Heating assembly for aerosol generator

Abstract

The present invention relates to a heating assembly for an aerosol generating device, the heating assembly may comprise one or more of a heater casing, a heating element, a connector frame, and an electrical circuit. The heating element may comprise at least two heater contacts. The connector frame may be disposed on the heater casing. The connector frame may comprise at least two connector contacts. The two connector contacts may be electrically connected to the two heater contacts. The two connector contacts may be electrically connected to the electrical circuit.

Description

Technical Field

[0001] The present invention relates to a heating assembly for an aerosol generating device. The present invention further relates to an aerosol generating device and a method of manufacturing a heating assembly.

Background Art

[0002] It is known to provide an aerosol generating device for generating inhalable vapor. Such a device may heat an aerosol forming substrate to a temperature at which one or more components of the aerosol forming substrate volatilize without burning the aerosol forming substrate. The aerosol forming substrate may be provided as part of an aerosol generating article. The aerosol generating article may have a rod shape for insertion into a cavity (e.g., a heating chamber, etc.) of the aerosol generating device. The heating assembly may be disposed in or around the heating chamber to heat the aerosol forming substrate when the aerosol generating article is inserted into the heating chamber of the aerosol generating device.

[0003] It would be desirable to have a heating assembly for an aerosol generating device having improved reliability. It would be desirable to have a heating assembly for an aerosol generating device having improved manufacturing quality. It would be desirable to have a heating assembly for an aerosol generating device having improved robustness during manufacture. It would be desirable to have a heating assembly for an aerosol generating device that is easier to manufacture.

Summary of the Invention

[0004] According to one embodiment of the present invention, a heating assembly for an aerosol generator is provided, which may comprise one or more of a heater casing, a heating element, a connector frame, and an electrical circuit. The heating element may comprise at least two heater contacts. The connector frame may be disposed on the heater casing. The connector frame may comprise at least two connector contacts. The two connector contacts may be electrically connected to two heater contacts. The two connector contacts may be electrically connected to an electrical circuit.

[0005] According to one embodiment of the present invention, a heating assembly for an aerosol generator is provided, the heating assembly comprising a heater casing, a heating element, a connector frame, and an electrical circuit. The heating element comprises at least two heater contacts. The connector frame is disposed on the heater casing. The connector frame comprises at least two connector contacts. The two connector contacts are electrically connected to two heater contacts. The two connector contacts are electrically connected to an electrical circuit.

[0006] The presence of a connector frame makes the manufacturing of heated assemblies easier. Because the connector frame is used to electrically connect the heating element to the electrical circuit, no electrical wiring is required between the connector frame and the electrical circuit. Therefore, the connector frame can be easily connected to the electrical circuit manually or automatically during manufacturing, without any electrical wiring or soldering required.

[0007] The heater casing can be configured as a support frame. Other components of the heating assembly can be mounted on the heater casing. The support frame may be formed from any suitable electrical insulating material. Preferably, the support frame is formed from a material suitable for molding onto other components of the heating assembly. The support frame may be formed from a polymer material. In particular, the support frame may be formed from a moldable polymer. It is preferable that the support frame be formed from a material suitable for use in molding processes such as injection molding. Particularly suitable polymer materials include thermoplastics and thermosetting polymers. Suitable polymer materials include polyphthalamide (PPA), polycarbonate (PC), a blend of polycarbonate and acrylonitrile butadiene styrene (PC-ABS), polyphenylsulfone (PPSU), polyether ether ketone (PEEK), polypropylene (PP), polyethylene (PE), polyimide (PI), thermoplastic polyimide (TPI), polyamide imide (PAI), and polyetherimide (PEI). The polymer materials may be composites. The composite polymer material may include other materials such as fibrous filler materials containing one or more of carbon fibers and glass fibers. The material is preferably lightweight and not brittle.

[0008] Components of a heated assembly, such as a connector frame, may be at least partially embedded within a support frame. As used herein, the term “embedded” refers to a component that is surrounded by another component and fixed within another component. In other words, at least a portion of the connector frame is surrounded by and fixed within the support frame.

[0009] Components of the heat-treated assembly, such as the connector frame, may be at least partially embedded within the support frame in an appropriate manner. The support frame may be formed by a molding process such as injection molding. Preferably, at least a portion of the components of the heat-treated assembly, such as the connector frame, may be overmolded with an electrical insulating material forming the support frame. In some preferred embodiments, the support frame is formed by overmolding an electrical insulating material over the base frame and the electrical connector, thereby at least partially embedding the base frame and the electrical connector within the support frame.

[0010] The connector frame may be rigid. The connector frame may be attached to or fixed to the heater casing. However, it is preferable that the connector frame be integrally formed with the heater casing. The connector frame may be made from the same material as the heater casing. The connector contacts may be mounted on the connector frame.

[0011] The heater contacts of the heating element may be electrically connected to the connector contacts via at least two contact wires. At least two contact wires may be located within the heater casing. The two contact wires can be electrically connected to the heater contacts. The other end of each contact wire can be electrically connected to the connector contacts.

[0012] Alternatively, the heater contacts of the heating element may be electrically connected to the connector contacts via rigid contacts. The rigid contacts can make electrical contact with the heater contacts. The other end of the rigid contacts can make electrical contact with the connector contacts. Providing rigid contacts has the advantage of eliminating the need for manual attachment of contacts during manufacturing, such as manual soldering.

[0013] Connector contacts may be rigid. Providing rigid connector contacts is preferable because it offers the advantage of easily establishing a connection between the connector contacts and the electrical circuit. In particular, during manufacturing, the electrical connection between the connector frame and the electrical circuit can be established by pressing the rigid contacts of the connector frame into contact with the electrical circuit. No additional steps may be required. In particular, manual connections, such as soldering the contacts, may not be necessary.

[0014] The heater contacts may be rigid. The heater contacts may be in electrical contact with the heating element. Providing rigid heater contacts can be advantageous during manufacturing because it eliminates the need for manual soldering to connect the rigid heater contacts to the connector contacts. This embodiment is particularly advantageous when the connection between the heater contacts and the connector contacts is formed by rigid contacts. In this case, the entire connection between the heating element and the connector frame is formed by rigid contacts.

[0015] The term "rigidity" refers to the physical properties of a contact. Such a contact is unlikely to be bent or deformed during normal manufacturing. In contrast, contact wires are not rigid in this application because the wire can be easily bent.

[0016] An electrical circuit may include a printed circuit board. An electrical circuit is a printed circuit board.

[0017] The connector contacts may be elongated. Providing elongated connector contacts can be advantageous for making contact with the electrical circuit. The electrical circuit may be positioned slightly away from the rest of the heating assembly. In this case, the elongated connector contacts can bridge the gap between the electrical circuit and other elements of the heating assembly. This embodiment is particularly advantageous when the connector contacts are also rigid. Providing rigid, elongated connector contacts facilitates and ensures reliable electrical connection between the connector contacts and the electrical circuit during manufacturing.

[0018] The "distance" between the elements of a heated assembly and the electrical circuit may refer to the closest physical distance between the elements of the heated assembly and the electrical circuit. However, it is preferable that the "distance" between the elements of the heated assembly and the electrical circuit refers to the distance between the connector frame and the electrical circuit. It is preferable that this distance be filled by connector contacts.

[0019] The connector contacts may be positioned to make direct contact with the electrical circuit. In other words, no other component may be provided between the connector contacts and the electrical circuit. In this case, the connector contacts are shaped such that they reach the electrical circuit during manufacturing and that an electrical connection is made by the connector contacts. This embodiment is particularly advantageous when the connector contacts are rigid and elongated or more.

[0020] Connector contacts may be flat. Providing flat connector contacts may improve the mechanical stability of the connector contacts. Similarly, heater contacts may be flat to improve the mechanical stability of the heater contacts.

[0021] The heating assembly may further include an internal conductive structure. The internal conductive structure can connect heater contacts to connector contacts. The internal conductive structure may be located within the heater casing.

[0022] The heating assembly may further include a temperature sensor. The temperature sensor may have at least two sensor contacts. The connector frame may have at least two additional connector contacts that are electrically connected to the sensor contacts.

[0023] In this embodiment, the connector frame comprises four separate contacts. Two of these contacts may be configured to make electrical contact with the heating element. The other two contacts may be configured to make electrical contact with the temperature sensor. At the other ends of these four separate contacts, these contacts can be electrically connected to an electrical circuit. Thus, the output of the temperature sensor may be transmitted to the electrical circuit. Further, the electrical circuit can control the supply of electrical energy to the heating element via each contact that contacts the heating element.

[0024] Two separate connector contacts may be configured to make direct contact with the electrical circuit. In other words, the two separate connector contacts that electrically connect the temperature sensor to the electrical circuit can be configured in the same manner as the two connector contacts described herein for electrically connecting the heating element to the electrical circuit. This means, in particular, that these two separate connector contacts are one or more of flat, rigid, and elongated, and may have the same advantages as those described herein for the connector contacts for contacting the heating element with the electrical circuit.

[0025] The present invention further relates to an aerosol generating device comprising a heating assembly as described herein.

[0026] The aerosol generating device may comprise a cavity for receiving an aerosol-generating article. The heating assembly may be arranged to at least partially surround the cavity.

[0027] The side wall of the cavity may be formed of a tube as described herein, preferably a stainless steel tube. The heating assembly may be mounted on the stainless steel tube, or the tube may be part of the heating assembly and may be mounted within the housing or inner frame of the aerosol generating device.

[0028] The present invention further relates to a method of manufacturing a heating assembly for an aerosol generating device, the method comprising providing a heater casing, A step of providing a heating element, wherein the heating element has at least two heater contacts A step of providing a connector frame, wherein the connector frame is integrally formed with the heater casing and the connector frame has at least two connector contacts A step of providing an electrical circuit A step of electrically connecting two connector contacts to two heater contacts A step of electrically connecting two connector contacts to an electrical circuit, including one or more of the above

[0029] The present invention further relates to a method for manufacturing a heating assembly for an aerosol generator, the method comprising A step of providing a heater casing A step of providing a heating element, wherein the heating element has at least two heater contacts A step of providing a connector frame, wherein the connector frame is integrally formed with the heater casing and the connector frame has at least two connector contacts A step of providing an electrical circuit A step of electrically connecting two connector contacts to two heater contacts A step of electrically connecting two connector contacts to an electrical circuit, including

[0030] The heating assembly may comprise a first substrate layer, which is an electrically insulating substrate layer. The heating element may be disposed on the first substrate layer. The heating assembly may further comprise a second substrate layer, which may be an electrically insulating substrate layer. The second substrate layer may be disposed so as to cover the heating element and the first substrate layer. The temperature sensor can be disposed on the second substrate layer. The heating assembly may further comprise a third substrate layer, which may be an electrically insulating substrate layer. The third substrate layer may be disposed so as to at least partially cover the temperature sensor and cover the second substrate layer

[0031] The terms “covering” or “overlapping” may mean that the first layer can be positioned on the second layer such that the first layer has substantially the same surface size as the second layer, and so the surface area of ​​the second layer facing the first layer substantially overlaps with that of the first layer. When the first layer is positioned to cover the second layer, the surface size of the first layer may be at least 90% of the surface area of ​​the second layer, preferably at least 80% of the surface area of ​​the second layer, more preferably at least 70% of the surface area of ​​the second layer, and most preferably at least 60% of the surface area of ​​the second layer.

[0032] In the final heated assembly, it is preferable that the heating element and the temperature sensor are placed on opposing surfaces of the second substrate layer. Therefore, the heating element is electrically insulated from the temperature sensor by the second substrate layer.

[0033] The heating element is protected by a first substrate layer and by a second substrate layer.

[0034] The temperature sensor is protected by a second substrate layer and a third substrate layer.

[0035] The heating element may be a resistance heater. The heating element may include a heating track. The heating track may be configured to generate heat. The heating track may be an electrical resistance heating track. The heating element may include electrical contacts for making electrical contact with the heating track. The electrical contacts may be attached to the heating track by any known means, for example, by soldering or welding. The first electrical contact may be attached to the first end of the heating track, and the second electrical contact may be attached to the second end of the heating track. The first end of the heating track may be the proximal end of the heating track, and the second end of the heating track may be the distal end of the heating track, or vice versa.

[0036] The heating track may be made from stainless steel. The heating track may be made from stainless steel with a thickness of about 50 μm. Preferably, the heating track may be made from stainless steel with a thickness of about 25 μm. The heating track may be made from Inconel with a thickness of about 50.8 μm. The heating track may be made from Inconel with a thickness of about 25.4 μm. The heating track may be made from copper with a thickness of about 35 μm. The heating track may be made from Constantan with a thickness of about 25 μm. The heating track may be made from nickel with a thickness of about 12 μm. The heating track may be made from brass with a thickness of about 25 μm.

[0037] The heating element, preferably the heating track, may be printed on the first substrate layer. The heating track may be photoprinted on the substrate layer. The heating track may be chemically etched on the substrate layer.

[0038] The term "heating track" encompasses a single heating track. The heating element or heating track may be printed on the first substrate layer.

[0039] The heating track may be located in the center of the first substrate layer. The heating track may have a bench shape. The heating track may have a curved shape.

[0040] The heated assembly may be rolled into a tubular shape. The heating track may be flat before the substrate layer is rolled into a tubular shape. The heating track or heating element may be flexible. The heating track or heating element may conform to the tubular shape of the substrate layer when the substrate layer is rolled into a tubular shape.

[0041] The third substrate layer may have at least two openings. The two openings are provided to allow the sensor contacts to be contacted through the third substrate layer.

[0042] The two openings may be aligned so that the sensor contacts are not covered by the third substrate layer. The two openings may be positioned adjacent to opposing ends of the third substrate layer. The two openings may correspond to the arrangement of electrical contacts on the temperature sensor.

[0043] In addition to the two openings, another opening may be provided in the third substrate layer. The third opening may be located in the center of the third substrate layer. This third opening can improve the mechanical strength of the third substrate layer in this region. In particular, the central opening of the third substrate layer may strengthen the fixation of the contacts that come into contact with the sensor contacts, as the contacts in this region come into contact with the adhesive layer beneath the second substrate layer. Sensor contacts can be attached to the temperature sensor by any known means, for example, by soldering or welding. The first electrical contact may be attached to the first end of the temperature sensor, and the second electrical contact may be attached to the second end of the temperature sensor. The first end of the temperature sensor may be the proximal end, and the second end may be the distal end, or vice versa.

[0044] The temperature sensor may have a temperature sensor track.

[0045] The heated assembly may include a tube, preferably a metal tube, around which a substrate layer may be wrapped or wound. The metal tube is preferably a stainless steel tube. Alternatively, the tube may be a ceramic tube. The tube can define the tubular shape of the heated assembly. The outer diameter of the tube may correspond to the inner diameter of the first substrate layer after it has been wrapped.

[0046] The heating assembly may further comprise a heating chamber conforming to the tubular shape of the heating assembly. The base layer may be wound together with the heating element and temperature sensor to conform to the tube forming the heating chamber. In this configuration, the first base layer may form an inner layer facing the tube, and the third base layer may be an outer layer. The first base layer may be adjacent to a metal tube forming the innermost layer of the heating assembly.

[0047] The tube may be made of stainless steel. The tube may have a length of 10 mm to 35 mm, preferably 12 mm to 30 mm, preferably 13 mm to 22 mm. The tube may be hollow. The hollow tube may have an inner diameter of 4 mm to 9 mm, preferably 5 mm to 6 mm, or 6.8 mm to 7.5 mm, preferably about 5.35 mm or about 7.3 mm. The tube may have a thickness of 70 μm to 110 μm, preferably 80 μm to 100 μm, preferably about 90 μm. The tube may have a cylindrical cross-section. The tube may have a circular cross-section.

[0048] The length of the first substrate layer may be less than or equal to the circumference of the tube. The first substrate layer may completely enclose the tube. The first substrate layer may wrap around the tube once, after it has wrapped around the tube, so that the surface of the tube is covered by the first substrate layer.

[0049] The heating chamber tube may have a thickness of 70 μm to 110 μm, preferably 80 μm to 100 μm, and preferably about 90 μm.

[0050] The temperature sensor may be an NTC, Pt100, or preferably a Pt1000 temperature sensor. The temperature sensor may be attached to the second substrate layer by an adhesive layer. The temperature sensor may be photoprinted on the second substrate layer. Chemical etching may be used to form one or both of the heating track and the temperature sensor track of the heating element. The sensor contacts may then be welded onto the temperature sensor track through an opening in the third substrate layer.

[0051] The temperature sensor may be positioned on the second substrate layer such that, when the heated assembly is wound, the temperature sensor can be positioned in a region corresponding to the center of the first substrate layer. By positioning the temperature sensor in this way, the heating element may map the temperature sensor so that it is positioned adjacent to the hottest part of the heating element. The hottest part adjacent to the temperature sensor can be the center of the first substrate layer. The heating element may be positioned at the center of the first substrate layer. The temperature sensor may be positioned directly adjacent to the heating element, separated from it by the thickness of the second substrate layer.

[0052] One or more of the following additional layers may be provided.

[0053] The first adhesive layer may be provided between the first substrate layer and the heating element. A second adhesive layer may be provided between the heating element and the second substrate layer. A third adhesive layer may be provided between the second adhesive layer and the temperature sensor. A fourth adhesive layer may be provided between the temperature sensor and the third substrate layer.

[0054] The first adhesive layer facilitates attachment between the first substrate layer and the heating element. The first adhesive layer further facilitates attachment between the first substrate layer and the second substrate layer in areas of the first substrate layer not covered by the heating element. The second adhesive layer facilitates attachment between the heating element and the second substrate layer. The third adhesive layer facilitates attachment between the second substrate layer and the temperature sensor. The third adhesive layer further facilitates attachment between the second substrate layer and the third substrate layer in areas of the third adhesive layer not covered by the temperature sensor. The fourth adhesive layer facilitates attachment between the temperature sensor and the third substrate layer.

[0055] One or more of the adhesive layers may have a thickness of 2 μm to 10 μm, preferably 3 μm to 7 μm, and more preferably about 5 μm.

[0056] One or more of the adhesive layers may be silicone-based adhesive layers. The adhesive layers may include one or both of PEEK-based adhesives and acrylic adhesives.

[0057] One or more of the first, second, and third substrate layers may contain a polyamide or polyimide film. Any of the substrate layers may be made from polyimide or polyamide. The substrate layers can be configured to withstand temperatures of 220°C to 320°C, preferably 240°C to 300°C, and preferably about 280°C. Any of the substrate layers may be made from Pyralux.

[0058] The heat-shrinkable layer may be placed around the heated assembly.

[0059] A heat-shrinkable layer can be placed around a heated assembly if the heated assembly is rolled into a tubular shape. The heat-shrinkable layer can be configured to shrink when heated. The heat-shrinkable layer can hold the heated assembly together tightly. The heat-shrinkable layer can be configured to apply uniform inward pressure to the heated assembly. The heat-shrinkable layer can improve contact between the tube and the first substrate layer, and between the first substrate layer and the second substrate layer, or both. The heat-shrinkable layer can tightly hold together most or all of the components of the heated assembly. The heat-shrinkable layer may be used instead of the glue or adhesive layer described herein. Alternatively, the heat-shrinkable layer may be used in addition to the glue or adhesive layer described herein.

[0060] The thickness of the heat-shrinkable layer may be 100 μm to 300 μm, preferably about 180 μm.

[0061] The heat-shrinkable layer may be made of PEEK. The heat-shrinkable layer may be made of one or more of Teflon and PTFE, or may contain both.

[0062] One or more of the substrate layers may have a thickness of 10 μm to 50 μm, preferably 20 μm to 30 μm, and more preferably about 25 μm.

[0063] The heating element, preferably made from stainless steel, may have a thickness of 20 μm to 60 μm, preferably 30 μm to 50 μm, and more preferably about 40 μm. The heating track, preferably made from stainless steel, may have a thickness of 20 μm to 60 μm, preferably 30 μm to 50 μm, and more preferably about 40 μm.

[0064] An insulating layer may be provided surrounding the heat-shrinkable layer. The insulating layer is preferably made of aerogel.

[0065] As used herein, the terms “upstream” and “downstream” are used to describe the relative position of a component or part of a component of an aerosol generator with respect to the direction in which air flows through the aerosol generator during use. The aerosol generator according to the present invention has a proximal end, and during use, the aerosol exits the device through the proximal end. The proximal end of the aerosol generator may also be called the mouth end or the downstream end. The mouth end is downstream of the distal end. The distal end of the aerosol generating article may also be called the upstream end. Components or parts of aerosol generators may be described as being upstream or downstream of each other based on their relative positions with respect to the airflow path of the aerosol generator.

[0066] In all aspects of this disclosure, the heating element may include an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, conductive ceramics (e.g., molybdenum disilide), carbon, graphite, metals, alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics.

[0067] As described, in any aspect of this disclosure, the heating element may include an external heating element, where “external” refers to the aerosol-forming substrate. The external heating element can take any suitable form. For example, the external heating element may take the form of one or more flexible heating foils or heating tracks on a dielectric substrate such as polyimide. The dielectric substrate is a substrate layer. The flexible heating foils or heating tracks may be shaped to fit the periphery of the heating chamber. Alternatively, the external heating element may take the form of a metal grid, a flexible printed circuit board, a molded circuit component (MID), a ceramic heater, a flexible carbon fiber heater, or may be formed on a substrate layer of suitable shape using a coating technique such as plasma deposition. The external heating element may also be formed using a metal having a clear relationship between temperature and resistivity. In such exemplary devices, the metal may be formed as a track between a first substrate layer and a second substrate layer. The external heating element formed in this manner may be used during operation for both heating the external heating element and monitoring its temperature.

[0068] The heating element advantageously heats the aerosol-forming substrate by means of conduction. Alternatively, heat from either an internal or external heating element may be conducted to the substrate by a thermally conductive element.

[0069] During operation, the aerosol-forming substrate may be completely enclosed within the aerosol generator. In this case, the user may inhale through the mouthpiece of the aerosol generator. Alternatively, during operation, the smoking article containing the aerosol-forming substrate may be partially enclosed within the aerosol generator. In this case, the user may inhale directly through the smoking article.

[0070] The heating element may be configured as an induction heating element. The induction heating element may comprise an induction coil and a susceptor. Generally, a susceptor is a material that has the ability to generate heat when penetrated by an alternating magnetic field. According to the present invention, the susceptor may be conductive, magnetic, or both conductive and magnetic. An alternating magnetic field generated by one or more induction coils heats the susceptor, which then transfers heat to an aerosol-forming substrate so that an aerosol is formed. Heat transfer may also be mainly by thermal conduction. Such heat transfer is best when the susceptor is in close thermal contact with the aerosol-forming substrate. When an induction heating element is employed, the induction heating element may be configured as an external heater as described herein. When the induction heating element is configured as an external heating element, the susceptor element is preferably configured as a cylindrical susceptor that at least partially encloses the heating chamber. The heating track described herein may be configured as a susceptor. The susceptor may be positioned between the first substrate layer and the second substrate layer. The second substrate layer may be surrounded by an induction coil. The susceptor and induction coil may be part of the heating assembly.

[0071] Preferably, the aerosol generator includes a power source configured to supply power to one or both of the heating element and the heating assembly. The power source preferably includes a power supply. The power supply is preferably a battery, such as a lithium-ion battery. Alternatively, the power supply may be another form of charge storage device, such as a capacitor. The power supply may require recharging. For example, the power supply may have sufficient capacity to enable continuous aerosol generation for approximately six minutes, or for a period of time that is a multiple of six minutes. In another example, the power supply may have sufficient capacity to enable a predetermined number of fume extractions or discontinuous starts of the heating assembly.

[0072] The aerosol generator may include control electronics. The control electronics may include a microcontroller. Preferably, the microcontroller is a programmable microcontroller. The electrical circuit may include further electronic components. The electrical circuit may be configured to regulate the supply of power to the heating assembly. Power may be supplied to the heating assembly continuously after the system is started up, or intermittently (for example, with each smoke extraction). Power may be supplied to the heating assembly in the form of pulses of current.

[0073] Similarly, the length of the electrical connection between the heating element and the control electronic circuit may be longer than the distance between the heating element and the control electronic circuit. This has the beneficial effect of preventing harmful effects on the electrical contacts between the heating element and the control electronic circuit caused by thermal expansion of the contacts during the operation of the aerosol generator. The electrical connection is preferably configured as an electric wire.

[0074] As used herein, the term “aerosol-forming substrate” refers to a substrate having the ability to release volatile compounds that can form aerosols. Volatile compounds may be released by heating or burning the aerosol-forming substrate. As an alternative to heating or burning, in some cases, volatile compounds may be released by chemical reactions or by mechanical stimuli such as ultrasound. The aerosol-forming substrate may be solid or liquid, or may contain both solid and liquid components. The aerosol-forming substrate may be part of an aerosol-generating article.

[0075] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate having the ability to release volatile compounds capable of forming aerosols. Aerosol-generating articles may be disposable.

[0076] As used herein, the term “aerosol generator” refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. An aerosol generator may interact with either or both an aerosol-generating article containing an aerosol-forming substrate and / or a cartridge containing an aerosol-forming substrate. In some embodiments, the aerosol generator may heat the aerosol-forming substrate to facilitate the release of volatile compounds from the substrate. An electrically operated aerosol generator may include an atomizer, such as an electric heater, for heating the aerosol-forming substrate to form an aerosol.

[0077] As used herein, the term "aerosol generating system" refers to a combination of an aerosol-forming substrate and an aerosol generating device. When the aerosol-forming substrate forms part of an aerosol-generating article, the aerosol generating system refers to a combination of an aerosol-generating article and an aerosol generating device. In an aerosol generating system, the aerosol-forming substrate and the aerosol generating device work together to generate an aerosol.

[0078] Features described in reference to one embodiment may also apply equally to other embodiments of the present invention. [Brief explanation of the drawing]

[0079] The present invention will be further explained with reference to the following attached drawings, which are for illustrative purposes only.

[0080] [Figure 1] Figure 1 shows the heated assembly. [Figure 2] Figure 2 shows an aerosol generator. [Figure 3] Figure 3 shows another perspective view of the heated assembly. [Modes for carrying out the invention]

[0081] Figure 1 shows a heating assembly 10. The heating assembly 10 includes a heater casing 12. A first sealing ring 14 and a second sealing ring 16 are positioned next to the heater casing 12. A tube holder 18 follows the first sealing ring 14 and the second sealing ring 16.

[0082] Figure 1 further shows a heating element 38. A contact wire 22 for contacting the heating element 38 is shown in Figure 1. The heating element 38 is surrounded by an aerogel 24 for thermal insulation. Furthermore, an insulating film 26 surrounding the aerogel 24 may be provided.

[0083] Figure 1 further shows the top heater casing 28 as part of the heating assembly 10.

[0084] Figure 2 shows an embodiment of the heating assembly 10, which has a tubular shape to form a heating chamber. The heating element 38 may include a heating track 30. The layer surrounding the heating track 30 is transparent so that the heating track 30 and the heater contacts 32 can be seen. In contrast to the embodiment shown in Figure 1, the heating element 38 is in contact by the heater contacts 32 rather than via the contact wires 22. The heater contacts 32 are rigid, in contrast to the non-rigid contact wires 22 shown in Figure 1.

[0085] The heater contact 32 is configured to extend inward through the heater casing 12 toward the connector frame 36. The connector frame 36 includes connector contacts 40. The connector contacts 40 are rigid, flat, and elongated. The heater contact 32 is positioned to electrically contact the heating element 38 with two of the four connector contacts 40 shown in Figure 2.

[0086] Two connector contacts 40, electrically connected to the heating element 38 via heater contacts 32, are configured to electrically contact the electrical circuit 34. The electrical circuit 34 is preferably configured as a printed circuit board. By providing a rigid connector frame 36 and rigid connector contacts 40, a simple and reliable connection can be established between the heater casing 12 containing the heating element 38 and the electrical circuit 34.

[0087] Two other connector contacts 40 are configured to electrically connect a temperature sensor (not shown) of the heating assembly 10 to the electrical circuit 34. The temperature sensor is preferably positioned around the heating element 38 and is transparent in Figure 2. In other words, the connector frame 36 having four individual connector contacts 40 facilitates reliable and easy electrical contact between the heating element 38 and temperature sensor on one side and the electrical circuit 34 on the other side.

[0088] Figure 3 shows an alternative embodiment of the heating assembly 10. All components of the heating assembly 10 are identical to those of the embodiment shown in Figure 2, except that a contact wire 22 is provided in addition to the rigid heater contact 32. For example, the contact wire 22 may be arranged to electrically contact a temperature sensor at one end and two of the connector contacts 40 at the other end. In this case, the rigid heater contact 32 is provided to electrically contact the heating element 38 with the connector contact 40. Where possible, the contact wire 22 may also be used to electrically connect the heating element 38 with the connector contact 40, and the rigid contact may be used to electrically contact the temperature sensor with the connector contact 40. Similar to the embodiment in Figure 2, the connector contact 40 is elongated and rigid to electrically contact the heating element 38 with the electrical circuit 34 at the temperature sensor.

Claims

1. A heating assembly for an aerosol generator, wherein the heating assembly is Heater casing and A heating element comprising a heating element having at least two heater contacts, Connector frame and Equipped with an electrical circuit, A heating assembly comprising a connector frame disposed on a heater casing, the connector frame having at least two connector contacts, the two connector contacts being electrically connected to the two heater contacts, the two connector contacts being electrically connected to the electrical circuit, the connector contacts being arranged to directly contact the electrical circuit, the connector contacts being flat, and the heater contacts being flat and rigid.

2. The heating assembly according to claim 1, wherein the heater contact of the heating element is electrically connected to the connector contact via at least two contact wires.

3. The heating assembly according to claim 1, wherein the heater contact of the heating element is electrically connected to the connector contact via a rigid contact.

4. The heated assembly according to any one of claims 1 to 3, wherein the connector contacts are rigid.

5. The heating assembly according to any one of claims 1 to 4, further comprising an internal conductive structure, wherein the internal conductive structure connects the heater contact to the connector contact.

6. The heated assembly according to any one of claims 1 to 5, wherein the electrical circuit comprises a printed circuit board.

7. The heated assembly according to any one of claims 1 to 6, wherein the connector contact is elongated.

8. The heating assembly according to any one of claims 1 to 7, wherein the heating assembly further comprises a temperature sensor.

9. The heating assembly according to claim 8, wherein the temperature sensor comprises at least two sensor contacts, and the connector frame comprises at least two other connector contacts electrically connected to the sensor contacts.

10. The heated assembly according to claim 9, wherein the two other connector contacts are configured to directly contact the electrical circuit.

11. An aerosol generating device comprising a heated assembly according to any one of claims 1 to 10.

12. A method for manufacturing a heated assembly for an aerosol generator, wherein the method is The process of installing the heater casing, A step of providing a heating element, wherein the heating element comprises at least two heater contacts, A step of providing a connector frame, wherein the connector frame is integrally formed with the heater casing, and the connector frame has at least two connector contacts; The process of installing an electrical circuit, The process of electrically connecting the two connector contacts to the two heater contacts, A method comprising the step of electrically connecting the two connector contacts to the electrical circuit, wherein the connector contacts are arranged to directly contact the electrical circuit, the connector contacts are flat, and the heater contacts are flat and rigid.

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