Aerosol Delivery Device

Abstract

To provide a battery support for an aerosol provision device.SOLUTION: An aerosol provision device includes a battery support. The battery support includes a main portion defining a longitudinal axis, a first end portion at a first end of the main portion along the longitudinal axis, and a second end portion at a second end of the main portion along the longitudinal axis. The first and second end portions extend away from a first side of the main portion in a first direction substantially perpendicular to the longitudinal axis. The device further includes a battery supported between the first and second end portions, and a heater assembly comprising an inductor coil. The device further includes a printed circuit board (PCB) engaged with a second side of the main portion and positioned between the main portion and the heater assembly, where ends of the inductor coil are connected to the PCB.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device and a battery support for an aerosol delivery device. [Background technology]

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

[0003] According to a first aspect of the present disclosure, A battery support, a main portion defining a longitudinal axis; a first end portion at a first end of the main portion along the longitudinal axis; a second end portion at a second end of the main portion along the longitudinal axis, the first end portion and the second end portion extending away from the first side of the main portion in a first direction substantially perpendicular to the longitudinal axis; a battery supported between the first end portion and the second end portion; a heater assembly comprising a coil; a printed circuit board (PCB) engaged with the second side of the main portion and positioned between the main portion and the heater assembly, the end of the coil connected to the PCB; An aerosol delivery device is provided, comprising:

[0004] According to a second aspect of the present disclosure, a main portion defining a longitudinal axis; a first end portion disposed at a first end of the main portion along the longitudinal axis; a second end portion disposed at a second end of the main portion along the longitudinal axis, the first end portion and the second end portion extending away from the first side of the main portion in a first direction substantially perpendicular to the longitudinal axis, the first end portion and the second end portion are configured to receive a battery therebetween; A battery support is provided, with the second side of the main portion configured to engage a printed circuit board (PCB).

[0005] 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]

[0006] [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] Figure 5A is a cross-sectional view of a heating assembly in an aerosol delivery device, and Figure 5B is a detailed view of a portion of the heating assembly of Figure 5A. [Figure 6] FIG. 2 is a perspective view of a battery support and a battery. [Figure 7] FIG. [Figure 8] FIG. 10 is a perspective view of a second battery support part. [Figure 9] FIG. 1 shows a portion of an aerosol delivery device. DETAILED DESCRIPTION OF THE INVENTION

[0007] As used herein, the term "aerosol-forming material" includes materials that provide volatilization upon heating, typically in the form of an aerosol. Aerosol-forming materials can include any tobacco-containing material, such as one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials can also include other non-tobacco products, which may or may not contain nicotine, depending on the product. Aerosol-forming materials can be in the form of, for example, a solid, liquid, gel, or wax. Aerosol-forming materials can also be, for example, a combination or blend of materials. Aerosol-forming materials are sometimes known as "smoking materials."

[0008] Devices are known that heat aerosol-generating materials without burning or combusting the aerosol-generating materials to volatilize at least one component of the aerosol-generating materials, typically forming an inhalable aerosol. Such devices are sometimes described as "aerosol-generating devices," "aerosol-delivery devices," "non-combustion heating devices," "tobacco heating product devices," or "tobacco heating devices," or the like. Similarly, there are so-called e-cigarette devices, which typically vaporize aerosol-generating materials in liquid form, which may or may not contain nicotine. The aerosol-generating materials may take the form of, or be provided as part of, a rod, cartridge, cassette, or the like that can be inserted into the device. A heater for heating and volatilizing the aerosol-generating materials may be provided as a "permanent" part of the device.

[0009] The aerosol delivery device can accept an article containing an aerosol-forming material for heating. An "article" in this context refers to a component that, in use, contains or contains the aerosol-forming material, and optionally other components, and the article is heated to volatilize the aerosol-forming material. A user can insert the article into the aerosol delivery device, which then heats to generate an aerosol, which is subsequently inhaled by the user. The article can be, for example, of a predetermined or specific size configured to be placed within a heating chamber of the device sized to accept the article.

[0010] A first aspect of the present disclosure defines an aerosol delivery device including a battery support. The battery support includes a main portion, a first end portion, and a second end portion. The first end portion and the second end portion extend away from a first side of the main portion and receive a battery therebetween. A printed circuit board (PCB) engages the second side of the main portion and is disposed between the main portion and a heater assembly. The heater assembly includes at least one coil, the end of which is connected to the PCB. Thus, the battery support not only supports the battery to hold it in place, but also serves as a support to which other components of the device can be attached and connected. Such a battery support provides stability to the device. Additionally, the device assembly process can be simplified, allowing various components to be attached to the battery support during device assembly. Thus, the device can be assembled starting from the battery support.

[0011] In certain constructions, the battery support is rigid for stability. In one example, the battery support is made from a plastic material such as polyetheretherketone (PEEK). Any material used should be able to withstand the heat generated by the heater assembly. In certain examples, the heater assembly includes a susceptor that is heated to approximately 250°C to 300°C. The melting point of PEEK is approximately 343°C.

[0012] In certain configurations, the battery support is electrically insulating to avoid shorting the battery.

[0013] As mentioned above, the PCB engages with the second side of the main portion of the battery support, which may be through an adhesive, snap-fit ​​connection, or by being received on the second side.

[0014] A first side of the main portion may define a receptacle and may include a base and two opposing sidewalls. The two sidewalls may extend along the length of the base in a direction parallel to the longitudinal axis and extend away from the base in a first direction. A battery may be disposed in the receptacle between the first and second end portions and the two sidewalls. In such a configuration, the sidewalls may provide, for example, impact protection and / or additional rigidity to the sides of the battery. The length of the base is measured in a direction parallel to the longitudinal axis.

[0015] In some examples, at least a portion of the two side walls abut the battery. For example, edges of the side walls can abut the battery. By contacting the side walls, the battery is held more firmly in place and lateral movement of the battery is prevented or reduced.

[0016] In certain configurations, the two side walls each include an edge shaped to fit the outer surface of the battery, and the edge abuts the battery. For example, the edge can be curved to fit the curved outer surface of the battery. This allows the battery to be more securely supported.

[0017] The base can define an opening between a first side of the main portion and a second side of the main portion, with the opening positioned below the PCB. Thus, there is a hole / cutout through the main portion. This can allow for better thermal management. For example, the opening allows air to circulate below the PCB. Additionally, the opening means that less material is used, thereby reducing the mass of the device and reducing costs. Furthermore, the opening can facilitate assembling and connecting components to the PCB. For example, the PCB can be mounted to the main portion, and the opening allows access to the underside of the PCB while the PCB is held in place. The opening also allows components to be mounted on both sides of the PCB.

[0018] The device may further include a first conductive member that contacts the first battery terminal and a second conductive member that contacts the second battery terminal. The first and second conductive members may extend through the opening and connect to the PCB. The conductive members may be wires or conductive strips that connect the battery to the PCB and / or other components of the device. The first and second terminals may be positive or negative terminals, or vice versa. The opening thus makes it easier to connect the battery to the PCB because the conductive members do not need to be routed around the battery carrier. This configuration therefore also allows the device to be more compact, and by reducing the length of the conductive members, reduces the likelihood of shorting the battery.

[0019] The PCB can define a first through-hole through which the first conductive member extends. The PCB can further define a second through-hole through which the second conductive member extends. Thus, the PCB can define one or more through-holes that receive one or more ends of the conductive members. This can allow the battery to be connected to the other side of the PCB without requiring the conductive members to be routed around the PCB and / or battery carrier. This can maximize space within the device. Additionally, the through-holes can also allow for a more secure attachment to the PCB.

[0020] The device can further include an end member. The end member (i) defines a receptacle, (ii) includes a first mounting element, and (iii) includes an end surface that defines a portion of the exterior surface of the aerosol delivery device. A second end portion of the battery support and at least a portion of the heater assembly are disposed within the receptacle. The battery support can also include a second mounting element that engages with the first mounting element, such that the end member is connected to one end of the battery support.

[0021] Thus, the battery support may include mounting elements configured to engage corresponding mounting elements on the end members, thereby allowing the end members to be connected to the battery support. The end members may provide protection to the ends of the device and may help to support and secure the heater assembly.

[0022] In certain configurations, the main portion comprises a second attachment element, which may also be known as an attachment feature, attachment component, or attachment member.

[0023] In one example, the first and second attachment elements provide a snap-fit ​​connection. For example, the second attachment element may include: a channel extending in a direction parallel to the longitudinal axis; a first surface disposed at one end of the channel; The first surface defines a plane disposed perpendicular to the longitudinal axis. an elongated portion extending away from the end face; a second surface disposed on one end side of the elongated portion, the second surface defines a plane disposed perpendicular to the longitudinal axis; The elongated portion is received within the channel, with the first surface and the second surface engaging.

[0024] Thus, when the first and second mounting elements are mated together, two surfaces abut. These surfaces prevent the end member from moving relative to the battery support in a direction parallel to the longitudinal axis. The channel prevents the end member from moving relative to the battery support in a direction perpendicular to the longitudinal axis. The elongated portion resides within the channel, thereby providing a mounting mechanism with a low profile. The channel can be provided by two spaced apart, angled side walls that push the elongated portion outward and then "snap" back into place before the two surfaces engage.

[0025] In certain configurations, the first mounting element is substantially "T" shaped, where the underside of the horizontal bar of the "T" provides the second surface and the upright portion of the "T" provides the elongated portion.

[0026] In some examples, the battery support includes a third mounting element and the end member includes a fourth mounting element engaged with the third mounting element.

[0027] The device may further include an outer cover, and the end member may further include one or more side surfaces extending away from the end surface. The outer cover may enclose the battery, the heater assembly, the battery support, and one or more sides of the end member.

[0028] Thus, the outer cover can also be supported by the battery support. In an exemplary device including an attachment element having an elongated portion and a channel, the outer cover helps secure the connection between the battery support and the end member. For example, the outer cover holds the elongated portion within the channel, thus holding the first and second surfaces in an engaged position.

[0029] In one example, the outer cover abuts one or more sides of the end member. In certain configurations, the device can include a second end member disposed at the other end of the device, such that the outer cover is received between the two end members.

[0030] The second side of the main portion includes a first PCB retention member and a second PCB retention member, the first PCB retention member and the second PCB retention member (i) both extending away from the second side of the main portion in a second direction opposite the first direction, and (ii) disposed on opposite sides of the main portion and engaging opposite sides of the PCB, the second direction being perpendicular to the longitudinal axis.

[0031] The first and second PCB retention members provide stability by preventing movement of the PCB relative to the battery support.

[0032] In some configurations, the PCB retention member provides an interference fit.

[0033] The PCB can include a first notch that receives the first PCB retention member and a second notch that receives the second PCB retention member, and the notches can thus limit movement of the PCB in a direction parallel to the axis.

[0034] The PCB can define a first coil through-hole and a second coil through-hole, with a first end of the coil extending through the first coil through-hole and a second end of the coil extending through the second coil through-hole. The coil through-holes allow for more secure and robust attachment of the coil to the PCB. For example, when the coil is soldered to the PCB, less stress is applied to the solder.

[0035] In one configuration, the main portion includes a first connector and a second connector extending in a direction parallel to the longitudinal axis and away from one of the first and second end portions, and the device further includes a second PCB, the second PCB defining a first connector through hole and a second connector through hole, the first connector extending through the first connector through hole and the second connector extending through the second connector through hole.

[0036] Thus, the second PCB can be connected to the battery support via the first and second connectors. In one example, the first and second connectors are configured to be heated until they melt when received in the first and second connector holes. Melting the ends of the first and second connectors means that the second PCB cannot be removed.

[0037] The second PCB can be connected to the first PCB, and the second PCB can be positioned substantially orthogonal to the first PCB.

[0038] In some examples, the coil is configured to, when in use, cause heating of at least one electrically conductive heating component / element (also known as a heater component / element), thereby enabling thermal energy to be conducted from the at least one electrically conductive heating component to the aerosol-generating material, thereby causing heating of the aerosol-generating material.

[0039] In some examples, the coil is configured to, in use, generate a varying magnetic field that penetrates at least one heating component / element, thereby causing inductive heating and / or magnetic hysteresis heating of the at least one heating component. In such configurations, the heating configuration or each heating component may be referred to as a "susceptor." A coil configured to, in use, generate a varying magnetic field that penetrates at least one electrically conductive heating component, thereby causing inductive heating of the at least one electrically conductive heating component may be referred to as an "induction coil" or "inductor coil."

[0040] The device can include a heating component, e.g., an electrically conductive heating component, which can be suitably positioned or positionable relative to the coil to enable such heating of the heating component. The heating component can be in a fixed position relative to the coil. Alternatively, at least one heating component, e.g., at least one electrically conductive heating component, can be included in an article for insertion into a heating zone of the device, the article also including the aerosol-generating material and removable from the heating zone after use. Alternatively, both the device and such article can include at least one respective heating component, e.g., at least one electrically conductive heating component, and the coil can be for causing heating of each heating component of the device and the article when the article is within the heating zone.

[0041] In some examples, the coil is a helix. In some examples, the coil surrounds at least a portion of a heating zone of the device configured to receive the aerosol-generating material. In some examples, the coil is a helical coil surrounding at least a portion of the heating zone. The heating zone can be a receptacle shaped to receive the aerosol-generating material.

[0042] In some examples, the device includes an electrically conductive heating component at least partially surrounding the heating zone, and the coil is a helical coil surrounding at least a portion of the electrically conductive heating component. In some examples, the electrically conductive heating component is tubular. In some examples, the coil is an inductor coil.

[0043] Preferably, the device is a tobacco heating device, also known as a non-combustion heating device.

[0044] 1 shows an example of an aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. In general, 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.

[0045] The device 100 comprises a housing 102 (in the form of an outer cover) that encloses and contains 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 a heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly where it can be heated by one or more components of the heater assembly.

[0046] 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 Figure 1, the lid 108 is shown in an open configuration, but the cap 108 is movable to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "A."

[0047] 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 may turn device 100 on by operating switch 112.

[0048] Device 100 may also include electrical components such as a socket / port 114 that can receive a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port. In some examples, socket 114 may also or alternatively be used to transfer data between device 100 and another device, such as a computing device.

[0049] 2 shows the device 100 of FIG. 1 with the outer cover 102 removed and without the article 110. The device 100 defines a longitudinal axis 134.

[0050] 2, first end member 106 is disposed at one end of device 100, and second end member 116 is disposed at the opposite 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. An edge of outer cover 102 can also define a portion of the end surface. In this example, lid 108 also defines a portion of the top surface of device 100.

[0051] The end of the device nearest opening 104 is sometimes known as the proximal end (mouth end) of device 100 because it is closest to the user's mouth during use. During use, a user inserts item 110 into opening 104, operates user control 112 to initiate heating of the aerosol-generating material, and inhales the aerosol generated within the device, causing the aerosol to flow through device 100 along the flow path toward the proximal end of device 100.

[0052] The other end of the device furthest from opening 104 may be known as the distal end of device 100, as it is the end furthest from a user's mouth in use. When a user inhales the aerosol generated within the device, the aerosol flows away from the distal end of device 100.

[0053] Device 100 further includes a power source 118. Power source 118 can be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heater 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. Central support 120 may also be known as a battery support or battery carrier.

[0054] The device further includes at least one electronics module 122. The electronics 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 include one or more electrical tracks for electrically connecting the various electronic components of the device 100 together. 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 a battery via electrical tracks.

[0055] 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 via an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly can 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 within 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 via Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., by the varying orientation of magnetic dipoles in the magnetic material as a result of coordination with the varying magnetic field. In induction heating, heat is generated within the susceptor, allowing for faster heating, compared to heating by conduction, for example, and there is no need for physical contact between the induction heater and the susceptor, allowing for greater flexibility in construction and application.

[0056] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are made from a conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made from litz wire / cable wound in a helical shape to provide the helical inductor coils 124, 126. The litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. The litz wire is designed to reduce skin effect losses in the conductor. In the exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are made from copper litz wire having a rectangular cross-section. In other examples, the litz wire can have other cross-section shapes, such as circular.

[0057] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along the longitudinal axis 134 of the device 100 (i.e., the first inductor coil 124 and the second inductor coil 126 do not overlap). The susceptor structure 132 can include a single susceptor or two or more separate susceptors. Ends 130 of the first inductor coil 124 and the second inductor coil 126 can be connected to the PCB 122.

[0058] It will be appreciated that in some examples, the first inductor coil 124 and the second inductor coil 126 can have at least one characteristic that differs from one another. For example, the first inductor coil 124 can have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 can have a different inductance value than the second inductor coil 126. In FIG. 2 , the first inductor coil 124 and the second inductor coil 126 are of different lengths, such that the first inductor coil 124 is wound around a smaller section of the susceptor 132 than the second inductor coil 126. As such, the first inductor coil 124 can include 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 can be made of a different material than the second inductor coil 126. In some examples, the first inductor coil 124 and the second inductor coil 126 can be substantially identical.

[0059] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, initially, the first inductor coil 124 may be operating to heat a first section of the article 110, and at a later time, the second inductor coil 126 may be operating to heat a second section of the article 110. Winding the coils in opposite directions helps reduce current flow in inactive coils when used in conjunction with certain types of control circuitry. In FIG. 2, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124, 126 can be wound in the same direction, or the first inductor coil 124 can be a left-handed spiral and the second inductor coil 126 can be a right-handed spiral.

[0060] The susceptor 132 in this example is hollow, thus defining a receptacle for receiving the aerosol-generating material therein. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 132 is tubular with a circular cross section.

[0061] 2 further includes an insulating member 128 that may be generally tubular and at least partially surrounds 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 serve to insulate various components of the device 100 from heat generated within the susceptor 132.

[0062] The insulating member 128 can also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 2 , the first inductor coil 124 and the second inductor coil 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 inductor coil 124 and the second inductor coil 126. For example, there can be a small gap between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

[0063] 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 .

[0064] 3 shows a side view, partially in cross section, of device 100, in this example with outer cover 102 present. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 are more clearly visible.

[0065] 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.

[0066] The device may also include a second printed circuit board 138 associated within the control element 112 .

[0067] The device 100 further includes a second lid / cap 140 and a spring 142 disposed distally of the device 100. The spring 142 allows 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.

[0068] The device 100 further comprises an expansion chamber 144 extending from the proximal end of the susceptor 132 towards the opening 104 of the device. A retention clip 146 is at least partially disposed within the expansion chamber 144 for abutting and retaining the article 110 when received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0069] FIG. 4 is an exploded view of the device 100 of FIG. 1 with the outer cover 102 omitted.

[0070] FIG. 5A of FIG. 5 shows a cross-sectional view of a portion of the device 100 of FIG. 1. FIG. 5B of FIG. 5 shows a detailed view of the area of ​​FIG. 5A. FIGS. 5A and 5B of FIG. 5 show an article 110 received within a susceptor 132, where the article 110 is sized so that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures the most efficient heating. In this example, the article 110 includes an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also include other components, such as a filter, packaging material, and / or cooling structure.

[0071] 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.

[0072] 5B further illustrates that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is approximately 0.05 mm. In another example, the distance 152 is substantially 0 mm, such that the inductor coils 124, 126 abut and contact the insulating member 128.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] FIG. 6 shows the battery support 120 of FIGS. 2 and 4 in more detail. The battery support 120 comprises a main portion 202, a first end portion 204, and a second end portion 206. The main portion 202 defines a longitudinal axis 208 parallel to the y-axis. The first end portion 204 is disposed at a first end of the main portion 202, and the second end portion 206 is disposed at a second end of the main portion 202. The first end portion 204 and the second end portion 206 extend away from a first side of the main portion 202 in a first direction 210 that is substantially perpendicular to the longitudinal axis 208. Thus, the first side of the main portion 202 is the side facing outward from the main portion 202 in the first direction 210. The first direction is parallel to the x-axis.

[0077] In this example, the battery 118 is shown disconnected from the battery support 120. The battery 118 can be connected to the battery support 120 by moving the battery 118 toward the battery support 120 in the direction of arrow 200. When connected to the battery support 120, the battery 118 is held between a first end portion 204 and a second end portion 206. For example, an upper end 118a of the battery 118 is received by the first end portion 204, and a lower end 118b of the battery 118 is received by the second end portion 206. One or more end supports 212a, 212b can also be present to help secure the battery 118 in place. The end supports 212a, 212b may be integral with the first end portion 204 and the second end portion 206 so as to form part of the first end portion 204 and the second end portion 206, or may be separate and connected to the first end portion 204 and the second end portion 206.

[0078] 6 further shows PCB 122 engaged with a second side of main portion 202. The second side of main portion 202 is the side facing away from main portion 202 in a second direction 214 opposite and parallel to first direction 210. Second direction 214 is also parallel to the x-axis and perpendicular to longitudinal axis 208. PCB 122 may be attached to main portion 202 or may be connected via another means, such as a friction fit, a snap fit, or the like. In this example, PCB 122 defines a longitudinal axis that is parallel to longitudinal axis 208 of main portion 202.

[0079] As described above, the aerosol delivery device 100 includes a heater / heating assembly including at least one inductor coil 124, 126. FIG. 4 illustrates the arrangement of the one or more inductor coils 124, 126 relative to the battery support. The heater assembly is disposed on a second side of the main portion 202, and the PCB 122 is disposed between the main portion 202 and the heater assembly. As shown in FIGS. 2 and 3 , an end 130 of the one or more inductor coils 124, 126 can be connected to the PCB 122.

[0080] In the example of FIG. 6 , the first side of the main portion 202 includes two opposing sidewalls 216 a, 216 b and a base 218. In this particular example, the base 218 defines an opening between the first side of the main portion 202 and the second side of the main portion 202, with the opening disposed below the PCB 122. Thus, holes / cutouts exist through the main portion 202 such that the base 218 is primarily a “void.” This allows access to the underside of the PCB 122. The opening can include multiple through-holes rather than a single through-hole. For example, the base can include one or more dividing structures 218 a (shown in FIG. 8 ) that separate the opening into two or more through-holes. Such dividing structures can provide additional rigidity, for example. In other examples, the base 218 is rigid, such that no openings exist through the main portion 202.

[0081] The two side walls 216a, 216b extend along the length of the base 218 in a direction parallel to the longitudinal axis 208. The two side walls 216a, 216b also extend away from the base 218 in the first direction 210. The two side walls 216a, 216b and the base 218 together define a receptacle 220. As shown most clearly in FIG. 4 , when the battery 118 is connected to the battery support 120, the battery 118 is at least partially disposed within the receptacle 220 between the first end portion 204 and the second end portion 206 and between the two side walls 216a, 216b.

[0082] In some examples, at least a portion of the two side walls 216a, 216b abuts the battery 118. For example, when the battery is connected to the battery support 120, the outer edges 222a, 222b of the two side walls 216a, 216b abut the battery 118. In other examples, the battery 118 does not contact the edges 222a, 222b of the two side walls 216a, 216b.

[0083] 6, the two side walls 216a, 216b each include edges 222a, 222b that are shaped to fit the outer surface of the battery 118. The battery in this example is cylindrical, and the edges 222a, 222b are curved to better secure the battery 118. The receptacle 220 can also have a shape that fits the outer surface of the battery 118. For example, the receptacle 220 can have a "U" shape to receive the battery 118.

[0084] 6 , the battery 118 includes a first conductive member 224 that contacts a first battery terminal and a second conductive member 226 that contacts a second battery terminal. The first and second battery terminals may be, for example, positive and negative terminals. The conductive members 224, 226 may be wires or conductive strips that connect the battery 118 to the PCB 122. The conductive members 224, 226 generally extend away from the battery 118 toward the PCB 122 in the second direction 214.

[0085] When the battery 118 is connected to the battery support 120, the first conductive member 224 and the second conductive member 226 extend through openings in the base 218 so that they can be connected to the PCB 122.

[0086] The PCB 122 may define a through hole through which the first conductive member 224 extends. The PCB 122 may further define a second through hole through which the second conductive member 226 extends. To this end, the PCB 122 may include one or more through holes that receive ends of the conductive members 224, 226.

[0087] As shown in Figures 2 and 4, end member 116 is disposed at one end of device 100. Figure 7 shows end member 116 in more detail. As shown, end member 116 defines a receptacle 302. End member 116 also includes at least one attachment element 304a, 304b, which allows end member 116 to be connected to battery support 120. End member 116 includes an end surface 306 that defines a portion of the exterior surface of aerosol delivery device 100. For example, end surface 306 can form the bottom surface of device 100.

[0088] When the end member 116 is connected to the battery support 120, the second end portion 206 of the battery support 120 and at least a portion of the heater assembly are received in the receptacle 302. For example, as shown in Figure 4, the support 136, which engages one end of the susceptor 132, is received in the receptacle 302. Figure 3 most clearly shows the support 136 and second end portion 206 positioned within the receptacle 302 when the device is assembled.

[0089] As described above, the end member 116 includes at least one mounting element 304a, 304b. Similarly, the battery support 120 also includes at least one mounting element. For example, as shown in FIG. 6, the battery support 120 includes a second mounting element 304c that engages with the first mounting element 304a of the end member 116. This allows the end member 116 to be connected to the bottom end of the battery support 120.

[0090] In the example shown, the main portion 202 includes the second mounting element 304c, however, the mounting element can be located anywhere on the battery support 120.

[0091] In this example, the first and second mounting elements 304a, 304c provide a snap-fit ​​connection. For example, the second mounting element 304c includes a channel 228 extending in a direction parallel to the longitudinal axis 208. The channel 228 can be provided by two side walls 232a, 232b. The second mounting element 304c includes a first surface 232a, 232b disposed at one end of the channel. 231 The first surface 231 defines a plane disposed perpendicular to the longitudinal axis 208. 231 is defined by one or both of the upper surfaces of the two side walls 232a, 232b.

[0092] First mounting element 304a includes an elongated portion 308 extending away from end face 306 in a direction parallel to longitudinal axis 208. First mounting element 304a further includes a second surface 310 disposed toward one end of elongated portion 308. Second surface 310 defines a plane disposed perpendicular to longitudinal axis 208. Second surface 310 is defined by one or both of the undersides of an upper portion 312 of first mounting element 304a. Thus, in this example, first mounting element 304a is "T" shaped, with the underside of the horizontal bar of the "T" providing second surface 310 and the upright portion of the "T" providing elongated portion 308.

[0093] When the end member 116 is moved in a third direction 314 (parallel to the longitudinal axis 208) toward the battery support 120, the first mounting element 304a engages the second mounting element 304c, where the elongated portion 308 is received within the channel 228 and the first surface 231 and the second surface 310. For example, the upper portion 312 of the first mounting element 304a contacts the inclined surfaces of the side walls 232a, 232b, causing the first mounting element 304a to bend outward. When the upper portion 312 of the first mounting element 304a is moved beyond the top surfaces of the two side walls 232a, 232b, the first mounting element 304a again moves inward, thereby causing the first surface 231 and second surface 310 abut against each other. Channel 228 has a width equal to or greater than the width of elongated portion 308, so that elongated portion 308 is within channel 228. 231 and second surface 310, end member 116 cannot be separated from battery support 120 without bending first mounting element 304a outward and lifting upper portion 312 over side walls 232a, 232b. Figure 2 shows end member 116 connected to battery support 120.

[0094] 7 further shows an optional third mounting element 304b that is substantially identical to the first mounting element 304a and that can engage with a fourth mounting element located on the opposite side of the battery support 120.

[0095] Although Figures 2, 4, 6 and 7 show one particular type of snap-fit ​​attachment element, other snap-fit ​​attachment elements may alternatively be used.

[0096] As described in connection with FIG. 1 , the device 100 may further include an outer cover 102 that surrounds and houses the various components of the device 100. The outer cover may surround the battery 118, the heater assembly, the battery support 120, and one or more sides 316 of the end member 116. FIG. 7 shows the end member 116 having continuous sides 316 that extend around the end member 116 and longitudinal axis 208 (when the end member 116 is attached to the battery support 120). In other examples, the end member 116 may have a square or rectangular footprint such that there are four sides extending around the end member 116. One or more sides 314 extend away from the end face 306 in a third direction 314. The end member 116 and / or the battery support 120 may include one or more attachment elements to hold the outer cover 102 in place.

[0097] In this example, the outer cover 102 abuts one or more sides 316 of the end member 116 , which can help retain the elongated portion 308 within the channel 228 .

[0098] As mentioned above, the device 100 may include a further end member 106 disposed at the other end of the device 100 such that the outer cover 102 is received between the two end members 106, 116.

[0099] 8 shows an example of another battery support 420. Battery support 420 may include any or all of the features of battery support 120, which will not be described again for the sake of brevity. Battery support 420 may be used in place of battery support 120 in device 100. The features of battery support 420 described below may also be incorporated into battery support 120.

[0100] The battery support 420 includes a main portion 402, a first end portion 404, and a second end portion 406. The main portion 402 defines a longitudinal axis 408 parallel to the y-axis. A first side of the main portion 402 includes two opposing sidewalls 416a, 416b and a base 418. The base 418 includes an opening and one or more dividing structures 218a that separate the opening into two through holes.

[0101] Unlike the exemplary battery support 120 illustrated in FIG. 6 , the battery support 420 of FIG. 8 further includes a first PCB retention member 422 a and a second PCB retention member 422 b. The first PCB retention member 422 a and the second PCB retention member 422 b both extend away from the second side of the main portion 402 in the second direction 214 and are disposed on opposite sides of the main portion 402. The first PCB retention member 422 a and the second PCB retention member 422 b are configured to engage opposite sides of the PCB 122. For example, the PCB 122 can be received between the first PCB retention member 422 a and the second PCB retention member 422 b to secure the PCB 122 in place. The PCB 122 can be held in place by, for example, a friction fit.

[0102] Figure 9 shows a portion of device 100 including battery support 420 of Figure 8. In this example, end member 116 is connected to battery support 116 via an attachment element. In this example, first inductor coil 124 and second inductor coil 126 have circular cross-sections rather than the rectangular cross-sections shown in Figure 2.

[0103] The PCB 122 includes a first notch (not visible) that receives the first PCB retention member 422a and a second notch 424b that receives the second PCB retention member 422b. The notches engage with the retention members 422a, 422b to better secure the PCB 122.

[0104] 9 more clearly shows the ends 130 of the first inductor coil 124 and the second inductor coil 126 connected to the PCB 122. The PCB has first inductor coil through-hole 426a and second inductor coil through-hole 426b. Demarcate the boundaries of The PCB may also have a first end 130a of the first inductor coil 124 extending through the first inductor coil through-hole 426a and a second end 130b of the first inductor coil 124 extending through the second inductor coil through-hole 426b. Demarcate the boundaries of a first end of the second inductor coil 126 can extend through the third inductor coil through-hole, and a second end of the second inductor coil 126 can extend through the fourth inductor coil through-hole.

[0105] Returning to FIG. 6, the main portion 202 includes a first connector 229 and a second connector (not visible in the figure). Connector 229 and the second connection Ta is , extending away from either or both of the first end portion 204 and the second end portion 206 in a direction parallel to the longitudinal axis 208. Connector 229 and the second connection Ta is , extending away from the second end portion 206. The device 100 further comprises a second PCB 230. The second PCB 230 may be associated with and connected to, for example, the socket / port 114. The second PCB 230 defines the first connector through-hole and the second connector through-hole, and may be connected to the first connector 229 extends through the first connector through-hole, and the second connector extends through the second connector through-hole. Connector 229 and the second connector can be connected to the battery support 120. In the example shown, the second PCB 230 is connected to the first PCB 122 via conductive tracks / wires. 230 may be positioned substantially orthogonal to the first PCB 122.

[0106] In one example, the second PCB 230 is the first Connector 229 and the second connection Ta When inserted into the first and second connector through holes, they are held in place by a friction fit. Connector 229 and the second connection Ta's The cross-sectional area of ​​the end is Connector 229 and the second connection Ta The cross-sectional area can be increased when inserted into the first and second connector through-holes, thereby holding the second PCB 230 in place. Connector 229 and the second connection Ta's The ends can be increased by heating and melting. Connector 229 and the second connection Ta's The ends can be bent.

[0107] 8 shows similar first and second connectors 428a, 428b. As in FIG. 6, each connector 428a, 428b has a first, wider portion and a second, narrower portion. The second PCB 230 can receive the first and second connectors 428a, 428b until the PCB 230 abuts the wider portion.

[0108] The above-described embodiments are to be understood as illustrative examples of the present invention. Further embodiments of the present invention are envisioned. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other described features, and may 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 also be employed without departing from the scope of the present invention, which is defined in the appended claims. The present specification discloses the following embodiments. (Embodiment 1) A battery support, a main portion defining a longitudinal axis; a first end portion at a first end of the main portion along the longitudinal axis; a battery support having a second end portion at a second end of the main portion along the longitudinal axis, the first end portion and the second end portion extending away from a first side of the main portion in a first direction substantially perpendicular to the longitudinal axis; a battery supported between the first end portion and the second end portion; a heater assembly comprising a coil; a printed circuit board engaged with a second side of the main portion and positioned between the main portion and the heater assembly, an end of the coil connected to the printed circuit board; An aerosol delivery device comprising: (Embodiment 2) the first side of the main portion defines a receptacle and includes a base and two opposing side walls; the two side walls extend along the length of the base in a direction parallel to the longitudinal axis; the two side walls extend away from the base in the first direction; 2. The aerosol delivery device of embodiment 1, wherein the battery is positioned in the receptacle between the first end portion and the second end portion and between the two side walls. (Embodiment 3) 3. The aerosol delivery device of embodiment 2, wherein at least a portion of the two side walls abuts the battery. (Embodiment 4) 4. The aerosol delivery device of embodiment 3, wherein the two side walls each have an edge shaped to fit the outer surface of the battery, the edge abutting the battery. (Embodiment 5) An aerosol delivery device as described in any of embodiments 2 to 4, wherein the base defines an opening between the first side of the main portion and the second side of the main portion, the opening being positioned below the printed circuit board. (Embodiment 6) a first conductive member in contact with the first battery terminal; a second conductive member in contact with the second battery terminal; Equipped with 6. The aerosol delivery device of embodiment 5, wherein the first conductive member and the second conductive member extend through the opening and are connected to the printed circuit board. (Embodiment 7) 7. The aerosol delivery device of embodiment 6, wherein the printed circuit board defines a first through hole through which the first conductive member extends. (Embodiment 8) An end member, defining a receptacle; a first mounting element; an end member having an end surface defining a portion of an exterior surface of the aerosol delivery device; 1. An aerosol delivery device comprising: the second end portion of the battery support and at least a portion of the heater assembly are disposed within the receptacle; An aerosol delivery device described in any one of embodiments 1 to 7, wherein the battery support has a second mounting element that engages with the first mounting element, and the end member is connected to one end of the battery support. (Embodiment 9) The main portion includes the second mounting element, the second mounting element comprising: a channel extending in a direction parallel to the longitudinal axis; a first surface disposed at one end of the channel, the first surface defining a plane disposed perpendicular to the longitudinal axis; The first mounting element comprises: an elongated portion extending away from the end face; a second surface disposed toward one end of the elongated portion, the second surface defining a plane disposed perpendicular to the longitudinal axis; 9. The aerosol delivery device of embodiment 8, wherein the elongated portion is received within the channel and the first surface and the second surface engage. (Embodiment 10) Further comprising an outer cover; the end member further comprising one or more side surfaces extending away from the end surface; 10. The aerosol delivery device of embodiment 8 or 9, wherein the outer cover surrounds one or more sides of the battery, the heater assembly, the battery support, and the end member. (Embodiment 11) the second side of the main portion comprises a first printed circuit board retention member and a second printed circuit board retention member, the first printed circuit board retention member and the second printed circuit board retention member comprising: both extending in a second direction opposite the first direction and away from the second side of the main portion; 11. The aerosol delivery device of any one of embodiments 1 to 10, wherein the aerosol delivery device is disposed on opposite sides of the main portion and engages with opposite sides of the printed circuit board. (Embodiment 12) An aerosol delivery device as described in embodiment 11, wherein the printed circuit board has a first notch that receives the first printed circuit board holding member and a second notch that receives the second printed circuit board holding member. (Embodiment 13) An aerosol delivery device as described in any one of embodiments 1 to 12, wherein the printed circuit board defines a first coil through-hole and a second coil through-hole, and a first end of the coil extends through the first coil through-hole and a second end of the coil extends through the second coil through-hole. (Embodiment 14) the main portion includes a first connector and a second connector extending in a direction parallel to the longitudinal axis and away from one of the first end portion and the second end portion, and the device includes: An aerosol delivery device as described in any one of embodiments 1 to 13, further comprising a second printed circuit board, the second printed circuit board defining a first connector through hole and a second connector through hole, the first connector extending through the first connector through hole, and the second connector extending through the second connector through hole. (Embodiment 15) a main portion defining a longitudinal axis; a first end portion at a first end of the main portion along the longitudinal axis; a second end portion at a second end of the main portion along the longitudinal axis, the first end portion and the second end portion extending away from a first side of the main portion in a first direction substantially perpendicular to the longitudinal axis, the first end portion and the second end portion are configured to receive a battery therebetween; A battery support, wherein the second side of the main portion is configured to engage a printed circuit board. (Embodiment 16) An aerosol delivery device according to any one of embodiments 1 to 14; an article comprising an aerosol-forming material; An aerosol delivery system comprising:

Claims

1. A battery support, a main portion defining a longitudinal axis; a first end portion at a first end of the main portion along the longitudinal axis; a second end portion at a second end of the main portion along the longitudinal axis, the first end portion and the second end portion extending away from a first side of the main portion in a first direction substantially perpendicular to the longitudinal axis; a battery supported between the first end portion and the second end portion; a heater assembly comprising a coil; a first printed circuit board on a second side of the main portion, an end of the coil connected to the first printed circuit board; a second printed circuit board on the battery support, the second printed circuit board connected to the first printed circuit board and positioned substantially orthogonal to the first printed circuit board; An aerosol delivery device comprising:

2. the first side of the main portion defines a receptacle and includes a base and two opposing side walls; the two side walls extend along the length of the base in a direction parallel to the longitudinal axis; the two side walls extend in the first direction away from the base; the battery is disposed in the receptacle between the first end portion and the second end portion and between the two side walls; The aerosol delivery device of claim 1 .

3. At least a portion of the two side walls abuts against the battery. The aerosol delivery device of claim 2 .

4. The two side walls each have an edge shaped to fit the outer surface of the battery, and the edge abuts against the battery. The aerosol delivery device of claim 3 .

5. the base defines an opening between the first side of the main portion and the second side of the main portion, the opening being disposed below the first printed circuit board; The aerosol delivery device according to any one of claims 2 to 4.

6. a first conductive member in contact with the first battery terminal; a second conductive member in contact with the second battery terminal; Equipped with the first conductive member and the second conductive member extend through the opening and are connected to the first printed circuit board.

6. The aerosol delivery device of claim 5.

7. the first printed circuit board defines a first through hole through which the first conductive member extends; The aerosol delivery device of claim 6 .

8. An end member, defining a receptacle; a first mounting element; an end member having an end surface defining a portion of an exterior surface of the aerosol delivery device; 1. An aerosol delivery device comprising: the second end portion of the battery support and at least a portion of the heater assembly are disposed within the receptacle; the battery support includes a second mounting element that engages with the first mounting element, such that the end member is connected to one end of the battery support; The aerosol delivery device according to any one of claims 1 to 7.

9. the main portion includes the second mounting element; The second attachment element comprises: a channel extending in a direction parallel to the longitudinal axis; a first surface disposed at one end of the channel, the first surface defining a plane disposed perpendicular to the longitudinal axis; The first mounting element comprises: an elongated portion extending away from the end face; a second surface disposed toward one end of the elongated portion, the second surface defining a plane disposed perpendicular to the longitudinal axis; the elongated portion is received within the channel, the first surface and the second surface engaging; 9. The aerosol delivery device of claim 8.

10. Further comprising an outer cover; the end member further comprising one or more side surfaces extending away from the end surface; the outer cover encloses one or more sides of the battery, the heater assembly, the battery support, and the end member; 10. The aerosol delivery device of claim 8 or 9.

11. the second side of the main portion comprises a first printed circuit board retention member and a second printed circuit board retention member; the first printed circuit board retention member and the second printed circuit board retention member both extend in a second direction opposite the first direction and away from the second side of the main portion; disposed on opposite sides of the main portion and engaging opposite sides of the first printed circuit board; The aerosol delivery device according to any one of claims 1 to 10.

12. the first printed circuit board includes a first notch for receiving the first printed circuit board retention member and a second notch for receiving the second printed circuit board retention member; 12. The aerosol delivery device of claim 11.

13. the first printed circuit board defines a first coil through-hole and a second coil through-hole, a first end of the coil extending through the first coil through-hole and a second end of the coil extending through the second coil through-hole; The aerosol delivery device of any one of claims 1 to 12.

14. the main portion includes first and second connectors extending in a direction parallel to the longitudinal axis and away from one of the first and second end portions; the second printed circuit board defines a first connector through hole and a second connector through hole, the first connector extending through the first connector through hole and the second connector extending through the second connector through hole; The aerosol delivery device according to any one of claims 1 to 13.

15. an aerosol delivery device according to any one of claims 1 to 14; an article comprising an aerosol-forming material; An aerosol delivery system comprising:

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