EP4602944A1

EP4602944A1 - Method of manufacturing an aerosol generating apparatus

Info

Publication number: EP4602944A1
Application number: EP24157757.6A
Authority: EP
Inventors: designation of the inventor has not yet been filed The
Original assignee: Imperial Tobacco Ltd United Kingdom
Current assignee: Imperial Tobacco Ltd United Kingdom
Priority date: 2024-02-15
Filing date: 2024-02-15
Publication date: 2025-08-20
Also published as: WO2025172407A1

Abstract

A method of manufacturing an elongate aerosol generating apparatus (210) from plural components comprising: an elongate sub-assembly (200) having a sub-assembly longitudinal axis, the elongate sub-assembly comprising an interaction element (204); and, an elongate external housing (202) having a housing longitudinal axis, the external housing configured to house the sub-assembly, the external housing including a receiving aperture (206), wherein the method comprises the steps of: flexing or tilting a carrying portion of the sub-assembly away from the sub-assembly longitudinal axis such that the interaction element moves in a direction transverse to the sub-assembly longitudinal axis; inserting the flexed or tilted sub-assembly into the external housing along the housing longitudinal axis, such that the interaction element aligns with the receiving aperture; and, unflexing or untilting the carrying portion of the sub-assembly such that the interaction element moves towards the receiving aperture.

Description

FIELD

The present disclosure relates to a method of manufacturing an aerosol generating apparatus.

BACKGROUND

A typical known aerosol generating apparatus comprises a power supply, an aerosol generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user.
A drawback with known aerosol generating apparatuses is that there may be difficulties in the manufacturing process. For example, components of the aerosol generating apparatus may be damaged during the manufacturing process, and/or the manufacturing process may be complex.
In spite of the effort already invested in the development of aerosol generating apparatuses/systems further improvements are desirable.

SUMMARY

The present disclosure provides a method of manufacturing an elongate aerosol generating apparatus from plural components comprising: an elongate sub-assembly having a sub-assembly longitudinal axis, the elongate sub-assembly comprising an interaction element;; and, an elongate external housing having a housing longitudinal axis, the external housing configured to house the sub-assembly, the external housing including a receiving aperture, wherein the method comprises the steps of: flexing or tilting a carrying portion of the sub-assembly away from the sub-assembly longitudinal axis such that the interaction element moves in a direction transverse to the sub-assembly longitudinal axis; inserting the flexed or tilted sub-assembly into the external housing along the housing longitudinal axis, such that the interaction element aligns with the receiving aperture; and, unflexing or untilting the carrying portion of the sub-assembly such that the interaction element moves towards the receiving aperture.
In this way, a sub-assembly including an interaction element, such as a button operable to actuate a function of the aerosol generating apparatus, may be inserted into an external housing of the aerosol generating apparatus without a carrying portion of the sub-assembly scraping along the inner surface of the external housing. Advantageously then, insertion of the sub-assembly into the external housing may be facilitated. Additionally, or alternatively, damage of the sub-assembly and/or the external housing may be prevented or reduced during insertion of the sub-assembly into the external housing.
As such, flexing or tilting the carrying portion of the sub-assembly may include flexing or tilting the carrying portion of the sub-assembly such that when the flexed or tilted sub-assembly is inserted into the external housing, there is a separation between the carrying portion of the sub-assembly and an inner surface of the external housing. The inner surface may include a portion of the receiving aperture.
The receiving aperture may be referred to as an interaction element-receiving aperture. The carrying portion of the sub-assembly may be referred to as an interaction element-carrying portion.
It will be appreciated that the steps of flexing or tilting the carrying portion of the sub-assembly may be carried out before the step of inserting the flexed or tilted sub-assembly into the external housing. The step of unflexing or untilting the carrying portion of the sub-assembly may be carried after the step of inserting the flexed or tilted subassembly into the external housing such that the interaction element aligns with the receiving aperture.
It will further be appreciated that the carrying portion of the sub-assembly may comprise the interaction element.
The sub-assembly longitudinal axis may correspond to a longitudinal axis of the sub-assembly when the sub-assembly is unflexed or untilted.
The flexed or tilted sub-assembly may be inserted into the external housing such that the interaction element aligns with and faces the receiving aperture.
In this way, unflexing or untilting the sub-assembly may allow the interaction element to move towards the receiving aperture without contacting the external housing. Thus, damage of the interaction element and/or the external housing may be avoided.
In some examples, in the finished elongate aerosol generating apparatus, the sub-assembly longitudinal axis and the housing longitudinal axis may be parallel, for example aligned. Inserting the flexed or tilted sub-assembly into the external housing may include inserting the flexed or tilted sub-assembly into the external housing along the housing longitudinal axis and along the sub-assembly longitudinal axis.
In this way, this insertion step may be achieved by movement of one or more components of the aerosol generating apparatus (i.e., the sub-assembly and/or the external housing) along their longitudinal axes. Thus, the movements of the components may be along a single straight axis. Such a movement may be uncomplicated for a human or for an assembly machine to make, and thus manufacture of the aerosol generating apparatus may be facilitated.
The insertion step may be carried out, for example, using a manual toggle press, or using an automated insertion process.
In some examples, unflexing or untilting the carrying portion of the sub-assembly extends the interaction element through the receiving aperture. In such examples, the interaction element may correspond to a user-interface element.
Advantageously then, the sub-assembly may be inserted into the external housing without the carrying portion of the sub-assembly scraping along an inner surface of the external housing, even in cases in which the interaction element is configured to extend into the receiving aperture of the external housing.
The interaction element can thereby, in the finished aerosol generating apparatus, protrude from the external housing or be flush with the housing surface surrounding the aperture without the risk of scrape damage to the interaction element during manufacture.
It will be appreciated that the steps of the method may result in the interaction element being snap-fit into the receiving aperture.
In some examples, the interaction element may correspond to a button operable to actuate a function of the finished aerosol generating apparatus. In such examples, the receiving aperture may be referred to as a button-receiving aperture, and/or the carrying portion may be referred to as a button-carrying portion.
The button may be operable to switch the aerosol generating apparatus on and off, for example to switch a heating element of the aerosol generating apparatus on and off. The button may be operable to change a power mode of the aerosol generating apparatus, such as a power mode of the heating element.
Access to such buttons and/or reliable activation of such buttons may be important for safety of the finished aerosol generating apparatus, for example where the button can be used for turning off the heating element of the aerosol generating apparatus.
In some examples, the sub-assembly may include a printed circuit board (PCB). The PCB may include a PCB switch operable to actuate the function of the finished aerosol generating apparatus. The PCB switch may be operable to switch the aerosol generating on and off, or to change a power mode of the aerosol generating apparatus, for example. The PCB switch may correspond to a microswitch or a tactile switch, for example.
In some examples, the sub-assembly may comprise a lower chassis configured to house at least a portion of the PCB. The lower chassis may be tubular. In such examples, the method may further comprise a preliminary step of building the sub-assembly, which may include performing a sub-step of inserting the portion of the PCB into the lower chassis. In particular, in some examples, the sub-assembly may comprise a lower chassis configured to house substantially all of the PCB. In such examples, the method may further comprise building the sub-assembly, which may include inserting substantially all of the PCB into the lower chassis.
In this way, the sub-assembly may include components which may be manufactured separately. As such, production line logistics may be facilitated. Additionally, or alternatively, housing the PCB in the lower chassis may protect the PCB and components thereon from damage, for example during manufacture.
The lower chassis may be elongate, having a lower chassis longitudinal axis, and inserting the portion PCB into the lower chassis may include inserting the portion of the PCB into the lower chassis along the lower chassis longitudinal axis. The PCB may be elongate, having a PCB longitudinal axis. In some examples, in the finished elongate aerosol generating apparatus, the lower chassis longitudinal axis and the PCB longitudinal axis may be parallel, for example aligned. Inserting the PCB into the lower chassis may include inserting the portion of the PCB into the lower chassis along the lower chassis longitudinal axis and along the PCB longitudinal axis.
In this way, this insertion step may be achieved by movement of one or more components of the aerosol generating apparatus (i.e., the lower chassis and/or the PCB) along their longitudinal axes. Thus, the movements of the components may be along a single straight axis. Such a movement may be uncomplicated for a human or for an assembly machine to make, and thus manufacture of the aerosol generating apparatus may be facilitated.
The lower chassis longitudinal axis may correspond to the sub-assembly longitudinal axis.
In some examples, the lower chassis may include one or more grooves configured to receive the PCB. In such examples, the sub-step of inserting the portion of the PCB into the lower chassis may comprise sliding the PCB into the lower chassis along the one or more grooves. The one or more grooves may be parallel to the lower chassis longitudinal axis.
In this way, insertion of the PCB into the lower chassis may be facilitated. As such, damage to the PCB during manufacture may be inhibited. Additionally, or alternatively, in this way, insertion of the PCB by an axial movement of the PCB along the lower chassis longitudinal axis may be achieved.
In some examples, the lower chassis may include two aligning ridges which form the groove between them. In such examples, sliding the PCB into the lower chassis along the groove includes sliding the PCB between the aligning ridges.
In some examples, the lower chassis may include two grooves, each groove configured to receive an opposing side of the PCB.
In this way, the PCB may be stably inserted into the lower chassis.
In some examples, the button may correspond to the PCB switch.
In some examples, the button may correspond to a user interface button (Ul) button. Accordingly, the button-carrying portion may include a Ul button-carrying portion. The Ul button may be mounted on the button-carrying portion. The UI button may be configured to be user activated.
The UI button may be formed of light guide material. The UI button may be configured to illuminate. For example, the UI button, or an edge of the UI button, may be configured to align with an LED on the PCB. Accordingly, in some examples the method may further comprise a preliminary step of building the sub-assembly, which may include performing the sub-step of aligning the UI button, or an edge of the UI button with an LED on the PCB.
In this way an improved user interface and/or user experience may be achieved.
In the examples in which the button corresponds to the UI button, the UI button may extend through the aperture. Unflexing or untiliting the button-carrying portion of the sub-assembly may include unflexing or untilting the button-carrying portion of the sub-assembly such that the UI button extends through the button-receiving aperture.
In some examples, the PCB switch may be operable via the interaction element, for example the UI button, to actuate the function of the finished aerosol generating apparatus. In other examples, the PCB switch may be configured to operate the interaction element in the finished aerosol generating apparatus. The interaction element may be aligned with the PCB switch. For example, the UI button may be operable to interact or engage with the PCB switch to actuate a function of the finished aerosol generating apparatus. The UI button engaging with the PCB switch may refer to the UI button engaging with the PCB switch directly, for example by the UI button contacting the PCB switch, or to the UI button engaging with the PCB switch indirectly, for example through an intermediate component.
Accordingly, in some examples the method may further comprise a preliminary step of building the sub-assembly, which may include performing a sub-step of aligning the PCB switch with the interaction element, for example the UI button.
In some examples, the lower chassis may comprise, or may be coupled to the interaction element, for example, the UI button. In particular, the interaction element may be coupled to an outer surface of the lower chassis. As such, the method may comprise inserting the portion of the PCB into the lower chassis such that the PCB switch aligns with the interaction element, such as the UI button. Further, the method may comprise inserting the portion of the PCB into the lower chassis such that the UI button, or an edge of the UI button, aligns with an LED on the PCB.
In some examples, the lower chassis may include a flexible arm, and the interaction element, for example the UI button, may be coupled to an outer surface of the flexible arm. An inner surface of the flexible arm may face or oppose the PCB switch. The flexible arm may be biased in an unflexed configuration in which a longitudinal axis of the flexible arm may be parallel to, for example may align with a longitudinal axis of the lower chassis. In the finished aerosol generating apparatus, when the flexible arm is in the unflexed configuration the interaction element, for example the UI button, may be disengaged from the PCB switch. The flexible arm may be moveable or bendable into a flexed configuration in which the longitudinal axis of the flexible arm may be bent relative to a longitudinal axis of the lower chassis. In the finished aerosol generating apparatus, when the flexible arm is in the flexed configuration, in which the interaction element, for example the UI button, may be engaged with the PCB switch, the interaction element may operate the PCB switch.
In this way, the PCB switch may be operable via the interaction element, for example the UI button. For example, when the UI button is pressed, the flexible arm may flex inwards and may engage with the PCB switch such as to operate the PCB switch. Thus, the flexible arm may provide a bias of the interaction element.
In some examples, the carrying portion of the sub-assembly may include the flexible arm. As such, in the method of manufacturing the elongate aerosol generating apparatus, flexing or tilting the carrying portion of the sub-assembly may include flexing or tilting the flexible arm. Unflexing or untiliting the carrying portion of the sub-assembly may include unflexing or untilting the flexible arm.
In this way, the steps of flexing or tilting and/or unflexing or untilting the sub-assembly, such as to prevent the carrying portion scraping on the inner surface of the external housing, may be facilitated.
In the method of manufacturing the aerosol generating apparatus, flexing or tilting the carrying portion of the sub-assembly may include flexing or tilting a PCB switch-carrying portion of the PCB. The carrying portion of the sub-assembly may include the PCB switch-carrying portion. It will be appreciated that the PCB switch may be mounted on the switch-carrying portion of the PCB. Unflexing or untilting the carrying portion of the sub-assembly may include unflexing or untilting a PCB switch -carrying portion of the PCB.
In this way, insertion of the sub-assembly into the external housing may be facilitated, and/or damage of the components of the sub-assembly may be reduced. For example, when the PCB is housed within the lower chassis, flexing or tilting the PCB switch -carrying portion, as well as the carrying portion, for example the UI button-carrying portion, may prevent damage of the PCB and/or the lower chassis during flexing or tilting of the carrying portion.
The PCB may be naturally assume an unflexed configuration. The PCB may be moveable or bendable into a flexed configuration. In the finished aerosol generating apparatus, the PCB may be in the unflexed configuration, in which a longitudinal axis of the PCB may be parallel to, for example may align with the external housing longitudinal axis and/or the sub-assembly longitudinal axis.
In some examples, the PCB switch -carrying portion may be fixedly coupled to the carrying portion, for example the UI button-carrying portion, such that flexing or tilting the carrying portion causes flexing or tilting of the PCB switch-carrying portion.
In some examples, the sub-assembly may further comprise a battery, configured to be electrically coupled to the PCB. Thus, the method may include a step of electrically connecting the battery to the PCB. In some examples, the lower chassis may be configured to house at least a portion, or substantially all, of the battery. Thus, the method may include a step of inserting the battery into the lower chassis. The battery, which may be elongate, may be inserted into the lower chassis along a longitudinal axis of the lower chassis and/or along a longitudinal axis of the battery. It will be appreciated that the step of inserting the battery into the lower chassis may be carried out before the step of inserting the lower chassis into the external housing, and/or before the step of flexing or tilting the carrying portion of the sub-assembly.
As such, electrical connections of the battery to components of the PCB may be made before insertion of the PCB and the battery into the external housing. In this way, manufacture may be facilitated and/or damage to the PCB may be inhibited.
In some examples, the aerosol generating apparatus may comprise an upper chassis. That is, the plural components from which the aerosol generating apparatus is manufactured may comprise an upper chassis. The upper chassis may be generally tubular. The external housing may be configured to house the upper chassis. The upper chassis may have a support wall. The support wall may be configured to engage with the PCB to inhibit the PCB from flexing or tilting away from the external housing, for example the receiving aperture, in use, such as when the button is operated by a user of the apparatus. In such examples, the method may further comprise inserting the upper chassis into the external housing such that the support wall engages the PCB to inhibit the switch-carrying portion of the PCB from flexing or tilting away from the receiving aperture in use, for example when the button is operated by a user of the apparatus.
Advantageously then, the PCB may be inhibited from undesirably flexing or tilting away from the receiving aperture in use (in the finished, manufactured apparatus), such as when the button is operated by a user of the apparatus. As such, the PCB switch may be operated more effectively. Additionally, or alternatively, wear on the PCB may be reduced.
During insertion of the upper chassis, the support wall may engage with a lower surface of the PCB. The lower surface of the PCB may be opposite to an upper surface of the PCB. The PCB switch may extend from an upper surface of the PCB.
In this way, the support wall may engage with a surface of the PCB opposite to that on which one or more components of the PCB are located. Thus, damage to components of the PCB may be inhibited.
It will be appreciated that the step of inserting the upper chassis may be carried out after the step of unflexing the or untilting the carrying portion of the sub-assembly.
In this way, inserting the upper chassis may result in the PCB being held in an unflexed or untilted configuration.
In some examples, during insertion of the upper chassis, the support wall may urge the PCB, for example the PCB switch-carrying portion, towards an inner surface of the external housing, and/or towards the receiving aperture.
In this way, inserting the upper chassis may result in the PCB being moved into and/or held in an unflexed or untilted configuration. As such, the carrying portion of the sub-assembly may be flexible or tiltable, without the PCB being undesirably flexible or tiltable in the finished, manufactured aerosol generating apparatus.
The upper chassis may be inserted into the external housing along the housing longitudinal axis. The upper chassis may be elongate, having an upper chassis longitudinal axis. In some examples, in the finished elongate aerosol generating apparatus, the upper chassis longitudinal axis and the housing longitudinal axis may be parallel, for example aligned. Inserting the upper chassis into the external housing may include inserting the upper chassis into the housing along the housing longitudinal axis and along the upper chassis longitudinal axis.
In this way, this insertion step may be achieved by movement of one or more components of the aerosol generating apparatus (i.e., the upper chassis and/or the external housing) along their longitudinal axes. Thus, the movements of the components may be along a single straight axis. Such a movement may be uncomplicated for a human or for an assembly machine to make, and thus manufacture of the aerosol generating apparatus may be facilitated.
As a further advantage, a transverse displacement of a component of the aerosol generating apparatus may be achieved by the movement of components along their longitudinal axes. For example, inserting the upper chassis into the external housing along the longitudinal axis of the external housing may cause the PCB to be urged towards an inner surface and/or towards the receiving aperture of the external housing by the support wall of the upper chassis.
In some examples, the upper chassis has a ramp extending from an engagement end of the upper chassis to the support wall. In such examples, inserting the upper chassis into the external housing may comprise inserting the upper chassis into the external housing via the engagement end such as to engage the ramp with the PCB, which then slides the PCB up the ramp to engage the PCB with the support wall.
In this way, transverse displacement of the PCB may be facilitated by a longitudinal movement of the upper chassis. Additionally or alternatively, the ramp may enable a gradual engagement of the PCB with the support wall. In this way, insertion of the upper chassis into the external housing may be facilitated, and/or moving the PCB into the unflexed or untilted configuration may be facilitated.
The ramp may extend in a direction along the upper chassis longitudinal axis as well as in a direction along an upper chassis transverse axis. Thus, when the upper chassis is inserted into the external housing along the upper chassis longitudinal axis, the ramp may engage with the PCB and the ramp may act to push the PCB in a direction parallel to the upper chassis transverse axis. In the finished elongate aerosol generating apparatus, the upper chassis transverse axis may be parallel, for example aligned with an external housing transverse axis, which may extend through the receiving aperture. Thus, when the upper chassis is inserted into the external housing along the housing longitudinal axis, the ramp may engage with the PCB and the ramp may act to push the PCB towards the receiving aperture.
Sliding the PCB up the ramp may be achieved, for example, by moving the upper chassis along the housing longitudinal axis.
Thus, advantageously, a transverse displacement of a component of the aerosol generating apparatus may be achieved by the movement of the components along their longitudinal axes. For example, inserting the upper chassis into the external housing along the longitudinal axis of the external housing may cause the PCB to be urged towards an inner surface and/or towards the receiving aperture of the external housing by the ramp of the upper chassis.
In some examples, an engagement end of the upper chassis may be configured to engage with the lower chassis. Thus, the method may comprise inserting the upper chassis until, or such that, an engagement end of the upper chassis engages with the lower chassis. The engagement end of the upper chassis may correspond to a lower end of the upper chassis.
In some examples, the upper chassis may be configured to house one or more components of the aerosol generating apparatus. For example, the upper chassis may be configured to house a heating element, and/or a heating element chassis which is fixedly coupled to, and which supports the heating element. Thus, the method may comprise inserting the one or more components into the upper chassis. The one or more components may be inserted into the upper chassis along a longitudinal axis of the upper chassis. The method may further comprise coupling a cap of the aerosol generating apparatus. The cap may be coupled to an upper end of the upper chassis and/or to the external housing.
In some examples, the method of manufacturing the elongate aerosol generating apparatus may include using an assembly nest to flex or tilt the carrying portion of the sub-assembly. In more detail, the step of flexing or tilting the carrying portion may be performed by engaging the sub-assembly with an assembly nest, wherein the assembly nest flexes or tilts the carrying portion of the sub-assembly away from the sub-assembly longitudinal axis such that the interaction element moves in a direction transverse to the sub-assembly longitudinal axis. Then, the step of inserting the flexed or tilted sub-assembly into the housing may is performed with the sub-assembly still engaged with the assembly nest.
In this way, the flexing or tilting of the carrying portion of the sub-assembly may be facilitated.
In some examples, the step of unflexing or untilting the carrying portion is performed by disengaging the sub-assembly from the assembly nest to unflex or untilt the carrying portion of the sub-assembly.
In this way, the unflexing or untilting of the carrying portion of the sub-assembly may be facilitated.
The assembly nest may include a ramped surface configured to engage with the carrying portion of the sub-assembly to flex or tilt the carrying portion of the sub-assembly.
In some examples, the aerosol generating apparatus may correspond to a heat-not-burn (HNB) aerosol generating apparatus.
The present disclosure may provide an aerosol generating apparatus, which may be manufactured according to a method of manufacturing an elongate aerosol generating apparatus disclosed herein.
The present disclosure may provide an elongate aerosol generating apparatus comprising an elongate sub-assembly, the elongate sub-assembly comprising: a printed circuit board (PCB) including a PCB switch operable to actuate a function of the aerosol generating apparatus; and, an elongate external housing which houses the sub-assembly, an upper chassis having a support wall, wherein the support wall engages with the PCB to inhibit the PCB from flexing or tilting away from the external housing in use .
Advantageously then, the PCB may be inhibited from flexing or tilting away from external apparatus in use. As such, the PCB switch may be operated more effectively. Additionally, or alternatively, wear on the PCB may be reduced.
In some examples, the external housing may include a button-receiving aperture aligned with the PCB switch. The external housing may include a receiving aperture aligned with the PCB switch. In such examples, the support wall may engage with the PCB to inhibit the PCB from flexing or tilting away from the receiving aperture in use, for example when the PCB switch is operated by a user of the apparatus.
Advantageously then, the PCB may be inhibited from flexing or tilting away from the receiving aperture in use when the PCB switch is operated by a user of the apparatus. As such, the PCB switch may be operated more effectively. Additionally, or alternatively, wear on the PCB may be reduced. In some examples, the elongate sub-assembly may further comprise a interaction element. In some examples, the interaction element, which may be a UI button for example, may be operable to actuate a function of the aerosol generating apparatus via the PCB switch. Thus, a user may operate the PCB switch via the interaction element.
In such examples, the receiving aperture may align with the interaction element. For example, the receiving aperture may receive the interaction element, such that the interaction element extends through the receiving aperture. The support wall may engage with the PCB to inhibit the PCB from flexing or tilting away from the receiving aperture in use when the interaction element, for example the UI button, is operated by a user of the apparatus.
In some examples the upper chassis further comprises a ramp extending from an engagement end of the upper chassis to the support wall. The engagement end of the upper chassis may be inserted into the external housing to slide the PCB up the ramp into engagement with the support wall. The sub-assembly may further comprise a lower chassis housing a portion of the PCB. The engagement end of the upper chassis may engage with the lower chassis.
Advantageously, the manufacture of the aerosol generating apparatus may be facilitated by the presence of the ramp, as is discussed in detail earlier in this specification.
The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.

Fig. 1 is a block system diagram showing an example aerosol generating apparatus.
Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol generating apparatus is configured to generate aerosol from a liquid precursor.
Figs. 3A and 3B are schematic diagrams showing an example implementation of the apparatus of Fig. 2.
Fig. 4 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol generating apparatus is configured to generate aerosol from a solid precursor.
Fig. 5 is a schematic diagram showing an example implementation of the apparatus of Fig. 4.
Fig. 6 is a flow diagram showing an example method of manufacturing an aerosol generating apparatus.
Fig. 7 is an exploded view of a portion of an example aerosol generating apparatus.
Fig. 8 is an exploded view of an example aerosol generating apparatus.
Fig. 9 is a flow diagram showing an example method of manufacturing an aerosol generating apparatus.
Fig. 10 is a perspective view of an upper chassis of an example aerosol generating apparatus.

DETAILED DESCRIPTION OF EMBODIMENTS

Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and/or methods described herein could be embodied differently and/or be practiced or carried out in various alternative ways.
Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.
Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.
All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.
The use of the term "a" or "an" in the claims and/or the specification may mean "one," as well as "one or more," "at least one," and "one or more than one." As such, the terms "a," "an," and "the," as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.
The use of the term "or" in the present disclosure (including the claims) is used to mean an inclusive "and/or" unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition "A or B" is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
As used in this specification and claim(s), the words "comprising, "having," "including," or "containing" (and any forms thereof, such as "comprise" and "comprises," "have" and "has," "includes" and "include," or "contains" and "contain," respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase "in one embodiment," "according to an embodiment," and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an,' 'one,' or 'some' embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.
The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably:
As used herein, an "aerosol generating apparatus" (or "electronic(e)-cigarette") may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally/alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and/or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of a button and/or an airflow sensor.
Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an "activation" of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength/duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).
The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.
As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to/include a vapour. An aerosol may include one or more components of the precursor.
As used herein, a "precursor" may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and/or glycerine. The term "flavouring" may refer to a component that provides a taste and/or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.
As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.
As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.
As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.
As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.
As used herein, a "puff" (or "inhale" or "draw") by a user may refer to expansion of lungs and/or oral cavity of a user to create a pressure reduction that induces flow through the flow path.
As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol generating apparatus.
As used herein, a "heating system" may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.
As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. With liquid or gel implementations of the precursor, e.g. an e-liquid, the consumable may be referred to as a "capsule" or a "pod" or an "e-liquid consumable". The capsule/pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.
As used herein "heat-not-burn" (or "HNB" or "heated precursor") may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).
Referring to Fig. 1, an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and/or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.
Electrical circuitry (not shown in Fig. 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6. The electrical circuitry may be located on a printed circuit board (PCB) within the aerosol generating apparatus.
In variant examples, which are not illustrated, the power supply 2 may be omitted since, e.g. an aerosol generating unit implemented as an atomiser with flow expansion may not require a power supply.
Fig. 2 shows an implementation of the apparatus 1 of Fig. 1, where the aerosol generating apparatus 1 is configured to generate aerosol from a liquid precursor.
In this example, the apparatus 1 includes a device body 10 and a consumable 30.
In this example, the body 10 includes the power supply 4. The body may additionally include any one or more of electrical circuitry 12, a memory 14, a wireless interface 16, one or more other components 18. The electrical circuitry 12 may be located on a printed circuit board PCB within the body 10.
The electrical circuitry 12 may include a processing resource for controlling one or more operations of the body 10 and consumable 30, e.g. based on instructions stored in the memory 14.
The wireless interface 16 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.
The other component(s) 18 may include one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 3).
The consumable 30 includes a storage portion implemented here as a tank 32 which stores the liquid precursor 6 (e.g. e-liquid). The consumable 30 also includes a heating system 34, one or more air inlets 36, and a mouthpiece 38. The consumable 30 may include one or more other components 40.
The body 10 and consumable 30 may each include a respective electrical interface (not shown) to provide an electrical connection between one or more components of the body 10 with one or more components of the consumable 30. In this way, electrical power can be supplied to components (e.g. the heating system 34) of the consumable 30, without the consumable 30 needing to have its own power supply.
In use, a user may activate the aerosol generating apparatus 1 when inhaling through the mouthpiece 38, i.e. when performing a puff. The puff, performed by the user, may initiate a flow through a flow path in the consumable 30 which extends from the air inlet(s) 34 to the mouthpiece 38 via a region in proximity to the heating system 34.
Activation of the aerosol generating apparatus 1 may be initiated, for example, by an airflow sensor in the body 10 which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the mouthpiece), or by actuation of a button included in the body 10. Upon activation, the electrical circuitry 12 (e.g. under control of the processing resource) may supply electrical energy from the power supply 2 to the heating system 34 which may cause the heating system 32 to heat liquid precursor 6 drawn from the tank to produce an aerosol which is carried by the flow out of the mouthpiece 38.
In some examples, the heating system 34 may include a heating filament and a wick, wherein a first portion of the wick extends into the tank 32 in order to draw liquid precursor 6 out from the tank 32, wherein the heating filament coils around a second portion of the wick located outside the tank 32. The heating filament may be configured to heat up liquid precursor 6 drawn out of the tank 32 by the wick to produce the aerosol.
In this example, the aerosol generating unit 4 is provided by the above-described heating system 34 and the delivery system 8 is provided by the above-described flow path and mouthpiece 38.
In variant embodiments (not shown), any one or more of the precursor 6, heating system 34, air inlet(s) 36 and mouthpiece 38, may be included in the body 10. For example, the mouthpiece 36 may be included in the body 10 with the precursor 6 and heating system 32 arranged as a separable cartomizer.
Figs. 3A and 3B show an example implementation of the aerosol generating device 1 of Fig. 2. In this example, the consumable 30 is implemented as a capsule/pod, which is shown in Fig. 3A as being physically coupled to the body 10, and is shown in Fig. 3B as being decoupled from the body 10.
In this example, the body 10 and the consumable 30 are configured to be physically coupled together by pushing the consumable 30 into an aperture in a top end 11 the body 10, with the consumable 30 being retained in the aperture via an interference fit.
In other examples (not shown), the body 10 and the consumable 30 could be physically coupled together in other ways, e.g. by screwing one onto the other, through a bayonet fitting, or through a snap engagement mechanism, for example.
The body 10 also includes a charging port (not shown) at a bottom end 13 of the body 10.
The body 10 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a light 15, which may e.g. be configured to illuminate when the apparatus 1 is activated. In some examples, the button operable to actuate the aerosol generating apparatus 1 may correspond to the user interface device, as the button may be configured to illuminate. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.
In this example, the consumable 30 has an opaque cap 31, a translucent tank 32 and a translucent window 33. When the consumable 30 is physically coupled to the body 10 as shown in Fig. 3A, only the cap 31 and window 33 can be seen, with the tank 32 being obscured from view by the body 10. The body 10 includes a slot 15 to accommodate the window 33. The window 33 is configured to allow the amount of liquid precursor 6 in the tank 32 to be visually assessed, even when the consumable 30 is physically coupled to the body 10.
Fig. 4 shows an implementation of the apparatus 1 of Fig. 1, where the aerosol generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.
In this example, the apparatus 1 includes a device body 50 and a consumable 70.
In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62. The electrical circuitry 56 may be located on a printed circuit board PCB within the body 50.
The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58.
The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.
The other component(s) 62 may include a button, one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 5).
The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid precursor 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.
Fig. 5 shows an example implementation of the aerosol generating device 1 of Fig. 4.
As depicted in Fig. 5, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end 53 of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6.
The consumable 70 includes the solid precursor 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid precursor 6 may be a reconstituted tobacco formulation.
In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. Other heating element shapes are possible, e.g. the at least one heating element may be blade-shaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile).
In this example, the body 50 includes a cap 51. In use the cap 51 is engaged at a top end 53 of the body 50. Although not apparent from Fig. 5, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.
The body 50 also includes a button 55 extending through a button-receiving aperture.
The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as one or more lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and/or to indicate a charging state of the power supply 4. In some examples, the button operable to actuate the aerosol generating apparatus 1 may correspond to the user interface device, as the button may be configured to illuminate. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.
The body may also include an airflow sensor which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.
In this example, the consumable 70 includes a flow path which transmits aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable.
In this example, the aerosol generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.
Referring to Fig. 6 an example of a method of manufacturing an elongate aerosol generating apparatus, which may be used to manufacture any of the preceding examples, is shown as a flow diagram.
The elongate aerosol generating apparatus includes an elongate sub-assembly 200 and an elongate external housing 202. Examples of such components of the aerosol generating apparatus are shown in Fig. 7. The elongate sub-assembly 200 includes a button 204 operable to actuate a function of the aerosol generating apparatus, which may correspond to a button 55 discussed above with reference to Figs. 2 to 5. The elongate external housing 202 is configured to house the sub-assembly 200 and includes a button-receiving aperture 206 configured to align with the button 204. In the example shown in Fig. 7, the button 204 corresponds to a UI button, which is configured to extend through the button-receiving aperture 206. The button 204 is coupled to a flexible arm 208 of the sub-assembly.
As shown in Fig. 6, at a first step 100 the method includes flexing or tilting a button-carrying portion of the sub-assembly 200 away from the longitudinal axis of the sub-assembly 200, such that the button 204 moves in a direction transverse to the longitudinal axis of the sub-assembly 200.ln the example sub-assembly 200 shown in Fig. 7, the button-carrying portion includes the flexible arm 208 and thus this step includes flexing the flexible arm 208 of the sub-assembly downwards 200. Then, at a second step 102, the method includes inserting the flexed or tilted sub-assembly 200 into the external housing 202, along the longitudinal axis of the housing 202. The sub-assembly 200 is inserted into the external housing 202 such that the button 204 aligns with the button-receiving aperture 206. Then, at a third step 104, the method includes unflexing or untilting the button-carrying portion of the sub-assembly such that the button 204 moves towards the button-receiving aperture 206. In the example sub-assembly 200 shown in Fig. 7, this step includes unflexing the flexible arm 208, such that the flexible arm 208 moves upwards (in Fig 7) and the UI button 204 extends through the button-receiving aperture 206.
Fig. 8 shows an exploded view of an elongate aerosol generating apparatus 210, which may be manufactured according to a method of manufacturing an elongate aerosol generating apparatus 210 described herein. Fig. 8 shows additional components of the elongate aerosol generating apparatus 210, to those shown in Fig. 7.
The aerosol generating apparatus 210 corresponds to a heat-not-burn (HNB) aerosol generating apparatus 210, and thus may correspond to an aerosol generating apparatus as described above with reference to Figs. 4 and 5. In other embodiments, the aerosol generating apparatus is configured to generate aerosol from a liquid precursor.
Similarly to Fig. 7, Fig. 8 shows that the elongate aerosol generating apparatus 210 comprises an elongate external housing 202 with a button-receiving aperture 206 which is configured to receive a UI button 204 of the sub-assembly 200.
The sub-assembly includes a lower chassis 212, a PCB 214, and a battery 216.
The PCB 214 includes a PCB switch operable to actuate a function of the aerosol generating apparatus. The PCB switch is operable via the UI button 204, as the UI button is operable to engage with the PCB switch to actuate the function of the aerosol generating apparatus.
The UI button 204 is coupled to a flexible arm 208 of the lower chassis 212. In particular, the UI button 204 is coupled to an outer surface of the flexible arm 208. In the manufactured aerosol generating device 210, the inner surface of the flexible arm 208 faces the PCB switch. The flexible arm 208 is biased in an unflexed configuration in which the UI button is disengaged from the PCB switch and is moveable into a flexed configuration in which the UI button is engaged with the PCB switch to thereby operate the PCB switch.
The battery 216 is configured to be electrically coupled to the PCB 214.
As shown in Fig. 8, the aerosol generating device further comprises an upper chassis 218. The external housing 202 is configured to house the upper chassis 218.
An engagement end of the upper chassis 218 is configured to engage with the lower chassis 212. The upper chassis 218 comprises a support wall 220 configured to engage with the PCB 214. The support wall 220 is configured to inhibit the PCB 214 from flexing or tilting away from the button-receiving aperture 206 in use when the UI button 204 is operated by a user of the apparatus 210.
The upper chassis 218 is tubular such as to be configured to house one or more components of the aerosol generating apparatus 210. As shown in Fig. 8, these components include a heating element 222 and a heating element chassis 224.
The aerosol generating apparatus further comprises a cap 226, which, in the manufactured aerosol generating apparatus 210, is coupled to the external housing 202.
Fig. 9 is a flow diagram showing an example of a method of manufacturing an elongate aerosol generating apparatus, which may correspond to the elongate aerosol generating apparatus shown in Fig. 8.
The method shown in the flow diagram of Fig. 9 is a specific example of a method in accordance with the flow diagram of Fig. 6.
As shown in Fig. 9, at a first step 300, the method includes inserting the PCB 214 into the lower chassis 212 such that the PCB switch aligns with the UI button 204. In more detail, the method includes sliding the PCB 214 into the lower chassis 212 along grooves within the lower chassis 212, which are parallel to the longitudinal axis of the lower chassis. The grooves ensure that the PCB switch aligns with the UI button 204. As such, the insertion of the PCB 214 into the lower chassis is along a longitudinal axis of the lower chassis 212.
At a second step 302, the method includes inserting the battery 216 into the lower chassis along a longitudinal axis of the lower chassis 212.
Thus, in the first 300 and second steps 302, the sub-assembly 200 may be built.
Then, in the third step 304, the method of manufacturing includes flexing the flexible arm 208 of the lower chassis 212 and the PCB switch-carrying portion of the PCB 214 in a direction transverse to the longitudinal axis of the sub-assembly. Specifically, the flexible arm 208 and the PCB switch-carrying portion are flexed downwards in Figs. 7 and 8.
The flexing of the flexible arm 208 and the PCB switch-carrying portion is carried out using an assembly nest. In more detail, the method comprises engaging the sub-assembly 200 with the assembly nest, and the assembly nest flexes the flexible arm 208 and the PCB button-carrying portion of the sub-assembly.
After the flexing step 304, in a fourth step 306, the flexed sub-assembly 200, engaged with the assembly nest, is inserted into the external housing 202 along the longitudinal axis of the external housing. The sub-assembly 200 is inserted such as to align the UI button 204 on the lower chassis 212 with the button-receiving aperture 206 in the external housing 202.
Because the sub-assembly 200 is inserted into the external housing 202 while in a flexed configuration, the sub-assembly 200 may be inserted into the external housing 202 without the UI button 204 or the flexible arm 208 of the sub-assembly 200 scraping along the inner surface of the external housing 202. Advantageously then, insertion of the sub-assembly 200 into the external housing may be facilitated. Additionally, or alternatively, damage of the sub-assembly 200 and/or the external housing 202 may be prevented or reduced during insertion of the sub-assembly 200 into the external housing 202.
In a fifth step 308, the method includes disengaging the assembly nest from the sub-assembly 200 to unflex sub-assembly, i.e., to unflexthe flexible arm 208 and the PCB switch-carrying portion. Because the UI button 204 is aligned with the button-receiving aperture 206, the unflexing of the flexible arm 208 results in the UI button extending through the button receiving aperture 206.
After the unflexing, the method includes, in a sixth step 310, inserting the upper chassis 218 into the external housing 202 along the longitudinal axis of the external housing 202. During insertion of the upper chassis 218, the support wall 220 of the upper chassis 218 engages the lower surface of the PCB 214. Thus, in use the PCB 214 is inhibited from flexing or tilting away from the button-receiving aperture 206 when the UI button 204 is operated by a user of the apparatus 210.
As shown in Fig. 10, in some examples, the upper chassis 218 may include a ramp 228 extending from the engagement end of the upper chassis 218 to the support wall 220. In such examples, inserting the upper chassis 218 into the external housing 202 includes inserting the upper chassis 218 into the housing 202 via the engagement end such as to engage the ramp 228 with the PCB 214 and slide the PCB 214 up the ramp 228 to engage the PCB 214 with the support wall 220.
The ramp 228 extends in a direction along the longitudinal axis of the upper chassis 218 as well as in a direction along a transverse axis of the upper chassis 218. Thus, when the upper chassis 218 is inserted into the external housing 202, the ramp 228 acts to push the PCB 214 towards the button-receiving aperture 206.
Turning back to Fig. 9, in a seventh step 312, the method of manufacturing the aerosol generating apparatus includes inserting the heating element chassis 224 into the upper chassis 218.
Then, in a final step 314, the method of manufacturing the aerosol generating apparatus includes coupling the cap 226 to the external housing 202.

Claims

A method of manufacturing an elongate aerosol generating apparatus (210) from plural components, the plural components comprising:
an elongate sub-assembly (200), having a sub-assembly longitudinal axis, the elongate sub-assembly (200) comprising an interaction element; and,

an elongate external housing (202) having a housing longitudinal axis, the external housing (202) configured to house the sub-assembly (200), the external housing (202) including a receiving aperture (206),
wherein the method comprises steps of:
flexing or tilting a carrying portion of the sub-assembly (200) away from the sub-assembly longitudinal axis such that the interaction element (204) moves in a direction transverse to the sub-assembly longitudinal axis;

inserting the flexed or tilted sub-assembly (200) into the housing (202) along the housing longitudinal axis, such that the interaction element (204) aligns with the receiving aperture (206); and,

unflexing or untilting the carrying portion of the sub-assembly (200) such that the interaction element (204) moves towards the receiving aperture (206).
A method according to claim 1, wherein unflexing or untilting the carrying portion of the sub-assembly (200) extends the interaction element (204) through the receiving aperture (206).
A method according to claim 1 or claim 2, wherein the interaction element (204) is a user interface (UI) button.
A method according to claim 3, wherein the sub-assembly (200) further comprises a printed circuit board (PCB) (214) including a PCB switch operable via the interaction element (204) to actuate a function of the finished aerosol generating apparatus (210).
A method according to claim 4 wherein the sub-assembly (200) comprises a lower chassis (212) configured to house at least a portion of the PCB (214), and wherein the method further comprises a preliminary step of:
building the sub-assembly (200), including performing a sub-step of inserting the portion of the PCB (214) into the lower chassis (212).
A method according to claim 5, wherein the lower chassis (212) includes a groove configured to receive the PCB (214), and wherein the sub-step of inserting the portion of the PCB (214) into the lower chassis (212) comprises:
sliding the PCB (214) into the lower chassis (212) along the groove.
A method according to any of claims 4 to 6, wherein the method further comprises the step of:
building the sub-assembly (200), which includes performing a sub-step of aligning the PCB switch with the interaction element (204).
A method according to any of claims 4 to 7, wherein the lower chassis (212) comprises the interaction element (204).
A method according to claim 8, wherein the carrying portion includes a flexible arm (208) provided by the lower chassis (212), the interaction element (204) being coupled to an outer surface of the flexible arm (208).
A method according to any of claims 4 to 9, wherein the carrying portion of the sub-assembly includes a PCB switch-carrying portion of the PCB on which the switch is mounted.
A method according to claim 10, wherein the plural components of the aerosol generating apparatus (210) further comprise an upper chassis (218) having a support wall (220), and wherein the method further comprises a subsequent step of:
inserting the upper chassis (218) into the external housing (202), such that the support wall (220) engages the PCB (214) to inhibit the switch-carrying portion PCB (214) from flexing or tilting away from the receiving aperture (206) in use when the interaction element (204) is operated by a user of the apparatus (210).
A method according to claim 11, wherein the upper chassis (218) has a ramp (228) extending from an engagement end of the upper chassis (218) to the support wall (220), and wherein inserting the upper chassis (218) into the external housing (202) comprises:
inserting the upper chassis (218) into the external housing (202) via the engagement end such as to engage the ramp (228) with the PCB (214), which then slides the PCB (214) up the ramp (228) to engage with the support wall (220).
A method according to any of the preceding claims, wherein the step of flexing or tilting the carrying portion is performed by:
engaging the sub-assembly (200) with an assembly nest, wherein the assembly nest flexes or tilts the carrying portion of the sub-assembly (200) away from the sub-assembly longitudinal axis such that the interaction element (204) moves in a direction transverse to the sub-assembly longitudinal axis; and,
the step of inserting the flexed or tilted sub-assembly (200) into the housing (202) is performed with the sub-assembly (200) still engaged with the assembly nest.
An elongate aerosol generating apparatus (210) comprising:
an elongate sub-assembly (200) comprising:
a printed circuit board (PCB) (214) including a PCB switch operable to actuate a function of the aerosol generating apparatus (210) via a switch of the PCB; and,

an elongate external housing (202) which houses the sub-assembly (200),

an upper chassis (218) having a support wall (220), wherein the support wall (220) engages with the PCB (214) to inhibit the PCB (214) from flexing or tilting away from the external housing in use.
An aerosol generating apparatus (210) according to claim 14, wherein the upper chassis (218) has a ramp (228) extending from an engagement end of the upper chassis (218) to the support wall (220), wherein the engagement end of the upper chassis (218) is inserted into the external housing (202) to slide the PCB (214) up the ramp into engagement with the support wall (220).