FRAME FOR AN AEROSOL-GENERATING DEVICE AND METHOD OF FORMING A FRAME

Abstract

A frame for an aerosol-generating device is provided, the frame including: a base frame formed from an electrically conductive material; an electrical connector having a plurality of electrical contacts arranged on a connector frame formed from an electrically insulating material, the electrical connector being secured to the 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, in which the base frame and electrical connector are at least partially embedded in the support frame. A method of manufacturing a frame for an aerosol-generating device, and an aerosol-generating device including a frame, are also provided.

Claims

1.-15. (canceled)

16. 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 being arranged on a connector frame formed from an electrically insulating material, the electrical connector being secured to the 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, wherein the base frame and electrical connector are at least partially embedded in the support frame.

17. The frame according to claim 16, wherein the electrical connector is secured to the base frame at the electrical contact.

18. The frame according to claim 16, wherein the support frame at least partially overlaps the electrical connection between the base frame and the electrical contact.

19. The frame according to claim 16, wherein the base frame is elongate, having a proximal end and a distal end opposite the proximal end, and wherein the electrical connector is secured to the base frame at the distal end.

20. A method of manufacturing a frame for an aerosol-generating device, the method comprising: 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 being arranged on a connector frame formed from an electrically insulating material; securing 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 in a support frame formed from an electrically insulating material.

21. The method of manufacturing a frame according to claim 20, wherein the base frame is secured to the electrical connector at the electrical contact.

22. The method of manufacturing a frame according to claim 20, wherein the base frame is secured to the electrical connector by laser welding.

23. The method of manufacturing a frame according to claim 20, wherein the support frame at least partially overlaps the electrical connection between the base frame and the electrical contact.

24. The method of manufacturing a frame according to claim 20, wherein the support frame is formed by overmoulding the electrically insulating material over the base frame and the electrical connector to at least partially embed the base frame and the electrical connector in the support frame.

25. The method of manufacturing a frame according to claim 20, wherein the step of providing the electrical connector comprises: providing a plurality of electrical contacts; and at least partially embedding the plurality of electrical contacts in a connector frame formed from an electrically insulating material to form an electrical connector.

26. The method of manufacturing a frame according to claim 20, wherein the base frame is electrically connected to each of the electrical contacts of the electrical connector.

27. A frame for an aerosol-generating device manufactured by the method according to claim 20.

28. An aerosol-generating device comprising a frame according to claim 16.

Description

[0142] FIGS. 1 to 7 show schematic illustrations of a frame 10 for an aerosol-generating device 100 in accordance with an embodiment of the present disclosure. The frame 10 provides support for electrical components of the aerosol-generating device 100 and electrically conductive pathways that enable electrical connection of different electrical components of the aerosol-generating device 100. The frame of the present disclosure is particularly compact and straightforward to manufacture in comparison to other known frames for aerosol-generating devices.

[0143] FIG. 1 shows a perspective view of a base frame 20 and electrical connector 40 for use in an aerosol-generating device. The aerosol-generating device is described in further detail below.

[0144] The base frame 20 is elongate, and comprises a proximal end and a distal end, opposite the proximal end. The electrical connector 40 is disposed at the distal end of the base frame 20.

[0145] The base frame 20 generally comprises a plurality of elongate electrically conductive elements. More specifically, the base frame 20 comprises two electrical tracks 22, 24 disposed between two ground plane portions 26. A first electrical track 22 comprises a proximal end 221 and a distal end 222. A second electrical track 224 comprises a proximal end 241 and a distal end 242. Each ground plane portion 26 comprises a proximal end 261 and a distal end 262.

[0146] In this embodiment, the base frame 20 is formed by pressing a single laminar blank. In this embodiment, the blank is formed from brass. The laminar blank may be stamped either in a single stamping process or in multiple stamping processes to fold the blank into the desired shape and to 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 the ground plane portions 26.

[0147] The electrically conductive elements are arranged and shaped to form a cavity 28 suitable for receiving an electrical power supply of an aerosol-generating device, in a position between the proximal and distal ends of the electrically conductive elements.

[0148] Towards the proximal ends 221, 241, 261 of the electrical tracks 22, 24 and the ground plane portions 26, the electrically conductive elements are provided with a plurality of electrically conductive pins 30. The pins 30 are configured to electrically connect the base frame 20 to an electronic circuit board, such as a PCB, of an aerosol-generating device. Some of the pins 30 are formed by shaping the proximal ends of the electrically conductive elements of the base frame 20, and some of the pins 30 are formed from separate elements of phosphor bronze. Pins 30 formed from separate elements of phosphor bronze are laser welded to the electrically conductive elements of the base frame 20 at the required locations.

[0149] The electrical connector 40 comprises three electrical contacts 41, 42, 43 supported on a connector frame 44. As shown in detail in FIG. 5, the electrical connector 40 generally comprises an annular front face, primarily defined by the third electrical contact 43, and a central recess 46 extending inwards from the front face. The recess 46 is substantially cylindrical, has a closed end formed by the first electrical contact 41, and a side wall substantially formed by the second electrical contact 42 extending between closed end and the front face.

[0150] The first and second electrical contacts 41, 42 are formed from phosphor bronze. The third electrical contact 43 is formed from an alloy of neodymium, such that the third electrical contact 43 forms a magnetic contact that may magnetically attract a complementary magnetic element of a complementary electrical connector. The first electrical contact 41 comprises a substantially planar metallic sheet, having a tab at one end bent substantially perpendicular to the sheet, for connection of the first electrical contact 41 to the base frame. The second electrical contact 42 comprises a substantially annular metallic 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 positioned in the electrical connector 40. The third electrical contact 43 forms an annular metallic disc. The third electrical contact 43 has a central passage with a diameter that is substantially similar to the outer diameter of the cylindrical tube of the second electrical contact 42. Accordingly, the second electrical contact 42 may fit within the central passage of the third electrical contact 43, with the third electrical contact 43 circumscribing the second electrical contact 42.

[0151] The second electrical contact 42 and the third electrical contact 43 are partially embedded in the connector frame 44. The connector frame 44 is formed from a mouldable polymer material, polyphthalamide (PPA), which is injection moulded over the second and third electrical contacts 42, 43. Overmoulding the second and third electrical contacts 42, 43 secures the second and third electrical contacts 42, 43 in the connector frame 44, and maintains a necessary separation between the second and third electrical contacts 42, 43 for electrical isolation from each other.

[0152] The connector frame 44 and the second and third electrical contacts 42, 43 generally form an annular disc, having a central passage that is open at both ends. The third electrical contact 43 generally forms the front face of the disc, and the second electrical contact 42 generally forms the inner wall of the central passage. The first electrical contact 41 is arranged at a rear face of the connector frame 44, opposite the third electrical contact 43 at the front face, and extends over one of the open ends of the central passage to form the closed end of the central recess 46. The first electrical contact 41 is positioned against a rear face of the connector frame 44, such that the first electrical contact 41 is electrically isolated from the second and third electrical contacts 42, 43.

[0153] The distal end 222 of the first electrical track 22 of the base frame 20 is in physical contact with the tab 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 tab of the second electrical contact 42 of the electrical connector 40, such that the second electrical track 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 in physical contact with the cylindrical outer sidewall of the third electrical contact 43 of the electrical connector 40, such that the ground plane portions 26 of the base frame 20 are electrically connected to the third electrical contact 43.

[0154] The distal portions 222, 242 of the first and second electrical tracks 22, 24 are laser welded to tabs 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 sidewall of the third electrical contact 43. Accordingly, in this embodiment, the base frame 20 is secured to the electrical connector 40 at all of the locations of the base frame 20 that are in physical contact with the electrical connector 40. It will be appreciated that in other embodiments the electrical contacts of the electrical connector may not be secured to the base frame, and in other embodiments only some of the electrical contacts may be secured to the base frame.

[0155] As shown in FIGS. 3, 4 and 5, the base frame 20 and electrical connector 40 are partially embedded in a support frame 50 to form the complete frame 10. In this embodiment, the support frame 50 is formed from a mouldable polymer material, polyphthalamide (PPA), which is injection moulded over the base frame 20 and electrical connector 40.

[0156] At a 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 elements of the base frame 20 are embedded in a portion of the support frame 50. A distal end portion 53 of the support frame 50 generally circumscribes and extends over the cylindrical outer sidewall 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 face of the connector frame 44 and the first electrical contact 41. Accordingly, the distal end portion 53 of the support frame 50 overlaps the interface between the base frame 20 and the electrical connector 40. In more detail, the distal end portion 53 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 tab of the first electrical contact 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 tab of the second electrical 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 base frame 20 and the outer sidewall of the third electrical contact 43 of the electrical connector. In this way, the support frame 50 further secures the connection between the base frame 20 and the electrical connector 40.

[0157] The front face of the electrical connector 40 is not covered by the support frame 50, such that the front face of the third electrical contact 43 and the first and second electrical contacts 41, 42 in the recess 46 are exposed. This enables the first, second, and third electrical contacts 41, 42, 43 to be brought into contact with complementary electrical contacts of a complementary electrical connector.

[0158] At a proximal end 54 of the support frame 50, the support frame 50 forms a seat 55 for receiving an electronic circuit board of an aerosol-generating device. The seat 55 generally comprises a shallow, rectangular cavity suitable for receiving an electronic circuit board, and includes additional deeper inner cavities arranged within the shallow cavity for receiving electrical components connected to the electronic circuit board. At the proximal end 54 of the support frame 50, the support frame 50 further comprises openings arranged to enable the proximal ends 221, 241, 261 of the electrically conductive elements of the base frame 20, and pins 30, to extend through the support frame 50, and electrically connect to an electronic circuit board received in the seat 55.

[0159] An intermediate portion 56 of the support frame 50, disposed between the distal end 52 and proximal end 54, defines a power supply cavity 57 for receiving an electrical power supply of an aerosol-generating device. The power supply cavity 57 comprises the cavity 28 defined by the electrically conductive elements of the base frame 20, and a generally arcuate portion of the support frame 50, as shown in the lateral cross-section of 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 inner faces 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 50 maintains a desired separation between the electrically conductive elements of the base frame 20. An inner surface of the arcuate portion of the support frame 50 is shaped to complement the outer surface of an electrical power supply of an aerosol-generating device, which enables the arcuate portion of the support frame 50 to cradle an electrical power supply, and inhibit movement of the electrical power supply within the power supply cavity 57.

[0160] At the power supply cavity 57, the ground plane portions 26 of the base frame 20 are bent into a substantially arcuate shape. Upper ends of the ground plane portions 26, opposite lower ends adjacent to the first and second electrical tracks 22, 24, are not embedded in the support frame 50. The upper ends of the ground plane portions 26 define an opening 265 to enable an electrical power supply to be inserted into the power supply cavity 57 and removed from the power supply cavity 57. Pairs of opposing resilient portions 266 are spaced at regular intervals along the length of the power supply cavity 57, at the upper ends of the ground plane portions 26. As shown in FIG. 7, each pair of opposing resilient portions 266 is bent to define a width of the opening 265 that is less than the diameter of an electrical power supply of an aerosol-generating device. This helps to retain an electrical power supply of an aerosol-generating device in the power supply cavity 57, as the opposing pairs of resilient portions 266 are required to be forced apart in order to be able to remove an electrical power supply from the electrical power supply cavity 57.

[0161] A further pair of opposing resilient portions 268 are arranged at the upper ends of the ground plane portions 26, and are bent outwards to engage with the housing of an aerosol-generating device. These further pair of opposing resilient portions 268 are bent inwards when the frame 10 is received in the housing of an aerosol-generating device, and press on an inner surface of the housing to provide an increased frictional force between the frame 10 and the housing of the aerosol-generating device. As such, the further pair of opposing resilient portions 268 help to retain the frame 10 within the housing of the aerosol-generating device.

[0162] At the proximal end of the support frame 50, the support frame defines a heater cavity 58 for receiving a base of a heater of an aerosol-generating device. Accordingly, the frame 10 is configured to receive and support an electrical power supply, an electronic circuit board and a heater of an aerosol-generating device.

[0163] FIGS. 6 and 7 show a schematic illustration of an aerosol-generating device 100 comprising the frame 10.

[0164] The aerosol-generating device 100 is a device configured to receive an aerosol-generating article (not shown) comprising a solid aerosol-forming substrate and a filter wrapped together in the form of a rod like a conventional cigarette. The aerosol-generating device 100 is a portable device that is configured to be held in the hand of a user, having a length of about 90 mm, a diameter of about 14 mm.

[0165] The aerosol-generating device 100 comprises an outer housing 102, which is generally cylindrical, and formed from a light and brittle plastics material, such as PEEK. The aerosol-generating device 100 also includes an inner housing 103, comprising a hollow cylindrical tube of aluminium that extends the length of the outer housing 102 and beyond a proximal end of the inner housing 103 to form an open, cylindrical cavity 104. The open, cylindrical cavity 104 is configured to receive the aerosol-forming substrate of an aerosol-generating article. An elongate heater 106, in the form of blade, extends into the cavity 104 for penetrating into the aerosol-forming substrate of an aerosol-generating article received in the cavity 104. The heater 106 comprises a blade having a plurality of resistive heating elements or tracks disposed on an electrically insulating polyimide substrate extending from a base 107.

[0166] A power supply 108, in the form of a lithium-ion battery with a capacity of about 120 milliampere-hours, is housed within the housing 102.

[0167] An electronic circuit board 110 is also housed within the housing 102. The electronic circuit board 110 comprises a controller having a microprocessor (not shown) mounted on a printed circuit board. The electronic circuit board 110 is connected to the heater 106 and the power supply 108, and the electronic circuit board 110 is configured to control the supply of power from the power supply 108 to the heater 106.

[0168] 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 the power supplied from the power supply 108 to the heater 106 based on measurements of resistance of the electrically resistive heating element.

[0169] The heater 106, electrical power supply 108 and electronic circuit board 110 are received by the frame 10 and supported by the frame 10. The base 107 of the heater 106 is received in the heater cavity 58 of the support frame 50. The electrical power supply 108 is received in the power supply cavity 57, as shown in FIG. 7. The electronic circuit board 110 is received in the seat 55 of the frame 10. The frame 10, heater 106, electrical power supply 108 and electronic circuit board 110 are all received in the inner housing 103, which provides some protection to the components from impacts and general wear and tear.

[0170] The electrical connector 40 at the distal end of the frame 10 is arranged at a distal end of the outer housing 102, opposite the cavity 104, and forms the distal end face of the aerosol-generating device 100.

[0171] The electronic circuit board 110 is electrically connected to each of the first, second and third electrical contacts 41, 42, 43 via the base frame 20.

[0172] The proximal ends 221, 241, 261 of the electrically conductive elements of the base frame 20, and the electrically conductive pins 30, extend through openings in the support frame 50 and are electrically connected to the electronic circuit board 110.

[0173] The first electrical contact 41 of the electrical connector 40 is connected to the electronic circuit board 110 via the first electrical track 22 of the base frame 20. In this embodiment, the first electrical track 22 and the first electrical contact 41 are configured for the transfer of power from an external power supply to the electronic circuit board 110. Accordingly, the first electrical track 22 may be referred to as the power track. The controller of the electronic circuit board 110 is configured to control the supply of power from an external power supply to the power supply 108 of the aerosol-generating device 100 for recharging the power supply.

[0174] The second electrical contact 42 of the electrical connector 40 is connected to the electronic circuit 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 for the transfer of data from an external device to the electronic circuit board 110. Accordingly, the second electrical track 24 may be referred to as the data track. The controller of the electronic circuit board 110 is configured to control the transfer of data between an external device and the controller of the aerosol-generating device 100.

[0175] The third electrical contact 43 of the electrical connector 40 is connected to the electronic circuit board 110 via both ground plane portions 26 of the base frame 20. In this embodiment, the ground plane portions 26 of the base frame 20 appear as an infinite ground potential to the components of electrical circuit board 110, such that the electrical connection of the electronic circuit board 110 to the ground plane portions 26 of the base frame enables the components of the electronic circuit board to be grounded. Furthermore, the third electrical contact 43 of the electrical connector 40 is configured to be connected to a corresponding ground contact of a complementary electrical connector.

[0176] It will be appreciated that in other embodiments of the disclosure other components of the aerosol-generating device may be connected to each other via portions of the base frame 20. For example, a heater of an aerosol-generating device may be directly connected to an electrical contact of the electrical connector, for direct supply of power from an external power supply to a heater of the aerosol-generating device. For example, a positive terminal of an electrical power supply of the aerosol-generating device may be connected to an electronic circuit 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.

[0177] FIG. 8 shows a flowchart for a method of manufacture of the frame 10 of FIGS. 1 to 7 according to an embodiment of the present disclosure.

[0178] In a first step 201, a blank in the form of a laminar sheet of brass is pressed to form the base frame 20, having the first electrical track 22, the second electrical track 24 and the ground plane portions 26.

[0179] In a second step 202, an annular disc of a neodymium alloy is provided to form the third electrical contact 43.

[0180] In a third step 203, an annular ring of phosphor bronze is provided to form the second electrical contact 42.

[0181] In a fourth step 204, the third electrical contact 43 and the second electrical contact 42 are overmoulded with PPA in an injection moulding process to form the connector frame 44, with the second and third electrical contacts 42, 43 being partially embedded in the connector frame 44.

[0182] In a fifth step 205, a substantially planar sheet of phosphor bronze is provided to form the first electrical contact 41.

[0183] In a sixth step 206, the first electrical contact 41 is arranged at a rear face of the connector frame 44, such that the first, second, and third electrical contacts 41, 42, 43 and the connector frame 44 form the electrical connector 40.

[0184] In a seventh step 207, the electrical connector 40 is arranged 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 in contact with the electrical contacts 41, 42, 43 of the electrical connector.

[0185] In an 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 elements 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 ground plane portions 26 of the base frame 20.

[0186] In a ninth step 209, the base frame 20 and the electrical connector 40 are overmoulded with PPA in an injection moulding process to form the support frame 50, with the base frame 20 and electrical connector 40 partially embedded in the support frame 50. The base frame 20, electrical connector 40 and support frame 50 together form the frame 10.

[0187] In an additional step (not shown), the electrically conductive pins 30 may be arranged on the base frame 20, in contact with the electrically conductive elements of the base frame 20, and laser welded to the base frame 20. This additional step may be performed directly after the first step of forming the base frame 20, directly before or after the eighth step of laser welding the electrical contacts of the electrical connector 40 to the base frame 20, or after the support frame 50 has been formed.

[0188] It will be appreciated that the frame of the present disclosure may be used in other types of aerosol-generating device, such as aerosol-generating devices adapted to vapourise a liquid aerosol-forming substrate. It will also be appreciated that other embodiments of frames in accordance with the present disclosure may have other forms and configurations and may be made from other materials. It will also be appreciated that other methods of manufacture may be used to form a frame in accordance with the present disclosure.