WO2024094501A1

WO2024094501A1 - Heater for an aerosol provision device

Info

Publication number: WO2024094501A1
Application number: PCT/EP2023/079678
Authority: WO
Inventors: Mark Potter
Original assignee: Nicoventures Trading Limited
Priority date: 2022-10-31
Filing date: 2023-10-24
Publication date: 2024-05-10
Also published as: GB202216112D0

Abstract

A method of manufacturing a heater for an aerosol provision device, the heater configured to be at least partially inserted into an article to heat aerosol generating material of the article, the method comprises: providing an elongate housing (302), the elongate housing defining a longitudinal axis, the elongate housing defining a void (308) within the housing (302), the void (308) having an internal dimension D1 measured in a direction perpendicular to the longitudinal axis, the elongate housing (302) comprising an opening (310) through which the void (308) is accessible; providing a coil (351), the coil (351) having width D2 greater than the internal dimension DI when the coil (351) is in an unstressed state; applying an extension force to the coil (351) to provide an extended coil (351) with reduced width D3; and inserting the extended coil (351) through the opening (310) into the void (308) such that the coil (351) is in the void (308) at the internal dimension D1.

Description

HEATER FOR AN AEROSOL PROVISION DEVICE

Technical Field

The present invention relates to a method of manufacturing a heater for an aerosol provision device and a heater for 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 resistive heating systems as heaters to create an aerosol from a suitable medium. Separately induction heating systems are known to be used as heaters.

Summary

According to an aspect there is provided a method of manufacturing a heater for an aerosol provision device, the heater configured to be at least partially inserted into an article to heat aerosol generating material of the article, the method comprising: providing an elongate housing, the elongate housing defining a longitudinal axis, the elongate housing defining a void within the housing, the void having an internal dimension D1 measured in a direction perpendicular to the longitudinal axis, the elongate housing comprising an opening through which the void is accessible; providing a heating element in the form of a coil, the coil having a width D2 greater than the internal dimension D1 when the coil is in an unstressed state; applying an extension force to the coil to provide an extended coil with reduced width D3; and inserting the extended coil through the opening into the void such that the coil is in the void at the internal dimension D1.

The method may comprise terminating applying the extension force to the coil after the coil has been inserted into the void.

The method may comprise applying a compressive force to the coil after the coil has been inserted into the void to force the coil further into the inner void.

The compressive force may be applied by pushing an end of the coil.

The method may comprise terminating applying the compressive force.

The extension force may be terminated after the entirety of the coil has been inserted into the void.

The compressive force may be terminated after the entirety of the coil has been inserted into the void.

The extension force may be applied by a tool, the tool configured to hold ends of the coil to maintain the coil in the extended position.

The extended coil may be inserted through the opening using the tool.

D3 may be less than D1.

The method may comprise introducing a mass of material into the void after insertion of the coil, the mass of material retaining the coil in the void.

The mass of material may be configured to retain the coil in a fixed position relative to the housing.

The mass of material may comprise an adhesive.

The mass of material may close the opening.

The mass of material may be introduced as a liquid configured to set to form a solid. The compressive force may be removed after the liquid has set. The heater may be a resistive heater. The coil may be configured to provide heat to heat the aerosol generating material when a current is passed through the coil. The coil may comprise a first electrical connector in electrical communication with a first end of the coil. The coil may comprise a second electrical connector in electrical communication with a second end of the electrical coil. The first and second electrical connectors may extend away from the coil in a common direction. The inserting the extended coil through the opening may comprise inserting the extended coil such that the first and second electrical connectors extend away from the coil towards the opening.

The housing may comprise an electrical insulator to prevent flow of current from the coil into the housing. The housing may be formed of an electrically insulative material. An internal surface of the housing may be coated with an electrically insulative material.

The coil comprises an electrical insulator to prevent flow of current from the coil into the housing. The electrical insulator may be a coating on an outside of the coil.

The heater may be a resistive heating heater.

The heating member may be a resistive heating member.

The heating element may be a resistive heating element.

The coil may be a resistive heating heater coil

The heater may be an inductive heating heater.

The heating element may be an inductive heating element.

The coil may be an inductive coil.

A heater for an aerosol provision device, the heater configured to be inserted into an article to heat aerosol generating material of the article, the heater comprising: an elongate housing, the elongate housing defining a longitudinal axis, the elongate housing defining a void within the housing, the void having an internal dimension D1 measured in a direction perpendicular to the longitudinal axis; a coil located inside the void, the coil having a width D2 greater than the internal dimension D1 when the coil is in an unstressed state, the coil thereby configured to push against the housing.

The aerosol provision device may comprise any of the features described above with respect to the method.

According to an aspect, there is provided aerosol provision device configured to heat an article comprising aerosol generating material, the device comprising a heater described above. The aerosol provision device may comprise a heating chamber, in which the heater is provided.

The aerosol provision device may comprise a power source, a controller and a heating chamber, in which the aerosol generating article is removeable received. The power source may be aligned along a longitudinal axis of the heating chamber. The power source may be aligned along a second longitudinal axis, parallel to the longitudinal axis of the heating chamber.

The aerosol provision device may be configured for wireless charging. The aerosol provision device may be provided with a charging port, such as a USB port, which is used to couple the power supply to an external power source for recharging.

According to an aspect there is provided an aerosol provision system comprising: an aerosol provision device as described above; and an article comprising aerosol generating material.

The aerosol provision system may comprise a charging unit having a cavity for removably receiving the aerosol provision device. The charging unit may comprise a moveable lid, which covers the aerosol provision device in a closed configuration. The charging unit may comprise a user display. The user display may be visible to a user when the moveable lid is in a closed position and is partially or fully concealed or obscured from sight by the lid when the lid is an open position.

According to another aspect there is provided a method of generating aerosol comprising: providing an aerosol provision device comprising a heater as described above; at least partially inserting an aerosol generating article into the receiving portion of the heating chamber.

The aerosol provision device may comprise any of the features of the heater described above.

The aerosol provision system may comprise any of the features of the heater described above.

The method of generating aerosol may comprise any of the features or steps described above with respect to the heater.

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 a perspective view of an aerosol provision system including an aerosol provision device located within a charging unit;

Fig. 2 shows a schematic cross-sectional view of part of the aerosol provision device of Fig. 1 ;

Fig. 3 shows a schematic cross-sectional view of part of the aerosol provision device of Fig. 1 and an aerosol generating article of the aerosol provision system;

Fig. 4 shows a perspective view of another aerosol provision device;

Fig. 5 shows a schematic cross-sectional view of the device of Fig. 4;

Fig. 6 shows a schematic cross-sectional view of a heater of the device of Fig. 1 or Fig. 4;

Fig. 7 shows a schematic cross-sectional view of a coil;

Fig. 8 shows a schematic cross-sectional view of an extended coil; and

Fig. 9 shows a schematic diagram of a method of manufacturing a heater.

Detailed Description

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 aerosol-generating 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 noncombustible aerosol provision device.

In some embodiments, the non-combustible aerosol provision device 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.

As used herein, the term “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 one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered 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 or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free. The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material.

The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

An aerosol provision device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into or onto the aerosol provision device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within or over a heater of the device which is sized to receive the article.

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.

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 aerosol- modifying 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.

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.

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.

Figure 1 shows an aerosol provision system 10 comprising an aerosol provision device 100 and a charging unit 101. The device is shown located within a cavity of a charging unit 101. The aerosol provision device 100 is arranged to generate aerosol from an aerosol generating article (refer to Figure 3) which may be inserted, in use, into the aerosol provision device 100. In embodiments, the article forms part of the aerosol provision system 10.

The aerosol provision device 100 is an elongate structure, extending along a longitudinal axis. Additionally, the aerosol provision device has a proximal end, which will be closest to the user (e.g. the user’s mouth) when in use by the user to inhale the aerosol generated by the aerosol provision device 100, as well as a distal end which will be furthest from the user when in use. The proximal end may also be referred to as the “mouth end”. The aerosol provision device 100 also accordingly defines a proximal direction, which is directed towards the user when in use. Further, the aerosol provision device 100 also likewise defines a distal direction, which is directed away from the user when in use. The terms proximal and distal as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along a longitudinal axis. The aerosol provision device 100 comprises an opening at the distal end, leading into a heating chamber.

The aerosol provision device 100 may be removably inserted into the charging unit 101 in order to be charged. The charging unit 101 comprises a cavity (refer to Figure 2) for receiving the aerosol provision device 100. The aerosol provision device 100 may be inserted into the cavity via an opening. The cavity may also comprise a longitudinal opening. A portion of the aerosol provision device 100 may comprise a first side. One or more user-operable control elements such as buttons 106 which can be used to operate the aerosol provision device 100 may be provided on the first side of the aerosol provision device 100. The first side of the aerosol provision device 100 may be received in the longitudinal opening provided in the charging unit 101.

In embodiments the cavity of the charging unit 101 may have a cross-sectional profile which only permits that the aerosol provision device 100 be inserted into the charging unit 101 in a single orientation. According to an embodiment the outer profile of the aerosol provision device 100 may comprise an arcuate portion and a linear portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also comprise a similar arcuate portion and a linear portion. The linear portion of the cross- sectional profile of the cavity may correspond with the longitudinal opening.

The charging unit 101 includes a slidable lid 103. When the aerosol provision device 100 is inserted into the charging unit 101 in order to be recharged, the slidable lid 103 may be closed so as to cover the opening into the aerosol provision device 100. In other embodiments, the charging unit 101 may have an alternative lid configuration, such as a hinged lid, or no lid may be provided.

The charging unit 101 may include a user interface such as display 108, which can be provided at any convenient location, such as in the position shown in Figure 1.

Figure 2 shows a cross sectional view of a portion of the aerosol provision device 100. The aerosol provision device 100 comprises a main housing 200. The main housing 200 defines a device body of the device 100. The device 100 defines a heating chamber 201. A receptacle 205 defines the heating chamber 201. An opening 203 is provided to provide access to the heating chamber 201. The receptacle 205 comprises a wall arrangement including a receptacle side wall 205a and a receptacle base 205b. The base 205b is at the distal end of the receptacle 205. A heating zone 201a is configured at least a portion of the article for heating.

A heating member 301 is provided in a portion of the main housing 200 and the heating member 301 extends or projects into the heating chamber 201. The heating member 301 may comprise a base portion 301a which may be located in a recess provided in a portion of the body of the device 100. The heating member 301 upstands in the heating chamber 201. The heating member 301 upstands from the distal end.

The heating member 301 comprises an elongate heating member in the form of a pin. The heating member 301 in other embodiments comprises other elongate configurations, such as a blade. The heating member 301 may be inserted, in use, into a distal end of an aerosol generating article 50 (refer to Figure 3) which is received within the heating chamber 201 in order to internally heat the aerosol generating article.

The housing comprises housing wall 200a. The housing wall 200a extends along the longitudinal axis of the aerosol provision device 100, surrounding the heating chamber 201. The housing wall 200a may, at least in part, define a receiving chamber of the aerosol provision device 100, as the volume which is enclosed within the wall 200a. A housing base 200b is at the distal end of the housing wall 200a. In the shown embodiment, the heating member 301 upstands from the housing base 200b. The heating member 301 protrudes through the receptacle base 205b. An aperture 206 is formed in the receptacle base 205b through which the heating member 301 protrudes. In embodiments, the heating member 301 is mounted to the receptacle base 205b. The heating member 301 upstands from the receptacle base 205b.

The aerosol provision device 100 further comprises a removal mechanism 204 which may be removably retained to the main housing 200 of the aerosol provision device 100. The removal mechanism 204 in embodiments is omitted. In embodiments, the housing wall 200a at least in part defines the receptacle 205. The removal mechanism 204 may be retained to the main housing 200 so that at least a portion of the removal mechanism 204 extends into the heating chamber 201. The removal mechanism 204 may comprise a longitudinal portion such as a peripheral wall portion 207a, which in the present embodiment is tubular, and a base wall portion 207b. The wall 207a may be a shape other than tubular, and may be any shape which encloses (e.g. encircles) and defines the heating chamber 201 there within.

In embodiments with the removal mechanism 204, the removal mechanism 204 defines the heating chamber 201. The removal mechanism 204 forms the receptacle 205. In embodiments in which the removal mechanism 204 is omitted, other features of the device 100 define the heating chamber 201, for example the housing side wall 200a and housing base 200b.

The base portion 207b has the aperture 206 through which the heating member 301 may project. In order to retain the removal mechanism 204 to the main housing 200, the removal mechanism 204 is pushed into engagement with the main housing 200 in the distal direction, i.e. towards the distal end of the main housing 200, until the removal mechanism 204 is able to move no further in the distal direction. In the following description, when the removal mechanism 204 is referred to as being “retained to” the main housing 200, this is when the removal mechanism 204 is engaged with the main housing 200, and can move no further in the distal direction.

Together, the peripheral portion 207a and the base portion 207b may define and enclose an article chamber for receiving, the aerosol generating article 50, as shown in Figure 3. The article chamber comprises an inner surface, which is configured to contact the aerosol generating article, the inner surface comprising a longitudinally extending portion which is provided by the tubular portion 207a, and an end portion which is provided by the base portion 207b. In embodiments, the article chamber and the heating chamber are the same. When the aerosol generating article 50 is received in the heating chamber, it may contact both the longitudinally extending portion of the inner surface, and the end portion of the inner surface. In particular, the article chamber (i.e. the peripheral portion 207a and the base portion 207b) may be configured to receive at least part of the aerosol generating article 50 which is in the form of rod which is longitudinally extending and cylindrical, such that the longitudinal axis of the article is parallel to (and optionally in line with) the longitudinal axis of the aerosol provision device 100 when received in the article chamber.

The article chamber may also be referred to as a receiving portion. When the removal mechanism 204 is retained to the main housing 200, in use, the article chamber of the removal mechanism 204 is arranged, at least partially, within the heating chamber 201. The heating member 301 may be arranged so as to project into the article chamber, through the aperture 206 provided in the base portion 207b of the removal mechanism 204. The removal mechanism 204 is therefore configured to receive at least a portion of the aerosol generating article in use.

In embodiments, the removal mechanism 204 may comprise a first magnet or a magnetisable material 208. The main housing 200 may comprise a second magnet or magnetisable material 209. In use, the removal mechanism 204 may be magnetically retained to the main housing 200 by the interaction of the first magnet or magnetisable material 208 and the second magnet or magnetisable material 209. In embodiments, the removal mechanism 204 is fully detachable from the main housing 200. The removal mechanism 204 may be retained to the main housing 200 by a magnetic force of attraction between the first magnet or magnetisable material 208 and the second magnet or magnetisable material 209. The removal mechanism 204 may be detached from the main housing 200 by overcoming the magnetic force between the first magnet or magnetisable material 208 and the second magnet or magnetisable material 209. In embodiments, the removal mechanism 204 is removably retained to the main housing 200 by other means. For example, the removal mechanism 204 may be configured to be removably retained to the main housing 200 by an interference fit with the main housing.

The removal mechanism 204 may comprise an internal element (comprising the tubular portion 207a and a base portion 207b) and an outer cap portion 210, wherein when retained to the main housing 200 the outer cap portion 210 encapsulates (e.g. covers) at least a portion of the main housing 200, such as the wall 200a of the main housing. The tubular portion 207a, base portion 207b and outer cap portion 210 may comprise an integral (e.g. unitary) component (formed, for example, by moulding). Alternatively, the tubular portion 207a and base portion 207b may comprise a first component and the outer cap portion 210 may comprise a second separate component. The first and second components may then be secured together.

Figure 4 shows another aerosol provision system 40. The system 40 comprises a one-piece aerosol provision device 400 for generating aerosol from an aerosol generating material, and the aerosol generating article 50 comprising the aerosol generating material. The device 400 can be used to heat the aerosol generating article 50 comprising the aerosol generating material, to generate an aerosol or other inhalable medium which can be inhaled by a user of the device 400.

The device 400 comprises a housing 500 which surrounds and houses various components of the device 400. The housing 500 is elongate. The device 400 has an opening 504 in one end, through which the article 50 can be inserted for heating by the device 400. The article 50 may be fully or partially inserted into the device 400 for heating by the device 400.

The device 400 may comprise a user-operable control element 506, such as a button or switch, which operates the device 400 when operated, e.g. pressed. For example, a user may activate the device 400 by pressing the switch 406.

The device 400 defines a longitudinal axis 509 along which an article 50 may extend when inserted into the device 400. The opening 504 is aligned on the longitudinal axis 509.

Figure 5 shows a cross-sectional schematic view of the aerosol provision system 40. Features described with reference to Figure 5 in embodiments are applicable to embodiments described above. The aerosol provision device 400 comprises a power source 410, a controller 420 and a heating chamber 401, in which the aerosol generating article 50 is removeable received.

The one-piece device of Figure 5 shows the power source 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of a one-piece aerosol generating device, the power source is aligned along a second longitudinal axis, parallel to the longitudinal axis of the heating chamber.

The heating member 301 comprises an elongate heating member in the form of a pin. The heating member 301 in embodiments comprises other elongate configurations, such as a blade. The heating member 301 is provided in the heating chamber. The heating member 301 of Figure 5 and the heating member 301 described above with reference to Figures 1 to 3, such that details described herein may be applied to each. The heating member 301 extends or projects into the heating chamber 401.

The heating member 301 may be inserted, in use, into a distal end of the aerosol generating article which is received within the heating chamber 401 in order to internally heat the aerosol generating article.

The aerosol provision devices 100, 400 comprise a heating arrangement 300. The heating arrangement 300 comprises a heater. The heating member 301 acts as the heater. The heater comprises a heating element 350 (refer to Figure 6), such as a resistive heating coil, arranged to be actuated to heat the heating member.

The heating arrangement 300 is a resistive heating arrangement. The heater is a resistive heating heater. The heating element, such as a heating coil, as will be described below is a resistive heating element. In such arrangements the heating assembly comprises a resistive heating generator including components to heat the heating element via a resistive heating process. In this case, an electrical current is directly applied to a resistive heating element, and the resulting flow of current in the heating element, acting as a heating component, causes the heating element to be heated by Joule heating. The resistive heating element comprises resistive material configured to generate heat when a suitable electrical current passes through it, and the heating arrangement comprises electrical contacts for supplying electrical current to the resistive material. In embodiments, the heating element forms at least part of the resistive heating member itself. In embodiments the resistive heating element transfers heat to the heating member, for example by conduction. The provision of a resistive heating arrangement allows for a compact arrangement. Resistive heating provides an efficient configuration.

Figure 6 shows a heating member 301 for use in an aerosol provision device as described above. The heating member 301 acts as or forms at least part of a heater 300. The heater 300 comprises the heating member 301. The heating member 301 comprises an elongate housing 302 and the heating element 350. The elongate housing 302 defines a longitudinal axis.

The elongate housing 302 is formed from a thermally conductive material, such as stainless steel. The elongate housing may comprise a coating on its outer surface. The elongate housing 302 is configured to transfer heat from the heating element 350 to the heating zone 201a.

The elongate housing 302 has a base end 303 and a free end 304. The base end 304 mounts to the device body. A mount 305 at the base end 303 mounts the heating member 301. It will be understood that different mounting arrangements may be used, for example a fixing, moulding, and bonding including adhering. The mount 305 may be a separate component or may be integrally formed with the elongate housing 302.

The elongate housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body 306 comprises a bore 307. The bore 307 defines a void 308 of the heating member 301. The void 308 is within the housing 302. The void 308 extends longitudinally. In embodiments, the void 308 is at least partially filled, for example with a filler. In embodiments, the void 308 is completely filled, for example with one or more fillers and/or components. In embodiments, the void 308 defines an air gap. An inner surface 309 is defined on an inner side of the elongate housing 302. An opening 310 to the void 308 is provided at the base end 303.

The free end 304 of the elongate housing 302 extends towards the proximal end of the heating chamber. The free end 304 of the heating member 301 is closed. The void 308 does not extend through the free end 304. A tip 311 is provided at the free end 304. The tip 311 extends to an apex 312. The tip 311 is conical. Other shapes and configurations of the tip 311 may be provided, for example the tip 311 may define a planar surface.

The heating element 350 extends in the heating member 301. The heating element 350 extends in the elongate housing 302 in the longitudinal direction. The heating element 350 is received in the void 308. The heating element 350 extends between the base end 303 and the distal end 304. In embodiments, the heating element 350 extends partially along the length of the void 308. In embodiments the heating element 350 extends to or beyond the open end 310.

The heating element 350 in embodiments comprises a heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. In embodiments the heating coil 351 comprises an electrically insulative coating, such as a ceramic, to electrically insulate the heating coil 351 from the elongate housing 302. The electrically insulative coating in embodiments is thermally conductive to provide for heat transfer from the heating element 350 to the elongate housing 302. In embodiments the electrically insulative coating is omitted. In embodiments, a separate electrically insulative arrangement, such as at least one of an electrically insulative member and an electrically insulative filler is provided. The electrically insulative member and electrically insulative filler in embodiments is thermally conductive to provide for heat transfer from the heating element 350 to the elongate housing 302.

The heating coil 351 is a resistive heating coil. The heating coil 351 is a helical coil. The heating coil 351 has a rectangular cross-sectional profile. It will be understood that other coil configurations are possible. In embodiments, the heating coil 351 has a circular cross-sectional profile. In embodiments, the heating arrangement 300 comprises two or more heating coils.

The heating arrangement 300 comprises electrical connectors. The electrical connectors extend from each end of the heating element 350. A base electrical connector 352 extends from the distal end of the heating element 350. A return electrical connector 353 extends from the proximal end of the heating element 350. The return electrical connector overlaps the longitudinal extent of the heating element 350. The electrical connectors are integrally formed with the heating element, for example as a single wire. The heating coil 351 is formed from a resistive material, such as a nickel/chrome alloy such as nichrome 80/20 (80% Nickel, 20% Chromium), an iron/chrome/aluminium alloy, or a copper/nickel alloy.

The void 308 has an internal dimension D1. The internal dimension D1 is measured in a direction perpendicular to the longitudinal axis 312. The internal dimension D1 is a width of the void 308. The internal dimension D1 is a diameter of the void 308. The internal dimension D1 is a minimum width of the void 308 between the opening 310 and the proximal end of the heating element 305. In the present example, the void 308 is of substantially constant width.

The heating member 301 comprises a mass of material 312. The mass of material 312 comprises an adhesive. The mass of material 312 is formed of an adhesive. The adhesive may be a potting compound. The mass of material 312 extends across the void 308. The mass of material 312 substantially seals the void 308. The mass of material 312 retains the coil 351 in its position in the void 308. The electrical connectors 352 353 extend through the mass of material 312. The mass of material 312 retains the coil 351 in its position in the void 308 by holding the electrical connectors 352 353.

Referring to Fig. 7, there is shown the coil 351 in an unstressed state. In the unstressed state, the coil 351 has a width D2. The width D2 is measured in a direction perpendicular to the longitudinal axis 312. Since the coil 351 is a helical coil, the width D2 is the diameter of the coil 351. The width of the coil 351 is substantially constant. The width D2 of the coil 351 is greater than the internal dimension D1.

Referring to Fig. 8, there is shown an extended coil 35T, which is the coil 351 in an extended state. In the extended state, an extension force is applied to the coil 351 to stretch the coil 351. This increases a length of the coil 351 and reduces the width (again, measured in a direction perpendicular to the longitudinal axis 312) of the coil 351. As such, the extended coil 35T has a width (in the present example, a diameter) D3. The width of the extended coil 35T D3 is less than the width of the coil D2. Additionally, the width D3 of the extended coil 35T is less than the internal dimension D1 of the void 308, which means that the extended coil 35T may be inserted into the void 308 more easily.

Referring Fig. 9, there is shown a method 500 of manufacturing the heating member 300 from the elongate housing 302 and the coil 351. The method comprises a first step 502, a second step 504, a third step 506, a fourth step 508, a fifth step 510 and a sixth step 512.

In the first step 502, an extension force is applied to the coil 351 to provide an extended coil 35T. The extension force acts to increase a distance between the proximal and distal ends of the coil 351. In the present example, the force is applied using the electrical connectors 352 353, with a pushing force applied to the return electrical connector 353 and a relative pulling force applied to the distal electrical connector 352. In other examples, a tool may be used to apply extension force. The tool may maintain the increased distance between the proximal and distal ends of the coil 351, thereby maintaining the coil as an extended coil 35T. The tool may apply the forces to the electrical connectors 352 353as described above. Alternatively, the tool may extend through the inside of the coil and grip ends of the coil to apply the extension force. As mentioned above, the extended coil 35T has a reduced width D3 relative to the width D2 when the coil 351 is in an unstressed state.

In the second step 504, the extended coil 35T is inserted through the opening 310 into the void 308. The extended coil 35T is maintained in the extended state during insertion to maintain the width D3 of the extended coil 35T less than the internal dimension D1 of the void 308. In other examples the tool may be used to apply the extension force between proximal and distal ends of the extended coil 35T.

In the third step 506, the extension force is removed. This causes the width of the coil 351 to increase. However, because the width D2 of the coil 351 in the unstressed state is greater than the internal dimension D1 of the void 308, the coil 351 is unable to return to the unstressed state. The coil 351 pushes against the elongate housing 306, which may help to retain the coil 351 in the void 308 and increase thermal conduction between the coil 351 and the elongate housing 306.

In the fourth step 508 a compressive force is applied to the coil 351 to force the coil 351 further into the void 308.

In the fifth step 512, the mass of material 312 is introduced into the void 308. The mass of material 312 extends across the width of the void 308 to substantially seal the void 308 and to close the opening 310. The mass of material 312 is introduced in liquid form and subsequently sets to form a solid. The mass of material 312 is an adhesive. The mass of material 312 is a potting compound. The electrical connectors 352 353 extend through the mass of material 312. The mass of material 312 thereby retains the coil 351 in its position in the void 308.

In the sixth step 510, after the mass of material 312 has set, the compressive force is removed. In some examples, where the coil 351 can be readily inserted a sufficient distance into the void 308 in the third step 506, the fourth 508 and fifth steps 510 may not be performed.

In the above described embodiments, the heating arrangement is a resistive heating arrangement. In embodiments, other types of heating arrangement are used, such as inductive heating. The configuration of the device is generally as described above and so a detailed description will be omitted.

An inductive heating arrangement comprises various components to heat the aerosol generating material of the article via an inductive heating process. Induction heating is a process of heating an electrically conducting heating member (such as a susceptor) by electromagnetic induction. An induction heating arrangement may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor (heating member) suitably positioned with respect to the inductive element. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive element and the susceptor, allowing for enhanced freedom in construction and application.

In inductive heating heat is generated in the susceptor (heating member) whereas in resistive heating heat is generated in the coil (heating element).

In embodiments, the heating member of the aerosol provision system is a part of the aerosol generating article, rather than being a part of the aerosol provision device. The heating element may be a resistive heating element, for example in the form of the resistive coil described above, which is provided as part of the aerosol generating article. Electrical connections may enable electric current to flow through the resistive heating element.

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 a heater for an aerosol provision device, the heater configured to be at least partially inserted into an article to heat aerosol generating material of the article, the method comprising: providing an elongate housing, the elongate housing defining a longitudinal axis, the elongate housing defining a void within the housing, the void having an internal dimension D1 measured in a direction perpendicular to the longitudinal axis, the elongate housing comprising an opening through which the void is accessible; providing a heating element in the form of a coil, the coil having a width D2 greater than the internal dimension D1 when the coil is in an unstressed state; applying an extension force to the coil to provide an extended coil with reduced width D3; and inserting the extended coil through the opening into the void such that the coil is in the void at the internal dimension D1.

2. A method according to claim 1 and comprising terminating applying the extension force to the coil after the coil has been inserted into the void.

3. A method according to claim 1 or 2 and comprising applying a compressive force to the coil after the coil has been inserted into the void to force the coil further into the inner void.

4. A method according to claim 3, wherein the compressive force is applied by pushing an end of the coil.

5. A method according to claim 3 or 4 and comprising terminating applying the compressive force.

6. A method according to any of claims 1 to 5, wherein the extension force is applied by a tool, the tool configured to hold ends of the coil to maintain the coil in the extended position.

7. A method according to claim 6, wherein the extended coil is inserted through the opening using the tool.

8. A method according to any of claims 1 to 7 and comprising introducing a mass of material into the void after insertion of the coil, the mass of material retaining the coil in the void.

9. A method according to claim 8, wherein the mass of material is configured to retain the coil in a fixed position relative to the housing.

10. A method according to claim 8 or 9, wherein the mass of material comprises an adhesive.

11. A method according to any of claims 8 -10, wherein the mass of material closes the opening.

12. A method according to any of claims 8 to 11 , wherein the mass of material is introduced as a liquid configured to set to form a solid, wherein the compressive force is removed after the liquid has set.

13. A method according to any of claims 1 to 12, wherein the heater is a resistive heater and the coil is configured to provide heat to heat the aerosol generating material when a current is passed through the coil, wherein the coil comprises a first electrical connector in electrical communication with a first end of the coil and a second electrical connector in electrical communication with a second end of the electrical coil, wherein the first and second electrical connectors extend away from the coil in a common direction.

14. A method according to any of claims 1 to 14, wherein the housing and/or the coil comprises an electrical insulator to prevent flow of current from the coil into the housing.

15. A heater for an aerosol provision device, the heater configured to be inserted into an article to heat aerosol generating material of the article, the heater comprising: an elongate housing, the elongate housing defining a longitudinal axis, the elongate housing defining a void within the housing, the void having an internal dimension D1 measured in a direction perpendicular to the longitudinal axis; a coil located inside the void, the coil having a width D2 greater than the internal dimension D1 when the coil is in an unstressed state.

16. A system comprising an aerosol provision device according to claim 15 and an aerosol generating article.