Two-part capsule connector

Abstract

A heating assembly for an aerosol-generating product may include a primary cap component defining a first aperture and a plurality of second apertures; a heating element configured to extend through the first aperture; and a secondary cap component configured to engage with the primary cap component so as to retain the heating element.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefits of U.S. Provisional Application No. 63 / 772,094, filed Mar. 14, 2025, the entire disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure relates to heated tobacco devices and consumables configured to generate an aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.

[0003] Some electronics configured to heat a plant material to a temperature that is sufficient to release constituents of the plant material while keeping the temperature below an ignition point of the plant material so as to avoid any substantial pyrolysis of the plant material. Such devices may be referred to as aerosol-generating devices (e.g., heated tobacco aerosol-generating devices or heated tobacco products (HTP)), and the plant material heated may be tobacco and / or cannabis. In some instances, the plant material may be introduced directly into a heating chamber of an aerosol-generating device. In other instances, the plant material may be pre-packaged in individual containers or consumables to facilitate insertion and removal from an aerosol-generating device.SUMMARY

[0004] Some example embodiments relate to a heating assembly for an aerosol-generating product, the heating assembly including a primary cap component defining a first aperture and a plurality of second apertures; a heating element configured to extend through the first aperture; and a secondary cap component configured to engage with the primary cap component so as to retain the heating element.

[0005] In some example embodiments the first aperture may be in a form of a slot.

[0006] In some example embodiments, the secondary cap component may be configured to be received within the primary cap component.

[0007] In some example embodiments, the secondary cap component may be configured to engage with the primary cap component via a snap-fit arrangement.

[0008] In some example embodiments, the secondary cap component may be configured to extend through the plurality of second apertures such that the secondary cap component is held in contact with the primary cap component and at least a portion of the heating element is vertically overlapped by the secondary cap component.

[0009] In some example embodiments, the secondary cap component may define a plurality of upstream air passages.

[0010] In some example embodiments, the heating element may include a heating region, a first terminal, and a second terminal.

[0011] In some example embodiments, the heating region may overlap the plurality of upstream air passages.

[0012] In some example embodiments, the secondary cap component may be between the first terminal and the second terminal of the heating element.

[0013] In some example embodiments, the plurality of upstream air passages may be between the first terminal and the second terminal of the heating element.

[0014] In some example embodiments, the heating region may be between the plurality of second apertures.

[0015] In some example embodiments, the plurality of second apertures may be between the first terminal and the second terminal of the heating element.

[0016] In some example embodiments, the first aperture may overlap the plurality of upstream air passages.

[0017] In some example embodiments, the plurality of second apertures may overlap the plurality of upstream air passages.

[0018] In some example embodiments, the primary cap component and the secondary cap component may define a cavity therebetween.

[0019] In some example embodiments, the heating assembly may include a plug material in the cavity.

[0020] In some example embodiments, the plug material may be permeable to air and impermeable to particles of an aerosol-forming substrate.

[0021] In some example embodiments, the primary cap component may define side air passages between the plurality of second apertures.

[0022] In some example embodiments, each of the side air passages may be in a form of a slot.

[0023] In some example embodiments, the side air passages may extend in a same direction as the first aperture.

[0024] In some example embodiments, the first aperture may be between the side air passages.

[0025] In some example embodiments, the secondary cap component may define a plurality of upstream air passages that extend orthogonally to the side air passages.

[0026] In some example embodiments, the heating element may include a planar section configured to extend between the side air passages.

[0027] In some example embodiments, the side air passages may overlap the secondary cap component.

[0028] In some example embodiments, the heating element may overlap the secondary cap component.

[0029] In some example embodiments, the heating element may include a winding portion configured to extend through the first aperture.

[0030] In some example embodiments, the secondary cap component may include a plurality of connecting portions configured to flex so as to establish a snap fit with the primary cap component.

[0031] In some example embodiments, the secondary cap component may define a plurality of upstream air passages between the plurality of connecting portions.

[0032] In some example embodiments, the first aperture may be between the plurality of connecting portions.

[0033] In some example embodiments, the primary cap component may include a plurality of connecting regions such that each connecting portion of the secondary cap component engages with at least a portion of a respective connecting region to establish the snap fit.

[0034] In some example embodiments, the heating element may include a heating region, a first terminal, and a second terminal.

[0035] In some example embodiments, the heating region may be between the plurality of connecting portions of the secondary cap component.

[0036] In some example embodiments, the primary cap component may define side air passages above the secondary cap component and below the heating region of the heating element, and the side air passages are between the plurality of connecting portions of the secondary cap component.

[0037] In some example embodiments, the plurality of connection portions of the secondary cap component may overlap the first terminal and the second terminal of the heating element.

[0038] In some example embodiments, the heating element may include a heating region, a first terminal, and a second terminal, the primary cap component defines side air passages above the secondary cap component and below the heating region of the heating element.

[0039] In some example embodiments, the heating region of the heating element may be between the side air passages of the primary cap component.

[0040] In some example embodiments, the first aperture may be between the side air passages.

[0041] In some example embodiments, the first aperture may be between the plurality of second apertures.

[0042] In some example embodiments, the first aperture may overlap the secondary cap component.

[0043] In some example embodiments, the secondary cap component may be housed within the primary cap component.

[0044] In some example embodiments the primary cap component may include a liquid crystal polymer as a material of construction.

[0045] In some example embodiments the secondary cap component may include a liquid crystal polymer as a material of construction.

[0046] A method of assembling a heater assembly may include inserting a heating element through an aperture in a primary cap component; and inserting a secondary cap component into the primary cap component, at least a portion of the secondary cap component overlapping the heating element in a second direction, the secondary cap component forming a snap fit with the primary cap component, and the secondary cap component defining at least one upstream air passage.

[0047] In some example embodiments, the heating element may include a first terminal, a second terminal, and a heating region.

[0048] In some example embodiments, the heating region, a portion of the first terminal, and a portion of the second terminal may define a planar portion of the heating element.

[0049] In some example embodiments, the planar portion of the heating element may be inserted through the aperture.

[0050] In some example embodiments, the heating region may be inserted through the aperture.

[0051] In some example embodiments, the secondary cap component may be inserted into the primary cap component in a same direction as the heating element.

[0052] In some example embodiments, the secondary cap component may be inserted through at least one secondary aperture in the primary cap component.

[0053] In some example embodiments, the secondary cap component may include at least one connecting portion extending through the at least one secondary aperture in the primary cap component cap component forming a snap fit connecting between the primary cap component and the secondary cap component.

[0054] In some example embodiments, the connecting portion may flex from a resting position while being inserted through the at least one secondary aperture.

[0055] In some example embodiments, the method may include inserting the primary cap component into a consumable housing.

[0056] In some example embodiments, a direction of insertion of the heating element through the primary cap component may be a first direction; a direction of insertion of the secondary cap component into the primary cap component may be a direction parallel to the first direction; and a direction of insertion of the primary cap component into the consumable housing may be a direction parallel to the direction to the first direction.

[0057] Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0058] The features and advantages of the non-limiting example embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, some dimensions of the drawings may have been exaggerated.

[0059] FIG. 1 depicts an upper perspective view of a heater insert according to some example embodiments.

[0060] FIG. 2 depicts a perspective view of a heater insert in combination with a consumable housing according to some example embodiments.

[0061] FIG. 3 depicts an exploded view of a heater insert and a consumable housing according to some example embodiments.

[0062] FIG. 4 depicts a top-down view of a primary cap component according to some example embodiments.

[0063] FIG. 5 depicts a bottom-up view of a primary cap component according to some example embodiments.

[0064] FIG. 6 depicts a peripheral view of a primary cap component according to some example embodiments.

[0065] FIG. 7 depicts a peripheral view of a heating element according to some example embodiments.

[0066] FIG. 8 depicts a top-down view of a secondary cap component according to some example embodiments.

[0067] FIG. 9 depicts an upper peripheral view of a secondary cap component according to some example embodiments.

[0068] FIG. 10 is a cross-sectional view of a heating element inserted into a primary cap component according to some example embodiments.

[0069] FIG. 11 is a cross-sectional view of a heater insert in combination with a consumable housing according to some example embodiments.

[0070] FIG. 12 is a cross-sectional view of a heater insert in combination with a consumable housing according to some example embodiments.

[0071] FIG. 13 is a bottom-up view of a heater insert according to some example embodiments.

[0072] FIG. 14 is a top-down view of a secondary cap component inserted into a primary cap component according to some example embodiments.

[0073] FIG. 15 is a schematic depiction of methods of manufacturing a heater insert according to some example embodiments.DETAILED DESCRIPTION

[0074] Accordingly, while example embodiments are capable of some modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.

[0075] Elements and / or properties thereof (e.g., structures, surfaces, directions, or the like) that are “substantially perpendicular”, “substantially parallel”, or “substantially coplanar” with regard to other elements and / or properties thereof will be understood to be “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof within manufacturing tolerances and / or material tolerances and / or have a deviation in magnitude and / or angle from “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof that is equal to or less than 10% (e.g., a. tolerance of ±10%).

[0076] It should be understood that when an element or layer is referred to as being “on,”“connected to,”“coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,”“directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0077] It should be understood that, although the terms first, second, third, etc. may be used herein to describe some elements, regions, layers and / or sections, these elements, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments.

[0078] Spatially relative terms (e.g., “beneath,”“below,”“lower,”“above,”“upper,” and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0079] The terminology used herein is for the purpose of describing some example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,”“including,”“comprises,” and / or “comprising,” specify the presence of stated features, integers, steps, operations, and / or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0080] When the terms “about” or “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value includes a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical value. Moreover, when the terms “generally” or “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. Furthermore, regardless of whether numerical values or shapes are modified as “about,”“generally,” or “substantially,” it will be understood that these values and shapes should be construed as including a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical values or shapes.

[0081] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0082] FIG. 1 illustrates a view of heater insert for use with a consumable for an aerosol-generating device (e.g., heated tobacco aerosol-generating device) according to some example embodiments.

[0083] FIG. 2 illustrates a peripheral view of a heater insert in combination with a consumable housing according to some example embodiments.

[0084] FIG. 3 illustrates an exploded view of a heater insert and consumable housing for use with the heater insert according to some example embodiments.

[0085] As illustrated in FIGS. 1-3, in some example embodiments, a heater insert 100 may include a primary cap component 102, a heating element 104, and a secondary cap component 106. The heater insert 100 may be configured to be inserted into a consumable housing 108. As depicted in FIGS. 1-3 the heater insert 100 and the consumable housing 108 may have a generally obround profile (e.g., stadium geometry). However, the example embodiments are not so limited thereto. For example, the heater insert 100 and the consumable housing 108 may have any such profile, for example, a circle, an oval, a quadrilateral, or any other such profile so long as the heater insert 100 may be inserted into the consumable housing 108.

[0086] For example, the primary cap component 102 of the heater insert 100 may be configured to form a friction fit with the consumable housing 108 at an interface between the consumable housing 108 and the primary cap component 102. Accordingly, the consumable housing 108 may surround a portion of the primary cap component 102, the heating element 104, and the secondary cap component 106.

[0087] FIG. 4 is a top-down view of a primary cap component according to some example embodiments. FIG. 5 is a bottom-up view of a primary cap component according to some example embodiments. FIG. 6 is a perspective view of a primary cap component according to some example embodiments.

[0088] As depicted in FIGS. 4-6, in at least one example embodiment of a primary cap component 102 may define a plurality of apertures. In some example embodiments, the primary cap component 102 may define a first aperture 110. For example, the first aperture 110 may be in the shape of a slot. For example, the first aperture 110 may have a longest dimension extending parallel to a longitudinal axis, for example a first direction, of the primary cap component 102. In some example embodiments, the first aperture 110 may be centrally aligned along the longitudinal axis of the primary cap component 102.

[0089] In at least one example embodiment, the primary cap component 102 may define a second aperture. In some example embodiments, the second aperture may include a plurality of second apertures 112. Although FIGS. 4-6 depict four second apertures 112, the example embodiments may not be so limited thereto. For example, there may be any number apertures such that the secondary cap component 106 discussed in greater detail below may extend therethrough and form a snap fit with the primary cap component 102. In some example embodiments, the plurality of second apertures 112 may be arranged symmetrically or asymmetrically around the primary cap component 102. For example, the plurality of second apertures 112 may be arranged symmetrically or asymmetrically around the first aperture 110. For example, the plurality of second apertures 112 may be spaced apart in a second direction perpendicular to the first direction by the first aperture 110. In some example embodiments, the plurality of second apertures 112 may be spaced apart in the first direction by side air passages 114 described in greater detail below. While the plurality of second apertures 112 are depicted in FIGS. 4-6 as a rectangular, the example embodiments are not so limited thereto and the plurality of secondary aperture 112 may be any such shape so long the secondary cap component 106 may extend therethrough and form a snap fit with the primary cap component 102.

[0090] In at least one example embodiment, the primary cap component may define at least one side air passage 114 extending therethrough. For example, the side air passage 114 may include two side air passages 114 spaced apart in the second direction by the first aperture 110. While only two side air passages 114 are depicted in FIGS. 4-6, the example embodiments are not so limited thereto. For example, the side air passages 114 may define a plurality of circular side air passages 114. While the side air passages 114 are depicted as symmetrically arranged in FIGS. 4-6, the example embodiments are not so limited thereto. For example, the side air passages 114 may be asymmetrically arranged, for example one side air passage 114 may be offset from another side air passage 114 in the first or second direction. While the side air passages 114 in FIGS. 4-6 are depicted as having an obround shape, the example embodiments are not so limited thereto. For example, the side air passages 114 may define a plurality of circular apertures or a plurality of rectangular apertures (e.g. slots) having a longest dimension in the first or second direction. In some example embodiments, a longest dimension of the side air passages 114 may extend in the first direction. In some example embodiments a longest dimension of the side air passages 114 may extend in the second direction. In some example embodiments, the side air passages may be centrally located along a central axis of the primary cap component 102 extending in a second direction.

[0091] The primary cap component 102 may include an insert portion 102a and a top portion 102b. The insert portion 102a may extend in a vertical direction perpendicular to the first direction and the second direction away from an inner edge of the top portion 102b. The top portion 102b may extend radially outward from an outer surface of the insert portion 102a. The top portion 102b may have an inner surface that may be coplanar with an inner surface of the insert portion 102a that collectively define a central opening in the primary cap component 102. The insert portion 102a may define the secondary apertures 112 and the side air passages 114. The insert portion 102a and the top portion 102b may collectively define the first aperture 110.

[0092] In some example embodiments, the primary cap component 102 may include a liquid crystal polymer (LCP). However, the example embodiments are not so limited thereto. In some example embodiments, the heating element 104 may be configured to extend through the first aperture 110.

[0093] FIG. 7 is a peripheral view of a heating element according to some example embodiments.

[0094] As depicted in FIG. 7, the heating element 104 may include a heating region 104a, a first terminal 104b, and a second terminal 104c. The heating region 104a may be between the first terminal 104b and the second terminal 104c and connect the first terminal 104b and the second terminal 104c. The heating region 104a may include a winding portion extending between the first terminal 104b and the second terminal 104c. The heating region 104a along with portions of the first terminal 104b and the second terminal 104c may define a planar portion of the heating element extending in the vertical direction. The first terminal 104b and the second terminal 104c may each include a contact portion extending in a direction parallel to the second direction. For example, each of the first terminal 104b and the second terminal 104c may include a contact portion that extends away from the planar portion in a direction parallel to the second direction before bending and then extending towards the planar portion in an opposite direction parallel to the second direction. While FIG. 7 depicts the contact portion of the first terminal 104b and the second terminal 104c extending in opposite directions, the example embodiments are not so limited thereto. For example, the contact portions may extend in the same direction. The heating element 104 may be a conductive material. For example, the heating element 104 may be a metal.

[0095] FIG. 8 is a top-down view of a secondary cap component according to some example embodiments.

[0096] FIG. 9 is a perspective view of a secondary cap component according to some example embodiments.

[0097] As depicted in FIGS. 8-9, some example embodiments of the secondary cap component 106 may have a substantially rectangular shape. For example, the secondary cap component 106 may have the shape of a rectangular prism or a trapezoidal prism. However, the example embodiments are not so limited thereto. For example, the secondary cap component 106 may have any such shape that it may fit within the primary cap component 102. The secondary cap component 106 may define at least one upstream air passage 118. For example, the secondary cap component 106 may define a plurality of upstream air passages 118. While the plurality of upstream air passages 118 are depicted as symmetrically arranged in FIGS. 8-9, the example embodiments are not so limited thereto. For example, the plurality of upstream air passages 118 may be asymmetrically arranged. The plurality of upstream air passages 118 may be centrically located in the first and second direction relative to the secondary cap component 106. Although the plurality of upstream air passages 118 are depicted in FIGS. 8-9 as having a longest dimension extending in the second direction, the example embodiments are not so limited thereto. Additionally, the shape of the plurality of upstream air passages 118 are not so limited to the obround shape depicted in FIGS. 8-9. For example, the plurality of upstream air passages 118 may have the shape of a circle, oval, rectangle, triangle, hexagon or any other polygon. The plurality of upstream air passages 118 may be between a plurality of connecting portions 120. However, the example embodiments are not so limited thereto.

[0098] In some example embodiments, the plurality of connecting portions 120 may extend in a vertical direction away from a body of the secondary cap component 106. The plurality of connecting portions 120 may be symmetrically or asymmetrically located around a periphery of the secondary cap component 106. For example, the plurality of connecting portions 120 may surround the upstream air passages 118. While FIGS. 8-9 depict four connecting portions 120, the example embodiments are not so limited thereto, and the secondary cap component 106 may include any number of connecting portions 120 sufficient to form a snap fit with the primary cap component 102. The plurality of connecting portions 120 may be flexible. For example, the connecting portions 120 may form a snap fit connection with the primary cap component 102 described in greater detail below. The plurality of connecting portions 120 may each include a protrusion at an end of the connecting portion 120 spaced apart from the body of the secondary cap component 106 in the vertical direction to facilitate a snap fit with the primary cap component 102.

[0099] The secondary cap component 106 may additionally include supporting structures 122. The supporting structures 122 may extend in a vertical direction between the connecting portions 120. The supporting structures 122 may extend in a vertical direction between the upstream air passages 118. For example, the supporting structures 122 may be on either side of the plurality of upstream air passages 118. The supporting structures 122 may be spaced apart in the first direction by the upstream air passages 118 and may be spaced apart in the second direction by gaps 124. As will be described in greater detail below, the gaps 124 may accommodate portions of the first terminal 104b and the second terminal 104c. In some example embodiments, the secondary cap component 106 may include a liquid crystal polymer.

[0100] FIG. 10 is a cross-sectional view of a heating element inserted into a primary cap component to some example embodiments.

[0101] As depicted in FIG. 10, in some example embodiments, a heating element 104 may be inserted through the first aperture of the primary cap component 102. For example, the planar portion of the heating element 104 may extend through the first aperture 110 while the contact portions of the first terminal 104b and the second terminal 104c extending in the second direction may contact bottom surfaces of the primary cap component 102 overlapping portions of the primary cap component 102 in the vertical direction. In some example embodiments, the heating element 104 may be inserted into the primary cap component 102 in the vertical direction from the top portion 102b toward the insert portion 102a. For example, the heating region 104a of the heating element 104 may extend completely through the first terminal 110 such that the heating region 104a is spaced apart from the primary cap component 102. In some example embodiments, portions of the first terminal 104b and the second terminal 104c may remain within the primary cap component 102. As depicted in FIG. 10, in at least some example embodiments, portions of the first terminal 104b and the second terminal 104c along with the primary cap component 102 may at least partially define a cavity 126. In some example embodiments, bottom surfaces of the contact portions of the first terminal 104b and the second terminal 104c may rest on bottom surfaces of the primary cap component 102 in the insert portion 102a. However, the example embodiments are not so limited thereto, for example bottom surfaces of the contact portions of the first terminal 102b and the second terminal 104c may be coplanar with a bottom surface of the top portion 102b.

[0102] FIG. 11 is a cross-sectional view of heater insert within a consumable housing according to some example embodiments.

[0103] FIG. 12 is a cross-sectional view of heater insert and plug material within a consumable housing according to some example embodiments.

[0104] FIG. 13 is a bottom view of a heater insert including a primary cap component, a heating element, and a secondary cap component according to some example embodiments.

[0105] FIG. 14 is a top-down view of a secondary cap component inserted into a primary cap component according to some example embodiments.

[0106] As depicted in FIGS. 1 and 11 a secondary cap component 106 may be inserted into the primary cap component 102 after the heating element 104 is inserted into the primary cap component 102. In some example embodiments, the secondary cap component 106 may be inserted into the primary cap component 102 in the vertical direction from the top portion 102b to the insert portion 102a such that the secondary cap component 106 is received by the insert portion 102a. For example, the secondary cap component 106 may be inserted into the primary cap component 102 in a direction parallel to, for example in the same direction, the direction in which the heating element 104 is inserted in the primary cap component 102. In some example embodiments, the primary cap component 102 may house the secondary cap component 106 (e.g., the primary cap component 102 may surround secondary cap component 6 in the first direction and the second direction). In some example embodiments, the secondary cap component 106 may be between the contact portions of the first terminal 104b and the second terminal 104c.

[0107] In some example embodiments, the upstream air passages 118 may vertically overlap the heating region 104a. In some example embodiments, the upstream air passages 118 vertically overlap the first aperture 110. In some example embodiments, the upstream air passages 118 vertically overlap the side air passages 114. In some example embodiments, the side air passages 114 may be at a vertical level above the upstream air passages 118 (e.g., between the upstream air passages 118 and the heating element 104 in a vertical direction). While the upstream air passages 118 are depicted as extending in a direction orthogonal to the side air passages 114, the example embodiments are not so limited thereto.

[0108] In some example embodiments, a bottom surface of the secondary cap component 106 may be coplanar with bottom surfaces of the contact portions of the first terminal 104b and the second terminal 104c. However, the example embodiments are not so limited thereto. For example, in some example embodiments, a bottom surface of the secondary cap component 106 may be coplanar with a bottom surface of the top portion 102b. In some example embodiments, the bottom surface of the secondary cap component 106 may be at a vertical level that is different from the bottom surface of contact portions of the first terminal104b and the second terminal 104c or the bottom surface of the top portion 102b. For example, the bottom surface of the secondary cap component 106 may be between the bottom surface of contact portions of the first terminal 104b and the second terminal 104c and the bottom surface of the top portion 102b.

[0109] In some example embodiments, the connecting portions 120 may extend through the second apertures 112 forming a snap fit with the primary cap component 102. For example, in some example embodiments, the connecting portions 120 may include protrusions extending outward from the connecting portions 120 in a horizontal direction. In some example embodiments, the connecting portions may be flexible. In some example embodiments, the protrusions may have an exterior surface that is angled with respect to the connecting portions 120 in a vertical direction. For example, in some example embodiments the protrusions may have a triangular or trapezoidal shape. In some example embodiments, the primary cap component 102 may bias the protrusions causing the connecting portions 120 to flex away (e.g. inward) from a resting position as the connecting portions 120 are inserted through the second apertures. In some example embodiments, once the connecting portions 120 are fully inserted through the second apertures 112, the primary cap component 102 may not bias the protrusions and the connecting portions 120 may return to a resting position. In some example embodiments, the protrusions may vertically overlap a portion of the primary cap component 102 such as a connecting region once the connecting portions 120 are fully inserted through the second apertures 112. In some example embodiments, the connecting regions of the primary cap component 102 may vertically overlap contact portions of the first terminal 104b and the second terminal 104c. In some example embodiments, the secondary cap component 106 may form a snap fit connection with the primary cap component 102. In some example embodiments, a top surface of the connecting portions 120 is coplanar with a top surface of the supporting structures 122.

[0110] In some example embodiments, portions of the first terminal 104b and the second terminal 104c may vertically overlap portions of the secondary cap component 106. For example, in some example embodiments, planar portions of the first terminal 104b and the second terminal 104c may extend between the connecting portions 120 and the supporting structures 122 into the gap 124. In some example embodiments, the primary cap component 102, heating element 104, and secondary cap component 106 may define a cavity 126. For example, the cavity 126 may be at least partially defined by the heating region 104a and the second cap component 106 in the vertical direction. In some example embodiments, the cavity 126 may be at least partially defined by the first terminal 104b and the second terminal 104c in the first horizontal direction. In some example embodiments, the supporting structures 122 may define the cavity in the first horizontal direction. For example, in some example embodiments, the supporting structure 122 may not include a gap 124. In some example embodiments, the cavity 126 may be defined by inner surfaces of side walls of the primary cap component 102 the second horizontal direction. In some example embodiments, the cavity 126 may overlap the side air passages 114 in the vertical direction.

[0111] In some example embodiments, a plug material 128 may be inserted into the cavity such that aerosol-forming substrate discussed in greater detail below may not travel through the upstream air passages 118. For example, the plug material 128 may be permeable to air and impermeable to the aerosol-forming substrate. In some example embodiments, the cavity 126 may vertically overlap the upstream air passages 118. However, the example embodiments are not so limited thereto, and in some example embodiments, the cavity 126 and the plug material 128 may be omitted.

[0112] In some example embodiments, secondary cap component 106 may be housed within the primary cap component 102 with at least a portion of the heating element 104 between the primary cap component 102 and the secondary cap component 106 forming a heater insert 100. In some example embodiments, the secondary cap component 106 and the primary cap component 102 may be held in contact by a snap fit connection.

[0113] As depicted in FIGS. 2, 3, and 11-12 in some example embodiments, a heater insert 100 may be inserted into a consumable housing 108. In some example embodiments, a direction of insertion of the heater insert 100 into the consumable housing 108 may be in a same direction as a direction of insertion of the heating element 104 into the primary cap component 102. In some example embodiments, the consumable housing 108 may be a thermally conductive material. In some example embodiments, the consumable housing 108 may be a metal. In some example embodiments, the consumable housing 108 may be aluminum. However, the example embodiments are not so limited thereto.

[0114] In some example embodiments, the consumable housing 108 in combination with the heater insert 100 may be configured to contain an aerosol-forming substrate within an interior space defined by the consumable housing 108. For example, the aerosol-forming substrate may be a solid aerosol-forming substrate. In some example embodiments, the housing 108 may be configured to additionally receive an end cap in an opening defined by an opposite end of housing 108. Although not depicted, the end cap may define air outlets. For example, an end cap as described in U.S. App. No. 24000NV-001143-US-PS1, which is incorporated herein in its entirety, may be implemented in combination with the housing 108 and the heater insert 100 to form a consumable for use with an aerosol forming device. However, the example embodiments are not so limited thereto. For example, the consumable housing 108 may have a closed end opposite the end of the consumable housing 108 that receives the heater insert 100. In some example embodiments, the closed end of the consumable housing 108 may define air outlets. In some example embodiments, the closed end of the consumable housing 108 may not define air outlets.

[0115] FIG. 15 is a schematic depiction of methods of manufacturing a heater insert according to some example embodiments.

[0116] Referring now to FIG. 15, some example embodiments of methods 200 of manufacturing a heater insert are provided.

[0117] The method 200 includes inserting a heating element 104 into a primary cap component 102 at 202. For example, the heating element 104, the primary cap component 102, and / or the insertion of 202 may be the same as described above.

[0118] The method 200 further includes inserting a secondary cap component 106 into the primary cap component 102 at 204. For example, the secondary cap component 106, the primary cap component 102, and / or the insertion of 204 may be the same as described above.

[0119] The method 200 may optionally further include inserting a plug material 128 into the primary cap component 102. For example, the plug material 128 may be inserted into the primary cap component 102 after step 202 but before step 204. However, the example embodiments are not so limited thereto.

[0120] The method 200 may optionally further include inserting the primary cap component 102 into a consumable housing 108. For example, the heating element 104, the consumable housing 108, and / or the insertion of the heating element 104 into the consumable housing 108 may be the same as described above. In some example embodiments, the primary cap component 102 may be inserted into the consumable housing 108 prior to the insertion 202. In some example embodiments, the primary cap component 102 may be inserted into the consumable housing 108 after the insertion 204. In some example embodiments, the primary cap component 102 may be inserted into the consumable housing 108 between the insertion 202 and the insertion 204.

[0121] Although described with reference to specific examples and drawings, modifications, additions and substitutions of example embodiments may be variously made according to the description by those of ordinary skill in the art. For example, the described techniques may be performed in an order different with that of the methods described, and / or elements such as the described system, architecture, devices, circuit, and the like, may be connected or combined to be different from the above-described methods, or results may be appropriately achieved by other elements or equivalents.

Examples

Embodiment Construction

[0074]Accordingly, while example embodiments are capable of some modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.

[0075]Elements and / or properties thereof (e.g., structures, surfaces, directions, or the like) that are “substantially perpendicular”, “substantially parallel”, or “substantially coplanar” with regard to other elements and / or properties thereof will be understood to be “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof within manufacturing tolerances and / or mate...

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefits of U.S. Provisional Application No. 63 / 772,094, filed Mar. 14, 2025, the entire disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure relates to heated tobacco devices and consumables configured to generate an aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.

[0003] Some electronics configured to heat a plant material to a temperature that is sufficient to release constituents of the plant material while keeping the temperature below an ignition point of the plant material so as to avoid any substantial pyrolysis of the plant material. Such devices may be referred to as aerosol-generating devices (e.g., heated tobacco aerosol-generating devices or heated tobacco products (HTP)), and the plant material heated may be tobacco and / or cannabis. In some instances, the plant material may be introduced directly into a heating chamber of an aerosol-generating device. In other instances, the plant material may be pre-packaged in individual containers or consumables to facilitate insertion and removal from an aerosol-generating device.SUMMARY

[0004] Some example embodiments relate to a heating assembly for an aerosol-generating product, the heating assembly including a primary cap component defining a first aperture and a plurality of second apertures; a heating element configured to extend through the first aperture; and a secondary cap component configured to engage with the primary cap component so as to retain the heating element.

[0005] In some example embodiments the first aperture may be in a form of a slot.

[0006] In some example embodiments, the secondary cap component may be configured to be received within the primary cap component.

[0007] In some example embodiments, the secondary cap component may be configured to engage with the primary cap component via a snap-fit arrangement.

[0008] In some example embodiments, the secondary cap component may be configured to extend through the plurality of second apertures such that the secondary cap component is held in contact with the primary cap component and at least a portion of the heating element is vertically overlapped by the secondary cap component.

[0009] In some example embodiments, the secondary cap component may define a plurality of upstream air passages.

[0010] In some example embodiments, the heating element may include a heating region, a first terminal, and a second terminal.

[0011] In some example embodiments, the heating region may overlap the plurality of upstream air passages.

[0012] In some example embodiments, the secondary cap component may be between the first terminal and the second terminal of the heating element.

[0013] In some example embodiments, the plurality of upstream air passages may be between the first terminal and the second terminal of the heating element.

[0014] In some example embodiments, the heating region may be between the plurality of second apertures.

[0015] In some example embodiments, the plurality of second apertures may be between the first terminal and the second terminal of the heating element.

[0016] In some example embodiments, the first aperture may overlap the plurality of upstream air passages.

[0017] In some example embodiments, the plurality of second apertures may overlap the plurality of upstream air passages.

[0018] In some example embodiments, the primary cap component and the secondary cap component may define a cavity therebetween.

[0019] In some example embodiments, the heating assembly may include a plug material in the cavity.

[0020] In some example embodiments, the plug material may be permeable to air and impermeable to particles of an aerosol-forming substrate.

[0021] In some example embodiments, the primary cap component may define side air passages between the plurality of second apertures.

[0022] In some example embodiments, each of the side air passages may be in a form of a slot.

[0023] In some example embodiments, the side air passages may extend in a same direction as the first aperture.

[0024] In some example embodiments, the first aperture may be between the side air passages.

[0025] In some example embodiments, the secondary cap component may define a plurality of upstream air passages that extend orthogonally to the side air passages.

[0026] In some example embodiments, the heating element may include a planar section configured to extend between the side air passages.

[0027] In some example embodiments, the side air passages may overlap the secondary cap component.

[0028] In some example embodiments, the heating element may overlap the secondary cap component.

[0029] In some example embodiments, the heating element may include a winding portion configured to extend through the first aperture.

[0030] In some example embodiments, the secondary cap component may include a plurality of connecting portions configured to flex so as to establish a snap fit with the primary cap component.

[0031] In some example embodiments, the secondary cap component may define a plurality of upstream air passages between the plurality of connecting portions.

[0032] In some example embodiments, the first aperture may be between the plurality of connecting portions.

[0033] In some example embodiments, the primary cap component may include a plurality of connecting regions such that each connecting portion of the secondary cap component engages with at least a portion of a respective connecting region to establish the snap fit.

[0034] In some example embodiments, the heating element may include a heating region, a first terminal, and a second terminal.

[0035] In some example embodiments, the heating region may be between the plurality of connecting portions of the secondary cap component.

[0036] In some example embodiments, the primary cap component may define side air passages above the secondary cap component and below the heating region of the heating element, and the side air passages are between the plurality of connecting portions of the secondary cap component.

[0037] In some example embodiments, the plurality of connection portions of the secondary cap component may overlap the first terminal and the second terminal of the heating element.

[0038] In some example embodiments, the heating element may include a heating region, a first terminal, and a second terminal, the primary cap component defines side air passages above the secondary cap component and below the heating region of the heating element.

[0039] In some example embodiments, the heating region of the heating element may be between the side air passages of the primary cap component.

[0040] In some example embodiments, the first aperture may be between the side air passages.

[0041] In some example embodiments, the first aperture may be between the plurality of second apertures.

[0042] In some example embodiments, the first aperture may overlap the secondary cap component.

[0043] In some example embodiments, the secondary cap component may be housed within the primary cap component.

[0044] In some example embodiments the primary cap component may include a liquid crystal polymer as a material of construction.

[0045] In some example embodiments the secondary cap component may include a liquid crystal polymer as a material of construction.

[0046] A method of assembling a heater assembly may include inserting a heating element through an aperture in a primary cap component; and inserting a secondary cap component into the primary cap component, at least a portion of the secondary cap component overlapping the heating element in a second direction, the secondary cap component forming a snap fit with the primary cap component, and the secondary cap component defining at least one upstream air passage.

[0047] In some example embodiments, the heating element may include a first terminal, a second terminal, and a heating region.

[0048] In some example embodiments, the heating region, a portion of the first terminal, and a portion of the second terminal may define a planar portion of the heating element.

[0049] In some example embodiments, the planar portion of the heating element may be inserted through the aperture.

[0050] In some example embodiments, the heating region may be inserted through the aperture.

[0051] In some example embodiments, the secondary cap component may be inserted into the primary cap component in a same direction as the heating element.

[0052] In some example embodiments, the secondary cap component may be inserted through at least one secondary aperture in the primary cap component.

[0053] In some example embodiments, the secondary cap component may include at least one connecting portion extending through the at least one secondary aperture in the primary cap component cap component forming a snap fit connecting between the primary cap component and the secondary cap component.

[0054] In some example embodiments, the connecting portion may flex from a resting position while being inserted through the at least one secondary aperture.

[0055] In some example embodiments, the method may include inserting the primary cap component into a consumable housing.

[0056] In some example embodiments, a direction of insertion of the heating element through the primary cap component may be a first direction; a direction of insertion of the secondary cap component into the primary cap component may be a direction parallel to the first direction; and a direction of insertion of the primary cap component into the consumable housing may be a direction parallel to the direction to the first direction.

[0057] Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0058] The features and advantages of the non-limiting example embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, some dimensions of the drawings may have been exaggerated.

[0059] FIG. 1 depicts an upper perspective view of a heater insert according to some example embodiments.

[0060] FIG. 2 depicts a perspective view of a heater insert in combination with a consumable housing according to some example embodiments.

[0061] FIG. 3 depicts an exploded view of a heater insert and a consumable housing according to some example embodiments.

[0062] FIG. 4 depicts a top-down view of a primary cap component according to some example embodiments.

[0063] FIG. 5 depicts a bottom-up view of a primary cap component according to some example embodiments.

[0064] FIG. 6 depicts a peripheral view of a primary cap component according to some example embodiments.

[0065] FIG. 7 depicts a peripheral view of a heating element according to some example embodiments.

[0066] FIG. 8 depicts a top-down view of a secondary cap component according to some example embodiments.

[0067] FIG. 9 depicts an upper peripheral view of a secondary cap component according to some example embodiments.

[0068] FIG. 10 is a cross-sectional view of a heating element inserted into a primary cap component according to some example embodiments.

[0069] FIG. 11 is a cross-sectional view of a heater insert in combination with a consumable housing according to some example embodiments.

[0070] FIG. 12 is a cross-sectional view of a heater insert in combination with a consumable housing according to some example embodiments.

[0071] FIG. 13 is a bottom-up view of a heater insert according to some example embodiments.

[0072] FIG. 14 is a top-down view of a secondary cap component inserted into a primary cap component according to some example embodiments.

[0073] FIG. 15 is a schematic depiction of methods of manufacturing a heater insert according to some example embodiments.DETAILED DESCRIPTION

[0074] Accordingly, while example embodiments are capable of some modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.

[0075] Elements and / or properties thereof (e.g., structures, surfaces, directions, or the like) that are “substantially perpendicular”, “substantially parallel”, or “substantially coplanar” with regard to other elements and / or properties thereof will be understood to be “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof within manufacturing tolerances and / or material tolerances and / or have a deviation in magnitude and / or angle from “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof that is equal to or less than 10% (e.g., a. tolerance of ±10%).

[0076] It should be understood that when an element or layer is referred to as being “on,”“connected to,”“coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,”“directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0077] It should be understood that, although the terms first, second, third, etc. may be used herein to describe some elements, regions, layers and / or sections, these elements, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments.

[0078] Spatially relative terms (e.g., “beneath,”“below,”“lower,”“above,”“upper,” and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0079] The terminology used herein is for the purpose of describing some example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,”“including,”“comprises,” and / or “comprising,” specify the presence of stated features, integers, steps, operations, and / or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0080] When the terms “about” or “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value includes a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical value. Moreover, when the terms “generally” or “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. Furthermore, regardless of whether numerical values or shapes are modified as “about,”“generally,” or “substantially,” it will be understood that these values and shapes should be construed as including a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical values or shapes.

[0081] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0082] FIG. 1 illustrates a view of heater insert for use with a consumable for an aerosol-generating device (e.g., heated tobacco aerosol-generating device) according to some example embodiments.

[0083] FIG. 2 illustrates a peripheral view of a heater insert in combination with a consumable housing according to some example embodiments.

[0084] FIG. 3 illustrates an exploded view of a heater insert and consumable housing for use with the heater insert according to some example embodiments.

[0085] As illustrated in FIGS. 1-3, in some example embodiments, a heater insert 100 may include a primary cap component 102, a heating element 104, and a secondary cap component 106. The heater insert 100 may be configured to be inserted into a consumable housing 108. As depicted in FIGS. 1-3 the heater insert 100 and the consumable housing 108 may have a generally obround profile (e.g., stadium geometry). However, the example embodiments are not so limited thereto. For example, the heater insert 100 and the consumable housing 108 may have any such profile, for example, a circle, an oval, a quadrilateral, or any other such profile so long as the heater insert 100 may be inserted into the consumable housing 108.

[0086] For example, the primary cap component 102 of the heater insert 100 may be configured to form a friction fit with the consumable housing 108 at an interface between the consumable housing 108 and the primary cap component 102. Accordingly, the consumable housing 108 may surround a portion of the primary cap component 102, the heating element 104, and the secondary cap component 106.

[0087] FIG. 4 is a top-down view of a primary cap component according to some example embodiments. FIG. 5 is a bottom-up view of a primary cap component according to some example embodiments. FIG. 6 is a perspective view of a primary cap component according to some example embodiments.

[0088] As depicted in FIGS. 4-6, in at least one example embodiment of a primary cap component 102 may define a plurality of apertures. In some example embodiments, the primary cap component 102 may define a first aperture 110. For example, the first aperture 110 may be in the shape of a slot. For example, the first aperture 110 may have a longest dimension extending parallel to a longitudinal axis, for example a first direction, of the primary cap component 102. In some example embodiments, the first aperture 110 may be centrally aligned along the longitudinal axis of the primary cap component 102.

[0089] In at least one example embodiment, the primary cap component 102 may define a second aperture. In some example embodiments, the second aperture may include a plurality of second apertures 112. Although FIGS. 4-6 depict four second apertures 112, the example embodiments may not be so limited thereto. For example, there may be any number apertures such that the secondary cap component 106 discussed in greater detail below may extend therethrough and form a snap fit with the primary cap component 102. In some example embodiments, the plurality of second apertures 112 may be arranged symmetrically or asymmetrically around the primary cap component 102. For example, the plurality of second apertures 112 may be arranged symmetrically or asymmetrically around the first aperture 110. For example, the plurality of second apertures 112 may be spaced apart in a second direction perpendicular to the first direction by the first aperture 110. In some example embodiments, the plurality of second apertures 112 may be spaced apart in the first direction by side air passages 114 described in greater detail below. While the plurality of second apertures 112 are depicted in FIGS. 4-6 as a rectangular, the example embodiments are not so limited thereto and the plurality of secondary aperture 112 may be any such shape so long the secondary cap component 106 may extend therethrough and form a snap fit with the primary cap component 102.

[0090] In at least one example embodiment, the primary cap component may define at least one side air passage 114 extending therethrough. For example, the side air passage 114 may include two side air passages 114 spaced apart in the second direction by the first aperture 110. While only two side air passages 114 are depicted in FIGS. 4-6, the example embodiments are not so limited thereto. For example, the side air passages 114 may define a plurality of circular side air passages 114. While the side air passages 114 are depicted as symmetrically arranged in FIGS. 4-6, the example embodiments are not so limited thereto. For example, the side air passages 114 may be asymmetrically arranged, for example one side air passage 114 may be offset from another side air passage 114 in the first or second direction. While the side air passages 114 in FIGS. 4-6 are depicted as having an obround shape, the example embodiments are not so limited thereto. For example, the side air passages 114 may define a plurality of circular apertures or a plurality of rectangular apertures (e.g. slots) having a longest dimension in the first or second direction. In some example embodiments, a longest dimension of the side air passages 114 may extend in the first direction. In some example embodiments a longest dimension of the side air passages 114 may extend in the second direction. In some example embodiments, the side air passages may be centrally located along a central axis of the primary cap component 102 extending in a second direction.

[0091] The primary cap component 102 may include an insert portion 102a and a top portion 102b. The insert portion 102a may extend in a vertical direction perpendicular to the first direction and the second direction away from an inner edge of the top portion 102b. The top portion 102b may extend radially outward from an outer surface of the insert portion 102a. The top portion 102b may have an inner surface that may be coplanar with an inner surface of the insert portion 102a that collectively define a central opening in the primary cap component 102. The insert portion 102a may define the secondary apertures 112 and the side air passages 114. The insert portion 102a and the top portion 102b may collectively define the first aperture 110.

[0092] In some example embodiments, the primary cap component 102 may include a liquid crystal polymer (LCP). However, the example embodiments are not so limited thereto. In some example embodiments, the heating element 104 may be configured to extend through the first aperture 110.

[0093] FIG. 7 is a peripheral view of a heating element according to some example embodiments.

[0094] As depicted in FIG. 7, the heating element 104 may include a heating region 104a, a first terminal 104b, and a second terminal 104c. The heating region 104a may be between the first terminal 104b and the second terminal 104c and connect the first terminal 104b and the second terminal 104c. The heating region 104a may include a winding portion extending between the first terminal 104b and the second terminal 104c. The heating region 104a along with portions of the first terminal 104b and the second terminal 104c may define a planar portion of the heating element extending in the vertical direction. The first terminal 104b and the second terminal 104c may each include a contact portion extending in a direction parallel to the second direction. For example, each of the first terminal 104b and the second terminal 104c may include a contact portion that extends away from the planar portion in a direction parallel to the second direction before bending and then extending towards the planar portion in an opposite direction parallel to the second direction. While FIG. 7 depicts the contact portion of the first terminal 104b and the second terminal 104c extending in opposite directions, the example embodiments are not so limited thereto. For example, the contact portions may extend in the same direction. The heating element 104 may be a conductive material. For example, the heating element 104 may be a metal.

[0095] FIG. 8 is a top-down view of a secondary cap component according to some example embodiments.

[0096] FIG. 9 is a perspective view of a secondary cap component according to some example embodiments.

[0097] As depicted in FIGS. 8-9, some example embodiments of the secondary cap component 106 may have a substantially rectangular shape. For example, the secondary cap component 106 may have the shape of a rectangular prism or a trapezoidal prism. However, the example embodiments are not so limited thereto. For example, the secondary cap component 106 may have any such shape that it may fit within the primary cap component 102. The secondary cap component 106 may define at least one upstream air passage 118. For example, the secondary cap component 106 may define a plurality of upstream air passages 118. While the plurality of upstream air passages 118 are depicted as symmetrically arranged in FIGS. 8-9, the example embodiments are not so limited thereto. For example, the plurality of upstream air passages 118 may be asymmetrically arranged. The plurality of upstream air passages 118 may be centrically located in the first and second direction relative to the secondary cap component 106. Although the plurality of upstream air passages 118 are depicted in FIGS. 8-9 as having a longest dimension extending in the second direction, the example embodiments are not so limited thereto. Additionally, the shape of the plurality of upstream air passages 118 are not so limited to the obround shape depicted in FIGS. 8-9. For example, the plurality of upstream air passages 118 may have the shape of a circle, oval, rectangle, triangle, hexagon or any other polygon. The plurality of upstream air passages 118 may be between a plurality of connecting portions 120. However, the example embodiments are not so limited thereto.

[0098] In some example embodiments, the plurality of connecting portions 120 may extend in a vertical direction away from a body of the secondary cap component 106. The plurality of connecting portions 120 may be symmetrically or asymmetrically located around a periphery of the secondary cap component 106. For example, the plurality of connecting portions 120 may surround the upstream air passages 118. While FIGS. 8-9 depict four connecting portions 120, the example embodiments are not so limited thereto, and the secondary cap component 106 may include any number of connecting portions 120 sufficient to form a snap fit with the primary cap component 102. The plurality of connecting portions 120 may be flexible. For example, the connecting portions 120 may form a snap fit connection with the primary cap component 102 described in greater detail below. The plurality of connecting portions 120 may each include a protrusion at an end of the connecting portion 120 spaced apart from the body of the secondary cap component 106 in the vertical direction to facilitate a snap fit with the primary cap component 102.

[0099] The secondary cap component 106 may additionally include supporting structures 122. The supporting structures 122 may extend in a vertical direction between the connecting portions 120. The supporting structures 122 may extend in a vertical direction between the upstream air passages 118. For example, the supporting structures 122 may be on either side of the plurality of upstream air passages 118. The supporting structures 122 may be spaced apart in the first direction by the upstream air passages 118 and may be spaced apart in the second direction by gaps 124. As will be described in greater detail below, the gaps 124 may accommodate portions of the first terminal 104b and the second terminal 104c. In some example embodiments, the secondary cap component 106 may include a liquid crystal polymer.

[0100] FIG. 10 is a cross-sectional view of a heating element inserted into a primary cap component to some example embodiments.

[0101] As depicted in FIG. 10, in some example embodiments, a heating element 104 may be inserted through the first aperture of the primary cap component 102. For example, the planar portion of the heating element 104 may extend through the first aperture 110 while the contact portions of the first terminal 104b and the second terminal 104c extending in the second direction may contact bottom surfaces of the primary cap component 102 overlapping portions of the primary cap component 102 in the vertical direction. In some example embodiments, the heating element 104 may be inserted into the primary cap component 102 in the vertical direction from the top portion 102b toward the insert portion 102a. For example, the heating region 104a of the heating element 104 may extend completely through the first terminal 110 such that the heating region 104a is spaced apart from the primary cap component 102. In some example embodiments, portions of the first terminal 104b and the second terminal 104c may remain within the primary cap component 102. As depicted in FIG. 10, in at least some example embodiments, portions of the first terminal 104b and the second terminal 104c along with the primary cap component 102 may at least partially define a cavity 126. In some example embodiments, bottom surfaces of the contact portions of the first terminal 104b and the second terminal 104c may rest on bottom surfaces of the primary cap component 102 in the insert portion 102a. However, the example embodiments are not so limited thereto, for example bottom surfaces of the contact portions of the first terminal 102b and the second terminal 104c may be coplanar with a bottom surface of the top portion 102b.

[0102] FIG. 11 is a cross-sectional view of heater insert within a consumable housing according to some example embodiments.

[0103] FIG. 12 is a cross-sectional view of heater insert and plug material within a consumable housing according to some example embodiments.

[0104] FIG. 13 is a bottom view of a heater insert including a primary cap component, a heating element, and a secondary cap component according to some example embodiments.

[0105] FIG. 14 is a top-down view of a secondary cap component inserted into a primary cap component according to some example embodiments.

[0106] As depicted in FIGS. 1 and 11 a secondary cap component 106 may be inserted into the primary cap component 102 after the heating element 104 is inserted into the primary cap component 102. In some example embodiments, the secondary cap component 106 may be inserted into the primary cap component 102 in the vertical direction from the top portion 102b to the insert portion 102a such that the secondary cap component 106 is received by the insert portion 102a. For example, the secondary cap component 106 may be inserted into the primary cap component 102 in a direction parallel to, for example in the same direction, the direction in which the heating element 104 is inserted in the primary cap component 102. In some example embodiments, the primary cap component 102 may house the secondary cap component 106 (e.g., the primary cap component 102 may surround secondary cap component 6 in the first direction and the second direction). In some example embodiments, the secondary cap component 106 may be between the contact portions of the first terminal 104b and the second terminal 104c.

[0107] In some example embodiments, the upstream air passages 118 may vertically overlap the heating region 104a. In some example embodiments, the upstream air passages 118 vertically overlap the first aperture 110. In some example embodiments, the upstream air passages 118 vertically overlap the side air passages 114. In some example embodiments, the side air passages 114 may be at a vertical level above the upstream air passages 118 (e.g., between the upstream air passages 118 and the heating element 104 in a vertical direction). While the upstream air passages 118 are depicted as extending in a direction orthogonal to the side air passages 114, the example embodiments are not so limited thereto.

[0108] In some example embodiments, a bottom surface of the secondary cap component 106 may be coplanar with bottom surfaces of the contact portions of the first terminal 104b and the second terminal 104c. However, the example embodiments are not so limited thereto. For example, in some example embodiments, a bottom surface of the secondary cap component 106 may be coplanar with a bottom surface of the top portion 102b. In some example embodiments, the bottom surface of the secondary cap component 106 may be at a vertical level that is different from the bottom surface of contact portions of the first terminal104b and the second terminal 104c or the bottom surface of the top portion 102b. For example, the bottom surface of the secondary cap component 106 may be between the bottom surface of contact portions of the first terminal 104b and the second terminal 104c and the bottom surface of the top portion 102b.

[0109] In some example embodiments, the connecting portions 120 may extend through the second apertures 112 forming a snap fit with the primary cap component 102. For example, in some example embodiments, the connecting portions 120 may include protrusions extending outward from the connecting portions 120 in a horizontal direction. In some example embodiments, the connecting portions may be flexible. In some example embodiments, the protrusions may have an exterior surface that is angled with respect to the connecting portions 120 in a vertical direction. For example, in some example embodiments the protrusions may have a triangular or trapezoidal shape. In some example embodiments, the primary cap component 102 may bias the protrusions causing the connecting portions 120 to flex away (e.g. inward) from a resting position as the connecting portions 120 are inserted through the second apertures. In some example embodiments, once the connecting portions 120 are fully inserted through the second apertures 112, the primary cap component 102 may not bias the protrusions and the connecting portions 120 may return to a resting position. In some example embodiments, the protrusions may vertically overlap a portion of the primary cap component 102 such as a connecting region once the connecting portions 120 are fully inserted through the second apertures 112. In some example embodiments, the connecting regions of the primary cap component 102 may vertically overlap contact portions of the first terminal 104b and the second terminal 104c. In some example embodiments, the secondary cap component 106 may form a snap fit connection with the primary cap component 102. In some example embodiments, a top surface of the connecting portions 120 is coplanar with a top surface of the supporting structures 122.

[0110] In some example embodiments, portions of the first terminal 104b and the second terminal 104c may vertically overlap portions of the secondary cap component 106. For example, in some example embodiments, planar portions of the first terminal 104b and the second terminal 104c may extend between the connecting portions 120 and the supporting structures 122 into the gap 124. In some example embodiments, the primary cap component 102, heating element 104, and secondary cap component 106 may define a cavity 126. For example, the cavity 126 may be at least partially defined by the heating region 104a and the second cap component 106 in the vertical direction. In some example embodiments, the cavity 126 may be at least partially defined by the first terminal 104b and the second terminal 104c in the first horizontal direction. In some example embodiments, the supporting structures 122 may define the cavity in the first horizontal direction. For example, in some example embodiments, the supporting structure 122 may not include a gap 124. In some example embodiments, the cavity 126 may be defined by inner surfaces of side walls of the primary cap component 102 the second horizontal direction. In some example embodiments, the cavity 126 may overlap the side air passages 114 in the vertical direction.

[0111] In some example embodiments, a plug material 128 may be inserted into the cavity such that aerosol-forming substrate discussed in greater detail below may not travel through the upstream air passages 118. For example, the plug material 128 may be permeable to air and impermeable to the aerosol-forming substrate. In some example embodiments, the cavity 126 may vertically overlap the upstream air passages 118. However, the example embodiments are not so limited thereto, and in some example embodiments, the cavity 126 and the plug material 128 may be omitted.

[0112] In some example embodiments, secondary cap component 106 may be housed within the primary cap component 102 with at least a portion of the heating element 104 between the primary cap component 102 and the secondary cap component 106 forming a heater insert 100. In some example embodiments, the secondary cap component 106 and the primary cap component 102 may be held in contact by a snap fit connection.

[0113] As depicted in FIGS. 2, 3, and 11-12 in some example embodiments, a heater insert 100 may be inserted into a consumable housing 108. In some example embodiments, a direction of insertion of the heater insert 100 into the consumable housing 108 may be in a same direction as a direction of insertion of the heating element 104 into the primary cap component 102. In some example embodiments, the consumable housing 108 may be a thermally conductive material. In some example embodiments, the consumable housing 108 may be a metal. In some example embodiments, the consumable housing 108 may be aluminum. However, the example embodiments are not so limited thereto.

[0114] In some example embodiments, the consumable housing 108 in combination with the heater insert 100 may be configured to contain an aerosol-forming substrate within an interior space defined by the consumable housing 108. For example, the aerosol-forming substrate may be a solid aerosol-forming substrate. In some example embodiments, the housing 108 may be configured to additionally receive an end cap in an opening defined by an opposite end of housing 108. Although not depicted, the end cap may define air outlets. For example, an end cap as described in U.S. App. No. 24000NV-001143-US-PS1, which is incorporated herein in its entirety, may be implemented in combination with the housing 108 and the heater insert 100 to form a consumable for use with an aerosol forming device. However, the example embodiments are not so limited thereto. For example, the consumable housing 108 may have a closed end opposite the end of the consumable housing 108 that receives the heater insert 100. In some example embodiments, the closed end of the consumable housing 108 may define air outlets. In some example embodiments, the closed end of the consumable housing 108 may not define air outlets.

[0115] FIG. 15 is a schematic depiction of methods of manufacturing a heater insert according to some example embodiments.

[0116] Referring now to FIG. 15, some example embodiments of methods 200 of manufacturing a heater insert are provided.

[0117] The method 200 includes inserting a heating element 104 into a primary cap component 102 at 202. For example, the heating element 104, the primary cap component 102, and / or the insertion of 202 may be the same as described above.

[0118] The method 200 further includes inserting a secondary cap component 106 into the primary cap component 102 at 204. For example, the secondary cap component 106, the primary cap component 102, and / or the insertion of 204 may be the same as described above.

[0119] The method 200 may optionally further include inserting a plug material 128 into the primary cap component 102. For example, the plug material 128 may be inserted into the primary cap component 102 after step 202 but before step 204. However, the example embodiments are not so limited thereto.

[0120] The method 200 may optionally further include inserting the primary cap component 102 into a consumable housing 108. For example, the heating element 104, the consumable housing 108, and / or the insertion of the heating element 104 into the consumable housing 108 may be the same as described above. In some example embodiments, the primary cap component 102 may be inserted into the consumable housing 108 prior to the insertion 202. In some example embodiments, the primary cap component 102 may be inserted into the consumable housing 108 after the insertion 204. In some example embodiments, the primary cap component 102 may be inserted into the consumable housing 108 between the insertion 202 and the insertion 204.

[0121] Although described with reference to specific examples and drawings, modifications, additions and substitutions of example embodiments may be variously made according to the description by those of ordinary skill in the art. For example, the described techniques may be performed in an order different with that of the methods described, and / or elements such as the described system, architecture, devices, circuit, and the like, may be connected or combined to be different from the above-described methods, or results may be appropriately achieved by other elements or equivalents.

Examples

Embodiment Construction

[0074]Accordingly, while example embodiments are capable of some modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.

[0075]Elements and / or properties thereof (e.g., structures, surfaces, directions, or the like) that are “substantially perpendicular”, “substantially parallel”, or “substantially coplanar” with regard to other elements and / or properties thereof will be understood to be “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof within manufacturing tolerances and / or mate...

Claims

1. A heating assembly for an aerosol-generating product, the heating assembly comprising:a primary cap component defining a first aperture and a plurality of second apertures;a heating element configured to extend through the first aperture; anda secondary cap component configured to engage with the primary cap component so as to retain the heating element.

2. The heating assembly of claim 1, wherein the first aperture is in a form of a slot.

3. The heating assembly of claim 1, wherein the secondary cap component is configured to be received within the primary cap component.

4. The heating assembly of claim 1, wherein the secondary cap component is configured to engage with the primary cap component via a snap-fit arrangement.

5. The heating assembly of claim 1, wherein the secondary cap component is configured to extend through the plurality of second apertures such that the secondary cap component is held in contact with the primary cap component and at least a portion of the heating element is vertically overlapped by the secondary cap component.

6. The heating assembly of claim 1, wherein the secondary cap component defines a plurality of upstream air passages.

7. The heating assembly of claim 1, wherein the primary cap component and the secondary cap component define a cavity therebetween.

8. The heating assembly of claim 7, further comprising:a plug material in the cavity.

9. The heating assembly of claim 8, wherein the plug material is permeable to air and impermeable to particles of an aerosol-forming substrate.

10. The heating assembly of claim 1, wherein the primary cap component defines side air passages between the plurality of second apertures.

11. The heating assembly of claim 10, wherein each of the side air passages are in a form of a slot.

12. The heating assembly of claim 10, wherein the side air passages extend in a same direction as the first aperture.

13. The heating assembly of claim 10, wherein the first aperture is between the side air passages.

14. The heating assembly of claim 1, wherein the heating element overlaps the secondary cap component.

15. The heating assembly of claim 1, wherein the heating element includes a winding portion configured to extend through the first aperture.

16. The heating assembly of claim 1, wherein the secondary cap component includes a plurality of connecting portions configured to flex so as to establish a snap fit with the primary cap component.

17. The heating assembly of claim 16, wherein the secondary cap component defines a plurality of upstream air passages between the plurality of connecting portions.

18. The heating assembly of claim 16, wherein the first aperture is between the plurality of connecting portions.

19. The heating assembly of claim 1, wherein the first aperture overlaps the secondary cap component.

20. A method of assembling a heater assembly, the method comprising:inserting a heating element through an aperture in a primary cap component; andinserting a secondary cap component into the primary cap component, at least a portion of the secondary cap component overlapping the heating element in a second direction, the secondary cap component forming a snap fit with the primary cap component, and the secondary cap component defining at least one upstream air passage.

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