RU2817586C2 - Frame for aerosol-generating device (versions), method for making frame and aerosol-generating device - Google Patents

Abstract

FIELD: tobacco industry.

SUBSTANCE: group of inventions relates to products imitating the tobacco smoking process. Frame for an aerosol-generating device comprises a base frame formed from an electrically conductive material, an electrical connector having a plurality of electrical contacts. Multiple electrical contacts are located on the connector frame formed from electrically insulating material. Electrical connector is attached to the base frame so that the base frame is electrically connected to at least one of the electrical contacts of the electrical connector. Support frame is formed from electrically insulating material. Base frame and the electrical connector are at least partially embedded in the support frame. According to the second version, the base frame is attached to the electrical connector by laser welding. To implement the method of making a frame for an aerosol-generating device, a base frame is provided, formed from electrically conductive material. Electrical connector having a plurality of electrical contacts is provided. Multiple electrical contacts are located on the connector frame formed from electrically insulating material. Base frame is attached to the electrical connector so that the base frame is electrically connected to at least one of the electrical contacts of the electrical connector. Base frame and the electrical connector are at least partially embedded in a support frame formed from an electrically insulating material. What is declared is an aerosol-generating device.

EFFECT: simplified design and increased strength of connection between base frame and electric connector.

17 cl, 8 dwg

Description

The present invention relates to a frame for an aerosol generating device. The present invention also relates to a method for forming a frame for an aerosol generating device. The present invention also relates to an aerosol generating device comprising a frame.

Aerosol-generating systems are known in the art in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than burned. The purpose of such aerosol-generating systems is to reduce known harmful smoke components produced by combustion and pyrolytic degradation of tobacco in conventional cigarettes. Typically, in such aerosol generating systems, the aerosol is generated by transferring energy from the aerosol generator of the aerosol generating device to an aerosol generating substrate or material in the aerosol generating article that is physically separate from the aerosol generating device. For example, the aerosol generator may be an electrical heater, and the aerosol may be generated by transferring heat from the electrical heater to the aerosol-forming substrate. The aerosol generating article may be located within, around, or downstream of the heater. During use, volatile compounds are released from the aerosol-forming substrate by heat transfer from the heater to the aerosol-forming substrate and are entrained by air passing through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol that can be inhaled by the consumer.

The components of the aerosol generating device are typically housed within a housing with a diameter approximately equivalent to a conventional smoking article such as a cigarette or cigar with a lighted end, which can be problematic. The limited size of the aerosol generating device also increases the difficulty of providing suitable electrical connections between the various components and increases the difficulty of manufacturing the devices in relatively large volumes.

WO 2016/150979 A1 describes an electrically controlled aerosol generating device comprising: a power supply; electronic circuit board; external power contact; a power supply line configured to electrically connect the external power supply contact to the electronic circuit board; and a ground plane. The grounding plate contains: an elongated conductive element configured to: electrically connect a power source to an electronic circuit board; and structural containment of the power supply and electronic circuit board. The ground plane also includes: means for electrically isolating the power line from the elongate conductive member; and means for mechanically connecting the power line to the elongated conductive member.

WO 2015/139985 A1 describes an electrically controlled aerosol generating device comprising: an electrical power source; electronic circuit board; an electric heating element configured to receive power from an electrical power source via an electronic circuit board; and a ground plane comprising an elongated electrically conductive member configured to: electrically connect a power source to the electronic circuit board and the electrical heating element; and structurally retaining the power source and a plurality of components of the electrically controlled aerosol generating device.

It would be desirable to provide an electrical aerosol generating device that facilitates manufacture of the device. It would be desirable to provide an electrical aerosol generating device that has a compact and robust frame. It would also be desirable to provide improved methods and apparatus for providing electrical connections between various components of a system of aerosol generating systems.

According to the present invention, a frame for an aerosol generating device is provided. The frame may include a base frame formed from an electrically conductive material. The frame may include an electrical connector having an electrical contact. The electrical connector may be attached to the base frame such that the base frame is electrically connected to an electrical contact of the electrical connector. The frame may include a support frame formed from an electrically insulating material, the base frame and the electrical connector being at least partially embedded in the support frame.

In particular, according to the present invention, a frame for an aerosol generating device is provided. The frame comprises: a base frame formed from an electrically conductive material; an electrical connector having an electrical contact, the electrical connector being attached to the base frame such that the base frame is electrically connected to the electrical contact of the electrical connector; and a support frame formed from an electrically insulating material, the base frame and the electrical connector being at least partially embedded in the support frame.

Advantageously, providing such a frame for an aerosol generating device may allow the size and complexity of the aerosol generating device to be reduced compared to aerosol generating devices having other frames. The size and complexity of the aerosol generating device can be reduced due to the fact that the base frame and the electrical connector are at least partially integrated into the same support frame, as described in more detail below.

The present invention also provides a method for manufacturing a frame for an aerosol generating device. The method may include providing a base frame formed from an electrically conductive material. The method may include providing an electrical connector having an electrical contact. The method may include attaching a base frame to an electrical connector such that the base frame is electrically connected to an electrical contact of the electrical connector. The method may include at least partially incorporating a base frame and an electrical connector into a support frame formed from an electrically insulating material.

In particular, according to the present invention, a method for manufacturing a frame for an aerosol generating device is provided. The method includes: providing a base frame formed from an electrically conductive material; providing an electrical connector having electrical contact; attaching the base frame to the electrical connector such that the base frame is electrically connected to an electrical contact of the electrical connector; and at least partially incorporating the base frame and the electrical connector into a support frame formed from an electrically insulating material.

A frame for the aerosol generating device may also be provided, the frame being manufactured according to the method described above.

Advantageously, providing such a frame for the aerosol generating device reduces the complexity of the manufacturing process. The reduction in complexity of the manufacturing process is due to the initial electrical and structural connection of the base frame and the electrical connector before they are further structurally connected by at least partial integration into the support frame. This manufacturing process may also be easier to automate than other manufacturing processes.

As used herein, the term "aerosol generating device" refers to a device that interacts with an aerosol-forming substrate to generate an aerosol.

As used herein, the term "aerosol-forming substrate" means a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds can be released by heating the substrate to form an aerosol. The aerosol-generating substrate is typically part of the aerosol-generating article.

As used herein, the term “aerosol-generating article” refers to an article containing an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. For example, an aerosol generating product may be one that generates an aerosol that is directly inhaled by a user inhaling or puffing from a mouthpiece at the proximal or user end of the system. The aerosol-generating product may be disposable. A product containing a substrate that forms an aerosol containing tobacco is called a tobacco stick.

As used herein, the term “aerosol generating system” refers to the combination of an aerosol generating device and an aerosol generating article. In an aerosol generating system, an aerosol generating article and an aerosol generating device cooperate to generate a respirable aerosol.

Some aerosol generating devices include frames in which a supporting frame of electrically conductive material is embedded in a support frame of electrically insulating material. The support frames of such frames typically include a connecting portion that is specifically shaped to allow connection to an electrical connector. The electrical connector portion may also be configured to be connected to a support frame connecting portion, such as by an interference fit, a snap connection, or a screw fit, and after connecting the support frame and the electrical connector, the base frame and one or more electrical contacts of the electrical connector are electrically connected together and secured in place by soldering or welding. The present inventors have found that it is possible to reduce the complexity of manufacturing such scaffolds and reduce the size of such scaffolds. This is partly due to the fact that known support frames and electrical connectors have parts that are configured to be connected together. The inventors of the present invention have found that incorporating the base frame and the electrical connector into a single support frame can eliminate the need to provide connecting structures in both the base frame and the electrical connector at the same time, and will create a frame that is smaller in size than other similar known frames, while also retaining all the properties known frameworks. In addition, embedding the base frame and electrical connector into a single support frame can reduce the number of steps required to manufacture the frame and reduce the amount of material required to manufacture the frame.

Advantageously, at least partially embedding both the base frame and the electrical connector into the support frame also provides a strong structural connection between the base frame and the electrical connector.

The base frame is formed from an electrically conductive material. As used herein, the term "electrically conductive" refers to materials having an electrical resistivity of 1 x10 ^-4 ohm-meter (Ohm-m), or less, at twenty degrees Celsius. The base frame is formed from an electrically conductive material so that the electrical components of the aerosol generating device can be electrically coupled to the base frame. The base frame may be formed from any suitable electrically conductive material.

The electrical contact of the electrical connector is also formed from an electrically conductive material. The electrical contact of the electrical connector is electrically connected to the base frame. The electrical contact of the electrical connector may be formed from any suitable electrically conductive material.

In some embodiments, the base frame and the electrical contact of the electrical connector are formed from the same electrically conductive material. In some embodiments, the base frame and the electrical contact of the electrical connector are formed from different electrically conductive materials.

Suitable electrically conductive materials may include metal. The base frame can be metal. The electrical contact of the electrical connector may be metal. Suitable metals include aluminum, copper, iron, gold, zinc, or any suitable alloy of such metals. Suitable alloys include some stainless steels and some copper alloys such as brass, copper-nickel alloys, copper-beryllium alloys, and phosphor bronze.

Preferably, the base frame is formed from brass. The use of brass for the base frame may be advantageous because it is malleable enough to allow the base frame to be folded into the required shape and can be soldered to allow the electrical components of the aerosol generating device to be connected to the base frame. The use of brass can provide suitable electrical resistance between the components of the aerosol generating device. In addition, brass can be resilient enough to support components of an aerosol generating device, such as a power supply.

The electrically conductive base frame material may have a thickness of from about 0.05 mm to about 1.0 mm, and may preferably have a thickness of about 0.2 mm. It will be apparent to those skilled in the art that other suitable thicknesses may be determined based on the flexural resistance of the material used and the necessary support to be provided by the base frame for other components of the device.

In some embodiments, the electrical contact of the electrical connector is formed from a magnetic material. As used herein, the term "magnetic material" refers to a material that is capable of interacting with a magnetic field, including both paramagnetic and ferromagnetic materials. The magnetizable material may be a paramagnetic material, in which case it remains magnetized only in the presence of an external magnetic field. Alternatively, the magnetizable material may be a material that becomes magnetized in the presence of an external magnetic field and that remains magnetized after the external field is removed (eg, a ferromagnetic material). The term "magnetic material" as used herein covers both types of magnetizable material as well as material that is already magnetized.

Suitable magnetic materials include neodymium alloys such as neodymium, iron and boron. In other words, the magnetic material may be a neodymium magnet. Suitable magnetic materials also include ferromagnetic stainless steel such as SS430 grade stainless steel.

The base frame is attached to the electrical connector. In some embodiments, the base frame may be removably attached to an electrical connector. Preferably, the base frame is fixedly attached to the electrical connector. As used herein, the term "fixed" refers to the permanent attachment of two components such that release of the fastening between the components is impossible without damaging or destroying the "fixed" components.

The base frame may be attached to the electrical connector in any suitable manner.

In some embodiments, the base frame is attached to the electrical connector by a support frame. In some embodiments, the base frame is permanently attached to the electrical connector by a support frame. The support frame may be molded over at least a portion of the base frame and at least a portion of the electrical connector to permanently attach the base frame to the electrical connector.

In some preferred embodiments, the base frame is attached to the electrical connector by soldering or welding. Preferably, the base frame is laser welded to the electrical connector. Laser welding the base frame to the electrical connector permanently attaches the base frame to the electrical connector. Particularly preferably, the base frame is laser welded to the electrical contact of the electrical connector.

The base frame can be attached to the electrical connector at one location. The base frame can be attached to the electrical connector in several places.

Preferably, the base frame is attached to the electrical connector at the electrical contact. This can guarantee a strong electrical connection between the base frame and the electrical contact of the electrical connector. The base frame can be attached to the electrical contact by welding. Particularly preferably, the base frame is laser welded to the electrical contact.

The base frame can be attached to the electrical contact in one place. The base frame can be attached to the electrical contact in several places.

The base frame may be attached to the electrical connector at any appropriate time during the manufacturing process. For example, the base frame may be attached to the electrical connector when the base frame and the electrical connector are at least partially embedded in the support frame. However, preferably the base frame is attached to the electrical connector before the base frame and the electrical connector are at least partially integrated into the support frame. Particularly preferably, the electrical contact of the electrical connector is laser welded to the base frame prior to at least partial integration of the base frame and the electrical connector into the support frame.

The base frame is electrically connected to the electrical contact of the electrical connector. As used herein, the terms "electrically connected" and "electrical connection" refer to connection via an electrically conductive path.

The base frame may be electrically connected to an electrical contact at one location. The base frame may be electrically connected to the electrical contact in several places.

The support frame is formed from an electrically insulating material. As used herein, the term “electrically insulating” refers to materials having an electrical resistivity of 1 x 10 ⁴ ohm meter (Ohm m) or greater at twenty degrees Celsius.

The support frame may be formed from any suitable electrically insulating material. Preferably, the support frame is formed from a material that is suitable for molding over the base frame and electrical connector. The supporting frame may be formed from a polymeric material. In particular, the support frame can be formed from a moldable polymer. Preferably, the support frame is formed from a material that is suitable for use in a molding process such as injection molding. Particularly suitable polymeric materials include thermoplastic materials and thermoset polymers. Suitable polymeric materials include: polyphthalamide (PPA), polycarbonate (PC), polycarbonate-acrylonitrile butadiene styrene (PC-ABS), polyphenylsulfone (PPSU), polyetheretherketone (PEEK), polypropylene (PP), polyethylene (PE), polyimide (PI), thermoplastic polyimide (TPI), polyamide imide (PAI) and polyether amide (PEI). The polymer material can be composite. The composite polymer material may contain other materials, such as fibrous filler materials, including one or more of carbon fibers and glass fibers. Preferably the material is light and non-fragile.

The base frame and the electrical connector are at least partially integrated into the support frame. In the context of this document, the term "embedded" refers to a component that is surrounded and anchored within another component. In other words, at least a portion of the base frame is surrounded and secured within the support frame. In other words, at least a portion of the electrical connector is surrounded and secured within the support frame.

The base frame and electrical connector may be at least partially integrated into the support frame in any suitable manner. The support frame may be formed through a molding process such as injection molding. Preferably, at least a portion of the base frame and the electrical connector are formed by multi-layer casting using an electrically insulating material that forms the support frame. In some preferred embodiments, the support frame is formed by multi-layer molding of electrically insulating material over the base frame and electrical connector to at least partially embed the base frame and electrical connector into the support frame.

The electrical connector may be any type of electrical connector suitable for electrical connection with a complementary electrical connector, in particular a complementary electrical connector of an external device. The electrical connector may be configured to transmit electrical power between one or more components of the aerosol generating device, including the frame, and an external power supply. The electrical connector may be configured to transmit data between one or more components of the aerosol generating device, including the frame, and an external device.

In some preferred embodiments, the electrical connector includes a connector frame. The connector frame may support electrical contact of the electrical connector.

Preferably, the connector frame is formed from an electrically insulating material. The connector frame may be formed from any suitable electrically insulating material. Preferably, the connector body is formed from a material that is suitable for use in a molding process such as injection molding. The connector frame may be formed from a polymeric material. In particular, the connector frame may be formed from a moldable polymer. Particularly suitable polymeric materials include thermoplastic materials and thermoset polymers. Suitable polymeric materials include: polyphthalamide (PPA), polycarbonate (PC), polycarbonate-acrylonitrile butadiene styrene (PC-ABS), polyphenylsulfone (PPSU), polyetheretherketone (PEEK), polypropylene (PP), polyethylene (PE), polyimide (PI), thermoplastic polyimide (TPI), polyamide imide (PAI) and polyether amide (PEI). The polymer material can be composite. The composite polymer material may contain other materials, such as fibrous filler materials, including one or more of carbon fibers and glass fibers. Preferably the material is light and non-fragile.

The electrical contact of the electrical connector may be of any suitable shape and size. For example, the electrical contact may be substantially circular or polygonal, such as triangular, square, pentagonal, or hexagonal. The electrical contact may be substantially circular. In other words, the electrical contact may be in the form of a ring or a coil. The electrical contact may be in the form of a pin. The electrical contact may be a resilient contact configured to move between an extended position and a depressed position. The electrical contact may be a resilient pin contact movable between an extended position and a depressed position.

The electrical contact of the electrical connector may be at least partially integrated into the connector frame. The electrical contact of the electrical connector may be partially integrated into the connector frame such that a portion of the electrical contact is exposed. The exposed electrical contact portion of the electrical connector may be configured to contact a complementary electrical contact of a complementary electrical connector of an external device.

In some embodiments, the electrical contact of the electrical connector may be completely integrated into the connector frame. In these embodiments, the electrical contact of the electrical connector may be electrically coupled to a complementary electrical contact of the complementary electrical connector via inductive coupling or capacitive coupling. In particular, the electrical connector may be configured to be electrically connected to a complementary electrical contact of the complementary electrical connector by induction. Accordingly, such electrical contact, completely integrated into the connector frame, can be provided in the form of an induction coil.

The electrical contact may be at least partially incorporated into the connector frame in any suitable manner. The connector frame may be formed through a molding process such as injection molding. Preferably, at least a portion of the electrical contact is formed by multi-layer casting using an electrically insulating material that forms the frame of the connector. In some preferred embodiments, the connector frame is formed by multi-layer molding of electrically insulating material over the electrical contact to at least partially embed the base frame and the electrical connector into the support frame.

An electrical connector includes an electrical contact formed from an electrically conductive material. In some preferred embodiments, the electrical connector includes multiple electrical contacts. The electrical connector may comprise any suitable number of electrical contacts. For example, an electrical connector may contain one, two, three, four, five, six, seven, eight, nine, or ten electrical contacts.

A plurality of electrical contacts may be located on a connector frame formed from an electrically insulating material. Multiple electrical contacts may be arranged on the connector frame in any suitable arrangement.

In some preferred embodiments, an electrical connector comprises a plurality of electrical contacts, the plurality of electrical contacts being located on a connector frame formed from an electrically insulating material.

If an electrical connector contains multiple electrical contacts, then each electrical contact may be electrically isolated from the other electrical contacts. If the electrical connector includes a connector frame formed from an electrically insulating material, the connector frame may be configured to support multiple electrical contacts such that each electrical contact is electrically isolated from the other electrical contacts.

One or more of the electrical contacts of the electrical connector may be at least partially integrated into the connector frame. One or more of the electrical contacts of the electrical connector may be fully integrated into the connector frame.

In some preferred frame manufacturing methods, the step of providing an electrical connector may include: providing multiple electrical contacts; and at least partially incorporating one or more electrical contacts into a connector frame formed from an electrically insulating material to form an electrical connector.

One or more of the plurality of electrical contacts may be at least partially incorporated into the connector frame in any suitable manner. The connector frame may be formed through a molding process such as injection molding. Preferably, at least a portion of each of the one or more electrical contacts that is at least partially embedded in the connector frame is formed by multi-layer casting using an electrically insulating material that forms the connector frame. In some preferred embodiments, one or more of the electrical contacts are provided or positioned on the connector frame after the connector frame is formed. In some embodiments, all electrical contacts are provided on the connector frame after the connector frame is formed. In some embodiments, an electrical connector includes one or more electrical contacts that are at least partially embedded in the connector frame and one or more electrical contacts supported on the connector frame. In these embodiments, one or more electrical contacts supported on the connector frame are not built into the connector frame.

In embodiments including an electrical connector comprising multiple electrical contacts, the base frame is electrically connected to at least one of the electrical contacts. The base frame may be electrically connected to multiple electrical contacts. The base frame may be electrically connected to each electrical contact. The base frame may also be attached to an electrical connector at at least one of the electrical contacts. The base frame can be attached to multiple electrical contacts. The base frame can be attached to each of the electrical contacts.

Advantageously, providing an electrical connector with multiple electrical contacts allows the electrical connector to be configured to serve multiple purposes. In some preferred embodiments in which there is an electrical connector comprising multiple electrical contacts, one or more electrical contacts of the electrical connector are configured to transmit power between the aerosol generating device comprising the frame and an external power supply, and the one or more electrical contacts of the electrical The connectors are configured to transmit data between the aerosol generating device containing the frame and an external device.

In some preferred embodiments, the electrical connector includes at least three electrical contacts. The second of the electrical contacts may at least partially surround the first of the electrical contacts. The third of the electrical contacts may at least partially surround the first of the electrical contacts. In some embodiments, the first electrical contact of the electrical connector may be substantially circular. In some embodiments, the second and third electrical contacts of the electrical connector are substantially circular. In some particularly preferred embodiments, each of the second and third electrical contacts defines a ring that substantially surrounds the first electrical contact. The second and third electrical contacts of the electrical connector may form concentric rings surrounding the first electrical contact.

In some particularly preferred embodiments, the electrical connector includes a surface and a recess located substantially in the center of the surface, the recess having a closed end, an open end at the surface, and a side wall extending between the open end and the closed end. The first electrical contact may be located at the closed end of the recess. The second electrical contact may be located on the side wall of the recess and substantially surround the first electrical contact. The third electrical contact may be located on the surface and substantially surround the first electrical contact.

The electrical connector may include a magnetic element. A magnetic element is an element formed from a magnetic material. Advantageously, providing an electrical connector with a magnetic element can allow the electrical connector to be magnetically attracted to a complementary electrical connector, and such magnetic attraction can provide a more reliable electrical connection between the electrical connector and the complementary electrical connector. The electrical connector may contain any suitable number of magnetic elements. An electrical connector may contain multiple magnetic elements. The magnetic element of the electrical connector may be at least partially integrated into the connector frame. The magnetic element of the electrical connector can be completely integrated into the connector frame. In some embodiments, the electrical contact of the electrical connector includes a magnetic element. In other words, the electrical contact of the electrical connector may be formed from a magnetic material.

The base frame can have any suitable shape. Typically the base frame is oblong. In other words, the base frame may have a length that is greater than other dimensions of the base frame, such as width and thickness.

As used herein, the term “length” refers to the major dimension in the longitudinal direction of a frame for an aerosol generating device, an aerosol generating device, or a component of an aerosol generating device.

As used herein, the term "width" refers to the major lateral dimension of a frame for an aerosol generating device, an aerosol generating device, or a component of an aerosol generating device at a specific location along its length. The term "thickness" refers to the dimension in the transverse direction perpendicular to the width.

As used herein, the term "cross section" is used to describe the cross-section of a frame for an aerosol generating device, an aerosol generating device, or a component of an aerosol generating device, in a direction perpendicular to the longitudinal direction at a specific location along its length.

The base frame may have a proximal end and a distal end. As used herein, the term “proximal” means the user end, or mouth end, of the aerosol generating device. The proximal end of the base frame is the end of the base frame closest to the user end, or mouthpiece end, of the aerosol generating device containing the frame. As used herein, the term "far" refers to the end opposite the near end. The electrical connector is usually located at the far end of the frame. An electrical connector may be located at a distal end of the aerosol generating device comprising the frame.

In some preferred embodiments, the base frame is elongated, has a proximal end and a distal end opposite the proximal end, and an electrical connector is attached to the base frame at the distal end.

The base frame is formed from an electrically conductive material. In this regard, the base frame can be used to electrically connect components of the aerosol generating device. Specifically, the base frame is electrically coupled to an electrical contact of the electrical connector, and the base frame may be used to electrically connect one or more electrical components of the aerosol generating device to one or more electrical contacts of the electrical connector.

Preferably, at least a portion of the base frame defines a ground plane. As used herein, the term “ground plane” refers to an electrically conductive surface that acts as an infinite ground potential for components of an aerosol-generating electrical device.

The ground plane portion of the base frame may have any suitable shape and configuration. For example, the ground plane portion of the base frame may be oblong. The ground plane portion of the base frame may have a rectangular cross-section.

The ground plane portion of the base frame may have a proximal end and a distal end. The distal end of the ground plane portion of the base frame may be electrically connected to an electrical contact of the electrical connector. The distal end of the ground plane portion of the base frame may be attached to an electrical contact of an electrical connector, for example by laser welding. The proximal end of the ground plane portion of the base frame may be configured to be electrically connected to an electrical component of the aerosol generating device comprising the frame.

The ground plane portion of the base frame may be electrically connected to a negative terminal of a power supply unit of the aerosol generating device containing the frame. The electronic board of the aerosol generating device may be electrically connected to a ground plane.

In some embodiments, the entire base frame may form a ground plane.

Preferably, at least a portion of the base frame forms an electrical path. The electrical path may be configured to transmit electrical power between an aerosol generating device component comprising a frame and an electrical contact of an electrical connector. The electrical path may be configured to transmit data in the form of an electrical signal between an aerosol generating device component comprising a frame and an electrical contact of an electrical connector. The electrical path can have any suitable shape and configuration. For example, an electrical track may be oblong. The electrical path may have a rectangular cross-section.

An electrical path can have a near end and a far end. The distal end of the electrical path may be electrically connected to an electrical contact of the electrical connector. The distal end of the electrical track may be attached to the electrical contact of the electrical connector, such as by laser welding. The proximal end of the electrical path may be configured to be electrically coupled to an electrical component of the aerosol generating device comprising the frame.

In some embodiments, the base frame portion may include a ground plane and the base frame portion may include an electrical path. If the base frame includes a ground plane and an electrical path, then the ground plane and the electrical path can be electrically isolated from each other. The ground plane portion and the electrical path may be spaced apart such that the ground plane portion is electrically isolated from the electrical path. Advantageously, at least partially embedding the base frame into the support frame will allow the support frame to maintain separation between the ground plane and the electrical path to electrically isolate the ground plane from the electrical path. The ground plane portion and the electrical path may be formed from separate pieces of electrically conductive material. The ground plane portion and the electrical path may be formed from a single piece of electrically conductive material and separated during formation of the base frame. If the ground plane portion and the electrical path are formed from a single piece of electrically conductive material and are separated during formation of the base frame, such separation can be achieved by punching a cavity between the ground plane portion and the electrical path.

In embodiments in which the base frame includes a ground plane portion and an electrical path, the ground plane portion and the electrical path may be formed from the same electrically conductive material. In some embodiments, the ground plane portion and the electrical path are formed from different materials. In some embodiments, the ground plane portion is formed from brass and the electrical path may be formed from phosphor bronze.

An electrical path may be used to electrically connect components of an aerosol generating device. For example, an electrical path may be used to electrically connect an electronic board of an aerosol generating device to an electrical contact of an electrical connector.

In some embodiments, the base frame may include multiple electrical tracks. Each electrical track can be electrically isolated from other electrical tracks. Each electrical track may be at least partially embedded in the support frame, and the support frame may maintain separation between the electrical tracks to electrically isolate each electrical track from other electrical tracks.

The base frame may be substantially rigid. Advantageously, providing a substantially rigid base frame can simplify the manufacturing process compared to using electrically conductive wires. The ground plane may be substantially rigid. One or more electrical tracks may be substantially rigid.

In some preferred embodiments, the base frame includes a ground plane portion and two electrical tracks. In some particularly preferred embodiments, the base frame comprises two ground plane portions and two electrical tracks. In these particularly preferred embodiments, two electrical paths may be located between the two parts in the form of a ground plane.

In some preferred embodiments, the electrical contact of the electrical connector is configured to transmit power between the aerosol generating device comprising the frame and an external device. In other words, the electrical connector may include a power supply contact. In some of these preferred embodiments, the base frame includes an electrical path electrically coupled to the power contact of the electrical connector. An electrical path electrically connected to the power pin of an electrical connector may be called a power path. The power path may be configured to electrically connect a power contact of an electrical connector to one or more electrical components of an aerosol generating device comprising a frame. The power path may be electrically isolated from the ground plane portion of the base frame and other electrical traces of the base frame. The power trace may be electrically isolated from the ground plane and other traces of the base frame by a support frame.

In some preferred embodiments, the electrical contact of the electrical connector is configured to transmit data between the aerosol generating device comprising the frame and an external device. In other words, the electrical connector may comprise an electrical data contact. In some of these preferred embodiments, the base frame includes an electrical path electrically connected to the electrical data contact of the electrical connector. An electrical trace electrically connected to an electrical data pin of an electrical connector may be referred to as a data trace. The data track may be configured to electrically connect an electrical data contact of an electrical connector to one or more electrical components of an aerosol generating device comprising a frame. The data trace may be electrically isolated from the ground plane portion of the base frame and other electrical traces of the base frame. The data track may be electrically isolated from the ground plane and other base frame tracks by a support frame.

The electrical connector may include multiple electrical data contacts, and the base frame may include multiple data tracks, each data track being configured to electrically connect the electrical data contact to a component of the aerosol generating device comprising the frame. Each electrical data contact of the electrical connector may be electrically isolated from other electrical data contacts of the electrical connector. Each base frame data track may be electrically isolated from other base frame data tracks.

The data track width may be smaller than the power track width.

The ground plane portion of the base frame may include one or more pins configured to be electrically connected to a component of the aerosol generating device comprising the frame. In particular, the proximal end of the ground plane portion of the base frame may include one or more pins.

The electrical track of the base frame may include one or more pins configured to be electrically connected to a component of the aerosol generating device containing the frame. In particular, the proximal end of the electrical track of the base frame may include one or more pins.

The pin may be configured to be placed in a corresponding hole in the electronic board of the aerosol generating device comprising the frame.

The pin may be formed integrally with a ground plane portion or electrical path. The pin may be a physically separate component from the ground plane or electrical trace portion. The pin may be attached to a ground plane part or electrical path, such as by laser welding. The pin is formed from an electrically conductive material. The pin may be formed from the same electrically conductive material as the ground plane portion or electrical trace. The pin may be formed from a different electrically conductive material than that used for the ground plane or electrical path portion.

In some embodiments, the base frame is formed from multiple pieces of electrically conductive material. In these embodiments, one or more of the fragments may form a ground plane. In these embodiments, one of the fragments may form an electrical path. In these embodiments, multiple fragments may define a ground plane and multiple fragments may define multiple electrical paths.

The base frame is preferably made from a single lamellar sheet of electrically conductive material. Preferably the material is brass. Advantageously, brass can be flexible enough to be rolled into the desired shape. The base frame can be shaped in any suitable manner. For example, the base frame can be shaped by compression. For example, the base frame can be shaped by stamping. For example, the base frame can be shaped by cutting. For example, the base frame can be shaped by molding. In some embodiments, the base frame may be formed from multiple pieces of electrically conductive material. Several pieces of electrically conductive material may be bonded together. Several pieces of electrically conductive material may be secured together by a support frame.

The base frame may be formed by any suitable means. Preferably, the base frame is formed by one or more of pressing, stamping, punching and bending. Preferably, the step of providing the base frame may include providing a preform for the base frame and pressing the preform into a predetermined shape to form the base frame. The workpiece can be clamped between the pressing tool and the die. The pressing step may include punching. In other words, the pressing step may include punching one or more holes through the workpiece.

In embodiments in which the various parts of the base frame are electrically isolated from each other, the step of forming the base frame may include the step of separating one part of the base frame from another. For example, the portion of the base frame that defines the ground plane may be separated from the portion of the base frame that defines the electrical path. Such separation may be accomplished during the pressing procedure, for example by punching a hole between two parts of the preform to separate the two parts of the base frame.

In embodiments comprising one or more pins for electrically connecting a ground plane or electrical path portion to an aerosol generating device component comprising a frame, the one or more pins may be formed in any suitable manner. The pin may be formed with a ground plane portion or an electrical data path through a pressing, stamping, or punching process. The pin may be provided as a physically separate component from the base frame and may be attached to a ground plane portion or electrical data trace. For example, the pin may be laser welded to a ground plane part or electrical data trace.

The base frame is preferably configured to form a power supply cavity configured to accommodate the power supply unit of the aerosol generating device. The power supply cavity preferably has an open portion to allow insertion of the power supply into the power supply cavity and removal of the power supply from the power supply cavity. A cavity for the power supply may be provided towards the distal end of the frame. The cavity for the power supply may be located adjacent to the electrical connector.

The power supply cavity may be configured to hold the power supply of the aerosol generating device. The base frame may include means for holding the power supply in the power supply cavity. For example, the base frame may include one or more resilient members on an open portion of the power supply cavity. One or more elastic elements may define a width of the open portion that is smaller than the width of the power supply. The power supply cavity may have a width at the open portion that is smaller than the width of the power supply. At least the portion of the base frame defining the cavity for the power supply may be resilient such that the power supply can be inserted into the cavity by increasing the width of the open portion of the cavity. Preferably, the inner surface of the cavity for the power supply is configured to electrically connect the power supply to the base frame.

The base frame is preferably configured to accommodate the electronic board of the aerosol generating device. The base frame is preferably configured to be electrically connected to an electronic board of the aerosol generating device comprising the frame. The proximal end of the electrical track of the base frame may be configured to be electrically coupled to an electronic circuit board of the aerosol generating device comprising the frame. The proximal end of the ground plane portion of the base frame may be configured to be electrically connected to an electronic circuit board of the aerosol generating device comprising the frame.

The base frame may include one or more pins configured to electrically connect the base frame to an electronic circuit board of the aerosol generating device comprising the frame. The base frame may contain several pins. Several pins may be configured to extend parallel to each other. The pins may be configured to electrically connect to electronic components of the aerosol generating device comprising the frame.

The frame includes a support frame formed from an electrically insulating material, the base frame and the electrical connector being at least partially embedded in the support frame.

Preferably, the support frame is molded integrally with the base frame and electrical connector. In other words, the support frame is molded over at least a portion of the base frame and a portion of the electrical connector.

Preferably, the support frame is formed by multi-layer molding of electrically insulating material over the base frame and the electrical connector to at least partially embed the base frame and the electrical connector into the support frame.

The support frame can have any suitable shape and configuration.

The support frame may define at least a portion of a cavity for housing a power supply unit of the aerosol generating device comprising the frame. The support frame may include a substantially arcuate portion defining at least a portion of a cavity for housing the power supply unit. A cavity for housing the power supply unit of the aerosol generating device may be located towards the distal end of the frame.

The support frame may include a slot for receiving an electronic circuit board of the aerosol generating device containing the frame. The receptacle may include a cavity in the support frame having a shape and configuration that is complementary to the electronic circuit board of the aerosol generating device. A socket for housing the electronic circuit board of the aerosol generating device may be located near the proximal end of the frame.

The support frame may include a cavity for housing an aerosol generator of the aerosol generating device. A cavity for housing the aerosol generator may be located at a proximal end of the aerosol generating device. The cavity for housing the aerosol generator may be configured to accommodate a mount or base for the aerosol generator.

In some preferred embodiments, the support frame at least partially covers the electrical connection between the base frame and the electrical contact. Advantageously, bridging the electrical connection between the base frame and the electrical contact of the electrical connector can provide a more reliable structural and electrical connection between the base frame and the electrical contact of the electrical connector.

In some embodiments, the base frame and the electrical connector are mated at a contact interface. Preferably, the support frame at least partially overlaps the interface between the base frame and the electrical connector. Advantageously, at least partially covering the interface between the base frame and the electrical connector can provide a more reliable structural and electrical connection between the base frame and the electrical contact of the electrical connector.

In some embodiments, the support frame at least partially surrounds the electrical connector. Advantageously, this can provide a particularly reliable structural connection between the support frame and the electrical connector.

The support frame may at least partially extend over the rear or proximal surface of the electrical connector. The support frame may at least partially overlap the rear or proximal surface of the electrical connector. In some embodiments, the rear or proximal surface of the electrical connector may define the end of the frame power supply cavity. The support frame may substantially extend over the rear or proximal surface of the electrical connector such that the support frame defines an end surface of the cage power supply cavity for housing the power supply of the aerosol generating device containing the frame. Advantageously, extending the support frame over at least a portion of the rear or proximal end surface of the electrical connector such that the support frame defines the end surface of the power supply cavity of the frame can ensure that the end of the power supply housing housed in the power supply cavity is electrically isolated from one or more more electrical contacts of the electrical connector.

According to the present invention, an aerosol generating device can also be provided. The aerosol generating device may comprise a frame comprising a base frame formed from an electrically conductive material; an electrical connector having an electrical contact, the electrical connector being attached to the base frame such that the base frame is electrically connected to the electrical contact of the electrical connector; and a support frame formed from an electrically insulating material, the base frame and the electrical connector being at least partially embedded in the support frame. The aerosol generating device may further comprise: a power supply unit supported by a frame; and an electronic board supported by the frame.

The electrical contact of the electrical connector may form a power supply contact of the aerosol generating device. The power supply pin may be configured for electrical connection to an external power supply. The base frame may include an electrical power path electrically coupled to a power contact of the electrical connector. The electrical power path may be configured to electrically connect the power supply contact to the electronic board.

In preferred embodiments, the electrical connector further comprises an electrical contact forming a data contact. The data pin may be configured to electrically connect to an external device. The base frame may include an electrical data trace electrically coupled to a data pin of the electrical connector. The electrical data path may be configured to electrically connect the data contact to the electronic board.

In preferred embodiments, the electrical connector further comprises an electrical contact forming a grounding contact. The ground pin may be configured to provide electrical connection to the ground pin of an external device. The base frame may include a ground plane electrically connected to a ground pin of the electrical connector. The ground plane may be configured to electrically connect the ground contact to the electronic board. The ground plane may be electrically connected to the negative terminal of the power supply.

The aerosol generating device contains an electronic board. Preferably, the aerosol generating device comprises a controller located on an electronic board. The electronic board may contain a controller. The controller may include a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated circuit (ASIC) or other electronic circuit capable of performing control. The controller may contain additional electronic components.

The aerosol generating device contains a power supply unit. The power supply may be a DC power supply. In preferred embodiments, the power supply is a battery. The power supply may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, or a lithium polymer battery. However, in some embodiments, the power supply may be another type of charge storage device, such as a capacitor. The power supply may require recharging and may have a capacity to store sufficient energy for one or more user operations, such as one or more aerosol generation sessions. For example, the power supply may have sufficient capacity to provide continuous heating of the aerosol-forming substrate for a period of approximately six minutes, which corresponds to the typical time required to smoke a conventional cigarette, or for a period that is a multiple of six minutes. In another example, the power supply may have sufficient capacity to enable a given number of puffs or individual activations of the aerosol generator.

Preferably, the aerosol generating device includes a cavity for housing the aerosol generating substrate. Preferably, the cavity for housing the aerosol-forming substrate is located at the proximal end of the device. Particularly preferably, the cavity for accommodating the aerosol-generating substrate is located at the proximal end of the device, and the electrical connector is located at the distal end of the aerosol-generating device, opposite the proximal end.

The aerosol generating device may comprise an aerosol generator. The aerosol generator may be configured to generate an aerosol from an aerosol-forming substrate housed in the device. Preferably, the aerosol generator is configured to receive power from the power supply via an electronic board. The aerosol generator may be supported by a frame.

The aerosol generator may include an electric heater.

The electric heater may include at least one internal heating element. As used herein, the term "internal heating element" refers to a heating element configured to be inserted into an aerosol-generating substrate. The internal heating element may be in the form of at least one of a plate, a pin and a cone. The internal heating element is preferably configured to be inserted into the aerosol-forming substrate. In embodiments in which the aerosol generating device includes a cavity for housing the aerosol generating substrate, preferably at least one internal heating element extends into the cavity.

The electric heater may include at least one external heating element. As used herein, the term “external heating element” refers to a heating element configured to heat the outer surface of the aerosol-forming substrate. The at least one external heating element is preferably configured to at least partially surround the aerosol-generating substrate housed in the aerosol-generating device. In embodiments in which the aerosol generating device includes a cavity for housing the aerosol generating substrate, preferably at least one external heating element at least partially surrounds the cavity.

In some embodiments, the heater includes at least one internal heating element and at least one external heating element.

The heater may include a resistive heating element. Preferably, the heater comprises a resistive heating element comprising a rigid electrically insulating substrate with one or more electrically conductive tracks or wires disposed on its surface. Preferably, the size and shape of the electrically insulating substrate allows it to be inserted directly into the aerosol-forming substrate. If the electrically insulating substrate is not sufficiently rigid, the heating element may contain additional reinforcing agent. Current may pass through one or more electrically conductive paths to heat the heating element and the aerosol-forming substrate. A resistive heating element may be located in the cavity. The aerosol generating device may contain only one resistive heating element. The aerosol generating device may contain several resistive heating elements.

The aerosol generator may include a transmission element. The transfer element may be configured to transfer the aerosol-forming liquid substrate to the electrical heater. The transmission element may include a capillary wick. Preferably the electric heater is in contact with the transmission element. The electric heater may include a resistive heating wire. At least a portion of the resistive heating wire may be wrapped around the transmission element. The electric heater may include a resistive heating grid.

The aerosol generator may include an induction heating arrangement. The induction heating arrangement may include an induction coil and a power supply configured to supply high frequency oscillating current to the induction coil. As used herein, the term “high frequency oscillatory current” means oscillatory current with a frequency between 500 kilohertz kHz and 30 megahertz MHz. The at least one heater may advantageously comprise a DC/AC converter for converting the DC current supplied by the DC power supply into AC current. The induction coil may be configured to generate a high-frequency oscillating electromagnetic field to receive the high-frequency oscillating current from the power supply. The induction coil may be configured to generate a high-frequency oscillatory electromagnetic field in a cavity of the device configured to accommodate an aerosol-forming substrate. In some preferred embodiments, the induction coil may substantially surround the cavity of the device. The induction coil may extend at least partially along the length of the cavity of the device.

In embodiments in which the aerosol generator provides an induction heating arrangement, the aerosol generator may include an induction heating element. The induction heating element can be an element in the form of a current collector (susceptor). As used herein, the term “susceptor element” (susceptor element) refers to an element containing a material that is capable of converting electromagnetic energy into heat. When an element in the form of a pantograph is in an alternating electromagnetic field, the pantograph heats up. Heating of the pantograph element may result from at least one of hysteresis losses and eddy currents induced in the pantograph, depending on the electrical and magnetic properties of the pantograph material. The susceptor element may be positioned such that when the aerosol generating article is placed in the cavity of the device, the oscillating electromagnetic field generated by the induction coil induces a current in the susceptor element, resulting in heating of the susceptor element. The element in the form of a current collector may be located in the cavity. The aerosol generating device may contain only one element in the form of a current collector. The aerosol generating device may contain several elements in the form of a current collector.

The current collector element may comprise any suitable material. The susceptor element may be formed from any material that can be inductively heated to a temperature sufficient to release volatile compounds from the aerosol-forming substrate. Suitable materials for the elongated current collector element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel compounds, titanium and composite metal materials. Preferred current collector elements comprise metal or carbon. Advantageously, the current collector element may contain or consist of a ferromagnetic material, for example ferritic iron, a ferromagnetic alloy such as ferromagnetic steel or stainless steel, ferromagnetic particles and ferrite.

The aerosol generator may include an element designed to transmit oscillations when power is supplied from the power supply. The aerosol generator may contain a piezoelectric element. The aerosol generator may include at least one nozzle. The piezoelectric element may be configured to expel droplets of a liquid substrate forming an aerosol through at least one nozzle. The aerosol generator may comprise a grid, wherein the grid defines at least one nozzle.

The mesh may be configured to impart vibration during use of the aerosol generating device. The oscillatory grid can be called an “active grid”. The mesh may be formed from a piezoelectric material. The mesh may be a piezoelectric element. The piezoelectric element may be formed separately from the mesh and is designed to vibrate the mesh during use.

The grid may be positioned such that it remains substantially stationary relative to the oscillating piezoelectric element during use of the aerosol generating device. A fixed mesh can be called a "passive mesh". The aerosol generator may include a reservoir located between the mesh and the piezoelectric element. The reservoir may be designed to accommodate a liquid substrate that forms an aerosol.

Preferably, the aerosol generating device comprises a housing. The housing may at least partially define a cavity for housing the aerosol-forming substrate. The housing may have a proximal end and a distal end. A cavity for housing the aerosol-forming substrate may be located at a proximal end of the device. At least a portion of the heater of the aerosol generating device may extend into the cavity. Particularly in embodiments containing an internal heater, a portion of the heater may extend into the cavity to accommodate the aerosol-forming substrate.

The body may be oblong. Preferably the housing is cylindrical in shape. 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 such materials, or thermoplastic materials suitable for use in the food or pharmaceutical industries, such as polypropylene, polyetheretherketone (PEEK) and polyethylene. Preferably the material is light and non-fragile.

Preferably, the aerosol generating device is portable. The aerosol generating device may have a length of from about 70 millimeters to about 120 millimeters. The aerosol generating device may be a hand-held device. In other words, the aerosol generating device may be sized and shaped to be held in the user's hand.

In some embodiments, the housing may include an elongated hollow tube. The frame and components supported on the frame may be provided within an elongated hollow tube. The cross-sectional shape of the elongated hollow tube is preferably circular. The elongated hollow tube may be formed from a metal such as aluminum. The elongated hollow tube can increase the strength of the device by providing additional protection to the frame and electrical components supported by the frame, both during manufacture and during use. The length of the elongated hollow tube is preferably greater than the length of the frame. The length of the elongated hollow tube may exceed the total length of the frame and heater if the heater is mounted on the frame. Thus, the elongated hollow tube can form a cavity to accommodate the aerosol-forming substrate. In addition, providing an elongated hollow tube that extends to cover the heater can protect the heating element both during manufacture and during use of the aerosol generating device.

Any feature described with respect to the manufacturing method of the present invention can also be applied to the frame and aerosol generating device of the present invention. Any feature described in relation to the frame or aerosol generating device according to the present invention can also be applied to the manufacturing method according to the present invention.

It should also be understood that individual combinations of the various features described above may be implemented, provided and used independently.

Embodiments of the present invention will now be described solely by way of example with reference to the accompanying drawings, in which:

in fig. 1 is a perspective view of a base frame and a frame electrical connector for an aerosol generating device in accordance with an embodiment of the present invention;

in fig. 2 is a perspective view of the electrical connection of the base frame and the electrical connector shown in FIG. 1;

in fig. 3 is a perspective view of the base frame and electrical connector shown in FIG. 1, partially embedded in a support frame to form a frame for an aerosol generating device in accordance with an embodiment of the present invention;

in fig. 4 is another perspective view of the frame shown in FIG. 3;

in fig. 5 is a perspective view of the distal end of the frame shown in FIG. 3;

in fig. 6 is a schematic diagram of an aerosol generating apparatus according to an embodiment of the present invention; And

in fig. 7 is a schematic cross-sectional view through a cavity for a power supply of the aerosol generating system shown in FIG. 6; And

in fig. 8 is a flowchart of a manufacturing method for the frame shown in FIG. 1-7, in accordance with an embodiment of the present invention.

In fig. 1-7 show schematic views of a frame 10 for an aerosol generating device 100 in accordance with an embodiment of the present invention. The frame 10 provides support for the electrical components of the aerosol generating device 100 and electrical conductive paths that provide electrical connection to the various electrical components of the aerosol generating device 100. The frame according to the present invention is particularly compact and easy to manufacture compared to other known frames for aerosol generating devices.

In fig. 1 is a perspective view of a base frame 20 and an electrical connector 40 for use in an aerosol generating apparatus. The aerosol generating device is described in more detail below.

The base frame 20 is elongated and includes a proximal end and a distal end opposite the proximal end. An electrical connector 40 is located at the distal end of the base frame 20.

The base frame 20 generally contains several elongated electrically conductive elements. More specifically, the base frame 20 includes two electrical tracks 22, 24 placed between two portions 26 as a ground plane. The first electrical path 22 includes a proximal end 221 and a distal end 222. The second electrical path 224 includes a proximal end 241 and a far end 242. Each ground plane portion 26 includes a proximal end 261 and a far end 262.

In this embodiment, the base frame 20 is formed by pressing a single plate blank. In this embodiment, the preform is formed from brass. The plate blank may be stamped in either a single stamping process or multiple stamping processes to fold the blank into the desired shape and punch holes between portions of the blank to electrically isolate the first electrical track 22 from the second electrical track 24 and to electrically isolate the first and second electrical tracks 22, 24 from parts 26 in the form of a ground plane.

The electrically conductive elements are arranged and shaped to define a cavity 28 suitable for housing the electrical power supply of the aerosol generating device in a position between the proximal and distal ends of the electrically conductive elements.

Towards the proximal ends 221, 241, 261 of the electrical tracks 22, 24 and the ground plane portions 26, electrically conductive elements are provided by a plurality of electrically conductive pins 30. The pins 30 are configured to electrically connect the base frame 20 to an electronic board, such as a PCB, of the device. , generating an aerosol. Some of the pins 30 are formed by molding the proximal ends of the electrical conductive elements of the base frame 20, and some of the pins 30 are formed from individual phosphor bronze elements. The pins 30, formed from individual phosphor bronze elements, are laser welded to the electrically conductive elements of the base frame 20 in the required locations.

Electrical connector 40 includes three electrical contacts 41, 42, 43 supported on connector frame 44. As shown in detail in FIG. 5, electrical connector 40 generally includes an annular surface that is primarily defined by a third electrical contact 43 and a central recess 46 extending inwardly from the front surface. Recess 46 is substantially cylindrical, has a closed end defined by a first electrical contact 41, and a side wall substantially defined by a second electrical contact 42 extending between the closed end and the front surface.

The first and second electrical contacts 41, 42 are formed from phosphor bronze. The third electrical contact 43 is formed from a neodymium alloy so that the third electrical contact 43 forms a magnetic contact that can magnetically attract a complementary magnetic element of a complementary electrical connector. The first electrical contact 41 comprises a substantially flat metal sheet in which a tab at one end is bent substantially perpendicular to the sheet to connect the first electrical contact 41 to the base frame. The second electrical contact 42 comprises a substantially annular metal sheet forming a cylindrical tube having a tab at one end that is bent to extend in the same direction as the tab of the first electrical contact 42 when the first and second electrical contacts 41, 42 are located in the electrical connector 40. The third electrical contact 43 forms an annular metal disk. The third electrical contact 43 has a central channel with a diameter that is substantially the same as the outer diameter of the cylindrical tube of the second electrical contact 42. Accordingly, the second electrical contact 42 can be placed in the central channel of the third electrical contact 43, with the third electrical contact 43 surrounding second electrical contact 42.

The second electrical contact 42 and the third electrical contact 43 are partially integrated into the connector frame 44. The connector frame 44 is formed from a moldable polymeric material, polyphthalamide (PPA), which is injection molded over the second and third electrical contacts 42, 43. Molding over the second and third electrical contacts 42, 43 secures the second and third electrical contacts 42, 43 to the frame 44 connector and maintains the necessary separation between the second and third electrical contacts 42, 43 for electrical isolation from each other.

The connector body 44 and the second and third electrical contacts 42, 43 generally form an annular disk having a central channel that is open at both ends. The third electrical contact 43 generally forms the front surface of the disc, and the second electrical contact 42 generally forms the inner wall of the central channel. The first electrical contact 41 is located on the rear surface of the connector frame 44, opposite the third electrical contact 43 on the front surface, and extends over one of the open ends of the central channel to form the closed end of the central recess 46. The first electrical contact 41 is located opposite the rear surface of the frame 44 connectors such that the first electrical contact 41 is electrically isolated from the second and third electrical contacts 42, 43.

The distal end 222 of the first electrical track 22 of the base frame 20 is in physical contact with the tongue of the first electrical contact 41 of the electrical connector 40 such that the first electrical track 22 is electrically connected to the first electrical contact 41. The distal end 242 of the second electrical track 24 of the base frame 20 is in physical contact with the tongue. the second electrical contact 42 of the electrical connector 40 such that the second electrical path 24 is electrically connected to the second electrical contact 42. The distal ends 262 of the ground plane portions 26 of the base frame 20 are physically in contact with the cylindrical outer side wall of the third electrical contact 43 of the electrical connector 40 such that that the ground plane portions 26 of the base frame 20 are electrically connected to the third electrical contact 43.

The distal portions 222, 242 of the first and second electrical tracks 22, 24 are laser welded to the tongues of the first and second electrical contacts 41, 42, and the distal portions 262 of the base frame portions 26 of the base frame 20 are laser welded to the outer side wall of the third electrical contact. 43. Accordingly, in this embodiment, the base frame 20 is attached to the electrical connector 40 at all locations of the base frame 20 that are physically in contact with the electrical connector 40. It should be appreciated that in other embodiments, the electrical contacts of the electrical connector may not be attached to base frame, and in other embodiments, only some of the electrical contacts may be attached to the base frame.

As shown in FIG. 3, 4 and 5, the base frame 20 and the electrical connector 40 are partially embedded in the support frame 50 to form the entire frame 10. In this embodiment, the support frame 50 is formed from a moldable polymeric material, polyphthalamide (PPA), which is injection molded over the frame. 20 base and 40 electrical connector.

At the distal end 52 of the support frame 50, the rear end of the electrical connector 40 and the distal ends 224, 242, 262 of the electrically conductive members of the base frame 20 are integrated into a portion of the support frame 50. The distal end portion of the support frame 50 generally surrounds and extends over the cylindrical outer the side wall of the third electrical contact 43 and the base frame 20. The distal end portion 53 of the support frame 50 also extends over the rear surface of the connector frame 44 and the first electrical contact 41. Accordingly, the distal end portion 53 of the support frame 50 spans the interface between the base frame 20 and the electrical connector 40. In more detail, the 53 in the form of the distal end of the support frame 50 extends over the connection between the distal end 222 of the first electrical track 22 of the base frame 20 with the first electrical contact tab 41 of the electrical connector 40, extends over the connection between the distal end 242 of the second electrical track 24 of the base frame 20 with the second electrical tab contact 42 of the electrical connector 40, and extends over the connection between the distal ends 262 of the ground plane portions 26 of the frame of the base 20 and the outer side wall of the third electrical contact 43 of the electrical connector. Thus, the support frame 50 further secures the connection between the base frame 20 and the electrical connector 40.

The front surface of the electrical connector 40 is not covered by the support frame 50, so that the front surface of the third electrical contact 43 and the first and second electrical contacts 41, 42 in the recess 46 are exposed. This allows the first, second and third electrical contacts 41, 42, 43 to contact complementary electrical contacts of the complementary electrical connector.

At the proximal end 54 of the support frame 50, the support frame 50 defines a socket 55 for housing the electronic board of the aerosol generating device. Socket 55 generally contains a shallow rectangular cavity suitable for housing an electronic board, and includes additional deeper internal cavities located within the shallow cavity for housing electrical components coupled to the electronic board. At the proximal end 54 of the support frame 50, the support frame 50 further includes openings for allowing the proximal ends 221, 241, 261 of the electrically conductive members of the base frame 20 and the pins 30 to pass through the support frame 50 and make electrical connection to an electronic board housed in the socket 55. .

An intermediate portion 56 of the support frame 50 located between the distal end 52 and the proximal end 54 defines a power supply cavity 57 for housing the electrical power supply of the aerosol generating device. The power supply cavity 57 includes a cavity 28 defined by the electrically conductive elements of the base frame 20 and the generally arcuate portion of the support frame 50, as shown in the cross section in FIG. 7. At the intermediate portion 56 of the support frame 50, the first and second electrical tracks 22, 24 are fully embedded in the arcuate portion of the support frame 50, and the inner surfaces of the ground plane portions 26 of the base frame 20 are embedded in the arcuate portion of the support frame 50. Accordingly, the arcuate portion of the support frame frame 50 maintains the desired separation between the electrically conductive elements of base frame 20. The inner surface of the arcuate portion of the support frame 50 is formed in a shape that complements the outer surface of the electrical power supply of the aerosol generating device, which allows the arcuate portion of the support frame 50 to hold the electrical power supply and prevent the electrical power supply from moving within the power supply cavity 57.

Near the power supply cavity 57, the ground plane portions 26 of the base frame 20 are bent into a substantially arcuate shape. The upper ends of the ground plane portions 26 opposite the lower ends adjacent the first and second electrical tracks 22, 24 are not integrated into the support frame 50. The upper ends of the ground plane portions 26 define an opening 265 for allowing the electrical power supply to be inserted into the cavity 57 for the power supply and removal from the cavity 57 for the power supply. Pairs of opposing resilient portions 266 are spaced at equal intervals along the length of the power supply cavity 57 at the upper ends of the portions 26 as a ground plane. As shown in FIG. 7, each pair of opposing elastic portions 266 is bent to define a width of the opening 265 that is smaller than the diameter of the electrical power supply of the aerosol generating device. This helps to retain the electrical power supply of the aerosol generating device in the power supply cavity 57, since the opposing pairs of resilient portions 266 must be moved apart to allow the electrical power supply to be removed from the electrical power supply cavity 57.

An additional pair of opposing resilient portions 268 are located at the upper ends of the portions 26 as a ground plane and are bent outwardly to engage the body of the aerosol generating device. This additional pair of opposing resilient portions 268 is folded inward when the frame 10 is placed in the aerosol generating device body and presses against the inner surface of the housing to provide increased frictional force between the frame 10 and the aerosol generating device body. In this regard, an additional pair of opposing elastic portions 268 helps to support the frame 10 within the body of the aerosol generating device.

At the proximal end of the support frame 50, the support frame defines a heater cavity 58 for housing the heater base of the aerosol generating device. Accordingly, the frame 10 is configured to house and support an electrical power supply, an electronic board, and a heater of the aerosol generating device.

In fig. 6 and 7 show a schematic illustration of an aerosol generating device 100 comprising a frame 10.

The aerosol generating device 100 is a device configured to accommodate an aerosol generating article (not shown) containing a solid aerosol-generating substrate and a filter wrapped together in a rod-like manner, as in a conventional cigarette. The aerosol generating device 100 is a portable device that is designed to be held by the user's hand, having a length of approximately 90 mm, a diameter of approximately 14 mm.

The aerosol generating device 100 includes an outer housing 102 that is generally cylindrical and formed from a lightweight and brittle plastic material such as PEEK. The aerosol generating device 100 also includes an inner housing 103 containing a hollow cylindrical tube of aluminum that extends along the length of the outer housing 102 and beyond the proximal end of the inner housing 103 to form an open cylindrical cavity 104. The open cylindrical cavity 104 is configured to receive a substrate. aerosol-generating product, aerosol-generating product. An elongated plate heater 106 extends into the cavity 104 to penetrate the aerosol generating substrate of the aerosol generating article placed in the cavity 104. The heater 106 includes a plate having a plurality of resistive heating elements or tracks located on an electrically insulating polyimide substrate extending from grounds 107.

A power supply 108 in the form of a lithium-ion battery with a capacity of approximately 120 milliamp-hours is located within the housing 102.

An electronic board 110 is also housed within a housing 102. The electronic board 110 includes a controller having a microprocessor (not shown) mounted on a printed circuit board. The electronic board 110 is connected to the heater 106 and the power supply 108, and the electronic board 110 is configured to control the supply of power from the power supply 108 to the heater 106.

In this embodiment, the controller is configured to measure the resistance of one of the electrically resistive heating elements of the heater 106. The electrical resistance of the electrically resistive heating element provides an indication of the temperature of the heater 106. The controller is configured to control the temperature of the heater 106 by controlling power supplied from power supply 108 to the heater 106, based on resistance measurements of an electrically resistive heating element.

The heater 106, the electrical power supply 108, and the electronic board 110 are housed in the frame 10 and supported by the frame 10. The base 107 of the heater 106 is housed in the heater cavity 58 of the support frame 50. The electrical power supply 108 is housed in the power supply cavity 57, as shown in FIG. 7. The electronic board 110 is housed in slot 55 of the frame 10. The frame 10, heater 106, electrical power supply 108, and electronic board 110 are housed together in an inner housing 103, which provides some protection to the components from shock and general wear.

The electrical connector 40 at the distal end of the frame 10 is located at the distal end of the outer housing 102, opposite the cavity 104, and forms the distal end surface of the aerosol generating device 100.

The electronic board 110 is electrically connected to each of the first, second and third electrical contacts 41, 42, 43 through the base frame 20.

The proximal ends 221, 241, 261 of the electrically conductive members of the base frame 20 and the electrically conductive pins 30 extend through holes in the support frame 50 and are electrically connected to the electronic board 110.

The first electrical contact 41 of the electrical connector 40 is connected to the electronic board 110 via the first electrical track 22 of the base frame 20. In this embodiment, the first electrical path 22 and the first electrical contact 41 are configured to transmit power from the external power supply to the electronic board 110. Accordingly, the first electrical path 22 may be referred to as a power path. The electronic board controller 110 is configured to control the supply of power from the external power supply to the power supply 108 of the aerosol generating device 100 to recharge the power supply.

The second electrical contact 42 of the electrical connector 40 is connected to the electronic board 110 via the second electrical track 24 of the base frame 20. In this embodiment, the second electrical track 24 and the second electrical contact 42 are configured to transmit data from an external device to the electronic board 110. Accordingly, the second electrical track 24 may be referred to as a data track. The controller of the electronic board 110 is configured to control the communication of data between the external device and the controller of the aerosol generating device 100.

The third electrical contact 43 of the electrical connector 40 is connected to the electronic board 110 through both parts 26 as a ground plane of the base frame 20. In this embodiment, the ground plane portions 26 of the base frame 20 act as an infinite ground potential for the components of the electrical board 110 such that electrical connection of the electronic board 110 to the ground plane portions 26 of the base frame allows the components of the electronic board to be grounded. In addition, the third electrical contact 43 of the electrical connector 40 is configured to be connected to a corresponding ground terminal of the complementary electrical connector.

It should be understood that in other embodiments of the present invention, other components of the aerosol generating device may be connected to each other using portions of the base frame 20. For example, a heater of the aerosol generating device may be directly coupled to an electrical contact of an electrical connector to directly supply power from an external power supply to the heater of the aerosol generating device. For example, the positive terminal of the electrical power supply of the aerosol generating device may be connected to the electronic board of the aerosol generating device via a portion of the base frame. In addition, the electrical connector may be provided with different numbers of electrical contacts.

In fig. 8 is a flowchart of a manufacturing method for the frame 10 shown in FIG. 1-7, according to an embodiment of the present invention.

In a first step 201, a brass plate-shaped preform is pressed to form a base frame 20 having a first electrical track 22, a second electrical track 24, and ground plane portions 26.

In a second step 202, a neodymium alloy annular disk is provided to form a third electrical contact 43.

In a third step 203, a phosphor bronze annular disk is provided to form a second electrical contact 42.

In a fourth step 204, PPA is injection molded over the third electrical contact 43 and the second electrical contact 42 to form a connector frame 44, with the second and third electrical contacts 42, 43 partially embedded in the connector frame 44.

In a fifth step, 205 provides a substantially flat phosphor bronze sheet to form the first electrical contact 41.

In a sixth step 206, the first electrical contact 41 is positioned on the rear surface of the connector frame 44 such that the first, second and third electrical contacts 41, 42, 43 and the connector frame 44 form an electrical connector 40.

In a seventh step 207, the electrical connector 40 is positioned at the distal end of the base frame 20, with the distal ends 222, 242, 262 of the electrically conductive elements of the base frame 20 contacting the electrical contacts 41, 42, 43 of the electrical connector.

In the eighth step 208, the electrical contacts 41, 42, 43 of the electrical connector 40 are laser welded to the distal ends 222, 242, 262 of the electrically conductive members of the base frame 20. More specifically, the first electrical contact 41 is laser welded to the distal end 222 of the first electrical track 22, the second electrical contact 42 is laser welded to the distal end 242 of the second electrical track 24, and the third electrical contact 43 is laser welded to the distal ends 262 of the parts 26 in in the form of the grounding plane of the base frame 20.

In a ninth step 209, PPA is injection molded over the base frame 20 and the electrical connector 40 to form a support frame 50, with the base frame 20 and the electrical connector 40 partially embedded in the support frame 50. The base frame 20, the electrical connector 40 and the support frame 50 together form the frame 10.

In an additional step (not shown), electrically conductive pins 30 may be positioned on base frame 20 in contact with electrically conductive elements of base frame 20 and laser welded to base frame 20. This additional step may be performed immediately after the first step of forming the base frame 20, immediately before or after the eighth step of laser welding the electrical contacts of the electrical connector 40 to the base frame 20, or after forming the support frame 50.

It should be understood that the frame in accordance with the present invention can be used in other types of aerosol generating devices, such as aerosol generating devices adapted to evaporate a liquid aerosol-forming substrate. It should also be understood that other embodiments of frames in accordance with the present invention may have other shapes and configurations, and may be made of other materials. It should also be understood that other manufacturing methods may be used to form the framework in accordance with the present invention.

Claims (34)

1. A frame for an aerosol generating device, the frame comprising: a base frame formed from an electrically conductive material; an electrical connector having a plurality of electrical contacts, the plurality of electrical contacts located on a connector frame formed from an electrically insulating material, the electrical connector being attached to a base frame such that the base frame is electrically connected to at least one of the electrical contacts of the electrical connector; And a support frame formed from an electrically insulating material, the base frame and the electrical connector being at least partially embedded in the support frame. 2. Frame according to claim 1, characterized in that the electrical connector is attached to the base frame on an electrical contact. 3. Frame according to claim 1 or 2, characterized in that the supporting frame at least partially covers the electrical connection between the base frame and the electrical contact. 4. Frame according to any one of paragraphs. 1-3, characterized in that the base frame is elongated, has a proximal end and a distal end opposite the proximal end, and an electrical connector is attached to the base frame at the distal end. 5. A method for manufacturing a frame for an aerosol generating device, the method comprising the steps of: providing a base frame formed from an electrically conductive material; providing an electrical connector having a plurality of electrical contacts, the plurality of electrical contacts located on a connector frame formed from an electrically insulating material; attaching the base frame to the electrical connector such that the base frame is electrically connected to at least one of the electrical contacts of the electrical connector; And at least partially embedding the base frame and the electrical connector into a support frame formed from an electrically insulating material. 6. The method for manufacturing a frame according to claim 5, characterized in that the base frame is attached to an electrical connector at an electrical contact. 7. A method for manufacturing a frame according to claim 5 or 6, characterized in that the base frame is attached to the electrical connector by laser welding. 8. A method for manufacturing a frame according to any one of claims. 5-7, characterized in that the support frame at least partially covers the electrical connection between the base frame and the electrical contact. 9. A method for manufacturing a frame according to any one of claims. 5-8, characterized in that the support frame is formed by multi-layer casting of electrically insulating material over the base frame and the electrical connector to at least partially embed the base frame and the electrical connector into the support frame. 10. Method for manufacturing a frame according to any one of claims. 5-9, characterized in that at the stage of providing an electrical connector: provide many electrical contacts; And at least partially incorporating a plurality of electrical contacts into a connector frame formed from an electrically insulating material to form an electrical connector. 11. Method for manufacturing a frame according to any one of claims. 5-10, characterized in that the base frame is electrically connected to each of the electrical contacts of the electrical connector. 12. A frame for an aerosol generating device manufactured by a method which includes stages in which: providing a base frame formed from an electrically conductive material; providing an electrical connector having a plurality of electrical contacts, the plurality of electrical contacts located on a connector frame formed from an electrically insulating material; attaching the base frame to the electrical connector such that the base frame is electrically connected to at least one of the electrical contacts of the electrical connector; And at least partially incorporating the base frame and the electrical connector into a support frame formed from an electrically insulating material, wherein The base frame is laser welded to the electrical connector. 13. The frame according to claim 12, characterized in that the support frame at least partially covers the electrical connection between the base frame and the electrical contact. 14. Frame according to any one of paragraphs. 12, 13, characterized in that the support frame is formed by multi-layer molding of electrically insulating material over the base frame and the electrical connector to at least partially embed the base frame and the electrical connector into the support frame. 15. Frame according to any one of paragraphs. 12-14, characterized in that at the stage of providing an electrical connector: multiple electrical contacts are provided; And a plurality of electrical contacts are at least partially embedded in a connector frame formed from an electrically insulating material to form an electrical connector. 16. Frame according to any one of paragraphs. 12-15, characterized in that the base frame is electrically connected to each of the electrical contacts of the electrical connector. 17. An aerosol-generating device containing a frame according to any one of claims. 1-4 or 12.

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