of, for example, greater than about 600°C, or greater than about 700°C, or greater than about 800°C, or greater than about 1000°C, or greater than about 1500°C.

[0055] According to a third aspect, there is provided a system for manufacturing an inductor coil for an aerosol delivery device, comprising: a support member according to any of the examples above; and a drive assembly configured to rotate the support member about an axis, such as a longitudinal axis of the support member, so that, during use, a multi-strand wire is wound onto the support member. The drive assembly rotates the support member, thereby enabling the multi-strand wire to be wound onto the support member. The drive assembly may comprise a rotated drum.

[0056] The system may further include a wire feeding assembly for feeding the multi-strand wire to the support member. In one example, the wire feeding assembly is passive, simply holding the multi-strand wire in place while the drive system rotates the support member. The rotating support member thus draws the wire onto the support member. A passive wire feeding assembly simplifies manufacturing. In another example, the wire feeding assembly is active, actively winding the wire onto the support member.

[0057] The drive assembly may be further configured to move the support member relative to the wire feeding assembly in a direction parallel to the axis. For example, the drive assembly may move the wire feeding assembly relative to a stationary support member, or the drive assembly may move the support member relative to a stationary wire feeding assembly. In certain examples, the drive assembly moves the drum (mounted on the support member) along guide rails oriented parallel to the axis of the support member.

[0058] The system may further include a heater for heating the support member. For example, the support member may be heated to activate an adhesive coating on the multi-strand wire.

[0059] The system may further include a fixture configured to hold a portion of the multi-strand wire against the support member when the multi-strand wire is wound around the support member, thus securing the multi-strand wire and preventing it from unwinding when the support member is rotated.

[0060] In one example, the support member comprises a threaded outer profile for receiving the multi-strand wire, the threaded outer profile thus forming a channel capable of receiving the multi-strand wire.

[0061] According to a fourth aspect, there is provided an inductor coil for an aerosol delivery device, the inductor coil being formed according to the method described above.

[0062] According to a fifth aspect, there is provided an inductor coil for an aerosol delivery device, the inductor coil defining an axis and comprising a multi-strand wire wound around the axis, the multi-strand wire having a cross-section with a maximum lateral dimension greater than a maximum longitudinal dimension, the maximum lateral dimension being measured in a direction perpendicular to the axis, and the maximum longitudinal dimension being measured in a direction perpendicular to the maximum lateral dimension.

[0063] According to a sixth aspect, there is provided an aerosol delivery device comprising: a receptacle for receiving at least a portion of an article comprising an aerosolizable material; and a heating assembly for heating the article when the article is placed in the receptacle. The heating assembly comprises at least one of the inductor coils of the fourth, fifth, or tenth aspects for generating a varying magnetic field for heating the susceptor. In some examples, the heating assembly comprises a susceptor that is heatable by penetration of the varying magnetic field.

[0064] According to a seventh aspect, a support member is provided that can be moved between two or more configurations. For example, the support member can be movable between a first configuration and a second configuration. As will become apparent, a support member that changes configuration / shape can make it easier to remove a formed inductor coil from the support member. As described above, the support member can define an axis (e.g., a longitudinal axis) about which the wire of the inductor coil can be wound. In the first configuration, the wire can be wound around the support member to form the inductor coil. In the second configuration, the cross-sectional width of the support member (measured perpendicular to the axis) is smaller than when the support member is in the first configuration. Thus, in the second configuration, the support member has a smaller cross-sectional width. It has been found that reducing the cross-sectional width of the support member (after the inductor coil is formed) can make it easier to remove the inductor coil from the support member. For example, reducing the cross-sectional width of the support member can at least partially separate / remove the wire / coil from the support member, thereby removing the inductor coil without damaging or deforming the inductor coil upon removal.

[0065] In the first configuration, the support member has a first cross-sectional width, and in the second configuration, the support member has a second cross-sectional width, the first cross-sectional width being greater than the second cross-sectional width.

[0066] In some instances, the wire is a multi-strand wire.

[0067] The cross-sectional width is measured perpendicular to the axis defined by the support member. The cross-sectional width can be measured along a second axis, which is perpendicular to the axis defined by the support member. The axis defined by the support member can be the first axis. In instances where the support member is substantially cylindrical, the cross-sectional width of the support member (first feature) is equal to the diameter of the support member.

[0068] In both of the above examples, the wire is wound around the support member to form the inductor coil, and therefore the wire becomes the inductor coil after being formed on the support member.

[0069] In one example, the support member is monolithic and formed from a single component, however, in other examples, the support member may be formed from multiple components / pieces.

[0070] In a particular example, the outer surface of the support member includes a channel for receiving the wire. As described above, the channel can receive the wire as it is wound around the support member. The spacing between adjacent turns in the channel can set the spacing between adjacent turns of the resulting inductor coil. In this particular example, the ability of the support member to change shape is even more useful. The nature of the channel means that the wire extends into the support member, making it difficult to remove the inductor coil from the support member. For example, because the inductor coil is at least partially disposed within the channel, it is difficult to slide it along the length of the support member. Reducing the cross-sectional width of the support member can make the inductor coil easier to remove. In one example, the cross-sectional width is reduced to at most one-half the depth dimension of the channel to ensure adequate clearance for the inductor coil.

[0071] The channel can have a depth measured parallel to the second axis and a width dimension measured parallel to the first axis.

[0072] The support member may be biased toward the second configuration, thus allowing the support member to "automatically" reconfigure to a configuration with a minimum cross-sectional width, and the device may retain the support member in the first configuration when needed.

[0073] In certain configurations, the support member may include one or more biasing mechanisms, such as one or more springs, for biasing the support member towards the second configuration.

[0074] The outer surface of the support member may be formed by a plurality of segments arranged circumferentially about the axis. Thus, in one example, the support member may be formed from a plurality of components. By moving one or more of these segments / components, the support member can be moved between a first configuration and a second configuration.

[0075] In one example, each segment extends along the length of the support member in a direction parallel to the longitudinal axis of the support member.

[0076] In instances where the support member is substantially cylindrical, each segment may have a curved profile, having an arc length that extends partially around the circumference of the support member.

[0077] The segments may abut one or more adjacent segments, which may provide a more continuous outer surface and may also improve heat transfer between the segments.

[0078] At least one of the plurality of segments may be configured to move relative to an adjacent one of the plurality of segments when the support member moves between the first and second configurations. Accordingly, the support member may be reconfigured as described above. In certain examples, at least one of the segments may rotate / pivot relative to an adjacent segment.

[0079] In some instances, only a portion of the segment is movable, for example, only a portion of the support member may change shape, yet the entire support member may still have a smaller cross-sectional width.

[0080] At least one segment of the plurality of segments may be connected to an adjacent segment of the plurality of segments by a hinge. Thus, there may be two segments joined by a hinge. The hinge provides a simple and effective way of moving the adjacent segments. One or more hinges may be biased such that the support member is biased toward the second configuration.

[0081] In some examples, at least one segment of the plurality of segments is not permanently connected to an adjacent segment of the plurality of segments, and thus not all segments are permanently connected (e.g., by a hinge), which allows one end of the support member to move away from the other end when the support member is moved from the first configuration to the second configuration.

[0082] In some examples, at least one of the segments has a stopper for limiting movement of the at least one segment relative to an adjacent segment, thereby limiting the extent to which the support member can move away from the second configuration. The "stopper" ensures that when the support member moves from the second configuration back to the first configuration, it does not extend beyond the first configuration but only moves to the first configuration. "Limiting the extent to which the support member can move from the second configuration" can mean that the cross-sectional width is not greater than the cross-sectional width of the support member at the first configuration. The stopper can reduce the likelihood that the hinge (connecting the two segments) will bend in the opposite direction.

[0083] In a specific example, the outer surface of at least one segment includes a protruding portion, and the outer surface of an adjacent segment includes a receiving portion for receiving the protruding portion as the support member moves from the second configuration to the first configuration. Thus, a "stop" can be provided by the receiving portion, and movement is limited by the protruding portion contacting the receiving portion. The protruding portion can be a lip or a flange. The outer surface of each segment is the portion furthest from the longitudinal axis extending along the center of the support member.

[0084] In one example, in the second configuration, the support member is in a spiral configuration. For example, the support member may roll or curl on itself as it moves from the first configuration to the second configuration. In examples where the support member includes multiple segments, the segments may enable the support member to roll into a spiral configuration. The spiral configuration may be most apparent when viewed along the longitudinal axis of the support member.

[0085] In one example, in the first configuration, the support member can define a hollow cavity for receiving a device for holding the support member in the first configuration. For example, the device can be inserted into the center of the support member and engage with the support member to support it in the first configuration. Such a device can be particularly useful when the support member is biased toward the second configuration. Thus, removal of the device can "automatically" move the support member to the second configuration, especially under a biasing force (when applied).

[0086] In one example, the device is an insert that contacts the inner surface of the support member. The insert can be moved into the hollow cavity in a first direction along the axis of the support member and can also be moved along the axis in a second direction opposite the first direction. The device / insertion can have a tapered profile such that as the device is moved in the first direction, the narrowest section of the device is inserted into the cavity first (when the support member is in the second configuration), and as the wider section of the device is inserted, the cross-sectional width of the support member gradually increases until the support member is in the first configuration.

[0087] According to an eighth aspect, there is provided a system comprising a support member according to the seventh aspect and a device configured to move the support member between the first and second configurations, which may be the same device inserted into the hollow cavity of the support member to hold the support member in the first configuration.

[0088] As briefly described, the device is movable along an axis to move the support member between a first configuration and a second configuration, providing an effective method of varying the cross-sectional width of the support member with simple automation and few moving parts.

[0089] The system may be configured such that when the support member is in the first configuration, the device is disposed in a first axial position within the hollow cavity of the support member to hold the support member in the first configuration, and when the support member is in the second configuration, the device is disposed in a second axial position different from the first position. In some examples, in the second configuration, the device may still be partially disposed within the hollow cavity. In other examples, the device may be completely removed from the hollow cavity.

[0090] The system may include a biasing mechanism for biasing the support member toward the second configuration. In some examples, the biasing mechanism may be separate from the support member. In other examples, the biasing mechanism may be part of the support member.

[0091] According to a ninth aspect, there is provided a method of forming an inductor coil for an aerosol delivery device, the method including the steps of: (i) providing a multi-strand wire comprising a plurality of wire strands, at least one of the plurality of wire strands comprising an adhesive coating, (ii) winding the multi-strand wire around a support member defining an axis, (iii) activating the adhesive coating such that the multi-strand wire substantially maintains a shape determined by the support member, (iv) reducing a cross-sectional width of the support member in a direction perpendicular to the axis, and (v) removing the multi-strand wire from the support member.

[0092] In one example, the step of winding the wire around the support member may include receiving the wire in a channel.

[0093] The step of reducing the cross-sectional width of the support member may include moving the support member between a first configuration and a second configuration, wherein when the support member is in the second configuration, the cross-sectional width of the support member perpendicular to the axis is smaller than when the support member is in the first configuration.

[0094] The step of reducing the cross-sectional width of the support member may include rolling the support member or folding the support member.

[0095] In one example, when the support member is in the first configuration, the device may be disposed at a first axial position within the hollow cavity of the support member to hold the support member in the first configuration. When the support member is in the second configuration, the device may be disposed at a second axial position different from the first position. Thus, moving the support member between the first and second configurations may include moving the device between the first and second positions.

[0096] As previously mentioned, the outer surface of the support member may be defined by a plurality of segments arranged circumferentially about the axis, and thus, reducing the cross-sectional width of the support member may include moving at least one of the plurality of segments relative to an adjacent one of the plurality of segments.

[0097] In one example, the winding step includes winding the multi-strand wire about an axis, and the removing step includes moving the multi-strand wire relative to the support member in a direction parallel to the axis. The support member can be moved in a direction parallel to the axis while the inductor coil is held in place. Alternatively, the inductor coil can be moved while the support member is fixed in place.

[0098] According to a tenth aspect, there is provided an inductor coil for an aerosol delivery device, the inductor coil being formed according to a method including the method of the ninth aspect.

[0099] 1 shows an example of an aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. Generally, device 100 can be used to heat a replaceable article 110 comprising an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0100] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and houses the various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 can be inserted for heating by the heating assembly. During use, the item 110 may be fully or partially inserted into the heating assembly, where it may be heated by one or more components of the heater assembly.

[0101] The device 100 in this example includes a first end member 106 with a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. In FIG. 1 , the lid 108 is shown in an open configuration, but the lid 108 can also be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "A."

[0102] Device 100 may also include a user-operable control element 112, such as a button or switch, that, when pressed, operates device 100. For example, a user can turn device 100 on by operating switch 112.

[0103] Device 100 may also include an electrical component, such as a socket / port 114, that can accept a cable to charge a battery of device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0104] 2 shows the device 100 of FIG. 1 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 344.

[0105] 2, first end member 106 is disposed at one end of device 100, and second end member 116 is disposed at the other end of device 100. First end member 106 and second end member 116 together at least partially define an end surface of device 100. For example, the bottom surface of second end member 116 at least partially defines the bottom surface of device 100. In this example, lid 108 also defines a portion of the top surface of device 100.

[0106] The end of device 100 closest to opening 104 is sometimes referred to as the proximal end (or mouth end) of device 100, as it is closest to the user's mouth during use. During use, a user inserts item 110 into opening 104 and operates user control 112 to initiate heating of the aerosol-generating material and draw aerosol generated by the device, which then flows along a flow path through device 100 toward the proximal end of device 100.

[0107] The other end of device 100 furthest from opening 104 is sometimes referred to as the distal end of device 100, as it is the end farthest from a user's mouth during use. When a user draws on the aerosol generated by the device, the aerosol flows out of the distal end of device 100.

[0108] Device 100 further includes a power source 118. Power source 118 can be a battery, such as a rechargeable or non-rechargeable battery. The battery is electrically coupled to the heating assembly to provide power to heat the aerosol-generating material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds battery 118 in place.

[0109] The device further comprises at least one electronic module 122. The electronic module 122 may include, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also comprise one or more electrical tracks for electrically connecting various electronic components of the device 100 to one another. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via electrical tracks.

[0110] In the exemplary device 100, the heating assembly is an induction heating assembly and includes various components for heating the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. An induction heating assembly may include an induction element, such as one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents in the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore, the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor includes a ferromagnetic material such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e., by the varying orientation of the magnetic dipoles of the magnetic material due to alignment with the varying magnetic field. In induction heating, heat is generated within the susceptor, allowing for rapid heating compared to, for example, heating by conduction. Furthermore, no physical contact is required between the induction heater and the susceptor, allowing for greater flexibility in design and application.

[0111] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (hereinafter referred to as the "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are formed from a conductive material. In this example, the first and second inductor coils 124, 126 are formed from a multi-strand wire, such as a Litz wire / cable, which is wound generally in a helical configuration to provide the inductor coils 124, 126. The Litz wire comprises multiple wire strands that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce skin effect losses of the conductor. In the exemplary device 100, the first and second inductor coils 124, 126 are formed from copper Litz wire having a rectangular cross-section. In other examples, the Litz wire can have cross-sections of other shapes.

[0112] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first region of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second region of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction parallel to a longitudinal axis 134 of the device 100. Ends 130 of the first and second inductor coils 124, 126 can be connected to the PCB 122.

[0113] It should be understood that the first and second inductor coils 124, 126 may have at least one characteristic that differs from one another in some examples. For example, the first inductor coil 124 may have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 2 , the first and second inductor coils 124, 126 are of different lengths, such that the first inductor coil 124 is wound over a smaller area of ​​the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 may be formed from a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0114] The susceptor 132 in this example is hollow and defines a receptacle in which the aerosol-generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular and has a circular cross section.

[0115] 2 further includes an insulating member 128, which may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 may help insulate various components of the device 100 from heat generated by the susceptor 132.

[0116] The insulating member 128 can also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 2 , the first and second inductor coils 124, 126 are disposed around the insulating member 128 and contact the radially outer surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, there may be a small gap between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0117] In a particular example, the susceptor 132 , the insulating member 128 , and the first and second inductor coils 124 , 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0118] 3 shows a partial cross-sectional side view of device 100. In this example, outer cover 102 is present.

[0119] The device 100 further comprises a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0120] The device may also include a second printed circuit board 138 associated within the control element 112 .

[0121] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward the distal end of the device 100. The spring 142 enables the second lid 140 to be opened, providing access to the susceptor 132. A user can open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0122] The device 100 further includes an expansion chamber 144 that extends from the proximal end of the susceptor 132 toward the opening 104 of the device. A retaining clip 146 is disposed at least partially within the expansion chamber 144 for abutting and holding the article 110 when received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0123] FIG. 4 is an exploded view of the device 100 of FIG. 1 with the outer cover 102 omitted.

[0124] FIG. 5A of FIG. 5 shows a cross-section of a portion of device 100 of FIG. 1. FIG. 5B of FIG. 5 shows an enlarged view of the area of ​​FIG. 5A of FIG. 5. FIGS. 5A and 5B of FIG. 5 show article 110 received within susceptor 132, with article 110 sized so that an outer surface of article 110 abuts an inner surface of susceptor 132. In this example, article 110 comprises aerosol-forming material 110a. Aerosol-forming material 110a is disposed within susceptor 132. Article 110 may also include other components, such as a filter, packaging material, and / or cooling structure.

[0125] 5B shows that the outer surface of the susceptor 132 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 mm to 3.5 mm, or about 3.25 mm.

[0126] 5B further illustrates that the outer surface of insulating member 128 is spaced from the inner surfaces of inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to longitudinal axis 158 of susceptor 132. In one particular example, distance 152 is approximately 0.05 mm. In another example, distance 152 is substantially 0 mm, such that inductor coils 124, 126 abut and contact insulating member 128.

[0127] In one example, the susceptor 132 has a wall thickness 154 of between about 0.025 mm and 1 mm, or about 0.05 mm.

[0128] In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

[0129] In one example, the insulating member 128 has a wall thickness 156 of between about 0.25 mm and 2 mm, between 0.25 mm and 1 mm, or about 0.5 mm.

[0130] 6 shows a portion of the heating assembly of device 100. As briefly mentioned above, the heating assembly includes first and second inductor coils 124 and 126 disposed adjacent to each other in a direction along axis 200. Inductor coils 124, 126 extend around an insulating member 128. A susceptor 132 is disposed within tubular insulating member 128. In this example, the wire forming first and second inductor coils 124, 126 has a circular or oval cross-section, although it may also have a different shaped cross-section, such as a rectangular, square, "L," "T," or triangular cross-section.

[0131] The axis 200 may be defined by one or both of the inductor coils 124, 126. For example, the axis 200 may be the longitudinal axis of one of the inductor coils 124, 126. The axis 200 is parallel to the longitudinal axis 134 of the device 100 and parallel to the longitudinal axis 158 of the susceptor. Thus, each inductor coil 124, 126 extends about the axis 200.

[0132] Each inductor coil 124, 126 is formed from a multi-strand wire, such as a Litz wire, that includes multiple wire strands. For example, each multi-strand wire can have between about 50 and about 150 wire strands. In this example, each multi-strand wire has about 115 wire strands.

[0133] Each individual wire strand has a diameter. For example, the diameter may be in the range of about 0.05 mm to about 0.2 mm. In some examples, the diameter is in the range of 34 AWG (0.16 mm) to 40 AWG (0.0799 mm), where AWG is American Wire Gauge. In this example, each wire strand has a diameter of 38 AWG (0.101 mm).

[0134] In examples where the multi-strand wire has a circular cross-section, the multi-strand wire may have a diameter in the range of about 1 mm to about 2 mm. In this example, the multi-strand wire has a diameter of about 1.3 mm to about 1.5 mm, for example about 1.4 mm.

[0135] As shown in FIG. 6 , the multi-strand wire of the first inductor coil 124 is wound approximately 6.75 times around the axis 202, and the multi-strand wire of the second inductor coil 126 is wound approximately 8.75 times around the axis 202. Because some ends of the multi-strand wire are bent away from the surface of the insulating member 128 before completing a full turn, the multi-strand wire does not form an integral number of turns. In other examples, the number of turns may vary. For example, each multi-strand wire may be wound approximately 4-15 times around the axis 202.

[0136] Figure 6 shows the gaps between successive windings / turns. These gaps can be, for example, in the range of about 0.5 mm to about 2 mm.

[0137] In some examples, each inductor coil 124, 126 has the same pitch, which is the length of the inductor coil over one complete turn (measured along the inductor coil axis 200 or along the susceptor longitudinal axis 158). In other examples, each inductor coil 124, 126 has a different pitch.

[0138] In one example, the inner diameter of the first and second inductor coils 124, 126 is about 12 mm in length and the outer diameter is about 14.3 mm in length. In another example, the inner diameter of the first and second inductor coils 124, 126 can be in the range of about 8 mm to about 15 mm and the outer diameter can be in the range of about 10 mm to about 17 mm.

[0139] 7 shows a flow diagram of a method 300 for forming an inductor coil for an aerosol delivery device. Such a method can be used to form one or both of the inductor coils 124, 126 described in connection with FIGS. 2-6.

[0140] The method includes, at block 302, providing a multi-strand wire comprising a plurality of wire strands, at least one of the plurality of wire strands comprising an adhesive coating. For example, a multi-strand wire having the parameters described above may be provided. As described above, the adhesive coating is a coating that surrounds the wire strands and can be activated (e.g., by heating) to bond strands within the multi-strand wire to one or more adjacent strands. The adhesive coating allows the multi-strand wire to be formed into the shape of the inductor coil of the support member, and the multi-strand wire maintains that shape after the adhesive coating is activated. Thus, the adhesive coating "sets" the shape of the inductor coil.

[0141] The method further includes winding the multi-strand wire around the support member at block 304. For example, the multi-strand wire can be wound helically around the support member.

[0142] 8 shows an exemplary system used to form an inductor coil 400 from a multi-strand wire. As shown, the multi-strand wire 402 may first be wound around a bobbin 404, and then unwound and wound around a support member 406. In this example, a drum 408 is rotated and moved parallel to a guide rail 410, which causes the multi-strand wire to wind along the length of the support member 406. The drum 408 and guide rail 410 form part of a drive assembly that together winds the multi-strand wire 402 onto the support member 406.

[0143] In a particular example, the support member 406 has a channel formed in its outer surface. Thus, when the multi-strand wire 402 is wound around the support member 406, the multi-strand wire 402 may be received in the channel. The channel provides a means for better control of the shape and dimensions of the multi-strand wire 402 that forms the inductor coil 400. The channel may extend in a spiral manner around the support member 406.

[0144] In some examples, the channel has a particular cross-sectional shape that is imparted to the multi-strand wire 402. Thus, the channel can act as a "mold" so that the multi-strand wire 402 takes on the shape of the channel.

[0145] 9A shows an alternative view of multi-strand wire 402 wrapped around support member 406. At this point, inductor coil 400 is only partially formed, with multi-strand wire 402 still wound around support member 406. A channel 412 can be seen extending around the outer surface of support member 406. Multi-strand wire 402 falls into channel 412 as it is wrapped around support member 406. The channel therefore provides a means to precisely control the spacing between adjacent turns of inductor coil 400.

[0146] 8 and 9A also show a wire feeding assembly 414 that enables or controls the feeding of the multi-strand wire 402 to the support member 406. In some examples, as shown in FIGS. 8 and 9A, the wire feeding assembly 414 is passive. For example, as described above, the system may include a drive assembly configured to rotate the support member 406 about a longitudinal axis 416 defined by the support member 406. The system may also include a fixture 418 that holds the end of the multi-strand wire 402 in place. When the drive assembly rotates the support member 406 in the direction indicated by arrow 420 and moves the support member 406 in a direction parallel to the longitudinal axis 416, the multi-strand wire 402 is pulled through the passive wire feeding assembly 414 and into the support member 406.

[0147] In other examples, the wire feeding assembly 414 is active and actively winds the multi-strand wire onto the support member 406. For example, the wire feeding assembly 414 can rotate around the support member 406 while the wire is being wound onto the support member 406.

[0148] FIG. 9B shows the system of FIG. 9A at a later point in time. At this point, the inductor coil 400 is still only partially formed, but the multi-strand wire 402 has been wound many more times around the support member 406. The drive assembly rotates the support member 406, moving it in a direction 422 parallel to the longitudinal axis 416 while the wire feeding assembly 414 remains stationary. In an alternative example, the drive assembly may move the wire feeding assembly 414 in a direction parallel to the longitudinal axis 416 while the longitudinal displacement of the support member 406 remains stationary. In either case, the drive assembly moves the support member 406 relative to the wire feeding assembly 414 to wind the multi-strand wire 402 onto the support member 406. The multi-strand wire 402 continues to be wound onto the support member 406 until the inductor coil 400 reaches the desired length. The multi-strand wire 402 can be cut to size using a cutting tool 424 (shown in FIG. 8).

[0149] As the multi-strand wire 402 is wound around the support member 406, the method 300 further includes, at block 306, activating the adhesive coating so that the multi-strand wire substantially maintains the shape provided by the channel. Alternatively, block 306 may occur after the multi-strand wire 402 is completely wound around the support member 406. In this example, the multi-strand wire has an enamel adhesive coating that is activated by heat. Thus, heat is applied to the multi-strand wire 402 while it remains on the support member 406 and within the channel 412. For example, the support member 406 may be heated by a heater (not shown), thereby heating the multi-strand wire 402. In one example, the multi-strand wire 402 is heated to an activation temperature of approximately 190°C, which reduces the viscosity of the adhesive coating. After a predetermined time, the application of heat is stopped, and the adhesive coating begins to cool. In some examples, the cooling process can be accelerated by the application of cold air. For example, an air gun or fan can be used to blow cooled / ambient air across the multi-strand wire 402. As the temperature of the adhesive coating decreases, the viscosity of the adhesive coating increases again, thereby bonding the individual wire strands within the multi-strand wire to one another.

[0150] In an alternative example, heated air is blown over the multi-strand wire 402. For example, the air is heated to an activation temperature suitable for activating the adhesive coating and blown across the inductor coil 400 by a fan or air gun.

[0151] In either instance, heat is preferably applied to the multi-strand wire 402 at the same time that the multi-strand wire 402 is wrapped around the support member 406 .

[0152] The combined effect of receiving multi-strand wire 402 within channel 412 and activating the adhesive coating imparts the cross-sectional shape of channel 412 to multi-strand wire 402. For example, multi-strand wire 402 may have a particular cross-sectional shape before being introduced into channel 412 and may have a different cross-sectional shape after being removed from channel 412. Channel 412 thus provides a means for modifying the cross-sectional shape of multi-strand wire 402. Various exemplary support members having channels with various predetermined cross-sectional shapes are described in conjunction with FIGS.

[0153] FIG. 10A of FIG. 10 shows a side view of a first exemplary support member 500. FIG. 10B of FIG. 10 shows an enlarged view of a portion of FIG. 10A of FIG. 10. Support member 500 defines a longitudinal axis 502 about which a multi-strand wire 504 can be wound. An outer surface of support member 500 includes a channel 506 for receiving multi-strand wire 504.

[0154] 10B, the channel 506 in this example includes a tapered mouth portion 508 and a wire-receiving portion 510. The tapered mouth portion 508 is disposed toward the outer surface of the support member 500, and the wire-receiving portion 510 is disposed radially inward, toward the center of the support member 500. In some examples, the tapered mouth portion 508 may be omitted.

[0155] Tapered mouth portion 508 defines a guide for guiding multi-strand wire 504 into wire-receiving portion 510 of channel 506. For example, the angled surface of tapered mouth portion 508 can "funnel" multi-strand wire 504 into channel 506 if multi-strand wire 504 is not precisely aligned with the channel when wound onto support member 500. Wire-receiving portion 510 is the portion of channel 506 that holds or abuts multi-strand wire 504 after it is fully received in channel 506.

[0156] In this example, wire-receiving portion 510 imparts a predetermined cross-sectional shape to multi-strand wire 504. Fig. 10B of Figure 10 shows multi-strand wire 504 having a generally circular cross-sectional shape prior to entering wire-receiving portion 510. When multi-strand wire 504 is fully received in wire-receiving portion 510, multi-strand wire 504 may be constricted in one or more dimensions, thereby deforming the cross-section of multi-strand wire 504.

[0157] 10B, channel 506 has a maximum depth dimension 512 measured in a direction perpendicular to longitudinal axis 502 and a maximum width dimension 514 measured in a direction perpendicular to maximum depth dimension 512. Thus, maximum depth dimension 512 is the overall depth of channel 506. In this example, maximum depth dimension 512 is greater than maximum width dimension 514. Overall, channel 506 has a width dimension that decreases with distance toward bottom 506a of channel 506. Similarly, wire-receiving portion 510 has a width dimension that decreases with distance toward bottom 506a of channel 506.

[0158] 10B, wire-receiving portion 510 has a maximum depth 516 measured in a direction perpendicular to longitudinal axis 502 and a maximum width 518 measured in a direction perpendicular to maximum depth 516. Thus, maximum depth 516 is the entire depth of wire-receiving portion 510. In this example, maximum depth 512 is greater than maximum width 514. Due to this particular shape, multi-strand wire 504 contracts / compresses in the dimension parallel to longitudinal axis 502 and expands in the dimension perpendicular to longitudinal axis 502 when the wire is fully received in channel 506. Thus, the cross-sectional shape of wire-receiving portion 510 is imparted to multi-strand wire 504. Thus, multi-strand wire 504 obtains the same cross-sectional shape provided by channel 506.

[0159] Thus, the resulting multi-strand wire 504 has a maximum transverse dimension that is greater than its maximum longitudinal dimension. The maximum longitudinal dimension is measured in a direction parallel to the longitudinal axis 502, and the maximum transverse dimension is measured in a direction perpendicular to the maximum longitudinal dimension. Thus, the maximum transverse dimension of the multi-strand wire 504 is substantially the same as the maximum depth 516. Similarly, the maximum longitudinal dimension of the multi-strand wire 504 is substantially the same as the maximum width 518.

[0160] In a particular example, multi-strand wire 504 has a diameter of approximately 1.4 mm before being introduced into channel 506. Maximum depth 516 is approximately 1.7 mm, and maximum width 518 is approximately 1.4 mm. Thus, after being received into channel 506, the maximum longitudinal dimension of multi-strand wire 504 remains approximately 1.4 mm. However, the maximum transverse dimension of the multi-strand wire is increased to approximately 1.7 mm. Thus, the wire strands within multi-strand wire 504 may be more closely packed in the dimension parallel to longitudinal axis 502. As the wire strands move, they may become less closely packed in the dimension perpendicular to longitudinal axis 502.

[0161] After the multi-strand wire is received in the channel and the adhesive coating is activated to impart the multi-strand wire with the predetermined cross-sectional shape of the channel, the method further includes removing the multi-strand wire from the support member at block 308. For example, the multi-strand wire can be unwound from the support member. Unwrapping the multi-strand wire itself and removing it from the support member may be suitable if the wire has sufficient elasticity to return to its coiled shape after unwrapping. Alternatively, removing the multi-strand wire from the support member may include one of the following: (i) loosening the support member from the coil (i.e., by rotating and withdrawing the support member while holding the coil stationary), or (ii) loosening the coil from the support member (i.e., by rotating and withdrawing the coil while holding the support member stationary), or (iii) sliding the coil off the support member, or vice versa (if the coil has sufficient elasticity to pass over the raised portions between adjacent troughs of the channel). In at least alternatives (i) and (ii), the channels may have a constant pitch along the length of the support member and / or may extend to one end of the support member so that the coil can be more easily separated from the support member.

[0162] By using an adhesive coating to set the shape of the multi-strand wire, the inductor coil substantially maintains its shape after removal from the support member. To facilitate removal from the support member, the support member may be formed from or coated with a material to which the multi-strand wire does not adhere strongly, so that the multi-strand wire does not adhere to the support member during the activation process. The support member may be made of, for example, a metal.

[0163] Once the inductor coil is formed and removed from the support member, it can be assembled to device 100. The inductor coil may be received in insulating member 128. For example, the inductor coil can be slid onto insulating member 128.

[0164] FIG. 10C shows another enlarged view of a portion of FIG. 10A of FIG. 10 to more clearly illustrate the tapered mouth portion 508 and the wire-receiving portion 510. In this example, the first surface 520 of the tapered mouth portion 508 has a first surface slope, and the second surface 522a of the wire-receiving portion 510 adjacent to the tapered mouth portion 508 has a second surface slope that is greater than the first surface slope. In other words, the slope angle 524 of the first surface 520 is less than the slope angle 526 of the second surface 522a. The surface slope and slope angle are defined relative to the longitudinal axis 502. A smaller slope angle indicates a shallower / less steep slope. The shallower slope of the tapered mouth portion 508 allows for a smoother transition as the multi-strand wire is guided into the channel 506. In this example, the second surface 522a (i.e., the surface directly adjacent to the tapered mouth portion 508) is vertical. In other examples, second surface 522a may not be vertical. For example, the surface adjacent tapered mouth portion 508 may have a slope similar to the slope of third surface 522b. Third surface 522b has a third surface slope that is greater than the first surface slope and a slope angle 528 that is greater than slope angle 524 of first surface 520.

[0165] 11 shows a side view of a second exemplary support member 550. Support member 550 defines a longitudinal axis 552 about which multi-strand wire 504 can be wound. The outer surface of support member 550 includes a helical channel 556 having a V-shaped cross-section for receiving multi-strand wire 554.

[0166] In this example, channel 556 includes a continuous tapered mouth portion 558 and a wire-receiving portion 560. That is, a first surface of tapered mouth portion 558 has a first surface slope, and a second surface of wire-receiving portion 560 adjacent tapered mouth portion 558 has a second surface slope that is equal to the first surface slope.

[0167] In this example, wire-receiving portion 560 imparts a predetermined cross-sectional shape to multi-strand wire 554. Figure 11 shows multi-strand wire 554 having a generally circular cross-sectional shape prior to entering wire-receiving portion 560. When multi-strand wire 554 is fully received in wire-receiving portion 560, multi-strand wire 554 may be constricted in one or more dimensions, thereby deforming the cross-section of multi-strand wire 554.

[0168] 10B, the maximum depth 566 of wire-receiving portion 560 is greater than the maximum width 568 of wire-receiving portion 560. With this particular shape, multi-strand wire 554 is contracted in a dimension parallel to longitudinal axis 552 and elongated in a dimension perpendicular to longitudinal axis 552 when the wire is fully received in channel 556. Thus, the cross-sectional shape of wire-receiving portion 560 is imparted to multi-strand wire 554. Multi-strand wire 554 therefore obtains the same cross-sectional shape provided by channel 556. Thus, multi-strand wire 554 has a maximum transverse dimension that is greater than its maximum longitudinal dimension.

[0169] FIG. 12 shows a side view of a third exemplary support member 600. This example support member 600 differs from those shown in FIGS. 10-11 in that the channel has a flat floor / bottom. Thus, the deepest area of ​​the channel 606 is flat. The exemplary support member 600 can be used to fabricate inductor coils, where the multi-strand wire has a shape with at least one flat side, such as a rectangle, and has a maximum longitudinal dimension that is greater than the maximum lateral dimension.

[0170] As with the previous example, the support member 600 defines a longitudinal axis 602 about which a multi-strand wire 604 can be wound. The outer surface of the support member 600 includes a channel 606 for receiving the multi-strand wire 604.

[0171] Channel 606 includes a tapered mouth 608 and a wire-receiving portion 610. In this example, wire-receiving portion 610 imparts a predetermined cross-sectional shape to multi-strand wire 604. Figure 12 shows multi-strand wire 604 having a generally circular cross-sectional shape prior to entering wire-receiving portion 610. When multi-strand wire 604 is fully received in wire-receiving portion 610, multi-strand wire 604 may be constricted in one or more dimensions, thereby deforming the cross-section of multi-strand wire 604.

[0172] In this example, the maximum width 618 of the wire-receiving portion 610 is greater than the maximum depth 616 of the wire-receiving portion 610. This particular shape provides the multi-strand wire 604 with a cross-sectional shape having a maximum longitudinal dimension that is greater than its maximum lateral dimension. Thus, the multi-strand wire 604 obtains the same cross-sectional shape as provided by the channel 606.

[0173] FIG. 13 shows a side view of a fourth exemplary support member 650. The support member 650 of this example differs from those shown in FIGS. 10-12 in that the channel does not have a tapered mouth portion but has a rounded bottom. Thus, the deepest section of the channel 656 is round. As with the previous examples, the support member 650 defines a longitudinal axis 652 about which the multi-strand wire 654 can be wound. The outer surface of the support member 650 includes a generally helical channel 656 having a U-shaped cross-section for receiving the multi-strand wire 654.

[0174] In this example, wire-receiving portion 660 imparts a predetermined cross-sectional shape to multi-strand wire 664. Figure 13 shows multi-strand wire 604 having a generally oval cross-sectional shape before entering wire-receiving portion 660. When multi-strand wire 604 is fully received in wire-receiving portion 660, multi-strand wire 654 may be constricted in one or more dimensions, thereby modifying the cross-section of multi-strand wire 654. In other examples, the rounded bottom of the channel may mean that multi-strand wire 654 substantially maintains its original cross-sectional shape.

[0175] As previously mentioned, channel 656 may not have a tapered mouth portion. That is, mouth portion 658 of channel 656 has a generally constant width dimension over the distance toward wire-receiving portion 660. In fact, it is wire-receiving portion 660 that has a width dimension that decreases with distance toward the bottom of channel 656.

[0176] Figure 14 shows a side view of a fifth support member 700. The support member 700 in this example is similar to that shown in Figure 13, except the channel has a tapered mouth portion 708. As with the previous example, the support member 700 defines a longitudinal axis 702 about which a multi-strand wire 704 can be wound. The outer surface of the support member 700 includes a generally U-shaped channel 706 for receiving the multi-strand wire 704.

[0177] In this example, wire-receiving portion 710 imparts a predetermined cross-sectional shape to multi-strand wire 704. Figure 13 shows multi-strand wire 704 having a generally circular cross-sectional shape before entering wire-receiving portion 710. When multi-strand wire 704 is fully received in wire-receiving portion 710, multi-strand wire 704 may be constricted in one or more dimensions, thereby modifying the cross-section of multi-strand wire 704. In other examples, the rounded bottom of the channel may mean that multi-strand wire 704 substantially maintains its original cross-sectional shape.

[0178] 15 shows a side view of a sixth support member 750. The support member 600 in this example has a flat bottom and a wire-receiving portion 760 with a maximum depth 766 that is greater than a maximum width 768 of the wire-receiving portion. As with the previous example, the support member 750 defines a longitudinal axis 752 about which a multi-strand wire 754 can be wound. The outer surface of the support member 750 includes a channel 756 for receiving the multi-strand wire 754.

[0179] Channel 756 includes a tapered mouth portion 758 and a wire-receiving portion 760. In this example, wire-receiving portion 760 imparts a predetermined cross-sectional shape to multi-strand wire 754. Figure 15 shows multi-strand wire 754 having a generally circular cross-sectional shape prior to entering wire-receiving portion 760. When multi-strand wire 754 is fully received in wire-receiving portion 760, multi-strand wire 754 may be constricted in one or more dimensions, thereby deforming the cross-section of multi-strand wire 754.

[0180] In this example, the maximum depth 766 of the wire-receiving portion 760 is greater than the maximum width 768 of the wire-receiving portion 760. This particular shape provides the multi-strand wire 754 with a cross-sectional shape having a maximum lateral dimension that is greater than the maximum longitudinal dimension. Thus, the multi-strand wire 754 obtains the same cross-sectional shape as provided by the channel 756. Thus, the multi-strand wire 754 may have a generally rectangular shape.

[0181] The support members in the examples described above have a fixed cross-sectional width perpendicular to the axis defined by the support member. In other examples, the cross-sectional width of the support member may be variable. Exemplary support members having variable cross-sectional widths are described in connection with FIGS. 16A-20. Note that the support member(s) described in the examples above may have a variable cross-sectional width in combination with the features described in those examples. Similarly, the support member(s) described in FIGS. 16A-20 may have any of the features described in the examples above.

[0182] Figure 16A shows an exemplary support member 800 that can move between two or more configurations. In Figure 16A, the support member 800 defines a first axis 802, such as a longitudinal axis. A second axis 804 is disposed perpendicular to the first axis 802. In Figure 16A, the support member 800 is disposed in a first configuration in which the support member 800 has a first cross-sectional width 806. Although the support member can have any shape, the support member 800 in this example has a cylindrical shape and a diameter equal to the first cross-sectional width 806.

[0183] The outer surface of the support member 800 has a channel 808, such as a helical channel, that extends along the length of the support member 800 about a first axis 802. As described above, a wire can be wound around the support member 800 and received within the channel 808. In other examples, the channel can be omitted, and the wire can be wound directly onto the outer surface of the support member 800. In either case, the support member 800 is positioned in a first configuration while the inductor coil is formed. FIG. 16B shows a wire 810 being wound around the support member 800 to form the inductor coil.

[0184] Figure 16C shows a cross-sectional view of the support member of Figure 16A taken along direction "A." Figure 16D shows a cross-sectional view of the support member of Figure 16B taken along direction "B."

[0185] In these examples, the channel 808 has a variable pitch along the length of the support member 800. In other words, the spacing between adjacent turns may vary along the length of the support member 800. However, in other examples, the channel 808 may have a constant pitch.

[0186] FIG. 17A shows support member 800 positioned in a second configuration after its cross-sectional width has been reduced. In FIG. 17A, support member 800 has a second cross-sectional width 812 that is smaller than first cross-sectional width 806. While this can be achieved by many different mechanisms, in this example, the support member has been collapsed by rolling support member 800 into a spiral configuration. FIG. 17A shows support member 800 without wire 810, while FIG. 17B shows wire 810 after it has been formed into an inductor coil. In contrast to FIG. 16B, FIG. 17B shows that as the cross-sectional width of support member 800 is reduced, wire 810 (and therefore inductor coil) becomes loose and can be easily removed from support member 800. The inductor coil can be moved along the length of support member 800 and completely removed from support member 800. By reducing the cross-sectional width of support member 800 after the inductor coil is formed, removal of the inductor coil is less likely to damage or distort the final shape of the coil.

[0187] Figure 17C shows a cross-sectional view of the support member of Figure 17A taken along direction "C." Figure 17D shows a cross-sectional view of the support member of Figure 17B taken along direction "D."

[0188] 16A, support member 800 is shown formed from a plurality of segments 814 arranged circumferentially about a first axis 802. That is, each segment extends partially around the outer periphery / perimeter of support member 800. Each segment 814 extends along the length of support member 800 in a direction parallel to first axis 802. Segments 814 are movable relative to one another to enable support member 800 to be moved between a first configuration and a second configuration.

[0189] Figure 18A shows an end view of the support member 800 of Figure 16A as viewed along a first axis 802. Thus, in Figure 18A, the support member 800 is positioned in a first configuration. Figure 18B shows an end view of the support member 800 of Figure 17A as viewed along the first axis 802. Thus, in Figure 18B, the support member 800 is positioned in a second configuration. In both Figures 18A and 18B, the first axis 802 extends into the page.

[0190] Support member 800 has eight segments in this example, but may have more or fewer segments in other examples. Three segments 814 a, 814 b, and 814 c are labeled for reference. Each segment has an arc length 818 that extends at least partially around the circumference of support member 800. Thus, the segments are circumferentially arranged about first axis 802.

[0191] Referring to FIG. 18A, a first segment 814a is positioned adjacent to a second segment 814b, and the first segment 814a is configured to move relative to the second segment 814b when the support member 800 moves between the first and second configurations. For example, the second segment 814b can rotate or pivot in a direction 816 relative to the first segment 814a. FIG. 18B shows the second segment 814b after rotating toward the first segment 814a. To enable this rotation, the adjacent segments 814a, 814b may be connected via a hinge 820. Note that for simplicity, only one hinge is shown in FIGS. 18A and 18B. Several other segments may also be connected by a hinge. Additionally, each pair of adjacent segments may be connected by multiple hinges.

[0192] The third segment 814c is positioned adjacent to the second segment 814b and is configured to move relative to the second segment 814b when the support member 800 moves between the first and second configurations. In this example, the second segment 814b is not permanently connected to the adjacent third segment 814c. The two segments 814b, 814c may abut when in the first configuration and may separate when the support member moves toward the second configuration (as shown in FIG. 18B). Thus, the second segment 814b may form one end of the circumference of the support member, and the third segment 814c may form the opposite end of the circumference. By moving these two segments 814b, 814c relative to each other, the support member 800 can be moved between the first and second configurations. In the second configuration, the support member 800 can be said to be configured in a spiral / roll configuration, as the outer edges of the support member curl inward as the segments are moved.

[0193] In some instances, it may be advantageous to prevent a segment from rotating in a direction opposite to its intended direction. For example, as shown in FIG. 18A, it may be useful to allow rotation only in the direction of arrow 816 and limit rotation in the direction of arrow 822. To limit this movement, each segment may include a stop to limit the movement of the segment relative to an adjacent segment. The stop thus limits the extent to which the support member 800 can move away from the second feature (i.e., it cannot move beyond the first feature). To provide the stop, each segment may include a receiving portion 824 for mating with a protruding portion 826 of an adjacent segment. This interlocking of the components, in addition to the support provided by the hinge, prevents adjacent segments from moving in opposite directions. The receiving portion may be in the form of a recessed or notched portion, and the protruding portion may be in the form of a lip or tip that mates with the receiving portion. In other instances, other forms of stoppers may be employed.

[0194] In this particular example, support member 800 is biased to the second configuration. That is, without the application of an external force, support member 800 assumes the second configuration. In one example, this is achieved by providing biased hinges 820 between adjacent segments. For example, one or more hinges may include a spring or other biasing mechanism for rotating adjacent segments toward one another. For example, biased hinge 820 may rotate second segment 814b in the direction of arrow 816. In other examples, the spring or other biasing mechanism may be separate from the hinge. Some or all of the hinges may be biased.

[0195] An external force may be applied to hold the support member 800 in the first configuration. For example, a device (not shown) may apply a force to the inner surface of the support member 800 at one or more locations. The device may be inserted into the hollow cavity 830 of the support member 800. Arrow 828 in FIG. 18A illustrates the application of a force to the inner surface of the second segment 814b to hold the segment in abutment with the third segment 814c. Due to the biased nature of the hinge 820, removal of the device (and therefore the force) causes the second segment 814b to rotate in the direction of arrow 816, moving the support member toward the second configuration in FIG. 18B.

[0196] In certain examples, the device is movable along a first axis 802 to move the support member 800 between the first and second configurations. For example, when the support member 800 is in the first configuration, the device may be disposed within the hollow cavity 830 of the support member at a first position along the axis 802 to hold the support member 800 in the first configuration, and when the support member 800 is in the second configuration, the device is disposed at a second position along the axis 802 that is different from the first position.

[0197] 19A shows a cross-sectional side view of an exemplary support member 800 and a device 832 inserted into a hollow cavity 830 of the support member 800, where the device 832 is positioned at a first position along a first axis 802. In FIG. 19A, the support member 800 is positioned in a first configuration, and the device 830 abuts the inner surface of the support member 800 to hold the support member 800 in the first configuration.

[0198] 19B shows support member 800 at a later point in time after device 832 has been moved along first axis 802 in the direction indicated by arrow 834. Device 832 has been at least partially withdrawn from hollow cavity 830 of support member 800 and is now positioned at a second position along first axis 802. In some instances, device 832 may be completely removed from the hollow cavity.

[0199] As shown, device 832 has a tapered profile, and as device 832 is moved in direction 834, a wider portion of device 832 is removed from the cavity, thus reducing the cross-sectional width of support member 800 until support member 800 assumes the second configuration. Due to the biased nature of support member 800, support member 800 reconfigures.

[0200] FIG. 20 shows a flow diagram of a method 900 for forming an inductor coil for an aerosol delivery device.

[0201] The method includes, at block 902, providing a multi-strand wire 810 comprising a plurality of wire strands, at least one of the plurality of wire strands comprising an adhesive coating. As described above, an adhesive coating is a coating that surrounds a wire strand and can be activated (such as by heating) to bond the strands within the multi-strand wire to one or more adjacent strands. The adhesive coating enables the multi-strand wire to be formed into the shape of an inductor coil of a support member, and the inductor coil maintains that shape after the adhesive coating is activated. Thus, the adhesive coating "sets" the shape of the inductor coil.

[0202] The method further includes, at block 904, winding a multi-strand wire around a support member 800 defining an axis 802. For example, the multi-strand wire may be wound helically around the support member 800.

[0203] Once the multi-strand wire 810 is wrapped around the support member 800, the method 900 further includes activating the adhesive coating at block 906 so that the multi-strand wire substantially maintains the shape determined by the support member 800 (e.g., the shape provided by the channel 808). Alternatively, block 906 may be performed after the multi-strand wire 810 is completely wrapped around the support member 800.

[0204] After the multi-strand wire has been wound and the adhesive coating has been activated, the method further includes reducing a cross-sectional width of the support member perpendicular to the axis at block 908. Reducing the cross-sectional width of the support member may include moving the support member between a first configuration and a second configuration, wherein when the support member is in the second configuration, the cross-sectional width of the support member perpendicular to the axis is smaller than when the support member is in the first configuration.

[0205] After the cross-sectional width of the support member has been reduced, the method further includes removing the multi-strand wire from the support member at block 910 .

[0206] The above-described embodiments should be understood as illustrative examples of the present invention. Further embodiments of the present invention are contemplated. It should be understood that any feature described with respect to any one embodiment can be used alone or in combination with other features described, and can also be used in combination with one or more features of any other embodiment or any combination of any other embodiments. Furthermore, equivalents and modifications not described above may be used without departing from the scope of the present invention, as defined in the appended claims.

Claims

1. 1. A method of forming an inductor coil for an aerosol delivery device, comprising: providing a multi-strand wire comprising a plurality of wire strands, at least one of the plurality of wire strands comprising an adhesive coating; wrapping the multi-strand wire around the support member such that the multi-strand wire is received in a channel formed in an outer surface of the support member; activating the adhesive coating such that the multi-strand wire substantially maintains the shape determined by the channels; removing the multi-strand wire from the support member; Including, the winding and activating steps include altering the cross-sectional shape of at least a portion of the multi-strand wire; The method, wherein the channel has a predetermined cross-sectional shape, and wherein the step of altering the cross-sectional shape comprises imparting at least a portion of the predetermined cross-sectional shape to the at least a portion of the multi-strand wire.

2. the support member defines an axis, and the winding step includes winding the multi-strand wire around the axis; The step of changing the cross-sectional shape comprises:

10. The method of claim 1, comprising modifying a cross-section of the multi-strand wire such that the cross-section has a maximum longitudinal dimension that is different from a maximum transverse dimension, the maximum longitudinal dimension being measured in a direction parallel to the axis and the maximum transverse dimension being measured in a direction perpendicular to the maximum longitudinal dimension.

3. the maximum longitudinal dimension is greater than the maximum lateral dimension; or The method of claim 2 , wherein the maximum longitudinal dimension is less than the maximum lateral dimension.

4. 4. The method of claim 3, wherein the step of modifying the cross-sectional shape of the multi-strand wire comprises compressing the multi-strand wire in a direction parallel to the axis to increase the density of the plurality of wire strands.

5. The method of any one of claims 1 to 4, wherein the step of activating the adhesive coating comprises heating the support member such that the adhesive coating is heated.

6. The method of claim 5 , wherein the heating step is performed simultaneously with the rolling step.

7. The method of claim 5 or 6, wherein the step of heating the support member comprises heating the support member to a temperature in the range of about 150°C to 350°C.

8. A method according to any preceding claim, comprising rotating the support member about its axis, thereby winding the multi-strand wire around the support member.

9. 1. A method of forming an inductor coil for an aerosol delivery device, comprising: providing a multi-strand wire comprising a plurality of wire strands, at least one of the plurality of wire strands comprising an adhesive coating; winding the multi-strand wire around a support member defining an axis; activating the adhesive coating so that the multi-strand wire substantially maintains the shape determined by the support member; reducing a cross-sectional width of the support member in a direction perpendicular to the axis; removing the multi-strand wire from the support member; Including, the winding and activating steps include altering the cross-sectional shape of at least a portion of the multi-strand wire; a channel formed in an outer surface of the support member having a predetermined cross-sectional shape, and the step of altering the cross-sectional shape includes imparting at least a portion of the predetermined cross-sectional shape to the at least a portion of the multi-strand wire.

10. the step of reducing the cross-sectional width of the support member comprises:

10. The method of claim 9, comprising moving the support member between a first configuration and a second configuration, wherein the cross-sectional width of the support member perpendicular to the axis when the support member is in the second configuration is smaller than when the support member is in the first configuration.

11. a device disposed within the hollow cavity of the support member at a first position along the axis when the support member is in the first configuration, to hold the support member in the first configuration; When the support member is in the second configuration, the device is positioned at a second position along an axis different from the first position; 11. The method of claim 10, wherein the step of moving the support member between a first configuration and a second configuration comprises moving the device between the first position and the second position.

12. 12. The method of claim 9, wherein the outer surface of the support member is formed by a plurality of segments arranged circumferentially about the axis, and wherein the step of reducing the cross-sectional width of the support member comprises moving at least one of the plurality of segments relative to an adjacent one of the plurality of segments.

13. the winding step includes winding the multi-strand wire around the axis; 13. The method of any one of claims 9 to 12, wherein the step of removing the multi-strand wire from the support member comprises moving the multi-strand wire relative to the support member in a direction parallel to the axis.

14. 14. The method of any one of claims 9 to 13, wherein the step of winding the multi-strand wire around the support member comprises receiving the multi-strand wire in a channel formed in an outer surface of the support member.

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