WO2024017954A1

WO2024017954A1 - Method of manufacturing an aerosol provision device

Info

Publication number: WO2024017954A1
Application number: PCT/EP2023/070039
Authority: WO
Inventors: Zheng XIAOYUAN; Michael Thomas
Original assignee: Nicoventures Trading Limited
Priority date: 2022-07-21
Filing date: 2023-07-19
Publication date: 2024-01-25

Abstract

The invention provides a method of manufacturing an aerosol provision device (100) comprising: providing a first housing having a proximal end and a distal end (103), providing one or more channels in a longitudinal direction along the device (100) from the distal end (103) of the housing and depositing or printing one or more electrically conductive tracks (120a-d) into the one or more channels.

Description

METHOD OF MANUFACTURING AN AEROSOL PROVISION DEVICE

TECHNICAL FIELD

The present invention relates to a method of manufacturing an aerosol provision device, an aerosol provision device, an aerosol generating system, a method of charging an aerosol provision device and a method of transmitting data to and/or from an aerosol provision device.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combusting. Examples of such products are so-called “heat not burn” products or tobacco heating devices or products, which release compounds by heating, but not burning, material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.

Aerosol provision systems, which cover the aforementioned devices or products, are known. Common systems use heaters to create an aerosol from a suitable medium which is then inhaled by a user. Often the medium used needs to be replaced or changed to provide a different aerosol for inhalation.

It is known to use a resistive heater to create aerosol from a suitable medium.

Conventional aerosol provision devices comprise a cylindrical heating chamber into which a rod shaped consumable is inserted.

It is known to provide an aerosol provision device which is charged by a charging unit and wherein electrical power is supplied by the charging unit to the aerosol provision device in order to charge the aerosol provision device.

It is desired to provide an improved aerosol provision device.

SUMMARY

According to an aspect there is provided a method of manufacturing an aerosol provision device comprising: providing a housing having a proximal end and a distal end; providing one or more channels in a longitudinal direction along the device from the distal end of the housing; and depositing or printing one or more electrically conductive tracks into the one or more channels.

According to various embodiments an aerosol provision device is provided wherein a plurality of electrical contacts are provided on a distal end of the housing by etching one or more channels into the distal end of the housing and then depositing or printing electrically conductive tracks into the one or more channels. Once deposited or printed, the electrically conductive tracks may be arranged to be substantially flush with the distal end of the housing. The channels and hence finished electrical contacts can follow tortuous paths which are not feasible using conventional wires. Furthermore, the finished electrical contacts can be made smaller than conventional wires and in contrast to conventional wires the cross-sectional profile of the electrical contacts may vary along the length of the conductive tracks. Accordingly, utilising conductive tracks which have been deposited into channels provides increased flexibility and freedom of design.

Optionally, the one or more electrically conductive tracks are non-planar.

Optionally, the one or more electrically conductive tracks follow a curved or tortuous path.

Optionally, wherein the curved or tortuous path is curved or tortuous in a radial direction.

Optionally, the one or more channels have a circular, oval, polygonal or rectangular cross-sectional profile.

Optionally, the one or more electrically conductive tracks comprise copper, silver, gold, zinc, aluminium, nickel, iron, platinum or tungsten.

Optionally, the step of providing one or more channels in a longitudinal direction along the distal end of the housing comprises etching.

Optionally, the step of etching comprises laser etching.

Optionally, the step of etching comprises wet etching.

Optionally, the aerosol provision device comprises a base portion and wherein at least a portion of the one or more conductive tracks is flush with the base portion. Optionally, the method further comprises locating the first housing within an outer housing.

Optionally, the outer housing comprises an electrical insulator. The outer housing may, for example, comprise polyetherethreketone (“PEEK”).

According to another aspect there is provided an aerosol provision device comprising: a first housing having a proximal end and a distal end; and one or more electrically conductive tracks provided in the distal end of the first housing, the one or more electrically conductive tracks comprising an electrically conductive material deposited or printed within one or more channels provided in the first housing.

Optionally, the one or more electrically conductive tracks are non-planar.

Optionally, the one or more electrically conductive tracks comprise copper.

Optionally, the one or more channels are provided by etching or laser etching.

Optionally, the aerosol provision device comprises a base portion and wherein at least a portion of the one or more conductive tracks is flush with the base portion.

Optionally, the first housing is located within an outer housing.

Optionally, the outer housing comprises an electrical insulator. The outer housing may comprise polyetherethreketone (“PEEK”).

According to another aspect there is provided aerosol generating system comprising: an aerosol provision device as described above; and a charging unit for charging the aerosol provision device.

Optionally, the charging unit comprises: a cavity for receiving the aerosol provision device; and a base portion, wherein the base portion further comprises one or more electrical and/or data connections for connecting to the one or more electrically conductive tracks provided on the aerosol provision device.

According to another aspect there is provided a method of electrically charging an aerosol provision device comprising connecting an aerosol provision device as described above to a charging unit.

According to another aspect there is provided a method of transmitting data to and/or from an aerosol provision device comprising connecting an aerosol provision device as described above to a charging unit.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings in which:

Fig. 1 shows an aerosol provision device located within a charging unit according to an embodiment;

Fig. 2 shows a cross-sectional view of an aerosol provision device located within a charging unit;

Fig. 3 shows a distal end of the aerosol provision device according to an embodiment showing a plurality of electrical contacts formed in a base portion of the aerosol provision device;

Fig. 4 shows electrical contacts formed on the distal end of an aerosol provision device according to various embodiments with the outer housing of the aerosol provision device removed, wherein the electrical contacts are formed by etching channels into the distal end of the aerosol provision device and then depositing or printing conductive tracks into the channels; and

Fig. 5 shows a lower portion of the charging unit showing a plurality of electrical contacts and an alignment feature, wherein the electrical contacts in the charging unit are arranged to contact the electrical contacts provided on the distal end of the aerosol provision device. DETAILED DESCRIPTION

Aspects and features of certain examples and embodiments are discussed or described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed or described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with conventional techniques for implementing such aspects and features.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosolgenerating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosolgenerating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosolgenerating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.

The aerosol-generating material may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosolmodifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

Non-combustible aerosol provision systems may comprise a modular assembly including both a reusable aerosol provision device and a replaceable aerosol generating article. In some implementations, the non-combustible aerosol provision device may comprise a power source and a controller (or control circuitry). The power source may, for example, comprise an electric power source, such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol provision device may also comprise an aerosol generating component. However, in other implementations the aerosol generating article may comprise partially, or entirely, the aerosol generating component.

For completeness, aerosol provision devices comprising an inductive element are known. The aerosol provision device may comprise one or more inductors and a susceptor which is arranged to be heated by the one or more inductors.

A susceptor is a heating material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically- conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The aerosol provision device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

Various embodiments will now be described in more detail.

Fig. 1 shows an aerosol provision device 100 according to an embodiment shown located within an elongate cavity of a charging unit 101. The charging unit 101 may comprise a power source (not shown). The power source may include, for example, a battery (single-use or rechargeable), a rechargeable super capacitor, a rechargeable solid-state battery (SSB), a rechargeable lithium-ion battery (LiB) or the like, a hermetically sealed battery, a pouch cell battery or some combination thereof.

The aerosol provision device 100 may be left in the charging unit 101 for a predetermined time in order to allow sufficient charging of the aerosol provision device 100. For example, the charging unit 101 may be arranged to charge the aerosol provision device 100 to full charge in a time of < 10 mins, 10-20 mins, 20-30 mins, 30-40 mins, 40-50 mins, 50-60 mins or > 60 mins.

The charging unit 101 and/or the aerosol provision device 100 may optionally have an indicator to give a visual or other representation to the user of the charging level of the aerosol provision device 100. Additionally, there may be a separate indicator to give a visual representation of the charge level of the charging unit 101. The current charge level of the aerosol provision device 100 and/or the charging unit 101 may be determined by control means disposed in the aerosol provision device 100 and/or the charging unit 101.

The visual indicator may comprise one or more light-emitting diodes (LEDs). However, other embodiments are contemplated where the visual indicator may be replaced by an audio indicator (e.g. a speaker) or a haptic indicator.

The aerosol provision device 100 may comprise an outer housing which may have a tubular and/or cylindrical shape. However, other embodiments are envisaged wherein the aerosol provision device 100 may take other desired forms e.g. the aerosol provision device 100 may be boxed shaped. According to an embodiment the outer housing of the aerosol provision device 100 may comprise an electrical insulator and may, for example, be formed of polyetheretherketone (“PEEK”).

According to an embodiment the distal end of the aerosol provision device 100 may comprise one or more orientation features and/or one or more magnets for securing the distal end of the aerosol provision device 100 to a base portion of the charging unit 101.

The aerosol provision device 100 may be inserted into the cavity of the charging unit 101 in order to recharge the aerosol provision device 100 by receiving electrical power from the charging unit 101. The charging unit 101 may comprise an internal battery to provide electrical power to the aerosol provision device 100. The charging unit 101 may also be connected to an external source of electrical power.

The charging unit 101 may comprise a lid or cover 102 which may be slid by a user between an open and closed position. The lid or cover 102 is provided at the entrance to the cavity which is provided within the charging unit 101 and which is configured to receive the aerosol provision device 100.

The aerosol provision device 100 includes an aerosol generator for generating aerosol from aerosol generating material. According to an embodiment the aerosol provision device 100 comprised a resistive heater for heating an aerosol generating article.

When the lid or cover 102 is in the open position an opening to the cavity is exposed thereby enabling a user to either remove the aerosol provision device 100 from the charging unit 101 (in order to use the aerosol provision device 100) or alternatively to insert the aerosol provision device 100 into the charging unit 101 (in order to charge the aerosol provision device 100).

Fig. 2 shows a cross-sectional view showing the aerosol provision device 100 located or docked within the charging unit 101. The aerosol provision device 100 comprises a main housing 105 wherein a resistive heating element 104 projects within the main housing 105. The aerosol provision device 100 further comprises a removable cap 106 which may be magnetically retained to the main housing 105.

The removal cap 106 includes a receptacle 120 for receiving a consumable. In use, an aerosol generating article is inserted in the receptacle 120. The receptacle comprises a tubular housing having a base portion 121. The base portion 121 of the receptacle 120 has an aperture and the resistive heating element 104 is arranged to project through the aperture. An aerosol generating article may be inserted into the aerosol provision device 100 by inserting the aerosol generating article through an opening in the removable cap 106 and then inserting the aerosol generating article into the receptacle 120 and onto the heating element 104. The heating element 104 has a blade like profile and in use an aerosol generating article may be forced onto the heating element 104 so that the blade like profile of the heating element 120 inserts into a distal end of the aerosol generating article. The heating element 104 is arranged to internally heat the aerosol generating article.

At the end of a session of use, when an aerosol generating article has been consumed, the removable cap 106 may then be detached from the main housing 105. It will be understood that the process of detaching the removable cap 106 will have the effect that the base portion 121 of the receptacle 120 will contact a bottom face of the aerosol generating article. As the removable cap 106 is withdrawn, then the base portion 121 of receptacle will contact the distal end of the aerosol generating article and will result in the aerosol generating article being pulled off or otherwise removed from the heating element 104.

Fig. 3 shows the distal end 103 of the aerosol provision device 100 according to an embodiment.

The cavity of the charging unit 101 may have a securing mechanism to secure the distal end 103 of the aerosol provision device 100 within the cavity of the charging unit 101 when the aerosol provision device 100 is inserted into the charging unit 101. The securing mechanism may, for example, comprise one or more magnets. According to an embodiment one or more first magnets may be disposed in a bottom portion of the cavity of the charging unit 101 and one or more second magnets 107 may be disposed on the distal end 103 of the aerosol provision device 100. The one or more magnets 107 provided on the distal end 103 of the aerosol provision device 100 may have an opposite polarity to the polarity of the one or more magnets located in the bottom portion of the cavity of the charging unit 101 such that when the aerosol provision device 100 is inserted into the cavity of the charging unit 101, there is an attractive magnetic force that attracts the distal end 103 of the aerosol provision device 100 towards the base portion of the charging unit 101.

Other securing mechanisms are contemplated such as e.g. a threaded mechanism at the distal end 103 of the aerosol provision device 100 and the base portion of the cavity of the charging unit 101. According to yet further embodiments the aerosol provision device 100 may make a press-fit engagement or an interference fit engagement with the charging unit 101.

The aerosol provision device 100 may be substantially rod-like, substantially tubular shaped, or substantially cylindrically shaped. In other examples, the aerosol provision device 100 may also be substantially rectangular, rhomboidal or triangular in cross-section, multifaceted shapes, or the like. It will be appreciated that the cavity of the charging unit 101 can be manufactured according to the shape of the aerosol provision device 100 e.g. the cavity of the charging unit 101 may be correspondingly substantially rod-like, substantially tubular shaped, or substantially cylindrically shaped, substantially rectangular, rhomboidal or triangular in cross-section, multifaceted shapes, or the like.

The aerosol provision device 100 comprises an outer housing 108 which may have a tubular and/or cylindrical shape. According to an embodiment the outer housing 108 of the aerosol provision device 100 may comprise an electrical insulator and may, for example, be formed of polyetheretherketone (“PEEK”). The outer housing 108 of the aerosol provision device 100 may surround or enclose a sub-assembly. According to an embodiment during manufacture a number of channels may be etched into the subassembly. The channels which are etched into the sub-assembly may then be filled with a conductive material which may be deposited into the channels or printed into or onto the channels. The process of etching channels into the sub-assembly may be carried out by, for example, wet etching wherein material of the sub-assembly may be dissolved by a suitable chemical solution. During the process of wet etching the sub-assembly, a mask may be used to mask areas other than the intended position of the channel(s) which are intended to be etched in order to allow selective etching.

According to other embodiments the channels may be formed by dry etching which may include a process such as physical etching, reactive ion etching, sputter etching or vapour phase etching. As will be understood, the one or more channels may be formed by a number of suitable methods. Once the one or more channels have been formed, one or more electrical conductive tracks 120 may be deposited into or printed into or onto the channels in order to form one or more electrical connections.

According to an embodiment the distal end 103 of the aerosol provision device 100 may comprise one or more orientation features 106 and/or one or more magnets 107 for securing the distal end of the aerosol provision device 100 to a base portion of the charging unit 101.

Fig. 4 shows in further detail a plurality of conductive tracks 120a-d which have been deposited or printed onto/into channels which were etched into a sub-assembly. According to an embodiment four conductive tracks 120a-d may be provided on the subassembly in the respective channels which have been etched into the sub-assembly. The conductive tracks 120a-b may be deposited or printed into the respective channels.

According to various embodiments the one or more conductive tracks 120a-d may be printed onto or into the channels formed in the sub-assembly by a laser activated process (“LAP”).

The one or more conductive tracks 120a-d may be formed of copper, but according to other embodiments the one or more conductive tracks 120a-d may be formed of a ferrite material. As will be described in more detail below, at least a portion of the conductive tracks 120a-d may form an electrical contact for contacting a corresponding electrical contact in the charging unit 101. According to an embodiment one conductive track may be used to transfer power from the charging unit 101 to the aerosol provision device 100, a second conductive track may be used for grounding purposes and the remaining two conductive tracks may be used for data transfer.

It has been found that l_AP conductive tracks 120a-d can take a thinner form in the housing 108 as compared with conductive wires which may conventionally be used. Furthermore, the LAP conductive tracks 120a-d are able to take the form of a complex or tortuous shape or path following paths which would not be possible using conventional conductive wires. Accordingly, the conductive tracks 120a-d provide greater design freedom.

As will be appreciated, as conventional wiring does not need to be used, there is also no need for a separate flex component to route the wiring in the channels. As a result, the use of LAP conductive tracks 120a-d results in a finished part that operates as a single part post manufacture. Furthermore, the LAP conductive tracks 120a-d turn a structural component into a dual functioning component, as the LAP conductive tracks can be routed three-dimensionally through the housing structure of the aerosol provision device 100.

Fig. 5 shows in more detail the base portion of the internal cavity of the charging unit 101. A plurality of electrical contacts 121 are shown provided in the base portion of the charging unit 101 which facilitate electrical and/or data connection with the aerosol provision device 100. In use, the conductive tracks 120a-d which are provided on the distal end of the aerosol provision device 100 form electrical and/or data connections with the contacts 121 provided on the charging unit 101.

The charging unit 101 may include a battery pack which can be used to charge the aerosol provision device 100 through the formed connections between the one of the conductive tracks 120a-d provided on the distal end of the aerosol provision device 100 and the one or more contacts 121 provided on the charging unit 101. According to various embodiments the number of conductive tracks 120a-d provided on the aerosol provision device 100 may correspond to the number of electrical contacts 121 provided in the base portion of the charging unit 101. One or more of the contacts may be utilised to facilitate power transfer, one or more of the contacts may be utilised to facilitate grounding and one or more of the contacts may be utilised to facilitate data transfer.

An optional orientation feature 140 and one or more magnets 160 may be provided in the base portion of the charging unit 101. The orientation feature 140 may be arranged to engage with a complementary shaped orientation feature 106 provided on the distal end of the aerosol provision device 100. The one or more magnets 160 provided in the base portion of the charging unit 101 may be arranged to interact with one or more magnets 107 provided on the distal end 103 of the aerosol provision device 100.

The orientation feature 106 provided on the distal end 103 of the aerosol provision device 100 may be recessed into the base of the sub-assembly or alternatively may be recessed into the outer housing 108 of the aerosol provision device 100.

The corresponding orientation feature 140 provided in the base portion of the charging unit 101 may comprise a protrusion, which may correspond to the volume of the indentation of the orientation feature 106 provided on the distal end of the aerosol provision device 100. As a result, the aerosol provision device 100 may be arranged so that it can only dock to the charging unit 101 in a single orientation in order to ensure that the one or more conductive tracks 120a-d provided on the distal end 103 of the aerosol provision device 100 connect with the correct corresponding contacts 121 provided in the base portion of the charging unit 101.

According to other embodiments the orientation feature 106 provided on the distal end 103 of the aerosol provision device 100 may instead comprise a protrusion and the orientation feature 140 provided in the base of the charging unit 101 may comprise a recess. The one or more magnets 107 provided on the distal end 103 of the aerosol provision device 100 may have an opposite polarity to the polarity of the one or more magnets 160 located in the base portion of the charging unit 101, such that when the aerosol provision device 100 is inserted into the cavity of the charging unit 101 , there is an attractive magnetic force that attracts the distal end 103 of the aerosol provision device 100 towards the base portion of the charging unit 101.

The magnetic attractive force causes the orientation feature 106 provided on the distal end 103 of the aerosol provision device 100 and the orientation feature 140 provided in the base portion of the charging unit 101 to connect to one another or dock together in a self guiding manner.

It will be appreciated, therefore, that the aerosol provision device 100 may be configured to connect to the charging unit 101 via the conductive tracks 120a-d provided on the distal end 103 of the aerosol provision device 100 and the contacts 121 provided in the base portion of the charging unit 101 in a self-guiding manner, once the user places the aerosol provision device 100 within the cavity of the charging unit 101. The cavity of the charging unit 101 and the aerosol provision device 100 may also include corresponding grooves e.g. grooves on the internal surface of the cavity and grooves on the outer surface of the aerosol provision device 100 to further ensure self-guiding occurs.

The magnetic force between the two opposing magnets 107,160 may be sufficient to ensure that the aerosol provision device 100 docks to the charging unit 101 in order to facilitate power/data transfer without the connection being interrupted e.g. by knocking, vibration or the like.

It will be appreciated, therefore, that according to various embodiments an aerosol provision device is provided and can be manufactured by etching a plurality of channels into a distal end of the aerosol provision device and depositing a conductive material such as copper into the channels which have been formed. The channels and conductive tracks can have a cross-sectional profile which varies along the length of the conductive tracks. The conductive tracks may be provided in a housing which is an electrical insulator and hence unlike conventional arrangements there is no need to use wires having an insulating sheath. The conductive tracks can make sudden changes in direction and angle which may not be possible using conventional wires. Furthermore, the conductive tracks can be integrated into the body portion of a housing in a manner which is not feasible with conventional wiring.

It will be apparent, therefore, that an aerosol provision device according to various embodiments and a method of manufacturing the aerosol provision device according to various embodiments is particularly beneficial.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. A method of manufacturing an aerosol provision device comprising: providing a first housing having a proximal end and a distal end; providing one or more channels in a longitudinal direction along the device from the distal end of the housing; and depositing or printing one or more electrically conductive tracks into the one or more channels.

2. A method as claimed in claim 1, wherein the one or more electrically conductive tracks are non-planar.

3. A method as claimed in claim 1 or 2, wherein the one or more electrically conductive tracks follow a curved or tortuous path.

4. A method as claimed in claim 1, 2 or 3, wherein the one or more channels have a circular, oval, polygonal or rectangular cross-sectional profile.

5. A method as claimed in any preceding claim, wherein the one or more electrically conductive tracks comprise copper, silver, gold, zinc, aluminium, nickel, iron, platinum or tungsten.

6. A method as claimed in any preceding claim, wherein the step of providing one or more channels in a longitudinal direction along the distal end of the housing comprises etching.

7. A method as claimed in any preceding claim, wherein the step of etching comprises laser etching, or chemical etching.

8. A method as claimed in any preceding claim, wherein the aerosol provision device comprises a base portion and wherein at least a portion of the one or more conductive tracks is flush with the base portion.

9. A method as claimed in any preceding claim, further comprising locating the first housing within an outer housing.

10. A method as claimed in claim 9, wherein the outer housing comprises an electrical insulator.

11. An aerosol provision device comprising: a first housing having a proximal end and a distal end; and one or more electrically conductive tracks provided in the distal end of the first housing, the one or more electrically conductive tracks comprising an electrically conductive material deposited or printed within one or more channels provided in the first housing.

12. An aerosol provision device as claimed in claim 11, wherein the one or more electrically conductive tracks are non-planar.

13. An aerosol provision device as claimed in claim 11 or 12, wherein the one or more electrically conductive tracks follow a curved or tortuous path.

14. An aerosol provision device as claimed in claim 11, 12 or 13, wherein the one or more channels have a circular, oval, polygonal or rectangular cross-sectional profile.

15. An aerosol provision device as claimed in any of claims 11-14, wherein the one or more electrically conductive tracks comprise copper, silver, gold, zinc, aluminium, nickel, iron, platinum or tungsten.

16. An aerosol provision device as claimed in any of claims 10-14, wherein the one or more channels are provided by etching, laser etching or chemical etching.

17. An aerosol provision device as claimed in any of claims 11-16, wherein the aerosol provision device comprises a base portion and wherein at least a portion of the one or more conductive tracks is flush with the base portion.

18. An aerosol provision device as claimed in any of claims 11-17, wherein the first housing is located within an outer housing.

19. An aerosol provision device as claimed in claim 18, wherein the outer housing comprises an electrical insulator.

20. An aerosol generating system comprising: an aerosol provision device as claimed in any of claims 11-19; a charging unit for charging the aerosol provision device.

21. An aerosol generating system as claimed in claim 20, wherein the charging unit comprises: a cavity for receiving the aerosol provision device; and a base portion, wherein the base portion further comprises one or more electrical and/or data connections for connecting to the one or more electrically conductive tracks provided on the aerosol provision device.

22. A method of electrically charging an aerosol provision device comprising connecting an aerosol provision device as claimed in any of claims 11-19 to a charging unit.

23. A method of transmitting data to and/or from an aerosol provision device comprising connecting an aerosol provision device as claimed in any of claims 11-19 to a charging unit.