Aerosol-generating device having heater mounted on sealing member

Abstract

There is provided an aerosol-generating device (100) for use with an aerosol-generating article (1), the aerosol-generating device comprising: a housing (102) having a recess (108) configured to receive at least a portion of the aerosol-generating article (1); a heater assembly (120) comprising: a heater (121) configured to heat the aerosol-generating article (1) to generate an aerosol; and a sealing member (130) configured to seal at least a portion of the aerosol-generating article (1) within the recess (108) during aerosolisation; wherein the heater (121) is mounted on the sealing member (130); wherein the sealing member (130) comprises a sealing frame (130) having a perimetral structure surrounding an aperture (132), the sealing frame (130) being configured to seal a perimeter of the recess (108); wherein the heater extends across the aperture (132); and wherein the heater assembly (120) further comprises a clamping member (134) which is resiliently urged towards the sealing frame (130), the clamping member (134) being shaped such that at least a portion of the clamping member can enter the aperture (132) to urge the heater (121) towards the recess (108).

Description

[0001] AEROSOL-GENERATING DEVICE HAVING HEATER MOUNTED ON SEALING MEMBER

[0002] The present disclosure relates to an aerosol-generating device for use with an aerosolgenerating article. In particular, but not exclusively, the present disclosure relates to a handheld electrically operated aerosol-generating device for heating an aerosol-forming substrate to generate an aerosol and for delivering the aerosol into the mouth of a user.

[0003] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco containing substrate, is heated rather than combusted are known in the art. In heated aerosol-generating articles, the aerosol is generated by heating the aerosol-generating substrate.

[0004] One type of aerosol-generating system is an electrically operated smoking system. Known handheld electrically operated smoking systems typically comprise an aerosolgenerating device comprising a rechargeable battery, control electronics and an electric heater for heating an aerosol-generating article designed specifically for use with the aerosolgenerating device. In some examples, the aerosol-generating article comprises an aerosolgenerating substrate, such as a tobacco rod or a tobacco plug, and the heater contained within the aerosol-generating device is inserted into or is located around the aerosol-forming substrate when the aerosol-generating article is inserted into the aerosol-generating device.

[0005] A heating element may be provided in an aerosol-generating device for generating an inhalable vapor. Such a device may heat the aerosol-generating substrate contained in the aerosol-generating article without burning the aerosol-generating substrate. In doing so, the aerosol-generating substrate may generate an aerosol which may be delivered to a user.

[0006] Such aerosol-generating articles may take the form of a conventional cigarette. Where this is the case, the aerosol-generating substrate may be wrapped in cigarette paper. This approach may be appropriate where the aerosol-generating substrate comprises strands or spaghettis of material, for example strands of cast leaf tobacco or strands of shredded tobacco.

[0007] However, this approach may not effectively retain other forms of aerosol-generating substrate, such as granulated or powdered aerosol-generating substrate. Such aerosolgenerating articles may be prone to leakage of the aerosol-generating substrates during storage, handling and use thereof. Leakage of the aerosol-generating substrates may be exacerbated by high environmental temperatures and humidities. Loss of aerosol-generating substrates through leakage may disadvantageously reduce the lifespan of the aerosolgenerating article comprising the aerosol-generating substrate. Leakage of aerosolgenerating substrates may negatively impact the overall performance of the aerosolgenerating article. For example, leakage of aerosol-generating substrates may negatively impact the consistency of the inhalable aerosol generated by an aerosol-generating system comprising the aerosol-generating article.

[0008] In order to provide an aerosol-generating article in which loss or leakage of the aerosolgenerating substrate is reduced or prevented even when the aerosol-generating article is heated to the temperatures required to generate an aerosol from the aerosol-generating substrate, an aerosol-generating article comprising a container of aerosol-generating substrate may be provided. Such an aerosol-generating article may be able to retain different forms of aerosol-generating substrate, such as granulated or powdered aerosol-generating substrate. Such an aerosol-generating article comprising a container may be readily handled and manipulated by a consumer when it is being used in combination with a suitable aerosolgenerating device.

[0009] However, aerosol-generating devices of the prior art may not be suitable for heating aerosol-generating articles comprising a container of aerosol-generating substrate. For example, inserting a heating element into an aerosol-generating article comprising a container may disadvantageously cause the aerosol-generating substrate to leak out of the container. Furthermore, existing aerosol-generating devices may allow aerosol to leak out of the aerosolgenerating article via routes other than an aerosol outlet for delivering the aerosol to the user. In addition, existing heaters configured to externally heat aerosol-generating articles may not provide efficient heating sufficient to generate a consistent aerosol from an aerosol-generating article comprising a container.

[0010] It would be desirable to provide an aerosol-generating device that is suitable for heating aerosol-generating articles comprising a container of aerosol-generating substrate. It would also be desirable to provide an aerosol-generating device that reduces the leakage of aerosol during heating and provides improved heating of the aerosol-generating article.

[0011] According to an example of the present disclosure, there is provided an aerosolgenerating device for use with an aerosol-generating article. The aerosol-generating device may comprise a housing. The housing may have a recess configured to receive at least a portion of the aerosol-generating article. The aerosol-generating device may comprise a heater assembly. The heater assembly may comprise a heater configured to heat the aerosolgenerating article to generate an aerosol. The heater assembly may comprise a sealing member configured to seal at least a portion of the aerosol-generating article within the recess during aerosolization. The heater may be mounted on the sealing member.

[0012] According to an example of the present disclosure, there is provided an aerosolgenerating device for use with an aerosol-generating article. The aerosol-generating device comprises a housing having a recess configured to receive at least a portion of the aerosolgenerating article. The aerosol-generating device comprises a heater assembly. The heater assembly comprises a heater configured to heat the aerosol-generating article to generate an aerosol. The heater assembly also comprises a sealing member configured to seal at least a portion of the aerosol-generating article within the recess during aerosolization. The heater is mounted on the sealing member.

[0013] As used herein, the term “sealing member” refers to a component of the heater assembly that significantly reduces, or preferably substantially prevents, aerosol escaping from the recess during heating or aerosolization other than via a dedicated aerosol outlet. Airflow through the recess is still permitted during aerosolization provided it is a via a dedicated airflow pathway, for example, from an air inlet into the recess to an aerosol outlet from the recess.

[0014] An advantage of providing a heater assembly comprising a sealing member is that it is capable of sealing the recess during aerosolization and helps to reduce aerosol escaping from the recess during aerosolization. This retains more of the aerosol for consumption by a user and reduces the likelihood of aerosol leaking into and condensing in other parts of the aerosol-generating device, which may be undesirable.

[0015] An advantage of mounting the heater on the sealing member is that it helps to improve thermal contact between the heater and the aerosol-generating article during heating. This helps to improve heating of the aerosol-generating article, which leads to the generation of a more consistent aerosol and an enhanced user experience. It also improves the energy efficiency of the aerosol-generating device.

[0016] The at least a portion of the aerosol-generating article sealed by the sealing member may be a portion of the aerosol-generating article containing an aerosol-forming substrate. The at least a portion of the aerosol-generating article sealed by the sealing member may be a container or compartment of aerosol-generating article. The sealing member may seal around a rim of the aerosol-generating article. Alternatively, the sealing member may seal the entire aerosol-generating article within the recess.

[0017] The heater may be mounted on a surface of the sealing member facing the recess.

[0018] The heater may be resiliently mounted on the sealing member such that the heater is resiliently urged towards the recess. Advantageously, this arrangement helps to improve the thermal contact between the heater and an aerosol-generating article when an aerosolgenerating article is received in the recess.

[0019] The heater may be resiliently mounted on the sealing member by means of one or more biasing elements. The biasing element may be a spring, for example, a helical spring.

[0020] The sealing member may be resiliently mounted on the housing such that the heater is resiliently urged towards the recess. Advantageously, this arrangement helps to improve the sealing between the sealing member and the outer perimeter of the recess. The sealing member may be resiliently mounted on the housing by means of one or more biasing elements. The biasing element may be a spring, for example, a helical spring.

[0021] The sealing member may be configured to deform at least a portion of the aerosolgenerating article to seal the aerosol-generating article within the recess. Advantageously, by deforming at least a portion of the aerosol-generating article, the seal between the sealing member and recess may be improved. This arrangement allows any gaps between the aerosol-generating article and a perimeter of the recess to be closed.

[0022] The heater may protrude from the sealing member in a direction towards the recess to allow the heater to directly contact the aerosol-generating article. Advantageously, this arrangement helps to improve thermal contact between the heater and the aerosol-generating article because the protruding portion of the heater is compressed into the aerosol-generating article.

[0023] The heater may be integral to the sealing member. The sealing member and heater may be formed as a unitary component. Advantageously, this provides a secure and mechanically robust connection between the sealing member and heater. This arrangement reduces the part count for the heater assembly which simplifies manufacture.

[0024] The heater may be fixedly attached to the sealing member. Any suitable method of fixedly attaching the heater to the sealing member may be used. For example, the heater may be adhered to the sealing member. The heater may be pinned to the sealing member. The heater may be potted into the sealing member. The heater may be clamped into the sealing member.

[0025] The heater may be substantially planar or flat. In particular, a heating surface of the heater may be substantially planar or flat. As used herein, “substantially planar” or “substantially flat” means formed predominantly in a single plane, that is, the heater extends more in two orthogonal dimensions than it does in a third orthogonal dimension. Advantageously, a planar heater can be easily handled during manufacture. Furthermore, a planar heater allows for effective thermal contact with an aerosol-generating article having at least one flat or planar surface.

[0026] The sealing member may comprise a sealing frame having a perimetral structure surrounding an aperture. The sealing frame is configured to seal a perimeter of the recess. Advantageously, this arrangement is effective at sealing around the perimeter of the recess. Furthermore, the aperture can be used accommodate further components.

[0027] The heater may extend across the aperture. Advantageously, this arrangement allows the region within the perimetral structure of the sealing frame to be heated and can provide effective heating to an aerosol-generating article.

[0028] The heater assembly may further comprise a clamping member. The clamping member may be resiliently urged towards the sealing frame. The clamping member may be shaped such that at least a portion of the clamping member can enter the aperture to urge the heater towards the recess. Advantageous, by providing a clamping member which is resiliently biased towards the sealing frame, sealing of the recess can be improved. Furthermore, by urging the heater towards the recess, thermal contact between heater and an aerosol-generating article can be improved.

[0029] The clamping member may further comprise elastic elements. The elastic elements may be arranged on a surface of the clamping member face the heater. The elastic elements may be configured to contact the heater to apply additional compressive force to the heater and aerosol-generating article. The elastic elements may comprise elastic strips. The elastic elements may extend transversely to a longitudinal dimension of the heater. The elastic elements may be formed from any suitable heat resistant elastomer. The elastic elements may be formed from silicone.

[0030] The heater assembly may be moveable between a sealed position in which the sealing member seals the recess and an unsealed position in which the sealing member is spaced apart from the recess to allow an aerosol-generating article to be inserted or removed from the recess. Advantageously, this arrangement provides a convenient way to insert or remove an aerosol-generating article. Furthermore, this arrangement allows the heater assembly to be moved relative to the recess when the heater assembly is in the unsealed position.

[0031] The aerosol-generating device may comprise a mechanism for moving the heater assembly between the sealed position and unsealed position.

[0032] The housing may comprise a first housing portion and a second housing portion. The first housing portion may comprise the recess. The second housing portion may comprise the heater assembly. The first housing portion may be moveable relative to the second housing portion between an open position in which the recess is exposed and a closed position in which the recess is enclosed by the second housing portion.

[0033] The heater assembly may be moved into the sealed position when the first and second housing portions are moved to the closed position and the heater assembly is moved into the unsealed position when the first and second housing portions are moved to the open position. Advantageously, this provides a convenient way of moving the heater assembly between the sealed and unsealed positions.

[0034] The heater may comprise one or more electric heating elements. The heater may comprise a plurality of electric heating elements. The electric heating elements may comprise an electrically resistive material. Suitable electrically resistive materials include but are not limited to: semiconductors such as doped ceramics, electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys and composite materials made of a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and metals from the platinum group. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminium- titanium- zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, gold- and iron-containing alloys, and superalloys based on nickel, iron, cobalt, stainless steel, Timetai™, Kanthal™ and other iron- chromium-aluminium alloys, and iron-manganese-aluminium based alloys. In composite materials, the electrically resistive material may optionally be embedded in, encapsulated or coated with an insulating material or vice-versa, depending on the kinetics of energy transfer and the external physicochemical properties required. Alternatively, the electric heaters may comprise one or more infra-red heating elements, photonic sources, or inductive heating elements.

[0035] The one or more heating elements may be formed using a metal or metal alloy having a defined relationship between temperature and resistivity. Heating elements formed in this manner may be used to both heat and monitor the temperature of the heating element during operation.

[0036] The aerosol-generating device may further comprise a power supply or source for supplying power to the heater. The power supply may be any suitable power supply, for example a DC voltage source. In one embodiment, the power supply is a Lithium-ion battery. Alternatively, the power supply may be a Nickel-metal hydride battery, a Nickel cadmium battery, or a Lithium based battery, for example a Lithium-Cobalt, a Lithium-lron-Phosphate or a Lithium-Polymer battery.

[0037] The aerosol-generating device is preferably a handheld aerosol-generating device that is comfortable for a consumer to hold between the fingers of a single hand.

[0038] The aerosol-generating device may further comprise a controller or control circuitry configured to control a supply of electrical power to the heater assembly. The control circuitry may comprise a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, or an application specific integrated chip (ASIC) or other electronic circuitry capable of providing control. The control circuitry may comprise further electronic components. For example, in some embodiments, the control circuitry may comprise any of: sensors, switches, display elements. Power may be supplied to the heater assembly continuously following activation of the device or may be supplied intermittently, such as on a puff-by-puff basis. The power may be supplied to the heater assembly in the form of pulses of electrical current, for example, by means of pulse width modulation (PWM).

[0039] The second housing portion may comprise the power supply and control circuitry. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example polypropylene, polyetheretherketone (PEEK) and polyethylene. The material is preferably light and non-brittle.

[0040] The aerosol-generating device may comprise an air inlet. The aerosol-generating device may comprise an aerosol outlet. The air inlet may be in fluid communication with the aerosol outlet to define an airflow pathway through the aerosol-generating device. The recess may be arranged at a location along the airflow pathway such that the airflow pathway passes through at least a portion of the recess, the recess being in fluid communication with both the air inlet and the air outlet. The aerosol-generating device may comprise a mouthpiece. The aerosol outlet may be arranged in the mouthpiece.

[0041] The first housing portion may comprise the airflow pathway. The first housing portion may comprise a first airflow pathway between the air inlet and the recess. The first housing portion may comprise a second airflow pathway between the recess and the aerosol outlet. Alternatively, the second housing portion may comprise the air inlet and at least a portion first airflow pathway. The portion of the first airflow pathway in the second housing portion may be brought into sealing engagement with the airflow pathway through the first housing portion when the first and second housing portions are in the closed position.

[0042] The aerosol-generating device may comprise a puff detector for detecting when a user is taking a puff. The puff detector may comprise a pressure sensor. The puff detector may be arranged in fluid communication with the airflow pathway to detect a change in pressure when a user takes a puff.

[0043] According to another example of the present disclosure, there is provided an aerosolgenerating system. The aerosol-generating system may comprise an aerosol-generating device according to any of the above-described examples. The aerosol-generating system may comprise an aerosol-generating article.

[0044] According to another example of the present disclosure, there is provided an aerosolgenerating system comprising: an aerosol-generating device according to any of the abovedescribed examples; and an aerosol-generating article.

[0045] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-forming substrate that, when heated in an aerosol-generating device, releases volatile compounds that can form an aerosol. An aerosol-generating article is separate from and configured for combination with an aerosol-generating device for heating the aerosolgenerating article.

[0046] The aerosol-generating article may be configured to be received within the recess of the aerosol-generating device.

[0047] The aerosol-generating article may comprise a container, the container comprising a first wall and a second wall. The first wall and second wall may together define a substrate compartment. An aerosol-generating substrate may be provided in the substrate compartment.

[0048] The first wall may comprise a different material to the second wall. The first wall may comprise a flexible cellulosic material. The second wall may have a higher stiffness than the first wall. Alternatively, the first wall may have a higher stiffness than the second wall.

[0049] At least a portion of the first wall may be porous. As used herein with reference to the present invention, the term “cellulosic material” refers to a material which is made from or is a derivative of cellulose.

[0050] The first wall may comprise any cellulosic material. The first wall may comprise a nonwoven material.

[0051] As used herein with reference to the present invention, the term “non-woven” refers to a manufactured sheet, web or batt of directionally or randomly orientated fibres, bonded by friction, and / or cohesion and / or adhesion, excluding products which are woven, knitted, tufted, stitch-bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibres may be of natural or man-made origin.

[0052] The first wall may comprise a moulded paper material.

[0053] The second wall may be non-porous. The second wall may comprise a substantially planar material. The second wall may comprise a paper material.

[0054] The aerosol-generating substrate may comprise at least one alkaloid.

[0055] As used herein with reference to the present invention, the term “alkaloid compound” is used to describe any one of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Generally, an alkaloid contains at least one nitrogen atom in an amine-type structure. This or another nitrogen atom in the molecule of the alkaloid compound can be active as a base in acid-base reactions. Most alkaloid compounds have one or more of their nitrogen atoms as part of a cyclic system, such as for example a heterocylic ring. In nature, alkaloid compounds are found primarily in plants, and are especially common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and fungi. In the context of the present invention, the term “alkaloid compounds” is used to describe both naturally derived alkaloid compounds and synthetically manufactured alkaloid compounds. Suitable alkaloid compounds for use in an aerosolgenerating element in accordance with the invention include, but are not limited to, nicotine and anatabine.

[0056] In preferred embodiments, the aerosol-generating substrate comprises nicotine or anatabine.

[0057] In particularly preferred embodiments, the aerosol-generating substrate comprises nicotine.

[0058] As used herein, the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt. In embodiments in which the aerosol-generating substrate comprises a nicotine base or a nicotine salt, the amounts of nicotine recited herein are the amount of free base nicotine or amount of protonated nicotine, respectively.

[0059] The aerosol-generating substrate may comprise natural nicotine or synthetic nicotine.

[0060] The aerosol-generating substrate may comprise one or more monoprotic nicotine salts.

[0061] As used herein with reference to the invention, the term “monoprotic nicotine salt” is used to describe a nicotine salt of a monoprotic acid.

[0062] The aerosol-generating substrate may comprise nicotine.

[0063] The aerosol-generating substrate may comprise an aerosol-former. The aerosolgenerating substrate may contain any amount of aerosol-former. The aerosol-generating substrate may comprise at least 50 weight percent, at least 60 weight percent, or at least 70 weight percent aerosol-former. The aerosol-generating substrate may comprise about 80 weight percent aerosol-former.

[0064] The aerosol-generating substrate may comprise a polyhydric alcohol.

[0065] The polyhydric alcohol acts as the aerosol-former for the aerosol-generating substrate. Polyhydric alcohols suitable for use in the aerosol-generating substrate include, but are not limited to, propylene glycol, triethylene glycol, 1 ,3-butanediol, and glycerin. Preferably, in an aerosol-generating substrate in accordance with the invention the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, and combinations thereof. In particularly preferred embodiments the polyhydric alcohol is glycerin.

[0066] The aerosol-generating substrate may comprise granules. The granules may have any diameter. The aerosol-generating substrate may comprise granules with a diameter of greater than or equal to 100 micrometres, greater than or equal to 250 micrometres, or greater than or equal to 500 micrometres.

[0067] The aerosol-generating substrate may comprise granules with a diameter of less than or equal to 5 millimetres, less than or equal to 4 millimetres, or less than or equal to 3 millimetres.

[0068] The aerosol-generating substrate may comprise granules with a diameter of between 500 micrometres and 3 millimetres. The aerosol-generating substrate may comprise granules with a diameter of about 1 .5 millimetres.

[0069] The substrate compartment may contain any mass of aerosol-generating substrate. For example, the substrate compartment may contain at least 80 milligrams of aerosolgenerating substrate, at least 85 milligrams of aerosol-generating substrate, or at least 90 milligrams of aerosol-generating substrate.

[0070] The substrate compartment may contain at no more than 300 milligrams of aerosolgenerating substrate, no more than 250 milligrams of aerosol-generating substrate, or no more than 200 milligrams of aerosol-generating substrate.

[0071] The substrate compartment may contain between 80 milligrams and 300 milligrams of aerosol-generating substrate, between 85 milligrams and 250 milligrams of aerosol-generating substrate, and between 100 milligrams and 200 milligrams of aerosol-generating substrate.

[0072] Features described in relation to one of the above examples may equally be applied to other examples of the present disclosure.

[0073] The invention is defined in the claims. However, below there is provided a non- exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0074] Example Ex1 : An aerosol-generating device for use with an aerosol-generating article, the aerosol-generating device comprising: a housing having a recess configured to receive at least a portion of the aerosol-generating article; and a heater assembly comprising a heater configured to heat the aerosol-generating article to generate an aerosol.

[0075] Example Ex2: An aerosol-generating device according to Example Ex1 , wherein the heater assembly further comprises a sealing member configured to seal at least a portion of the aerosol-generating article within the recess during aerosolization.

[0076] Example Ex3: An aerosol-generating device according to Example Ex2, wherein the heater is mounted on the sealing member.

[0077] Example Ex4: An aerosol-generating device according to Example Ex3, wherein the heater is mounted on a surface of the sealing member facing the recess.

[0078] Example Ex5: An aerosol-generating device according to Example Ex3 or Ex4, wherein the heater is resiliently mounted on the sealing member such that the heater is resiliently urged towards the recess.

[0079] Example Ex6: An aerosol-generating device according to Example Ex5, wherein the heater is resiliently mounted on the sealing member by means of one or more biasing elements.

[0080] Example Ex7: An aerosol-generating device according to any of Examples Ex2 to Ex6, wherein the sealing member is resiliently mounted on the housing such that the heater is resiliently urged towards the recess.

[0081] Example Ex8: An aerosol-generating device according to Example Ex7, wherein the sealing member is resiliently mounted on the housing by means of one or more biasing elements.

[0082] Example Ex9: An aerosol-generating device according to any of Examples Ex6 to Ex8, wherein the biasing element comprises a spring.

[0083] Example Ex10: An aerosol-generating device according to any of Examples Ex2 to Ex9, wherein the sealing member is configured to deform at least a portion of the aerosolgenerating article to seal the aerosol-generating article within the recess.

[0084] Example Ex11 : An aerosol-generating device according to any preceding example, wherein the heater protrudes from the sealing member towards the recess to allow the heater to directly contact the aerosol-generating article.

[0085] Example Ex12: An aerosol-generating device according to any preceding example, wherein the heater is integral to the sealing member.

[0086] Example Ex13: An aerosol-generating device according to any of Examples Ex2 to Ex11 , wherein the heater is fixedly attached to the sealing member.

[0087] Example Ex14: An aerosol-generating device according to Example Ex13, wherein the heater is adhered to the sealing member.

[0088] Example Ex15: An aerosol-generating device according to Example Ex13, wherein the heater is pinned to the sealing member.

[0089] Example Ex16: An aerosol-generating device according to Example Ex13, wherein the heater is potted into the sealing member.

[0090] Example Ex17: An aerosol-generating device according to Example Ex13, wherein the heater is clamped into the sealing member.

[0091] Example Ex18: An aerosol-generating device according to any preceding example, wherein the heater is substantially planar.

[0092] Example Ex19: An aerosol-generating device according to any preceding example, wherein the sealing member comprises a sealing frame having a perimetral structure surrounding an aperture, the sealing frame being configured to seal a perimeter of the recess.

[0093] Example Ex20: An aerosol-generating device according to Example Ex19, wherein the heater extends across the aperture.

[0094] Example Ex21 : An aerosol-generating device according to Example Ex20, wherein the heater assembly further comprises a clamping member, the clamping member being resiliently urged towards the sealing frame.

[0095] Example Ex22: An aerosol-generating device according to Example Ex21 , wherein the clamping member is shaped such that at least a portion of the clamping member can enter the aperture to urge the heater towards the recess.

[0096] Example Ex23: An aerosol-generating device according to Example Ex21 or Ex22, wherein the clamping member further comprises at least one elastic element arranged on a surface of the clamping member facing the heater, the at least one elastic element being configured to contact the heater to apply additional compressive force to the heater and aerosol-generating article.

[0097] Example Ex24: An aerosol-generating device according to Example Ex23, wherein the at least one elastic element comprises a plurality of elastic strips.

[0098] Example Ex25: An aerosol-generating device according to Example Ex23 or Ex24, wherein the at least one elastic element extends transversely to a longitudinal dimension of the heater.

[0099] Example Ex26: An aerosol-generating device according to any of Examples Ex23 to Ex25, wherein the at least one elastic element is formed from silicone.

[0100] Example Ex27: An aerosol-generating device according to any preceding example, wherein the heater assembly is moveable between a sealed position in which the sealing member seals the recess and an unsealed position in which the sealing member is spaced apart from the recess to allow an aerosol-generating article to be inserted or removed from the recess.

[0101] Example Ex28: An aerosol-generating device according to any preceding example, wherein the housing comprises a first housing portion and a second housing portion, the first housing portion comprising the recess and the second housing portion comprising the heater assembly.

[0102] Example Ex29: An aerosol-generating device according to Example Ex28, wherein the first housing portion is moveable relative to the second housing portion between an open position in which the recess is exposed and a closed position in which the recess is enclosed by the second housing portion.

[0103] Example Ex30: An aerosol-generating device according to Example Ex29, wherein the heater assembly is moved into the sealed position when the first and second housing portions are moved to the closed position and the heater assembly is moved into the unsealed position when the first and second housing portions are moved to the open position.

[0104] Example Ex31 : An aerosol-generating device according to any preceding example, wherein the aerosol-generating device comprises an air inlet and an aerosol outlet, the air inlet being in fluid communication with the aerosol outlet to define an airflow pathway through the aerosol-generating device.

[0105] Example Ex32: An aerosol-generating device according to Example Ex31 , wherein the recess is arranged at a location along the airflow pathway such that the airflow pathway passes through at least a portion of the recess, the recess being in fluid communication with both the air inlet and the air outlet. Example Ex33: An aerosol-generating device according to Example Ex31 or Ex32, further comprising a mouthpiece, the aerosol outlet being arranged in the aerosol outlet.

[0106] Example Ex34: An aerosol-generating device according to any of Examples Ex31 to Ex33, wherein the first housing portion comprises the airflow pathway.

[0107] Example Ex35: An aerosol-generating device according to Example Ex34, wherein the first housing portion comprises a first airflow pathway between the air inlet and the recess.

[0108] Example Ex36: An aerosol-generating device according to Example Ex35, wherein the first housing portion comprises a second airflow pathway between the recess and the aerosol outlet.

[0109] Example Ex37: An aerosol-generating device according to Example Ex31 or Ex32, wherein the second housing portion comprises the air inlet and at least a portion first airflow pathway.

[0110] Example Ex38: An aerosol-generating device according to Example Ex37, wherein the portion of the first airflow pathway in the second housing portion is brought into sealing engagement with the airflow pathway through the first housing portion when the first and second housing portions are in the closed position.

[0111] Example Ex39: An aerosol-generating device according to any of Examples Ex31 to Ex39, further comprises a puff detector for detecting when a user is taking a puff.

[0112] Example Ex40: An aerosol-generating device according to Example Ex39, wherein the puff detector comprises a pressure sensor, the pressure sensor being arranged in fluid communication with the airflow pathway to detect a change in pressure when a user takes a puff.

[0113] Example Ex41 : An aerosol-generating system comprising: an aerosol-generating device according to any of the preceding examples; and an aerosol-generating article.

[0114] Example Ex42: An aerosol-generating system according to Example Ex41 , wherein the aerosol-generating article comprises a container, the container comprising a first wall and a second wall, the first wall comprising a different material to the second wall, the first wall and second wall together defining a substrate compartment, and an aerosol-generating substrate provided in the substrate compartment, wherein the first wall comprises a flexible cellulosic material, and wherein the second wall has a higher stiffness than the first wall.

[0115] Examples will now be further described with reference to the figures in which:

[0116] Figure 1 is a side cross-sectional view of an aerosol-generating article to be used with an aerosol-generating device according to the present disclosure.

[0117] Figure 2A is a schematic cross-sectional view of an aerosol-generating device according to an example of the present disclosure, in a open position and about to receive an aerosol-generating article; Figure 2B shows a schematic cross-sectional view of the aerosol-generating device of Figure 2A and the aerosol-generating article, in a closed position;

[0118] Figures 3A to 3C are perspective views of an example heater assembly for an aerosolgenerating device according to the present disclosure showing the heater assembly in progressive stages of assembly;

[0119] Figure 4 shows a partial longitudinal cross-sectional view of the aerosol-generating device 100 of Figure 2B in the region of the heater assembly and showing the heater assembly in more detail;

[0120] Figure 5A is a partial longitudinal cross-sectional view of another example heater assembly for an aerosol-generating device according to the present disclosure;

[0121] Figure 5B is perspective view of the heater assembly of Figure 5A showing the features of the heater and elastic strips and with other features removed for clarity;

[0122] Figures 6A to 6D are schematic cross-sectional views of different mechanisms for engaging a heater assembly with an aerosol-generating article for an aerosol-generating device according to the present disclosure;

[0123] Figures 7A and 7B are schematic cross-sectional views of another example heater assembly for an aerosol-generating device according to the present disclosure showing the heater assembly in an unsealed and sealed position respectively;

[0124] Figures 8A and 8B are schematic cross-sectional views of another example heater assembly for an aerosol-generating device according to the present disclosure showing the heater assembly in an unsealed and sealed position respectively;

[0125] Figures 9A to 9F are schematic cross-sectional views of example heater assemblies for an aerosol-generating device according to the present disclosure showing different ways in which the heater can be coupled to the sealing frame.

[0126] The terms ‘“distal”, “proximal”, “upstream” and “downstream” are used herein to describe the relative positions of components, or portions of components, of an aerosolgenerating device or system. Aerosol generating devices or systems according to the present disclosure have a proximal end through which, in use, an aerosol exits the article or device for delivery to a user, and have an opposing distal end. The proximal end of the aerosol generating device or system may also be referred to as the mouth end. In use, a user draws on the proximal end of the aerosol generating device or system in order to inhale an aerosol generated by the aerosol generating device or system. The terms upstream and downstream are relative to the direction of airflow or aerosol movement through the aerosol generating device or system when a user draws on the proximal end of the aerosol-generating device or system. The proximal end of the aerosol-generating device or system is downstream of the distal end of the aerosol-generating device or system. Referring to Figure 1 , there is shown an aerosol-generating article 1 for use with an aerosol-generating device of the present disclosure. The aerosol-generating article 1 comprises a container 10. The container 10 comprises a first wall 6 and a second wall 2, which together define a substrate compartment 4. An aerosol-forming substrate 8 is provided in the substrate compartment 4.

[0127] In the example shown in Figure 1 , the first wall 6 is formed from a non-woven cotton material. The first wall 6 comprises between 80 weight percent and 90 weight percent cellulose, between 7 weight percent and 16 weight percent hemicellulose, and between 1 weight percent and 3 weight percent lignin. The first wall 6 is porous.

[0128] The second wall 2 comprises paper having a grammage of about 35 gsm. The second wall 2 is non-porous.

[0129] The second wall 2 is substantially planar. The second wall 2 has a higher stiffness than the first wall 6. In this way, the first wall 6 may generally take the form of a bag that is closed by the second wall 2. The area of the second wall 2 is larger than the cross-sectional area of the bag formed by the first wall 6 in the same plane such that the edges of the second wall 2 extend beyond the edges of the bag to form a rim 2a. The first wall 6 is adhered to the rim 2a of the second wall 2 using a suitable adhesive.

[0130] An aerosol-forming substrate 8 is provided in the substrate compartment 4. The aerosol-forming substrate 8 comprises granules of homogenised tobacco material, and an aerosol-former. The aerosol-former comprises glycerine. The substrate compartment 4 contains about 150 milligrams of aerosol-forming substrate 714.

[0131] Figure 2A shows a schematic cross-sectional view of an aerosol-generating device 100 according to an example of the present disclosure. The device 100 comprises a housing 102 having a first housing portion 102a and a second housing portion 102b. A sliding mechanism 104 connects the first housing portion 102a to the second housing portion 102b and is configured to allow sliding movement of the first housing portion 102a relative to the second housing portion 102b parallel to a longitudinal axis of the aerosol-generating device between a closed position and an open position. In the example of Figure 2A, the aerosolgenerating device 100 is shown in an open position. The sliding mechanism 104 is provided by a slide rail 106 arranged on the first housing portion 102a and a corresponding slide groove (not shown) provided on the second housing portion 102b.

[0132] The aerosol-generating device 100 is intended for use with an aerosol-generating article such as the aerosol-generating article 1 of Figure 1. The first housing portion 102a comprises a recess 108 for receiving the aerosol-generating article 1. In the open position of the aerosol-generating device, the recess 108 is exposed to allow for the aerosol-generating article 1 to be placed into the recess 108. In Figure 2A, the aerosol-generating article 1 is shown above the recess 108 about to be placed into the recess 108. The aerosol-generating article 1 is placed into the recess 108 such that the substrate compartment 4 is received within the recess 108 and the rim 2a of the second wall 2 of the aerosol-generating article 1 engages or rests on an upper perimeter of the recess 108.

[0133] The first housing portion 102a comprises a device air inlet 110. A first airflow pathway 112 connects the device air inlet 110 to a recess air inlet 113 arranged in a first side of the recess 108. The first airflow pathway 112 allows air to flow from the device air inlet 110 to the recess air inlet 113 and into the recess 108. A second airflow pathway 114 is arranged between a recess aerosol outlet 115 arranged in a second side of the recess 108 and a device aerosol outlet 116 arranged at a downstream or proximal end of the aerosol-generating device 100. The second airflow pathway 114 allows aerosol to leave the recess 108 via the recess aerosol outlet 115 and flow to the device aerosol outlet 116.

[0134] A mouthpiece 118 is provided at a downstream or proximal end of the first housing portion 102a, which corresponds to the downstream or proximal end of the aerosol-generating device 100. In the example of Figure 2A, the mouthpiece 1118 is integral with the first housing portion 102a. However, it will be appreciated that the mouthpiece 118 could alternatively be removably attachable to the first housing portion 102b.

[0135] The second housing portion 102b comprises a heater assembly 120 configured to heat the aerosol-generating article 1 when it is received in the recess 108. The heater assembly 120 comprises a heater 121 for heating the aerosol-generating article 1. The heater 121 may comprises one or more heating elements (not shown). In the open position of the aerosolgenerating device, as shown in Figure 2A, the heater assembly 120 is spaced apart from the recess 108 such that it is disengaged from the recess 108. In this position, the heater assembly 120 is in an unsealed position and the recess 108 is open. The heater assembly 120 cannot be activated in this position.

[0136] The second housing portion 102b further comprises a power supply 122 and a controller 124, which are electrically connected to the heater assembly 120. The power supply 122 is configured to supply power to the heater assembly 120, while the controller 124 is configured to control the supply of power. The second housing portion 102b also comprises a pressure sensor 126 for detecting airflow through the first airflow pathway 112. The pressure sensor 126 is also electrically connected to the controller 124 and the controller 124 is configured to activate the heater assembly 120 in response to a signal received from the pressure sensor 126. It will be appreciated that the heater assembly could be activated by means other than a pressure sensor, for example, an alternative sensor or a simple push button that is activated by a user.

[0137] Figure 2B shows a schematic cross-sectional view of the aerosol-generating device 100 of Figure 2A, in a closed position having received the aerosol-generating article 1 in the recess 108. The aerosol-generating device 100 in combination with the aerosol-generating article 1 may together be referred to as an aerosol-generating system.

[0138] In the closed position of the aerosol-generating device 100, the second housing portion 102b covers the recess 108 and helps to maintain the aerosol-generating article 1 within the aerosol-generating device 100. In this position, the heater assembly 120 is in a sealed position in which the heater assembly 120 seals the recess 108 by engaging the perimeter of the recess 108. The heater 121 is substantially planar and is located or mounted on a surface of the heater assembly facing the recess 108 and the aerosol-generating article 1. In the closed position of the aerosol-generating device 100, the heater 121 is engaged with or contacts the planar second wall 2 of the aerosol-generating article 1. In this position, the aerosolgenerating device 100 is configured to heat the aerosol-generating article 70.

[0139] In the closed position of the aerosol-generating device 100, the pressure sensor 126 is arranged adjacent to the first airflow pathway 112 so that it is able to detect airflow through the first airflow pathway 112. In particular, the pressure sensor 126 is configured to detect a drop in air pressure in the first airflow pathway 112 caused by a user puffing or inhaling on the mouthpiece 118. It will be appreciated that the pressure sensor 126 may alternatively be located in the first housing portion 102a. It will also be appreciated that the device air inlet 110 and first airflow pathway 112 could be arranged in the second housing portion 102b adjacent the pressure sensor 126. In this arrangement, the first airflow pathway 112 would be brought into fluid communication with the airflow pathway through the first housing portion 102a when the aerosol-generating device is in the closed position.

[0140] Before use and between uses of the aerosol-generating device 100, the user may keep the aerosol-generating device 100 in the closed position. To use the aerosol-generating device 100, the user moves the first housing portion 102a relative to the second housing portion 102b from the closed position, in which the recess 108 is closed by the second housing portion 102b, to the open position shown in Figure 2A, in which the recess 108 is open for insertion of the aerosol-generating article 1 . The user can then insert an aerosol-generating article 1 into the recess 108. The user then moves the first housing portion 102a relative to the second housing portion 102b from the open position to the closed position shown in Figure 2B, in which the recess 108 is closed by the second housing portion 102b. The aerosol-generating device 100 is then ready for use.

[0141] In use, a user places the mouthpiece 118 of the aerosol-generating device 100 between their lips and takes a puff or inhalation. Air is drawn into the device air inlet 110 and through the first airflow pathway 112, which airflow is detected by the pressure sensor 126. In response to a signal from the controller 124, electrical power from the power supply 122 is supplied to the heater 121 of the heater assembly 120 such that an electrical current passes through the heater 121 and heating the heater 121. Heat is transferred to the aerosolgenerating article 1 and the aerosol-generating substrate contained therein causing volatile compounds to be vaporised and released from the aerosol-generating substrate.

[0142] Whilst the user continues to puff or inhale on the mouthpiece 118, air is drawn from the first airflow pathway 112 into the recess 108. The air passes through the porous first wall of the aerosol-generating article 1 and through the aerosol-generating substrate. As the air passes through the aerosol-generating substrate, volatile compounds generated by the heating of the aerosol-generating substrate become entrained in the airflow. The airflow leaves the recess 108 via the recess aerosol outlet 115 and passes into the second airflow pathway 114 towards the device aerosol outlet 116. As the air flows from the recess 108 towards the device aerosol outlet 116, the volatile compounds cool to form an aerosol which is then delivered into the mouth of the user.

[0143] Figures 3A to 3C show perspective views of an example heater assembly 120 for the aerosol-generating device 100 of Figures 2A and 2B in progressive stages of assembly. The heater assembly 120 comprises a heater 121 , a sealing member 130 and a clamping member 134.

[0144] Figure 3A shows the heater 121 of the heater assembly 120. The heater 121 comprises a plurality of heating elements 121a made from an electrically resistive material, which is also elastic so that the plurality of heating elements 121a can be deformed and return to original shape.

[0145] Figure 3B shows the heater 121 assembled to the sealing member 130. In the example of Figure 3B, the sealing member 130 comprises a sealing frame 130 having a perimetral structure surrounding an aperture 132. The sealing frame 130 is configured to seal a perimeter of the recess 108 of the aerosol-generating device 100 and is dimensioned to be larger than the opening of the recess 108. The aperture 132 is substantially the same size and shape as the opening of the recess 108 and is positioned in the sealing frame 130 to align with the opening of the recess 108. The heater 121 rests on the sealing frame 130 and the plurality of heating elements 121a extend across the aperture 132. The plurality of heating elements 121a are shaped to conform to the longitudinal profile of the sealing frame 130 and extend down into and across the aperture 132. The sealing frame 130 provides mechanical support to the heater 121. The sealing frame 130 is made from an electrically insulating and heat resistant material such as polyetheretherketone (PEEK).

[0146] Figure 3C shows the clamping member 134 assembled to the heater assembly 120 on top of the sealing frame 130. The clamping member 134 is configured to seal around an upper perimeter of the aperture 132 formed in the sealing frame 130 and is dimensioned to be larger than the aperture 132. Springs 136 are arranged in blind bores formed in the upper surface of the clamping member 134. The other end of the springs 136 are configured to engage the second housing portion 102b of the aerosol-generating device 100 of Figures 2A and 2B. The springs 136 are configured to resiliently urge the heater assembly 120 towards the recess 108 in the first housing portion 102a when the aerosol-generating device 100 is in the closed position. The springs 136 exert pressure on the clamping member 134, which in turn exert pressure on the sealing frame 130 and heater 120 to seal the sealing frame 130 around the perimeter of the recess 108 and ensure effective thermal contact between the heater 120 and the aerosol-generating article 1.

[0147] Figure 4 shows a partial longitudinal cross-sectional view of the aerosol-generating device 100 of Figure 2B in the region of the heater assembly 120 in more detail. As in Figure 2B, the aerosol-generating device 100 is in the closed configuration in which the second housing portion 102b closes the recess 108 arranged in the first housing portion 102a. The heater assembly 120 is of the same construction as the heater assembly 120 shown in Figure 3C and comprises a heater 121 , a frame member 130 and a clamping member 134.

[0148] The springs 136 arranged between the clamping member 134 and second housing portion 102b resiliently urge the clamping member 134 towards the heater 121 and sealing frame 130 and resiliently urge the heater assembly 120 towards the recess 108. The outer region 134a of the clamping member 134 is arranged to engage an inner region 130a of the frame member 130 surrounding aperture 132. This forms a seal around the aperture 132 and also urges the frame member 130 into engagement with the first housing portion 102a to seal around the perimeter of the recess 108. The clamping member 134 has a protruding portion 134b that extends towards the recess 108 and is adapted to enter the aperture 132 to urge the heater 121 towards the recess 108 to ensure good thermal contact between the heater 121 and the aerosol-generating article (not shown).

[0149] The clamping member 134 may be provided with a feed-through 138 and a cavity 140 for holding a temperature sensor (not shown). The temperature sensor can be used to monitor the temperature of the heater 121 to ensure effective heating of the aerosol-generating article. The movement of the heater assembly 120 may be guided by pins (not shown) arranged in bores 142 form in the second housing portion 102b. In addition, the aerosol-generating device 100 may be provide with a mechanism such as a cam mechanism (not shown), which lifts the heater assembly 120 away from the recess 108 against the action of the springs 136 when the second housing portion 102b is moved into the open position.

[0150] Figure 5A is a partial longitudinal cross-sectional view of another example heater assembly 220 for an aerosol-generating device such as that illustrated in Figure 2A and 2B. The construction of heater assembly 220 is identical to that of the heater assembly 120 illustrated in Figure 4 with the exception that heater assembly 220 has two elastic strips 222 at the bottom of the clamping member 234. The elastic strips 222 are arranged between the bottom of the clamping member 234 and the heater 221. The elastic strips 222 are configured to apply additional compressive force to the heater 221 and the aerosol-generating article (not shown) when an aerosol-generating article is located in the recess (not shown). The elastic strips 222 are formed from a heat resistant elastomer such as silicone.

[0151] Figure 5B is a perspective view of the heater assembly 220 of Figure 5A showing the features of the heater 221 and elastic strips 222 and with the other features removed for clarity. The elastic strips 222 extend transversely across the plurality of heating elements 221a of the heater 221 to urge all of the heating elements 221a into contact with an underlying aerosolgenerating article (not shown).

[0152] Figures 6A to 6D are schematic cross-sectional views of different mechanisms for engaging a heater assembly with an aerosol-generating article in an aerosol-generating device. In each of Figures 6A to 6D, the lefthand figure shows the heater assembly in a disengaged or unsealed position, in which the sealing member is disengaged from or spaced apart from the recess, and the righthand figure shows the heater assembly having moved a distance Ax into an engaged or sealed position, in which the sealing member seals the recess. In each of Figures 6A to 6D, like reference numerals have been used to refer to like components.

[0153] The movement through distance Ax may be provided by a mechanism (not shown) which moves the heater assembly between the sealed and unsealed positions, for example, when first and second housing portions of the aerosol-generating device of Figures 2A and 2B are moved between the closed and open positions respectively. Although the heater assembly is shown located directly over the recess in each of the lefthand figures of Figures 6A to 6D, it will be appreciated that in practice the heater assembly could be laterally spaced apart from recess, for example, when the aerosol-generating device is in the open position, to permit insertion of an aerosol-generating article.

[0154] The aerosol-generating article in Figures 6A to 6D has the same construction as the aerosol-generating article 1 of Figure 1. The sealing member in Figures 6A to 6D can have the same construction as the sealing member in Figure 3B, that is, a sealing frame 130 with an aperture 132. Alternatively, the sealing member in Figures 6A to 6D could have a solid constructions, for example, a sealing plate.

[0155] Referring to Figure 6A, this shows a heater assembly 300a comprising a heater 302 and a sealing member 304. The sealing member 304 is resiliently mounted by means of a first spring 306 on a portion of the device housing (not shown), for example, the second housing portion 102b of Figures 2A and 2B. The first spring 306 is configured to resiliently urge the sealing member 304 towards an aerosol-generating article 1 located in a recess 308 formed in a second housing portion 310. The heater 302 is substantially planar. The heater 302 is resiliently mounted by means of a second spring 312 on the sealing member 304, in particular, the lower surface of the sealing member facing the recess 308. The second spring 312 is configured to resiliently urge the heater 302 towards the aerosol-generating article 1 located in the recess 308. In the lefthand figure of Figure 6A, the first 306 and second 312 springs are shown in their uncompressed states.

[0156] In the righthand figure of Figure 6A, in which the heater assembly 300a has been moved through distance Ax, the first 306 and second 312 springs are shown in their compressed states in which they are exerting a force on the sealing member 304 and heater 302 respectively. The force exerted by each of the first 306 and second 312 springs is proportional to distance by which each of the springs has been compressed. The first spring 306 forces the sealing member 304 downwards so that a downwardly protruding rim of the sealing member 304 seals the perimeter of the recess 308. In sealing the recess 308, the rim 2a of the planar second wall of the aerosol-generating article 1 is clamped between the downwardly protruding rim of the sealing member and the perimeter of the recess 308. The second spring 312 forces the heater 302 downwards to ensure good contact between the heater 302 and the aerosol-generating article 1.

[0157] Figure 6B shows another heater assembly 300b, which has a similar construction to the heater assembly 300a in Figure 6A in that the sealing member 304 is resiliently mounted by means of a spring 306. However, the heater 302 is not spring-loaded but is instead rigidly mounted or fixed to the sealing member 304. The heater 302 is mounted so that it protrudes below the sealing member 304, that is, it protrudes in a direction towards the recess to allow the heater 302 to contact the aerosol-generating article 1. In the lefthand figure of Figure 6B, the first springs 306 is shown in its uncompressed state.

[0158] In the righthand figure of Figure 6B, in which the heater assembly 300b has been moved through distance Ax, the spring 306 is shown in its compressed state in which it is exerting a force on the sealing member 304 and heater 302. In sealing the recess 308, the rim 2a of the planar second wall of the aerosol-generating article 1 is clamped between the downwardly protruding rim of the sealing member and the perimeter of the recess 308. The aerosol-generating article 1 is configured to be compressible and to deform to ensure good contact between the heater 302 and the aerosol-generating article 1.

[0159] Figure 6C shows another heater assembly 300c, which has a similar construction to the heater assembly 300a in Figure 6A in that the heater 302 is resiliently mounted by means of a spring 312 on the sealing member 304. However, the sealing member 304 is not spring- loaded but is instead rigidly mounted or fixed to a mechanism (not shown) for moving the heater assembly from the unsealed position to the sealed position. The spring 312 is configured to resiliently urge the heater 302 towards the aerosol-generating article 1 located in the recess 308. In the lefthand figure of Figure 6A, the spring 312 is shown in its uncompressed state.

[0160] In the righthand figure of Figure 6C, in which the heater assembly 300c has been moved through distance Ax, the spring 312 is shown in its compressed state in which it is exerting a force on the heater 302 to urge the heater into contact with the aerosol-generating article 1. In sealing the recess 308, the rim 2a of the planar second wall of the aerosolgenerating article 1 is clamped between the downwardly protruding rim of the sealing member and the perimeter of the recess 308. An effective seal is provided by the rim 2a of the planar second wall of the aerosol-generating article 1 which is configured to be deformable and to deform when the sealing member 304 is brought into engagement to seal between the rim of the recess and the rim of the sealing member 304.

[0161] Figure 6D shows another heater assembly 300d. In the heater assembly 300d, neither the sealing member 304 nor the heater 302 are spring-loaded. Instead, the sealing member 304 is rigidly mounted or fixed to a mechanism (not shown) for moving the heater assembly from the unsealed position to the sealed position. The heater 302 is rigidly mounted or fixed to the sealing member 304 such that it protrudes below the sealing member 304, that is, it protrudes in a direction towards the recess 308 to allow the heater 302 to contact the aerosolgenerating article 1.

[0162] In the righthand figure of Figure 6D, the heater assembly 300d has been moved through distance Ax towards the recess 308. In sealing the recess 308, the rim 2a of the planar second wall of the aerosol-generating article 1 is clamped between the downwardly protruding rim of the sealing member and the perimeter of the recess 308. An effective seal is provided by the rim 2a of the planar second wall of the aerosol-generating article 1 which is configured to be deformable and to deform when the sealing member 304 is brought into engagement to seal between the rim of the recess and the rim of the sealing member 304. The aerosol-generating article 1 is configured to be compressible and to deform to ensure good contact between the heater 302 and the aerosol-generating article 1.

[0163] Figures 7A and 7B are schematic cross-sectional views of another example heater assembly 400 for an aerosol-generating device showing the heater assembly 400 in an unsealed and sealed position respectively. Referring to Figure 7A, the heater assembly 400 comprises a heater 402 and a sealing member 404. In the unsealed position of Figure 7A, the sealing member 404 is disengaged from or spaced apart from a recess 408 arranged in a housing 410 of the aerosol-generating device. An aerosol-generating article 1 is located in the recess 408. The aerosol-generating article in Figures 7A and 7B has the same construction as the aerosol-generating article 1 of Figure 1.

[0164] The sealing member 404 has a rim 404a that extends downward towards the underlying recess 408. The heater 402 is integrated within the sealing member 404 such that the lower surface of the heater 402 is arranged above the downwardly facing edge of the rim 404a. The heater 402 extends across the gap between opposing sides of the rim 404a. Each end of the heater 402 is embedded in its respective side the rim 404a.

[0165] Figure 7B shows the heater assembly 400 in a sealed position, in which the sealing member 404 seals the recess 408. In sealing the recess 408, the rim 2a of the planar second wall 2 of the aerosol-generating article 1 is clamped between the downwardly protruding rim 404a of the sealing member 404 and the perimeter of the recess 408. The rim 2a of the planar second wall 2 of the aerosol-generating article 1 is sufficiently malleable to deform downwards under pressure such that the remainder of the second wall 2 overlying the substrate compartment 4 of the aerosol-generating article 1 extends into the gap between opposing sides of the rim 404a to contact the heater 402. Thus, this arrangement allows the heater 402 to be integrated within the sealing member 404.

[0166] Figures 8A and 8B are schematic cross-sectional views of another example heater assembly 500 for an aerosol-generating device showing the heater assembly 500 in an unsealed and sealed position respectively. Referring to Figure 8A, the heater assembly 500 comprises a heater 502 and a sealing member 504. In the unsealed position of Figure 8A, the sealing member 504 is disengaged from or spaced apart from a recess 508 arranged in a housing 510 of the aerosol-generating device. An aerosol-generating article 1 is located in the recess 508. The aerosol-generating article in Figures 8A and 8B has the same construction as the aerosol-generating article 1 of Figure 1.

[0167] The sealing member 504 has a rim 504a that extends downward towards the underlying recess 508. The heater 502 is mounted within the rim 504a on a pair of supports 504b that extend from the lower surface of the sealing member 504. The supports 504b are of such a length that the lower surface of the heater just protrudes below the downwardly facing edge of the rim 504a.

[0168] Figure 8B shows the heater assembly 500 in a sealed position, in which the sealing member 504 seals the recess 508. In sealing the recess 508, the rim 2a of the planar second wall 2 of the aerosol-generating article 1 is clamped between the downwardly protruding rim 504a of the sealing member 504 and the perimeter of the recess 408. The remainder of the second wall 2 overlying the substrate compartment 4 of the aerosol-generating article 1 is sufficiently malleable to deform downwards under the pressure exerted by the downwardly protruding heater 502. This provides for effective thermal contact between the heater 502 and the substrate compartment. Figures 9A to 9F are schematic cross-sectional views of example heater assemblies for an aerosol-generating device showing different ways in which the heater can be coupled to the sealing frame.

[0169] Figure 9A shows a heater assembly 600a in which the sealing member and heater are formed as a unitary component. Thus, the heater is integral to the sealing member. The heater assembly 600a is formed from a material that has both the requisite electrical conductivity characteristics and mechanical strength to perform both the function of heater and sealing member respectively.

[0170] Figure 9B shows a heater assembly 600b in which the heater 602 is adhered to the sealing member 604. The heater 602 is mounted on a series of supports 604b protruding from the lower surface of the sealing member 604. Adhesive 603 is applied at the interface between the supports 604b and the heater 602. Any suitable heat resistant adhesive may be used.

[0171] Figure 9C shows a heater assembly 600c in which the heater 602 is pinned to the sealing member 604. The heater 602 is mounted on a series of supports 604b protruding from the lower surface of the sealing member 604. Pins 605 are used to attach the heater 602 to each of the supports 604b. The heater 602 has an aperture for each of the pins 605.

[0172] Figure 9D shows a heater assembly 600d in which the heater 602 is potted into the sealing member 604. The sealing member 604 comprises a wall 607 that extends downwardly from its lower surface and surrounds a cavity for receiving the heater 602. An insulating material 609 is deposited into the cavity and the heater 602 is arranged in the insulating material 609 such that the upper and side surfaces of the heater 602 are encapsulated in the insulating material 609. The lower surface of the heater 602 is left exposed for heating. Any suitable insulating material may be used, which may be both thermally and electrically insulating.

[0173] Figure 9E shows a heater assembly 600e in which the heater 602 is clamped into the sealing member 604. The sealing member 604 comprises a wall 607 that extends downwardly from its lower surface and surrounds a cavity for receiving the heater 602. The ends of the heater 602 are embedded in the inwardly facing opposing sides of the wall 607 such that the lower surface of the heater 602 is arranged just above the downwardly facing edge of the wall 607.

[0174] Figure 9F shows another heater assembly 600f in which the heater 602 is clamped into the sealing member 604. The sealing member 604 comprises a wall 607 that extends downwardly from its lower surface and surrounds a cavity for receiving the heater 602. The ends of the heater 602 are formed with a flange or lip 602a which is embedded in the inwardly facing opposing sides of the wall 607. This arrangement allows the lower surface of the heater 602 to arranged flush with the downwardly facing edge of the wall 607. For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". In this context, therefore, a number A is understood as A ± 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

Claims1 . An aerosol-generating device for use with an aerosol-generating article, the aerosolgenerating device comprising: a housing having a recess configured to receive at least a portion of the aerosolgenerating article; a heater assembly comprising: a heater configured to heat the aerosol-generating article to generate an aerosol; and a sealing member configured to seal at least a portion of the aerosol-generating article within the recess during aerosolisation; wherein the heater is mounted on the sealing member; wherein the sealing member comprises a sealing frame having a perimetral structure surrounding an aperture, the sealing frame being configured to seal a perimeter of the recess; wherein the heater extends across the aperture; and wherein the heater assembly further comprises a clamping member which is resiliently urged towards the sealing frame, the clamping member being shaped such that at least a portion of the clamping member can enter the aperture to urge the heater towards the recess.

2. An aerosol-generating device according to claim 1 , wherein the heater is mounted on a surface of the sealing member facing the recess.

3. An aerosol-generating device according to claim 1 or 2, wherein the heater is resiliently mounted on the sealing member such that the heater is resiliently urged towards the recess.

4. An aerosol-generating device according to any preceding claim, wherein the sealing member is resiliently mounted on the housing such that the heater is resiliently urged towards the recess.

5. An aerosol-generating device according to any preceding claim, wherein the sealing member is configured to deform at least a portion of the aerosol-generating article to seal the aerosol-generating article within the recess.

6. An aerosol-generating device according to any preceding claim, wherein the heater protrudes from the sealing member towards the recess to allow the heater to directly contact the aerosol-generating article.

7. An aerosol-generating device according to any preceding claim, wherein the heater is integral to the sealing member.

8. An aerosol-generating device according to any of claims 1 to 6, wherein the heater is fixedly attached to the sealing member.

9. An aerosol-generating device according to any preceding claim, wherein the heater is substantially planar.

10. An aerosol-generating device according to any preceding claim, wherein the clamping member comprises elastic elements, the elastic elements being arranged on a surface of the clamping member facing the heater.

11. An aerosol-generating device according to claim 10, wherein the elastic elements extend transversely to a longitudinal dimension of the heater.

12. An aerosol-generating device according to claim 10 or 11 , wherein the elastic elements are formed from a heat resistant elastomer.

13. An aerosol-generating device according to any preceding claim, wherein the heater assembly is moveable between a sealed position in which the sealing member seals the recess and an unsealed position in which the sealing member is spaced apart from the recess to allow an aerosol-generating article to be inserted or removed from the recess.

14. An aerosol-generating device according to any preceding claim, wherein the housing comprises a first housing portion and a second housing portion, the first housing portion comprising the recess and the second housing portion comprising the heater assembly, wherein the first housing portion is moveable relative to the second housing portion between an open position in which the recess is exposed and a closed position in which the recess is enclosed by the second housing portion.

15. An aerosol-generating device according to claim 14, wherein the heater assembly is moved into the sealed position when the first and second housing portions are moved to the closed position and the heater assembly is moved into the unsealed position when the first and second housing portions are moved to the open position.

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