WO2024094656A1

WO2024094656A1 - Heater for an aerosol provision device

Info

Publication number: WO2024094656A1
Application number: PCT/EP2023/080288
Authority: WO
Inventors: Juan Esteban Paz JAUREGUI
Original assignee: Nicoventures Trading Limited
Priority date: 2022-10-31
Filing date: 2023-10-30
Publication date: 2024-05-10
Also published as: GB202216137D0

Abstract

A heater for an aerosol provision device is provided, comprising an elongate housing having a longitudinal axis, wherein the elongate housing comprises a free end, a base end and an inner cavity which extends in a longitudinal direction, wherein the base end defines a mouth of the inner cavity; and a heating coil located within the inner cavity of the elongate housing, wherein the heating coil extends within the inner cavity in the longitudinal direction; wherein the inner cavity has a first longitudinal extent and the heating coil has a second longitudinal extent, and wherein the first longitudinal extent is substantially the same as the second longitudinal extent.

Description

HEATER FOR AN AEROSOL PROVISION DEVICE

Technical Field

The present invention relates to a heater for an aerosol provision device, an aerosol provision device, an aerosol provision system, a method of generating an aerosol and a method of manufacturing 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 heater for an aerosol provision device comprising: an elongate housing having a longitudinal axis, wherein the elongate housing comprises a free end, a base end and an inner cavity which extends in a longitudinal direction, wherein the base end defines a mouth of the inner cavity; and a heating coil located within the inner cavity of the elongate housing, wherein the heating coil extends within the inner cavity in the longitudinal direction; wherein the inner cavity has a first longitudinal extent and the heating coil has a second longitudinal extent, and wherein the first longitudinal extent is substantially the same as the second longitudinal extent.

The inner cavity may have a first longitudinal extent L1 and the heating coil may have a second longitudinal extent L2. According to various embodiments the first longitudinal extent L1 is substantially the same as the second longitudinal extent L2. For example, the heating coil may have a length L2 which is at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% of the length or longitudinal extent L1 of the inner cavity.

The inner cavity may be at least partially filled with one or more of: (i) a potting compound; (ii) an adhesive; (iii) a thermosetting plastic; or (iv) an epoxy resin.

The inner cavity may be filled with a thermally and/or electrically insulating material, for example a potting compound, an adhesive, a thermosetting plastic or an epoxy resin.

Other embodiments are contemplated wherein the heating coil may more generally comprise a resistive heating element. For example, according to various embodiments an aerosol provision device may be provided comprising: an elongate housing having a longitudinal axis, wherein the elongate housing comprises a free end, a base end and an inner cavity which extends in a longitudinal direction. The base end defines a mouth of the inner cavity. A resistive heating element is located within the inner cavity of the elongate housing, wherein the resistive heating element extends within the inner cavity in the longitudinal direction. The inner cavity has a first longitudinal extent and the resistive heating element has a second longitudinal extent, wherein the first longitudinal extent is substantially the same as the second longitudinal extent.

The elongate housing may comprise a metal or a metal alloy. For example, the elongate housing may comprise stainless steel or aluminium. Alternatively, the housing may comprise a ceramic.

The heater may further comprise a heater mount for securing the heater within a chamber of an aerosol provision device.

The heater mount may comprise a base portion having an engagement surface which is arranged to engage with an end of the elongate housing. At least a portion of the base portion may comprise an electrical insulator and/or thermal insulator.

The engagement surface may have a first cross-sectional profile and the end of the elongate housing has a second cross-sectional profile, wherein the first and second cross-sectional profiles are substantially similar.

The heater mount may further comprise a projection portion which extends a distance d1 into the inner cavity of the elongate housing. According to various embodiments, the distance d1 may be < 10%, < 9%, <8%, < 7%, < 6%, < 5%, < 4%, < 3%, < 2% or < 1% of the length or longitudinal extent L1 of the inner cavity. In particular, the distance d1 may be < 5%, 4%, 3%, 2% or 1% of the axial length of the inner cavity. The base portion of the heater mount may further comprise a flange or base plate for securing the heater mount within a chamber of an aerosol provision device.

The heater mount may further comprise: one or more apertures, channels or passages; and one or more electrical connectors, cables or wires which extend through the one or more apertures, channels or passages and which connect to the heating coil.

The heater may further comprise: a first electrical connector, cable or wire connected to a first end of the heating coil, wherein the first end of the heating coil is located proximal to the free end of the elongate housing; and a second electrical connector, cable or wire connected to a second end of the heating coil, wherein the second end of the heating coil is located proximal to the base end of the elongate housing; wherein the first electrical connector, cable or wire extends through the one or more apertures, channels or passages and/or the second electrical connector, cable or wire extends through the one or more apertures, channels or passages.

One or more portions of the heater mount may comprise or are at least partially filled with a potting compound, an adhesive, a thermosetting plastic or an epoxy resin.

The base end of the elongate housing may comprise one or more holes, slots, apertures or depressions, wherein the one or more holes, slots, apertures or depressions are at least partially filled with a potting compound, an adhesive, a thermosetting plastic or an epoxy resin.

According to another aspect there is provided an aerosol provision device configured to heat an article comprising aerosol generating material, the device comprising a heater as described above.

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

According to another aspect there is provided a method of manufacturing a heater for an aerosol provision device comprising: providing an elongate housing having a longitudinal axis, a free end, a base end and an inner cavity extending in a longitudinal direction, wherein the base end defines a mouth of the inner cavity; and locating a heating coil in the housing so that the heating coil extends in the direction of the longitudinal axis; wherein the longitudinal extent of the inner cavity is substantially the same as the longitudinal extent of the heating coil.

According to various embodiments the inner cavity may have a longitudinal extent L1 and the heating coil may have a longitudinal extent L2. The heating coil may have a length L2 which is at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% of the length or longitudinal extent L1 of the inner cavity.

The first end of the housing may define a mouth through which the inner cavity can be accessed from outside the housing, wherein the heating coil is longitudinally extending, has a longitudinal axis, and wherein the method comprises locating the heating coil within the inner cavity so that the heating coil does not contact the housing.

The method may further comprise attaching a heater mount to an end of the housing, wherein the heater mount comprises a base portion having an engagement surface which is arranged to engage with an end of the elongate housing and a projection portion which extends a distance d1 into the inner cavity of the elongate housing.

The method may further comprise forming of at least a portion of the heater mount in situ from a potting compound, an adhesive, a thermosetting plastic or an epoxy resin.

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

The method may further comprise activating the aerosol provision device in order to generate aerosol from the aerosol generating article.

The heater may be a resistive heating heater. The heating coil may be a resistive heating member. The heating coil 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 coil may be an inductive heating element. The coil may be an inductive coil.

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.

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 as described above and at least partially inserting an aerosol generating article into the receiving portion of the heating chamber.

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:

Figure 1 shows a perspective view of an aerosol provision system including an aerosol provision device located within a charging unit;

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

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

Figure 4 shows a perspective view of another aerosol provision device;

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

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

Figure 7 shows an embodiment wherein a heating coil is located within an inner cavity of an elongate housing of a heater and wherein the longitudinal length of the heating coil is substantially the same as the longitudinal length of the inner cavity;

Figure 8 shows an embodiment a heating coil is located within an inner cavity of an elongate housing of a heater and wherein the housing abuts a heater mount having a projection portion, wherein the projection portion of the heater mount extends a short distance into the inner cavity;

Figure 9 shows an embodiment wherein a heating coil extends substantially the full length of an inner cavity of an elongate housing of a heater, and wherein a portion of the heating coil is disposed around a projection portion of a heater mount, and wherein the projection portion of the heater mount extends a short distance into the inner cavity; and

Figure 10 illustrates a method of manufacturing a heater for an aerosol provision device according to various embodiments.

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 non- combustible 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 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.

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 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 or pivoted 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 50.

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 50 which is received within the heating chamber 401 in order to internally heat the aerosol generating article 50.

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 301.

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 the 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. The heating arrangement 300 comprises the heating member 301. The heating member 301 comprises an elongate housing 302 and the heating element 350. The elongate housing 302 is an elongate member defining a longitudinal axis.

The elongate housing 302 is formed from a thermally conductive material, such as aluminium. Other suitable materials, such as stainless steel may be used. Alternatively, the housing may comprise a ceramic. 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.

A groove 302a or region of reduced cross-sectional diameter may be provided in the elongate housing 302 towards the base end 303 of the elongate housing 302. As will be discussed in more detail below, a heating coil 351 is located within an inner void 308 of the heating member 301. The groove 302a or region of reduced cross sectional diameter may be located, for example, along the length of the elongate housing 302 at a longitudinal position which is intermediate a first longitudinal position corresponding to the longitudinal position of an end of the heating coil 351 closest to the base end 303 and a second longitudinal position corresponding to the longitudinal position where a base end of the elongate housing 302 attaches to, abuts or is otherwise secured to the mount 305.

It will be understood that the groove 302a or region of reduced cross-sectional diameter reduces, restricts or diminishes the effect of heat conduction from the main body of the heating member 301 to the base end of the heating member 301 which is mounted to the mount 305. As a result, the flow of heat or thermal energy from the heating member 301 into the mount 305 is reduced. The groove 302a or region of reduced cross-sectional diameter can therefore be considered as having the function of acting as a thermal break which reduces heat bleed from the heating member 301 into the mount 305 or more generally into a mounting point.

Further embodiments are contemplated (not shown) wherein more than one groove or region of reduced cross-sectional diameter may be provided in the elongate housing to act as a thermal break. Although the groove 302a or region of reduced cross- sectional diameter is shown in Figure 6 as comprising an annular recess, wherein the annular recess has a rectangular cross-sectional profile, other embodiments are contemplated wherein the annular recess may have a different cross-sectional profile such as, for example, a V-notch or W-notch. Further embodiments are also contemplated wherein one or more grooves or regions of reduced cross sectional diameter may be provided on an inner surface of 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 an inner void 308 of the heating member 301. The inner void 308 extends longitudinally. In embodiments, the inner void 308 is at least partially filled, for example with a filler. In embodiments, the inner void 308 is completely filled, for example with one or more fillers and/or components. In embodiments, the inner void 308 defines an air gap. An inner surface 309 is defined on an inner side of the elongate housing 302. An open end 310 to the inner 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 inner 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. 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 inner void 308. The heating element 350 extends between the base end 303 and the distal end 304. In embodiments, the heating element extends partially along the length of the inner 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 connection paths. The electrical connection paths extend from each end of the heating element 350. A base electrical connection path 352 extends from the distal end of the heating element 350. A return electrical connection path 353 extends from the proximal end of the heating element 350. The return electrical connection path overlaps the longitudinal extent of the heating element 350. The electrical connection paths 352,352 are integrally formed with the heating element 350, for example as a single wire. In embodiments, connectors connect the electrical connection paths 352,353 with the heating element 350. 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.

Figure 7 shows a heater for an aerosol provision device according to various embodiments. The heater comprises an elongate housing 302 having a longitudinal axis. The elongate housing 302 comprises a free end 304, a base end 303 and an inner cavity 308 which extends in a longitudinal direction. The base end 303 defines a mouth of the inner cavity 308. The heater further comprises a heating coil 351 located within the inner cavity 308 of the elongate housing 302. The heating coil 351 extends within the inner cavity 308 in the longitudinal direction. The inner cavity 308 has a first longitudinal extent L1 and the heating coil 351 has a second longitudinal extent L2. The respective lengths L2 and L2 are shown in Figure 7. It will be appreciated that the dimensions can be applied to all embodiments described below. According to various embodiments the first longitudinal extent L1 is substantially the same as the second longitudinal extent L2. For example, the heating coil 351 may have a length L2 which is at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% of the length or extent L2 of the inner cavity 308.

When the longitudinal extends L1 and L2 have a large difference, for example when the longitudinal extent L2 of the heating coil is shorter than L1, energy may be lost to the system when parts not adjacent to the heating coil are provided with energy. When L1 is substantially the same as L2, the heater has an improved efficiency since essentially the full length of the heating member (i.e. the elongate housing which surrounds the heating coil) is disposed adjacent a portion of the heating coil. Heat is not lost to parts of the housing that are not adjacent to the heating coil thus improving heating efficiency. For example, the elongate housing may surround a heating element and substantially the full longitudinal extent of the elongate housing will be heated by the heating coil. The heating coil may be a resistive heating coil.

As a result of this arrangement of the heating element within the heater, an efficient energy transfer from the heating coil located within the inner cavity of the heater to the elongate housing of the heater may be achieved. A more efficient energy transfer from the heating element to the elongate housing may result in a reduction of the time to heat the elongate housing to a desired operating temperature, in other words a faster start up time for the heater and the overall device. .

Furthermore, since substantially the entire longitudinal extend of the elongate housing is heated by the heating element, the elongate housing may be heated more consistently along its length.

According to various embodiments since the first longitudinal extend L1 is substantially equal to the second longitudinal extent L2 then as a result the full longitudinal extent of the elongate housing 302 will be internally heated by the heating coil 351. When the heater is used to internally heat an aerosol generating article (not shown in Fig. 7), the article may according to various embodiments be internally heated along either its full length or along a substantial portion of its length. This reduces heat loss and, in turn, increases the efficiency of the device.

The inner cavity 308 may be at least partially filled with a thermally insulating material. As a result, a more efficient energy transfer from the heating element to the elongate housing may be achieved. This in turn may lead to a reduction in time required to heat the elongate housing to desired operating temperature. A further advantage may be that the energy transfer from the heating element to the elongate housing is more consistent along the length of the heating member, which would result in a more consistent heating of the heating member.

The thermally insulating material may be a potting compound, an adhesive, thermosetting plastic or an epoxy resin. According to various embodiments the potting compound may comprise an epoxy resin. For example, a two-component epoxy may be used consisting of a polymer resin and a hardener which when mixed together causes a chemical reaction which cross-links chemical bonds in the polymer chains to create a tough, rigid and strong compound. Other embodiments are contemplated wherein the potting compound comprises a polyurethane (“Pll”) e.g. a thermoset plastic. This may comprise a two-component compound consisting of a base resin with an isocyanate curing agent. Other embodiments are contemplated wherein the potting compound comprises a silicone. For example, silicone rubber may be utilised comprising a synthetic polysiloxane polymer that uses an additive catalyser (such as platinum) to transition from a liquid to a solid state.

The thermally insulating material, for example the potting compound, may prevent heat transfer to adjacent parts of the device. For example, the inner cavity 308 may comprise the potting compound at the free end 304 in order to reduce heat transfer to an article at the free end 304 if it is not desired. In embodiments, the potting compound may be comprised at the base end 304 of the inner cavity 308 in order to reduce heat transfer at the base end 304. The potting compound may also prevent air pockets and heat transfer to the housing of the aerosol provision device to provide a safer and improved user experience.

The inner cavity 308 may be filled with a thermally and/or electrically insulating material, for example a potting compound, an adhesive, a thermosetting plastic or an epoxy resin. When a material of this type is arranged to surround the heating coil, air pockets may be avoided.

The elongate housing 302 may comprise a metal or a metal alloy such as aluminium. Other suitable materials, such as stainless steel may be used. According to another embodiment the housing 302 may comprise a ceramic. As shown in Figure 7, the heater may further comprise a heater mount 305 for securing the heater within a chamber of an aerosol provision device.

The inner cavity 308 comprises an opening 310 at the distal end of the heater. The heater mount 305 is formed as a skirt which extends radially around the periphery of the base end 303 of the housing 302, away from the opening 310. The mount 305 may be a separate component or may be integrally formed with the elongate housing 302. The mount 305 engages with a housing of the device 100 to secure the heater within a chamber of the aerosol provision device.

Figure 8 shows an embodiment wherein a heating mount 800 is provided which comprises a base portion 810 and a projection portion 820. The base portion 810 has an engagement surface 812 which is arranged to engage with an end of the elongate housing 302. The base portion is arranged at the base end 303 of the elongate housing 302. At least a portion of the base portion 810 comprises an electrical insulator and/or thermal insulator. For example, the base portion may comprise a thermoplastic.

The engagement surface 812 may have a first cross-sectional profile and the end of the elongate housing 302 may have a second cross-sectional profile, wherein the first and second cross-sectional profiles may be substantially similar. This provides a suitably secure fit between the heating mount 800 and the elongate housing 302 to reduce energy loss in any gap between the components.

The heater mount 800 as shown in Figure 8 comprises a projection portion 820 which extends a distance d1 into the inner cavity 308 of the elongate housing 302. According to various embodiments the distance d1 may be < 5%, 4%, 3%, 2% or 1% of the axial length of the inner cavity. The heating coil 351 extends within the inner cavity 308 in the longitudinal direction. The inner cavity 308 has a first longitudinal extent L1 and the heating coil 351 has a second longitudinal extent L2. In embodiments, the distance d1 that the projection portion 820 extends into the inner cavity 308 may be the difference between the first longitudinal extent L1 and the second longitudinal extent L2. It will be understood that the longitudinal extent L1 of the inner cavity 308 may be substantially equal to the longitudinal extent L2 of the heating coil 351 and the distance d1 of the projection portion 820. It will also be understood that the heating coil 351 may have a length L2 which is at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% of the length or extent L2 of the inner cavity 308 and that L1 and L2 are substantially equal. In embodiments, the projection portion 820 may abut the distal end of the heating coil 351.

The base portion of the heater mount 800 may further comprise a flange or base plate 814 for securing the heater mount 800 within a chamber of an aerosol provision device. The flange or base plate 814 may be integral with the base portion 820 of the heater mount. Alternatively, the flange or base plate 814 may comprise a discrete component.

The heating mount 800 may comprise one or more apertures, channels or passages 816. As shown in Figure 8 the one or more apertures, channels or passages 816 may pass the through the heating mount 800 along its full longitudinal length. In embodiments, the apertures, channels or passages 816 may be positioned substantially through the center of the heating mount 800.

One or more electrical connectors, cables or wires (not shown) may be arranged to extend through the one or more apertures, channels or passages 816 and connect to the heating coil 351. The width of the one or more apertures, channels or passages 816 may be substantially the same as the width of the one or more electrical connectors, cables or wires that are arranged to extend therethrough.

According to various embodiments the heater may comprise a first electrical connector, cable or wire connected to a first end of the heating coil 351. The first end of the heating coil 351 is located proximal to the free end 304 of the elongate housing 302. The heater may further comprise a second electrical connector, cable or wire connected to a second end of the heating coil, wherein the second end of the heating coil is located proximal to the base end 303 of the elongate housing 302. According to various embodiments the first electrical connector, cable or wire extends through the one or more apertures, channels or passages 816 and/or the second electrical connector, cable or wire extends through the one or more apertures, channels or passages 816.

One or more portions of the heater mount 800 comprise or are at least partially filled with a potting compound, an adhesive, a thermosetting plastic or an epoxy resin. The base end of the elongate housing may comprise one or more holes, slots, apertures or depressions. The one or more holes, slots, apertures or depressions may be least partially filled with a potting compound, an adhesive, a thermosetting plastic or an epoxy resin. As a result, thermal transfer from the elongate housing 302 (which may be metallic such aluminium or stainless steel) to the housing of the aerosol provision device is reduced. Providing a metallic elongate housing 302 results in efficient energy transfer to the article that is to be heated. The heating coil comprises a resistive heating coil.

Figure 9 shows an embodiment wherein a heating mount 900 is provided having a base portion 910 and a projection portion 920. The base portion 910 is arranged to secure the heater mount within a chamber of an aerosol provision device. The projection portion 920 may extend within an end portion of the heating coil 351 at the base end 303 of the elongate housing 302.

The projection portion 920 extends a distance into the inner cavity 308 of the elongate housing 302. The cross-sectional area of the projection portion 920 is dimensioned to fit within the diameter of the heating coil 351. The projection portion 920 may be entirely surrounded by the heating coil 351.

The heating coil has a second longitudinal extent L2. The longitudinal extent L2 of the heating coil 351 is substantially equal to a first longitudinal extent L1 of the inner cavity 308. Part of the longitudinal extent L2 of the heating coil 351 at the base end 303 may surround the projection portion 920 of the mount 900.

The heating coil 351 having a longitudinal extent L2 substantially equal to the longitudinal extent L1 of the inner cavity 308 means that the coil is located adjacent to the housing along its full longitudinal length. This means that heating will be consistent along the full length of the heater and reduces energy loss. In embodiments where part of the heating coil 351 surrounds the projection portion 920 of the mount 900, there is increased protection for the heater coil 351 when it is inserted into an article.

The mount 900 may further comprise an engagement surface 912 that is arranged to engage with and end of the elongate housing 302. When the engagement surface 912 and the end of the elongate housing 302 are engaged, there may be no gap between the elongate housing 302 and the mount 900. This reduces heat loss through a gap that may otherwise be present.

In embodiments, the mount 900 may comprise one or more apertures, channels or passages 916 through which one or more electrical connectors, cables or wires may extend. According to embodiments, the one or more electrical connectors, cables or wires may comprise a first electrical connector, cable or wire which is connected to a first end of the heating coil 351. The first end of the heating coil 351 may be located proximal to the free end 304 of elongate housing 302. The first electrical connector, cable or wire may extend through the center of the heating coil along the longitudinal axis and through the one or more apertures, channels or passages 916.

It will be understood that the heater according to various embodiments and in particular as shown and described above in relation to Figures 6-9 may form part of an aerosol provision device configured to heat an article comprising aerosol generating material. Similarly, a system comprising an aerosol provision device as described above and an article comprising aerosol generating material is disclosed.

Figure 10 illustrates a method of manufacturing a heater for an aerosol provision device according to various embodiments. The method comprises a first step 1001 of providing an elongate housing having a longitudinal axis, a free end, a base end and an inner cavity extending in a longitudinal direction, wherein the base end defines a mouth of the inner cavity. The method further comprises a second step 1002 of locating a heating coil in the housing so that the heating coil extends in the direction of the longitudinal axis. The longitudinal extent of the inner cavity is substantially the same as the longitudinal extent of the heating coil.

The first end of the housing defines a mouth through which the inner cavity can be accessed from outside the housing. The heating coil is longitudinally extending and has a longitudinal axis. The method may comprise locating the heating coil within the inner cavity so that the heating coil does not contact the housing.

The coil may be located in the inner cavity which extends in the longitudinal direction. The inner cavity may have a first longitudinal extent and the heating coil may have a second longitudinal extend. The first and second longitudinal extents may be substantially equal. For example, the heating coil may have a length which is at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% of the length or extent of the inner cavity.

The method may further comprise a third step 1003 of attaching a heater mount to an end of the housing, wherein the heater mount comprises a base portion having an engagement surface which is arranged to engage with an end of the elongate housing and a projection portion which extends a distance d1 into the inner cavity of the elongate housing. In particular, the distance d1 may be < 5%, 4%, 3%, 2% or 1% of the axial length of the inner cavity.

In embodiments, the method may comprise attaching the mount such that the projection portion may extend into the inner cavity of the elongate housing to abut a distal end of the heating coil. In embodiments, the method may comprise attaching the mount such that part of the heating coil surrounds part of the projection portion.

According to various embodiments the method may further comprise forming at least a portion of the heater mount in situ from a thermally insulating material. The thermally insulating material may be a potting compound, an adhesive, a thermosetting plastic or an epoxy resin. The thermally insulating material reduces heat transfer to the heating mount and the surrounding at the base end of the heater.

In the above described embodiments, the heating arrangement is a resistive heating arrangement. In embodiments, other types of heating arrangement may be 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 heater for an aerosol provision device comprising: an elongate housing having a longitudinal axis, wherein the elongate housing comprises a free end, a base end and an inner cavity which extends in a longitudinal direction, wherein the base end defines a mouth of the inner cavity; and a heating coil located within the inner cavity of the elongate housing, wherein the heating coil extends within the inner cavity in the longitudinal direction; wherein the inner cavity has a first longitudinal extent and the heating coil has a second longitudinal extent, and wherein the first longitudinal extent is substantially the same as the second longitudinal extent.

2. A heater as claimed in claim 1 , wherein the inner cavity is at least partially filled with one or more of: (i) a potting compound; (ii) an adhesive; (iii) a thermosetting plastic; or (iv) an epoxy resin.

3. A heater as claimed in claim 1 or 2, wherein the elongate housing comprises a metal or a metal alloy.

4. A heater as claimed in claim 1 , 2 or 3, wherein the heater further comprises a heater mount for securing the heater within a chamber of an aerosol provision device.

5. A heater as claimed in claim 4, wherein the heater mount comprises a base portion having an engagement surface which is arranged to engage with an end of the elongate housing.

6. A heater as claimed in claim 5, wherein at least a portion of the base portion comprises an electrical insulator and/or a thermal insulator.

7. A heater as claimed in claim 5 or 6, wherein the engagement surface has a first cross-sectional profile and the end of the elongate housing has a second cross-sectional profile, wherein the first and second cross-sectional profiles are substantially similar.

8. A heater as claimed in any of claims 4-7, wherein the heater mount further comprises a projection portion which extends a distance d1 into the inner cavity of the elongate housing.

9. A heater as claimed in any of claims 4-8, wherein the base portion of the heater mount further comprises a flange or base plate for securing the heater mount within a chamber of an aerosol provision device.

10. A heater as claimed in any of claims 4-9, wherein the heater mount further comprises: one or more apertures, channels or passages; and one or more electrical connectors, cables or wires which extend through the one or more apertures, channels or passages and which connect to the heating coil.

11. A heater as claimed in claim 10, further comprising: a first electrical connector, cable or wire connected to a first end of the heating coil, wherein the first end of the heating coil is located proximal to the free end of the elongate housing; and a second electrical connector, cable or wire connected to a second end of the heating coil, wherein the second end of the heating coil is located proximal to the base end of the elongate housing; wherein the first electrical connector, cable or wire extends through the one or more apertures, channels or passages and/or the second electrical connector, cable or wire extends through the one or more apertures, channels or passages.

12. A heater as claimed in any of claims 4-11 , wherein one or more portions of the heater mount comprise or are at least partially filled with a potting compound, an adhesive, a thermosetting plastic or an epoxy resin.

13. A heater as claimed in any of claims 1-12, wherein the base end of the elongate housing comprises one or more holes, slots, apertures or depressions, wherein the one or more holes, slots, apertures or depressions are at least partially filled with a potting compound, an adhesive, a thermosetting plastic or an epoxy resin.

14. A heater as claimed in any of claims 1-13, wherein the heating coil comprises a resistive heating coil.

15. An aerosol provision device configured to heat an article comprising aerosol generating material, the device comprising a heater according to any of claims 1-14.

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

17. A method of manufacturing a heater for an aerosol provision device comprising: providing an elongate housing having a longitudinal axis, a free end, a base end and an inner cavity extending in a longitudinal direction, wherein the base end defines a mouth of the inner cavity; and locating a heating coil in the housing so that the heating coil extends in the direction of the longitudinal axis; wherein the longitudinal extent of the inner cavity is substantially the same as the longitudinal extent of the heating coil.

18. A method as claimed in claim 17, wherein the first end of the housing defines a mouth through which the inner cavity can be accessed from outside the housing, wherein the heating coil is longitudinally extending, has a longitudinal axis, and wherein the method comprises locating the heating coil within the inner cavity so that the heating coil does not contact the housing.

19. A method as claimed in claim 17 or 18, further comprising attaching a heater mount to an end of the housing, wherein the heater mount comprises a base portion having an engagement surface which is arranged to engage with an end of the elongate housing and a projection portion which extends a distance d1 into the inner cavity of the elongate housing.

20. A method as claimed in claim 19, wherein the method further comprises forming of at least a portion of the heater mount in situ from a potting compound, an adhesive, a thermosetting plastic or an epoxy resin.

21. A method of generating an aerosol comprising: providing an aerosol provision device as claimed in claim 15; and at least partially inserting an article comprising aerosol generating material into the aerosol provision device.

22. A method as claimed in claim 21 , wherein the method further comprises activating the aerosol provision device in order to generate aerosol from the aerosol generating article.