Heating assembly for an aerosol generating device and corresponding aerosol generating device

Abstract

The heating assembly is provided for an aerosol generating device configured for operating a consumable article (16) containing an aerosol generating material for generating an aerosol when heated. The heating assembly comprises a heating chamber (32) for receiving a consumable article (16), at least one heating element (36) configured for heating a consumable article received in the heating chamber (30) and a support (62) supporting each heating element (36), each heating element (36) being overmolded by the support (60).

Description

[0001] Heating assembly for an aerosol generating device and corresponding aerosol generating device

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to the field of aerosol generating devices configured to operate a consumable article, and in particular to a heating assembly configured for heating a consumable article inserted in the aerosol generating device.

[0004] Particularly, the consumable article contains a vaporizable material such as to form aerosol when the consumable article is heated by the aerosol generating device. Hence, aerosol generating devices of this type, also known as “heat-not-burn devices”, are adapted to heat, rather than burn to generate aerosol for inhalation.

[0005] BACKGROUND OF THE INVENTION

[0006] The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat or warm vaporizable materials as opposed to burning tobacco in conventional tobacco products.

[0007] A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or so called “heat-not-burn device”. Aerosol generation devices of this type generate aerosol or vapour by heating an aerosol substrate that is usually comprised in a consumable article separate from the aerosol generation devices. Typically, such aerosol substrate comprises moist leaf tobacco or other suitable vaporizable material that vaporizes at a temperature typically in the range of 150°C to 350°C. Heating an aerosol substrate, but not combusting or burning it, releases aerosol that comprises the components sought by the user but not by-products of combustion and burning. Furthermore, the aerosol produced by heating the vaporizable material contained in the aerosol substrate does not comprise the typical burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and the smoke that can be irritating and polluting for the surroundings. Consumable articles usable with such type of aerosol generating devices can take various shapes. Some of them can exhibit the shape of an elongated stick or any other suitable shape, like for example a flat shape. Generally, such a consumable article is received at least partially in a heating chamber of a heating assembly of the aerosol generating device which comprises one or several heating elements arranged to heat the consumable article received in the heating chamber.

[0008] The one or several heating elements are mounted onto a support of the heating assembly, said support advantageously delimiting the heating chamber for receiving the consumable article. Each heating element is for example an electrical heating element configured to generate heat when fed with electricity, in particular by Joule effect.

[0009] It is necessary to ensure a reliable mounting of each heating element onto the support to ensure an appropriate heating and to ensure the safety of the consumer when using the aerosol generating device. The heating assembly shall also be economical to produce.

[0010] SUMMARY OF THE INVENTION

[0011] One of the aims of the invention is to propose a heating assembly for an aerosol generating device which can ensure appropriate heating of the consumable article, with being safe to use and economical to produce.

[0012] To this end, the invention proposes a heating assembly for an aerosol generating device, the heating assembly comprising:

[0013] - a heating chamber for receiving a consumable article upon insertion of the consumable article in the aerosol generating device, the consumable article containing an aerosol generating material for generating an aerosol when heated,

[0014] - at least one heating element, each heating element being configured for heating a consumable article received in the heating chamber, and

[0015] - a support supporting each heating element, wherein each heating element is overmolded by the support.

[0016] Each heating element overmolded by the support allows manufacturing the heating assembly economically, along with permitting an appropriate and safe use of the aerosol generating device by the user. Each heating element overmolded by the support can be fixed appropriately and reliably to the support while being accurately positioned in close proximity or in contact with the consumable article inserted in the heating chamber of the heating assembly for an appropriate heating of the consumable article, with limiting any risk for the user.

[0017] In some examples, each heating element is flat shaped.

[0018] A flat shaped heating element can provide a large area for heat transfer with the consumable article, thus ensuring an appropriate and homogenous heating of the consumable article.

[0019] A flat shaped heating element can be overmoulded by the material of the support with a good cohesion between the flat shaped heating element and the support.

[0020] In some examples, each heating element has a heating surface parallel to an internal surface of the chamber.

[0021] The heating surface is configured for transferring heat, in particular to the consumable article received in the heating chamber.

[0022] The heating surface is orientated towards the inside of the heating chamber.

[0023] The heating surface parallel to the internal surface of the chamber allows efficient heating of the consumable article received in the heating chamber over a large area.

[0024] In some examples, each heating element has a heating surface which is flush with an internal surface of the chamber.

[0025] The heating surface flush with an internal surface of the chamber can be close or in contact with a surface of the consumable article inserted in the heating chamber, thus promoting the transfer of heat from the heating surface to the consumable article.

[0026] In some examples, each heating element has a heating surface which is flat. A flat heating surface provides a large area for heat transfer with a surface of the consumable article inserted in the heating chamber, in particular with a flat surface of the consumable article, in particular if the consumable article in flat shaped with a parallelepiped shape. In this case, the consumable article can be heated in a particularly fast and efficient way.

[0027] In some examples, the heating assembly comprises, for each heating element, a set of connection wires for connecting the heating element to an electric source. Each set of connection wires comprises for example two wires.

[0028] The connection of the heating element to an electric source allows passing an electric current via the heating element for generating heat in the heating element by Joule effect.

[0029] In some examples, the connection wires of each set of connection wires extend through the support, in particular through an opening provided in the support.

[0030] The extension of the connection wire through the support, in particular through an opening of the support, allows manufacturing the heating assembly with ease, e.g. with overmolding the support on the heating element provided with the connections wires connected to the heated element.

[0031] In some examples, each wire connection is connected to the corresponding heating element on a rear surface of the heating element facing opposite the heating chamber. The rear surface is opposite a heating surface of the heating element facing towards the inside of the heating chamber.

[0032] In some examples, the heating assembly comprises two heating elements facing each other, the two heating elements being located on opposed internal surfaces of the heating chamber.

[0033] With such an arrangement of the two heating elements, the consumable article is received in the heating chamber between the two heating elements, and the two heating elements transfer heat to the consumable article on either side of the consumable article, thus promoting heat transfer and homogeneous heating of the consumable article. In some examples, the support comprises two opposed walls, the heating chamber being delimited between the two opposed walls, each wall defining a respective internal surface of the heating chamber.

[0034] Preferably, the heating assembly comprises one single heating element overmolded in one to the two opposed walls or two heating elements, one respective heating element being overmolded in each one of the two opposed walls of the support.

[0035] The support can thus delimit the heating chamber for receiving the consumable article and support each heating element overmolded by the support. The manufacture of the heating assembly can thus be easy and economical.

[0036] In some examples, the support is made of a plastic material, in particular of a thermostable thermoplastic.

[0037] The support made of a plastic material can be molded, e.g. injection molded or compression molded, in particular with overmolding each heating element.

[0038] In some examples, the plastic material is a polyaryl ether ketone (PAEK), in particular a polyether ether ketone (PEEK).

[0039] Such material is adapted for molded and can withstand, without damages, high temperatures, in particular high continuous temperatures, as can be encountered in a heating assembly of an aerosol generating device.

[0040] In some examples, the plastic material is reinforced with fibers. The fibers comprise for example carbon fibers and / or nylon fibers.

[0041] The reinforcement fibers allow strengthening the support with still allowing molding of the support with overmolding the heating element, in particular when the fibres have a short length.

[0042] The support is for example injection molded or compression molded, and preferably injection molded. The invention also relates to an aerosol generating device configured for operating a consumable article comprising an aerosol generating material configured for generating an aerosol when heated, the aerosol generating device comprising a heating assembly as defined above, configured for heating the consumable article received in the heating chamber such as to generate an aerosol.

[0043] The invention also relates to an aerosol generating system comprising an aerosol generating device as defined above and a consumable article comprising an aerosol generating material configured for generating an aerosol when heated, the consumable article being receivable in the heating chamber of the heating assembly, the heating assembly being configured for heating the consumable article received in the heating chamber such as to generate an aerosol.

[0044] The invention also relates to a method of manufacturing a heating assembly for an aerosol generating device, the heating assembly comprising a heating chamber for receiving a consumable article containing an aerosol generating material configured for generating an aerosol when heated and at least one heating element, each heating element being configured for heating a consumable article received in the heating chamber, the manufacturing method comprising the step of molding a support such that each heating element is supported by the support and overmolded by the support.

[0045] BRIEF DESCRIPTION OF THE DRAWINGS

[0046] The invention and its advantages will be better understood upon reading the following description, which is given by way of non-limiting examples and which is made with reference to the appended drawings, in which:

[0047] - Figure 1 is a schematic sectional view of an aerosol generating assembly comprising an aerosol generating device and a consumable article;

[0048] - Figure 2 is a perspective view of the consumable article of Figure 1 ;

[0049] - Figure 3 is a longitudinal sectional view of the consumable article of Figure 2;

[0050] - Figure 4 is a longitudinal sectional view of a heating assembly of the aerosol generating device; - Figure 5 is a longitudinal sectional view of a mold for molding a support of the heating assembly, the mold being in an open configuration;

[0051] - Figure 6 is a longitudinal sectional view of a mold for molding a support of the heating assembly, the mold being in a closed configuration.

[0052] DETAILED DESCRIPTION OF THE INVENTION

[0053] Before describing the invention, it is to be understood that it is not limited to the details of construction set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the invention is capable of other embodiments and of being practiced or being carried out in various ways.

[0054] As used herein, the term “aerosol generating device” or “device” may include a vaping device to deliver an aerosol to a user, including an aerosol for vaping, by means of a heater element explained in further detail below. The device may be portable. “Portable” may refer to the device being for use when held by a user. The device may be adapted to generate a variable amount of aerosol, e.g. by activating the heating assembly for a variable amount of time (as opposed to a metered dose of aerosol), which can be controlled by a trigger. The trigger may be user activated, such as a vaping button. The device may include a temperature regulation control to drive the temperature of the heating assembly and / or the vaporizable material (aerosol pre-cursor) to a specified target temperature and thereafter to maintain the temperature at the target temperature that enables efficient generation of aerosol.

[0055] As used herein, the term “aerosol” may include a suspension of vaporizable material as liquid droplets and / or gas. Said suspension may be in a gas including air. Aerosol herein may generally refer to / include a vapour. Aerosol may include one or more components of the vaporizable material.

[0056] As used herein, the term “vaporizable material” or “precursor” may refer to a smokable material which may for example comprise nicotine or tobacco and an aerosol former. Tobacco may take the form of various materials such as shredded tobacco, granulated tobacco, tobacco leaf and / or reconstituted tobacco. Suitable aerosol formers include: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, acids such as lactic acid, glycerol derivatives, esters such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin or vegetable glycerin. In some embodiments, the aerosol generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate may also comprise at least one of a gelling agent, a binding agent, a stabilizing agent, and a humectant.

[0057] As illustrated on Figure 1 , an aerosol generating assembly 10 comprises an aerosol generating device 12 and a consumable set 14. The consumable set 14 comprises a consumable article 16 and a mouthpiece 18. The mouthpiece 18 may be exchangeable or be a re-usable part removably attached to the aerosol generating device 12. The consumable article 16 is configured to operate with the aerosol generating device 12.

[0058] The aerosol generating device 12 comprises a device body 20 extending along a device axis Y between a first end 22, or mouth end and a second end 24 or bottom end. The device body 20 is configured for receiving the consumable article 16 in a removable manner such as to operate the aerosol generating device 12 with the consumable article 16 for generating an aerosol.

[0059] The device body 20 delimits an internal space of the aerosol generating device 12 receiving various elements designed to carry out different functionalities of the aerosol generating device 12.

[0060] The device body 20 houses for example a battery 26 for powering the aerosol generating device 12, an electronic control module 28 for controlling the operation of the aerosol generating device 11 , and a heating assembly 30 for heating the consumable article 16.

[0061] The heating assembly 30 is part of the aerosol generating device 12 and is configured to heat the consumable article 16 inserted in the aerosol generating device 12. The heating assembly 30 is fixedly mounted in the aerosol generating device 12 for heating a consumable article 16 removably inserted in the aerosol generating device 12. The heating assembly 30 is separate from the consumable article 16.

[0062] The heating assembly 30 comprises a heating chamber 32. The heating chamber 32 is designed to receive at least partially the consumable article 16. As illustrated on Figure 1 , the heating chamber 32 opens for example at the first end 22 of the device body 20 via an insertion opening 34 for insertion of the consumable article 16 into the heating chamber 32. The mouthpiece 18 may for instance be slidably connected or pivotally attached to the device body 20 to allow the heating assembly 30 to be opened for insertion of the consumable article. The heating chamber 32 extends for example along a longitudinal axis A which is parallel or coincides for example with the device axis Y.

[0063] The heating assembly 30 is configured to receive and heat at least a portion of the consumable article 16 inserted in the heating chamber 32.

[0064] The heating assembly 30 comprises at least one heating element 36 configured for heating the consumable article 16 received in the heating chamber 32. Each heating element 36 is fixedly mounted relative to the heating chamber 32.

[0065] As illustrated on Figure 2 and 3, the consumable article 16 extends along an article axis X and comprises a tubular wrapper 40 extending along the article axis X between an inlet end 42 and an outlet end 44 of the consumable article 16, with forming a substrate portion 46, which receives an aerosol substrate 48, and, optionally, a cooling portion 50.

[0066] The wrapper 40 defines the external envelope of the consumable article 16.

[0067] The aerosol substrate 48 contains the vaporizable material. The vaporizable material is configured for vaporizing when the substrate portion 46 is heated, e.g. by the heating assembly 30 of the aerosol generating device 12 in which the consumable article 16 is received. The aerosol substrate 48 is configured for allowing air to flow through the aerosol substrate 48.

[0068] When provided, the cooling portion 50 is configured for the circulation of the aerosol from the substrate portion 46 to the outlet end 44 with cooling of the aerosol. The cooling of the aerosol in the cooling portion 50 avoids the unpleasant sensation of hotness in the mouth or throat of the user.

[0069] In such case, the substrate portion 46 and the cooling portion 50 are respective axial sections or axial length portions of the wrapper 40. The substrate portion 46 extends from the inlet end 42 to the cooling portion 50 and the cooling portion 50 extends from the substrate portion 46 to the outlet end 44 of the consumable article 16. In some embodiments, the cooling portion 50 can form a mouthpiece. In this case, a separate mouthpiece as explained above may not be necessary. In some embodiments, the cooling portion 50 may also comprise a filtering element.

[0070] The consumable article 16 exhibits for example a flat shaped.

[0071] By “flat shape” of the consumable article 16, it is understood that the consumable article 16 extends between two parallel first planes and two parallel second planes perpendicular to the first planes, the first planes and the second planes being parallel to the article axis, the distance between the second planes being at least 3 times, advantageously 5 times and preferably 10 times, greater than the distance between the first planes.

[0072] Such shape is particularly advantageous to ensure a fast preheating phase of the consumable article. Thus, the consumable article can be ready to generate aerosol only a few seconds (for example 5 s or 15 s or 20 s) after activating the heating.

[0073] The consumable article 16 is for example in the shape of parallelepiped, in particular a rectangular parallelepiped.

[0074] The consumable article 16 has a cross-section taken perpendicularly to the article axis X, i.e. in a plane perpendicular to the article axis X. The cross-section of the consumable article 16 is preferably constant along the article axis X.

[0075] The consumable article 16 exhibits for example a quadrangular cross-section, i.e. a cross section with four sides. The consumable article 16 exhibits for example a trapezoidal cross-section or preferably a rectangular cross-section.

[0076] The wrapper 40 comprises for example two wide peripheral walls 52, which are opposed and parallel to each other, and two opposed narrow peripheral walls 54. This allows imparting a plate shape to the consumable article 16.

[0077] The width of each peripheral wall (wide peripheral walls 52 or narrow peripheral walls 54) is the distance between the two edges of the peripheral wall which are parallel to article axis X. The width of each wide peripheral walls 52 is strictly higher than the width of each narrow peripheral wall 54.

[0078] The two wide peripheral walls 52 are spaced apart along a first transverse direction T 1 perpendicular to the article axis X. The two narrow peripheral walls 54 are spaced apart along a second transverse direction T2 perpendicular to the article axis X and to the first transverse direction T 1 .

[0079] The two wide peripheral walls 52 are preferably flat. The two narrow peripheral walls 54 are for example flat. Preferably, the two narrow peripheral walls 54 are parallel to each other as illustrated on Figure 2. This imparts a rectangular parallepiped shape to the consumable article 16. In a variant, the two narrow peripheral walls 54 are for example inclined one relative to the other with a non-zero angle. This imparts a trapezoidal crosssection to the cooling section 50.

[0080] The consumable article 16 has external dimensions including a length L taken along the article axis X between the inlet end 42 and the outlet end 44, a width W taken perpendicularly to the article axis X between the narrow peripheral walls 54, and a depth D taken perpendicularly to the article axis X between the wide peripheral walls 52. The width W of the consumable article 16 is taken along the second transverse direction T2 and the depth D of the consumable article 16 is taken along the first transverse direction T 1 .

[0081] In one example, the length L of the consumable article 16 is comprised between 20 mm and 45 mm, the width W of the consumable article 16 is comprised between 7 mm and 17 mm and / or the depth D of the consumable article 16 is comprised between 0.7 mm and 2.0 mm. In a particular example, the length L of the consumable article 16 substantially equals to 33 mm, the width W substantially equals to 12.4 mm and / or the depth D of the consumable article 16 substantially equals to 1.65 mm.

[0082] The width W of the consumable article 16 is for example at least three times the depth D of the consumable article 16, preferably at least five times the depth D of the consumable article 16, still preferably at least ten times the depth D of the consumable article 16. The width to depth ratio (W / D) of the consumable article 16 is for example equal or higher than three, in particular equal or higher than five, still in particular equal or higher than ten. When provided, the cooling section 50 is for example void or provided with at least one reinforcement element received in the cooling section 50 for reinforcing the cooling section 50, in particular for preventing the peripheral walls of the wrapper 40 (wide peripheral walls 50 and narrow peripheral walls 52) to collapse inwardly.

[0083] The thickness of the peripheral walls of the wrapper 40 (in all embodiments of the invention) may be preferably between 75 microns and 140 microns. In one example, the paper has a thickness of 125 microns. The wrapper may for instance be formed from a paper sheet having a basis weight of at least 70 g / m2, more preferably at least 75 g / m2, most preferably at least 78 g / m2. In one example, the paper has a basis weight of about 100 g / m2. The porosity of the paper may be less than 100 CU, preferably between 0 and 80 CU. In one example, the paper has a porosity of 40 CU.

[0084] The wrapper 40 comprises for example paper and / or non-woven fabric and / or aluminium foil. The wrapper 40 is preferably non-porous but in possible embodiments, the wrapper may be locally porous or perforated (e.g., by row(s) of through-holes) to allow air to enter in the cooling part.

[0085] The wrapper 40 preferably comprises paper. The paper can be similar to one used as a tipping paper in the conventional tobacco articles. In a variant, the paper is different from one of the conventional tobacco articles.

[0086] The wrapper 40 comprises for example aluminium. The aluminium extends in the substrate portion 46 to prevent condensation leakage and / or vapour leakage. The aluminium extends for example only in the substrate portion 46 or extends in the substrate portion 46 and the cooling portion 50.

[0087] In one example, the wrapper 40 is a laminate of paper and aluminium which extends along the entire length of the consumable article 16, from the inlet end 42 to the outlet end 44.

[0088] As illustrated on Figure 4, the heating assembly 30 comprises the heating chamber 32 which is configured for receiving the consumable article 16, preferably with the article axis X substantially coinciding with the longitudinal axis A. The heating chamber 32 comprises for example two opposite internal surfaces 32A facing each other. The heating chamber 32 is delimited between the two internal surfaces 32 A.

[0089] The heating assembly 30 comprises at least one heating element 36, each heating element 36 being configured for heating the consumable article 16 received in the heating chamber 32.

[0090] The heating assembly 30 comprises for example two heating elements 36 provided on the two opposed internal surfaces 32A of the heating chamber 32, the two heating elements 36 facing each other. The consumable article 16 inserted in the heating chamber 32 is received between the two heating elements 36. Upon heating operation, the two heating elements 36 heat the consumable article 16 on two opposed sides.

[0091] In a variant, the heating assembly 30 comprises only one heating element 36 provided on one of the two opposed internal surfaces 32A of the heating chamber 32. The other one of the two opposed internal surfaces 32A of the heating chamber 32 is deprived of heating element 36.

[0092] Each heating elements 36 has a heating surface 36A facing the inside of the heating chamber 32. The heating surface 36A is configured for transferring heat to the consumable article 16 received in the heating chamber 32 during heating operation.

[0093] The heating surface 36A of each heating element 36 is for example flat. The heating surface 36A of each heating element 36 has for example a polygonal contour, in particular a rectangular contour. Alternatively, each heating element 36 has a triangular contour or a polygonal contour with more than four sides. Still alternatively, each heating element 36 has a circular contour.

[0094] Each heating element 36 has for example two opposed and preferably parallel surfaces, one defining the heating surface 36A and the other a rear surface 36B. The rear surface 36B of each heating element 36 faces opposite the heating chamber 32.

[0095] Each heating element 36 is for example in the shape of a plate, in particular a flat plate. Each heating element 36 in the shape of plate has two opposed surfaces forming the heating surface 36A and the rear surface 36B of the heating element 36. Each heating element in a shape of a plate can be manufactured easily and cost effectively.

[0096] Each heating element 36 has for example a polygonal contour, in particular a rectangular contour. Alternatively, each heating element 36 has a triangular contour or a polygonal contour with more than four sides. Still alternatively, each heating element 36 has a circular contour.

[0097] The heating surface 36A of each heating element 36 is for example parallel to the internal surface 32A of the heating chamber 32 on which the heating element 36 is provided, and preferably flush with the internal surface 32A of the heating chamber 32 on which the heating element 36 is provided.

[0098] In particular, the heating surface 36A is configured to be close to and preferably to contact a surface of the consumable article 16 when the latter is inserted in the heating chamber 32.

[0099] Each heating element 36 is made of an electrically conductive material, in particular of metal. Such heating element 36 is adapted for generating heat by Joule effect by passing an electrical current through the heating element 36.

[0100] The heating assembly 30 comprises for example, for each heating element 36, a pair of connection wires 38 for electrically connecting the heating element 36 to an electric source, in particular the battery 26 of the aerosol generating device 12. The two connection wires 58 allow passing an electrical current via the heating element.

[0101] Each heating element 36 is mounted fixedly relative to the heating chamber 32.

[0102] The heating assembly 30 comprises a support 60 supporting each heating element 36, each heating element 36 being overmolded by the support 60.

[0103] Advantageously, the support 60 delimits the heating chamber 32. The support 60 extends along the longitudinal axis A and comprises for example a heating section 62 in which the heating chamber 32 is delimited, and, optionally, an inlet section 64 for guiding the consumable article 16 into the heating chamber 32. The heating section 62 is for example tubular along the longitudinal axis A. The heating section 62 has for example a four-sided cross-section and comprises two opposed main walls 65 and two opposed side walls 66 connecting the main walls 65.

[0104] The two main walls 65 define two opposed internal surfaces 32A of the chamber 32.

[0105] Each heating element 36 is provided on one of the two main walls 65. Each main wall 65 supporting a heating element 36 may also be referred to as a heating wall 65.

[0106] Each heating element 36 is preferably overmolded in one of the two opposed main walls 65.

[0107] The heating assembly comprises only one heating element 36 overmolded in one of the two main walls 65 of the support 60 or two heating elements 36, each heating element 36 being overmolded in a respective one of the two main walls 65 of the support 60.

[0108] The heating section 62 has for example a rectangular cross-section. Each main wall 65 is for example wide, each side wall 66 being narrow.

[0109] The connection wires 38 of each set of connection wires extend through the support 60, in particular through an opening 68 provided in the support 60. Each opening 68 extends advantageously through the main wall 65 supporting the heating element 34 to which the connection wires 38 are connected.

[0110] Each connection wire 38 comprises for example a proximal section 38A connected to the heating element 36 and a distal section 38B extending the proximal section 38A opposite the heating element 36 for connection to the electric source. The proximal section 38A extends between the distal section 38B and the heating element 36.

[0111] The proximal section 38A connects preferably to the rear surface 36B of the heating element 36 with extending through the opening 68 of the support 60.

[0112] The proximal section 38A and the distal section 38B define a non-zero angle between them. The proximal section 38A and the distal section 38B are for example perpendicular one with respect to the other. The proximal section 38A is for example perpendicular to the rear surface 36B of the heating element 36.

[0113] The proximal section 38A is in particular perpendicular to the heating element 36 when the heating element is flat shaped. The distal section 38B is for example parallel to the heating element 36.

[0114] Each connection wire 38 is for example bent between the proximal section 38A and the distal section 38B, in particular at 90°.

[0115] The support 60 is made a plastic material, in particular of a thermostable thermoplastic.

[0116] The plastic material is for example a polyaryl ether ketone (PAEK), in particular a polyether ether ketone (PEEK). PAEK and PEEK are thermostable thermoplastics which are stable at high temperature. The plastic material is for example continuously operable to a temperature up to 200°C, preferably up to 250°C. The thermoplastic is preferably operable to a temperature up to 300°C or 350°C, e.g. for short periods of time.

[0117] Optionally, the plastic material is reinforced with fibers. The fibers comprise for example carbon fibers and / or nylon fibers.

[0118] The support 60 is molded with overmoulding each heating element 36. The support 60 is for example injection molded or compression molded. The support 60 is preferably injection molded.

[0119] A method of fabrication the heating assembly 30 with overmoulding the support 60 onto each heating element 36 is illustrated on Figures 5 and 6.

[0120] As illustrated on Figures 5 and 6, a mold 70 comprises mold parts 72, 74 movable with respect to each other between an open configuration (Figure 5) in which the mold parts 72, 74 are moved away to each other and a closed configuration (Figure 6) in which the mold parts 72, 74 are moved closer to each other to define a mold cavity 78. The mold parts 72, 74 comprise for example two outer mold parts 72 and an inner mold part 74 which is inserted between the two outer mold parts 72 in the closed configuration for defining the heating chamber 32 within the support 60.

[0121] The inner mold part 74 is provided with one respective receiving surface 74A associated to each heating element 36 and configured for receiving said heating element 36 in the closed configuration of the mold 70, such that the support 60 is overmolded onto each heating element 36 which is then positioned on an inner surface 32A of the heating chamber 32.

[0122] The two outer mold parts 72 are provided with mold openings 72A allowing the connections wires 38 connected each heating element 36 to extend from the heating element 36 located inside the mold 70 to the outside of the mold 70.

[0123] The mold 70 optionally comprises plugs 76, each plug 76 being configured to sealing a mold opening 72A with a pair of connection wires 38 connected to a heating plate 36 extending through said plug 76. Each plug 76 is for example configured for each connection wire 38 to extend in a rectilinear manner through the plug 76, with the proximal portion 38A and the distal portion 38B aligned. Each connection wire 38 is for example subsequently bent between the proximal portion 38A and the distal portion 38B.

[0124] As illustrated on Figure 5, the manufacturing method comprises for example a first step of providing each heating element 36, preferably with the corresponding connection wires 38 attached to the rear face 36B the heating element 36, the connection wires 38 being in a rectilinear configuration. Each connection wire 38 is for example welded to the rear face 36B of the corresponding heating element 36.

[0125] The manufacturing method comprises a second step of providing a plug on the connection wires 38 of each heating element 36 and closing the mold 70 (Figure 6), such that each heating element 36 is received on the corresponding receiving surface 74A of the inner mold part 74, the mold parts 72, 74 being in the closed configuration with each connection wire 38 extending throught a plug 76 sealing a mold opening 72A.

[0126] The manufacturing method then comprises molding the support 60 in the mold cavity defined in the mold 70 with overmolding each heating element 76. The molding material of the support 60 is for example injected in the mold 70 via one or several feed. One or several feeds may be provided with being located on one or several of the mold parts for an appropriate feed of the mold material. One feed 72B formed in an outer mold part 72 is illustrated on Figures 5 and 6.

[0127] In an alternative embodiment in which the support 60 is compression molded, the material of the support is inserted in mold 70 in the open configuration and then closing the mold 70 whereby the material of the support 60 is shaped into the support 60 by being compressed between the mold parts 72, 74.

[0128] The manufacturing method then comprises opening the mold 70, with removing the plugs 76 from the connection wires 38 when such plugs 76 are provided, and, if necessary, bending each connection wire 38 between the proximal portion 38A and the distal portion 38B.

[0129] Owing to the invention, it is possible to provide a heating assembly 30 of an aerosol generating device 12 which can be manufactured easily with defining a heating chamber 32 and with a reliable mounting of each heating element 36 with an accurate positioning of each heating element 36 for efficient heating of a consumable article 16 inserted in the heating chamber 32.

Claims

CLAIMS1. Heating assembly for an aerosol generating device configured for operating a consumable article (16) containing an aerosol generating material for generating an aerosol when heated, the heating assembly comprising:- a heating chamber (32) for receiving a consumable article upon insertion of the consumable article in the aerosol generating device,- at least one heating element (36), each heating element (36) being configured for heating a consumable article received in the heating chamber (32), and- a support (62) supporting each heating element (36), wherein each heating element (36) is overmolded by the support (60), wherein the support (60) comprises two opposed walls (65), the chamber (32) being delimited between the two opposed walls (65), each wall (65) defining a respective internal surface (32A) of the chamber (32), wherein the heating assembly comprises one heating element (36) overmolded in one of the two opposed walls (65) or two heating elements (36), one respective heating element (36) being overmolded in each one of the two opposed walls (65) of the support (60).

2. Heating assembly as in claim 1 , wherein each heating element (36) is flat shaped.

3. Heating assembly as in claim 1 or 2, wherein each heating element (36) has a heating face (36A) parallel to an internal surface (32A) of the chamber (32).

4. Heating assembly as in any one of the preceding claims, wherein each heating element (36A) has a heating face (36A) flush with an internal surface( 32A) of the chamber (32).

5. Heating assembly as in any one of the preceding claims, comprising, for each heating element (36), a set of connection wires (38) for connecting the heating element (36) to an electric source.

6. Heating assembly as in claim 5, wherein the connection wires (38) of each set of connection wires (38) extend through the support (60), in particular through an opening (68) arranged in the support (60).

7. Heating assembly as in any one of the preceding claims, wherein the support (60) is made of a plastic material, in particular a polyaryl ether ketone or polyether ether ketone.

8. Heating assembly as in claim 10, wherein the plastic material is reinforced with fibers, in particular carbon fibers and / or nylon fibers.

9. Heating assembly as in any one of the preceding claims, wherein the support (60) is injection molded.

10. An aerosol generating device configured for operating a consumable article (16) comprising an aerosol generating material configured for generating an aerosol when heated, the aerosol generating device comprising a heating assembly (30) as in any one of the preceding claims, configured for heating the consumable article (16) received in the heating chamber (32) such as to generated an aerosol.

11. An aerosol generating system comprising an aerosol generating device as in claim 13 and a consumable article (16) comprising an aerosol generating material configured for generating an aerosol when heated, the a consumable article (16) being receivable in the heating chamber (32) of the heating assembly (30), the heating assembly (30) being configured for heating the consumable article (16) received in the heating chamber (32) such as to generate an aerosol.

12. A method of manufacturing a heating assembly (30) for an aerosol generating device, the heating assembly (30) comprising a heating chamber (32) for receiving a consumable article (16) containing an aerosol generating material configured for generating an aerosol when heated and at least one heating element (36), each heating element (36) being configured for heating a consumable article (16) received in the heating chamber (32), the manufacturing method comprising the step of molding a support (60) such that each heating element (36) is supported by the support (60) and overmolded by the support (60) wherein the support (60) comprises two opposed walls (65), the chamber (32) being delimited between the two opposed walls (65), each wall (65) defining a respective internal surface (32A) of the chamber (32), wherein the heating assembly comprises one heating element (36) overmolded in one of the two opposed walls (65) or two heating elements (36), one respective heating element (36) being overmolded in each one of the two opposed walls (65) of the support (60).

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