WO2025172409A1 - Aerosol generating apparatus - Google Patents

Abstract

An aerosol generating apparatus comprising an external shell and an internal component, the external shell housing the internal component, wherein the external shell comprises an inner surface including one or more retention recesses, wherein the internal component comprises an outer surface including one or more retention protrusions, and, wherein each retention recess is engaged with at least one of the retention protrusions to thereby fixedly couple the internal component to the external shell

Description

AEROSOL GENERATING APPARATUS

This application claims priority from EP24157763.4 filed 15 February 2024, the contents and elements of which are herein incorporated by reference for all purposes.

FIELD

The present disclosure relates to an aerosol generating apparatus.

BACKGROUND

A typical aerosol generating apparatus comprises a power supply, an aerosol generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user. An external shell houses internal components of the aerosol generating apparatus.

A drawback with known aerosol generating apparatuses is that aerosol generating apparatuses may be complex to manufacture.

In spite of the effort already invested in the development of aerosol generating apparatuses/systems further improvements are desirable.

SUMMARY

According to a first aspect, the present disclosure provides an aerosol generating apparatus that comprises an external shell and an internal component, the external shell housing the internal component, wherein the external shell comprises an inner surface including one or more retention recesses, wherein the internal component comprises an outer surface including one or more retention protrusions, and wherein each retention recess is engaged with at least one of the retention protrusions to thereby couple the internal component to the external shell.

Advantageously then, an external shell of an aerosol generating apparatus may be coupled to an internal component by engaging a retention protrusion of the internal component with a retention recess of the external shell. In this way, manufacture of the aerosol generating apparatus may be facilitated. Additionally, or alternatively, due to the coupling being achieved in this way, there may be no need for the aerosol generating apparatus to include a fixing means for fixing the external shell to the internal component which requires a through-hole in the external shell, such as a screw. Thus, an outer surface of the external shell may be as smooth, as continuous and/or as uninterrupted as possible resulting in a visually and haptically pleasing aerosol generating apparatus. This may also prevent or dissuade the user from disassembling the apparatus. The external shell may be an outermost component of the aerosol generating apparatus. The external shell may house the entire internal component. The outer surface of the external shell may correspond to a user-interface surface which is configured to be touched and/or held by a user.

The one or more retention recesses may not extend through the outer surface of the external shell . Each of the retention recesses may extend through only a portion of a thickness of the external shell. In some examples, each retention recess may take the form of a groove. In some examples, each retention protrusion may take the form of a pip.

In this way, user access to the retention recess and/or retention protrusion may be prevented. Thus, a user may be prevented or dissuaded from disassembling the apparatus.

Each retention recess being engaged with at least one of the retention protrusions may refer to each retention recess interlocking with at least one of the retention protrusions, or receiving at least one of the retention protrusions.

In some examples, each retention recess may be engaged with at least one of the retention protrusions to thereby fixedly couple the internal component to the external shell.

In some examples, each retention recess may be engaged with a corresponding one of the retention protrusions to thereby couple the internal components to the external shell.

It will further be appreciated that there may be a mutual engagement between each retention recess and each corresponding retention protrusion. Thus, it may be said that each retention protrusion is engaged with a corresponding one of the retention recesses.

Each retention recess may be complementary in shape to the corresponding retention protrusion with which the retention recess is engaged.

In this way, snug engagement of each retention recess and corresponding retention protrusion may be provided. Thus, relative movement of the external shell and the component may be inhibited.

In a central region of the retention recess, a cross-sectional shape of the retention recess may be generally rectangular. A depth of the retention recess may taper (e.g., decrease) towards each lateral end of the retention recess. A depth of the retention recess may taper towards each lateral end of the retention recess such that a base of the retention recess is continuous with a surrounding inner surface of the external shell at the lateral ends of the retention recess.

In this way, there may be more allowance for a difference in size and/or shape between each retention recess and each corresponding retention protrusion. As such, manufacture of the aerosol generating apparatus may be facilitated.

In some examples, the aerosol generating apparatus may be elongate, having a longitudinal axis.

In some examples, each retention recess and may be engaged with at least one of the retention protrusions to inhibit movement of the internal component relative to the external shell along the longitudinal axis of the aerosol generating apparatus. For example, each retention recess and/or each retention protrusion may extend transversely and/or along a radial line of the aerosol generating apparatus.

In this way, the external shell may be retained on the internal component, even when a user exerts a force along the longitudinal axis of the aerosol generating apparatus. As discussed in more detail below, the aerosol generating apparatus may include a device body and a cap configured to engage with the device body. A force along the longitudinal axis of the aerosol generating apparatus may be applied by a user, for example, when pulling the cap away from the device body of the aerosol generating apparatus. The external shell may correspond to an external shell of the cap, for example, and the internal component may correspond to an internal component of the cap. As another example, the external shell may correspond to an external shell of the device body, and the internal component may correspond to an internal component of the device body.

In some examples, each retention recess may extend circumferentially, with respect to the longitudinal axis of the aerosol generating apparatus, along a portion of the inner surface of the external shell. Accordingly, each retention protrusion may extend circumferentially, with respect to the longitudinal axis of the aerosol generating apparatus, along a portion of the outer surface of the internal component.

Advantageously then, there may be a stronger retention of the external shell on the internal component, because the engagement of each retention protrusion with its corresponding retention recess may occur across a larger surface area. It may be difficult for a user to separate the external shell from the internal component by pulling along the longitudinal axis of the external shell and/or the internal component.

In some examples, each of the retention recesses may extend axially along the longitudinal axis of the aerosol generating apparatus, along a portion of the inner surface of the external shell. Accordingly, each retention protrusion may extend axially along the longitudinal axis of the aerosol generating apparatus, along a portion of the outer surface of the internal component.

In this way, the external shell may inhibit transverse movement of the internal component relative to the external shell. Additionally, or alternatively, in this way it may be difficult for a user to twist the external shell relative to the internal component.

In some examples, a cross-sectional shape of the outer surface of the internal component may be complementary to a cross-sectional shape of the inner surface of the external shell. For example, a transverse cross-sectional shape of the outer surface of the internal component may be complementary to a transverse cross-sectional shape of the inner surface of the external shell. The external shell may sleeve the internal component. It will be appreciated that a transverse cross- sectional shape may refer to the shape of a cross-section in a plane transverse to a longitudinal axis of the aerosol generating apparatus. Thus, the outer surface of the internal component may abut the inner surface of the external shell circumferentially with respect to the longitudinal axis of the aerosol generating apparatus.

In this way, the external shell may inhibit transverse movement of the internal component relative to the external shell.

In some examples, the transverse cross-sectional shape of the outer surface of the internal component may be complementary to the transverse cross-sectional shape of the inner surface of the external shell at an engagement location of the aerosol generating apparatus. At an engagement location, one of the retention recesses may be engaged with a retention protrusion. The external shell may sleeve the internal component at the engagement location.

In this way, at an engagement location, transverse movement of the internal component relative to the external shell may be inhibited by an outer surface of the internal component circumferentially abutting the inner surface of the external shell, and further at the engagement location longitudinal movement of the internal component may be inhibited by a retention recess being engaged with a retention protrusions.

In some examples, a transverse cross-section of the external housing may have a generally obround shape. For example, a transverse cross-section of the inner surface of the external housing may have a generally obround shape. In some examples, a transverse cross-section of the internal component may have a generally obround shape. For example, a transverse cross-section of the outer surface of the internal component may have a generally obround shape. In some examples, the transverse cross-section of the internal component may and/or the transverse cross-section of the external housing may have a generally obround shape at the engagement location.

A transverse cross section may refer to a cross-section taken transverse to the longitudinal axis of the aerosol generating apparatus.

In this way, twisting of the external shell relative to the internal component may be inhibited. The aerosol generating apparatus may both include rounded sides, and be inhibited from having a twistable external shell.

In some examples, where the transverse cross-section of the external housing has a generally obround shape, one or more of the retention recesses may extend along a longer side of the obround shape of the cross-section. In some examples, where the transverse cross-section of the internal component has a generally obround shape, one or more of the retention protrusions may extend along a longer side of the obround shape of the cross-section.

In this way, there may be a stronger retention of the external shell on the internal component, because the engagement of each retention protrusion with each corresponding retention recess may occur across a larger surface area. In some examples, where the transverse cross-section of the external housing has a generally obround shape, one or more of the retention recesses may extend along a shorter side of the obround shape of the cross-section. In some examples, where the transverse cross-section of the internal component has a generally obround shape, one or more of the retention protrusions may extend along a shorter side of the obround shape of the cross-section.

In some examples, the one or more retention recesses may include a plurality of retention recesses, and the one or more retention protrusions may include a plurality of retention protrusions.

In this way, a stronger engagement between the internal component and external shell may be achieved.

In some examples, one or more of the retention recesses may be at different longitudinal positions to one another relative to the longitudinal axis of the aerosol generating apparatus. Accordingly, one or more of the retention protrusions may be at different longitudinal positions to one another relative to the longitudinal axis of the aerosol generating apparatus.

In some examples, the plurality of retention recesses may include two retention recesses. Accordingly, the internal component may include two retention protrusions, each corresponding to a respective on of the two retention recesses.

Each of the two retention recesses may be at a different longitudinal position relative to a longitudinal axis of the aerosol generating apparatus. Accordingly, each of the two retention protrusions may be at a different longitudinal position relative to a longitudinal axis of the aerosol generating apparatus.

Advantageously, such an arrangement of retention recesses and retention protrusions may provide a strong engagement of the internal component with the external shell. For example, such an arrangement may allow for the presence of a greater number of retention recesses and retention protrusions, and thus a surface area across which a retention force may be applied may be increased. For example, a retention recess/retention protrusion extending along a shorter side of the obround shape may be at different longitudinal position to a retention recess I retention protrusion extending along a longer side of the obround shape.

In some examples, the plurality of retention recesses may include two retention recesses, each of the two retention recesses being at the same longitudinal position relative to a longitudinal axis of the aerosol generating apparatus. Accordingly, the plurality of retention protrusions may include two retention protrusions, each of the two retention protrusions being at the same longitudinal position relative to a longitudinal axis of the aerosol generating apparatus.

In some examples, the plurality of retention recesses may include two opposing recesses. The two opposing recesses may be disposed across the longitudinal axis of the aerosol generating apparatus from one another. For example, the two opposing recesses may be on opposite sides of external housing. Two opposing recesses may refer to two recesses which are separated along a radial line and/or along a transverse axis of the aerosol generating apparatus.

Accordingly, the internal component may include two retention protrusions, each corresponding to one of the two opposing retention recesses. Such retention protrusions may be separated along a radial line and/or along a transverse axis of the aerosol generating apparatus.

Advantageously, such an arrangement of retention recesses and retention protrusions may provide a more effective engagement of the internal component with the external shell. For example, a retention force may be applied more evenly across the aerosol generating apparatus.

In some examples, the one or more retention recesses may correspond to one or more first retention recesses. In such examples, the inner surface of the external shell may further include one or more second retention recesses. Further, in some examples, the internal component may correspond to a first internal component, and the one or more retention protrusions may correspond to one or more first retention protrusions. The aerosol generating apparatus may further include a second internal component. The second internal component may comprise an outer surface including one or more second retention protrusions. In such examples, each first retention recess may be engaged with a corresponding one of the first retention protrusions, and each second retention recess may be engaged with a corresponding one of the second retention protrusions to thereby couple, or fixedly couple, the second internal component to the external shell.

Advantageously then, a plurality of internal components may be coupled, or fixedly coupled, to the external shell by engaging retention protrusions on the internal components with retention recesses in the external shell. In this way, manufacture of the aerosol generating apparatus may be facilitated. Further, due to the fixed coupling being achieved in this way, there may be no need for the aerosol generating apparatus to include a fixing means for fixing the internal components to the external shell which requires a through-hole in the external shell, such as a screw. Thus, an outer surface of the external shell may be as smooth, as continuous and/or as uninterrupted as possible resulting in a visually and haptically pleasing aerosol generating apparatus.

In some examples, each of the retention protrusions may be resiliently biased towards, or into, the corresponding retention recess, or the retention recess with which the retention protrusion is engaged. In such examples, each resiliently biased retention protrusion and the corresponding retention recess may be referred to as a clip.

Advantageously, this may enable a stronger engagement of the internal component with the external shell. Further, this may facilitate insertion of the internal component into the external shell during manufacture.

In some examples, each of the retention protrusions being resiliently biased may include each of the retention protrusions being coupled to a respective pivotable arm of the internal component, the pivotable arm being resiliently biased. The pivotable arm may be resiliently biased to align with a longitudinal axis of the aerosol generating apparatus. The retention protrusion may extend outwards from the pivotable arm. The pivotable arm may take the form of a flexible arm.

Such a mechanism for providing a resiliency biased retention protrusion may allow the retention protrusion itself to be difficult to compress. Advantageously, this may enable a stronger engagement of the internal component with the external shell.

Each of the retention recesses may be at least partially defined by a respective recess abutment surface, which may correspond to a portion of the inner surface of the external shell. Each recess abutment surface may be transverse to a longitudinal axis of the aerosol generating apparatus. Accordingly, each retention protrusion may include a protrusion abutment surface. Each protrusion abutment surface may be transverse to the longitudinal axis of the aerosol generating apparatus. Each protrusion abutment surface may abut a corresponding recess abutment surface.

In this way, there may be a stronger retention of the external shell to the internal component when a user exerts a force along a longitudinal axis of the aerosol generating apparatus.

In some examples, each recess abutment surface may be at an upper end of the respective retention recess. Accordingly, each protrusion abutment surface may be at an upper end of the respective protrusion. Upper ends may be ends which are closest to a mouthpiece or a consumable-receiving aperture of the aerosol generating apparatus.

In some examples, each recess abutment surface may be at a lower end of the respective retention recess. Accordingly, each protrusion abutment surface may be at a lower end of the respective protrusion. Lower ends may be ends which are farthest from a mouthpiece or a consumable-receiving aperture of the aerosol generating apparatus.

As a particular example, each retention protrusion may have a barbed shape.

This may facilitate insertion of the internal component into the external shell during manufacture, while providing a strong engagement of the external shell and the internal component.

For example, each retention protrusion may include a sloped surface. The sloped surface may be sloped or inclined with respect to the longitudinal axis of the aerosol generating apparatus. Each sloped surface may correspond to an upper face of the respective retention protrusion. That is, each sloped surface may be at an upper end of the respective retention protrusion. The sloped surface may be sloped downwards. “Downwards” may refer to a direction from a mouthpiece, or consumablereceiving aperture, to a battery of the aerosol generating apparatus.

As such, insertion of the internal component into the external shell during manufacture may be facilitated.

As mentioned above, due to the mechanism by which an internal component may be coupled, or fixedly coupled, to the external shell in the present disclosure, there may be no need for the aerosol generating apparatus to include a fixing means for fixing the internal component to the external shell which requires a through-hole in the external shell, such as a screw. Thus, an outer surface of the external shell may be as smooth, as continuous and/or as uninterrupted as possible.

For example, the external shell may be continuous/ unbroken/ smooth and/or uninterrupted at an engagement location (where one or more retention recesses is engaged with a corresponding retention protrusion).

In some examples the external shell may include a circumferential wall. The circumferential wall may be circumferential with respect to a longitudinal axis of the aerosol generating apparatus. An outer surface of the circumferential wall may be continuous. The circumferential wall may have a constant diameter along a longitudinal axis of the aerosol generating apparatus. For example, an outer surface of the circumferential wall may have a constant diameter along a longitudinal axis of the aerosol generating apparatus.

A surface being continuous may refer to a surface being smooth, unbroken, and/or uninterrupted.

Advantageously then, a more visually and haptically pleasing aerosol generating apparatus may be provided.

In some examples, the aerosol generating apparatus may correspond to a heat-not-burn (HNB) aerosol generating apparatus.

In some examples, the aerosol generating apparatus may include a device body. The aerosol generating apparatus may further comprise a cap configured to engage with the device body at an upper end of the device body. The cap may be moveable with respect to the device body. For example, the cap may be moveable with respect to the device body along the longitudinal axis of the aerosol generating apparatus.

The device body may comprise one or more components, which may correspond to one or more internal components. For example, the device body may comprise a power supply, electrical circuitry, a heating element, and/or a device body chassis configured to house and/or couple with one or more components of the device body.

The cap may comprise a consumable-receiving aperture configured to receive a consumable therethrough. The cap may comprise one or more components, which may correspond to one or more internal components. For example, the cap may comprise a cap chassis configured to house and/or couple with one or more components of the cap, such as a rotatable door.

In some examples, the internal component which includes the one or more retention protrusions may correspond to a support configured to support another component of the aerosol generating apparatus. For example, the internal component may correspond to a heating element support configured to support a heating element of the aerosol generating apparatus.

In some examples, the internal component which includes the one or more retention protrusions may correspond to a chassis, such as a device body chassis or a cap chassis. In some examples, the internal component which includes the one or more retention protrusions may correspond to a shell liner. The shell liner may be coupled to and/or may cover one or more other internal components of the aerosol generating device, such as a device body chassis or a cap chassis. In examples where the shell liner is an internal component of the cap, the shell liner may include one or more slots into which a respective one or more coupling arms of the device body extend. The slots may be longer along the longitudinal axis of the aerosol generating apparatus than the portion of the coupling arms which extend into the slots to enable the cap to be moveable with respect to the device body along the longitudinal axis of the aerosol generating apparatus.

In some examples, the external shell may correspond to an external shell of the cap. In such examples, the internal component which includes the one or more retention protrusions may correspond to an internal component of the cap. In other examples, the external shell may correspond to an external shell of the device body. In such examples, the internal component which includes the one or more retention protrusions may correspond to an internal component of the device body.

In some examples, the external shell may be an integrally formed element. The external shell may have been formed by deep drawing, for example. The one or more retention recesses of the external shell may be formed by machining.

Advantageously, the external shell corresponding to an integrally formed element may result in a more visually and haptically pleasing aerosol generating apparatus. For example, the external shell corresponding to an integrally formed element may reduce a number of split lines in an outer surface of the external shell.

In some examples, the external shell may include a front shell portion and a back shell portion, wherein the front shell portion and the back shell portion are fixedly coupled. The front shell portion and the back shell portion may have been formed separately. The front shell portion and the back shell portion may each have been formed by deep drawing.

Advantageously, the external shell including a front shell portion and a back shell portion which are fixedly coupled together may facilitate manufacture of the aerosol generating apparatus. For example, such an arrangement may facilitate the insertion of internal components into the external housing.

A cross-section of each of the shell portions, taken axially along the longitudinal axis of the aerosol generating apparatus, may have a generally obround shape.

In some examples, each shell portion may include a lip extending from a main portion of the shell portion. A gap may be defined between each of the lips. A cap of the aerosol generating apparatus may be slotted into the gap.

In some examples, the front shell portion or the back shell portion may include the one or more retention recesses. In some examples, both the front shell portion and the back shell portion may include the one or more retention recesses. That is, each of the front shell portion and the back shell portion may include a subset of the one or more retention recess.

In some examples, the front shell portion and/or the back shell portion may include a retention recess extending along sides of the obround shape of the axial cross section of the shell portion. For example, the front shell portion and/or the back shell portion may include a retention recess extending along a first longer side, along a first shorter side and along a second longer side. The front shell portion and/or the back shell portion may include a retention recess extending along a first longer side, along a second shorter side and along a second longer side.

In some examples, the external shell may be formed of a rigid material. The external shell may be formed of a material which can be deep drawn. For example, the external shell may be formed of a metal, e.g., aluminium.

As mentioned above, each of the retention recesses may extend through only a portion of the thickness of the external shell. A depth of each retention recess may be less than a thickness of the external shell.

In some examples, a depth of each retention recess may be at least 50% of the thickness of the external shell.

In this way, a strong engagement between each retention protrusion and each corresponding retention recess may be achieved.

In some examples, a depth of each retention recess may be no more than 95% of the thickness of the external shell.

In this way, a smooth outer surface of the external shell may be achieved.

A thickness of the external shell may be at least 0.5 mm and no more than 1 .5 mm. More specifically, a thickness of the external shell may be at least 0.7 mm and no more than 1 mm, for example 0.8 mm.

In some examples, a depth of each retention recess may be at least 0.2 mm and no more than 0.8 mm. More specifically, a depth of each retention recess may be at least 0.4 mm and no more than 0.7 mm, for example 0.5 mm or 0.65 mm.

According to a second aspect, the present disclosure provides a method of manufacturing an aerosol generating apparatus, the aerosol generating apparatus being according to the first aspect. The method comprises forming the one or more retention recesses by machining.

Advantageously then, the one or more retention recesses may be formed, even when the external shell is formed by a process such as deep drawing, which may not allow the formation of the retention recesses. In some examples, the method may comprise forming the one or more retention recesses using a slot cutter.

In some examples, the method may comprise forming a primary form of the external shell by deep drawing and forming the one or more retention recesses by machining the primary form of the external shell.

For example, the one or more retention recesses may be formed by machining an inner surface of the primary form of the external shell.

A primary form of the external shell may correspond to the external shell without the one or more retention recesses.

Advantageously, forming the aerosol generating apparatus in this way may result in an outer surface of the external shell may be as smooth, as continuous and/or as uninterrupted as possible resulting in a visually and haptically pleasing aerosol generating apparatus.

In some examples, the method may further comprise sliding the internal component into the external shell along a longitudinal axis of the aerosol generating apparatus to thereby engage each retention protrusion of the internal component with a corresponding retention recess of the external shell.

In this way, manufacture of the aerosol generating apparatus may be facilitated.

The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.

Fig. 1 is a block system diagram showing an example aerosol generating apparatus.

Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1 , where the aerosol generating apparatus is configured to generate aerosol from a liquid precursor.

Figs. 3A and 3B are schematic diagrams showing an example implementation of the apparatus of Fig. 2. Fig. 4 is a block system diagram showing an example implementation of the apparatus of Fig. 1 , where the aerosol generating apparatus is configured to generate aerosol from a solid precursor.

Fig. 5 is a schematic diagram showing an example implementation of the apparatus of Fig. 4.

Fig. 6 shows a perspective side view of an external shell of an aerosol generating apparatus.

Fig. 7 shows a perspective side view of an aerosol generating apparatus without an external shell.

Fig. 8 shows a perspective side view of an external shell of an aerosol generating apparatus.

Fig. 9 shows a perspective side view of a front portion of an external shell of an aerosol generating apparatus, and a perspective side view of a back portion of an external shell of an aerosol generating apparatus.

DETAILED DESCRIPTION OF EMBODIMENTS

Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and/or methods described herein could be embodied differently and/or be practiced or carried out in various alternative ways.

Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concepts) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.

Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

The use of the term “a” or “an” in the claims and/or the specification may mean “one,” as well as “one or more,” “at least one,” and “one or more than one.” As such, the terms “a,” “an,” and “the,” as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context. The use of the term “or” in the present disclosure (including the claims) is used to mean an inclusive “and/or” unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition “A or B” is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

As used in this specification and claim(s), the words “comprising, “having,” “including,” or “containing” (and any forms thereof, such as “comprise” and “comprises,” “have” and “has,” “includes” and “include,” or “contains” and “contain,” respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an “ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase “in one embodiment,” “according to an embodiment,” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to ‘an,’ ‘one,’ or ‘some’ embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by “or” may be used interchangeably:

As used herein, an "aerosol generating apparatus" (or “electronic(e)-cigarette ’) may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally/alternatively be referred to as a “smoking substitute apparatus”, if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible “smoking article” may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and/or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and/or an airflow sensor.

Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an “activation” of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength/duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).

The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.

As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to/include a vapour. An aerosol may include one or more components of the precursor.

As used herein, a “precursor” may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and/or glycerine. The term “flavouring" may refer to a component that provides a taste and/or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.

As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.

As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path. As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.

As used herein, a “puff” (or "inhale" or “draw”) by a user may refer to expansion of lungs and/or oral cavity of a user to create a pressure reduction that induces flow through the flow path.

As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol generating apparatus.

As used herein, a “heating system” may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.

As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. With liquid or gel implementations of the precursor, e.g. an e-liquid, the consumable may be referred to as a “capsule” or a “pod” or an “e-liquid consumable”. The capsule/pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a “stick” or “package” or “heat-not-burn consumable”. In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

As used herein, an "information carrying medium" may include one or more arrangements for storage of information on any suitable medium. Examples include: a computer readable medium; a Radio Frequency Identification (RFID) transponder; codes encoding information, such as optical (e.g. a bar code or QR code) or mechanically read codes (e.g. a configuration of the absence or presents of cut-outs to encode a bit, through which pins or a reader may be inserted).

As used herein “heat-not-burn” (or “HNB” or “heated precursor”) may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume). Referring to Fig. 1 , an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and/or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.

Electrical circuitry (not shown in Fig. 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

In variant examples, which are not illustrated, the power supply 2 may be omitted since, e.g. an aerosol generating unit implemented as an atomiser with flow expansion may not require a power supply.

Fig. 2 shows an implementation of the apparatus 1 of Fig. 1 , where the aerosol generating apparatus 1 is configured to generate aerosol from a liquid precursor.

In this example, the apparatus 1 includes a device body 10 and a consumable 30. The device body 10 includes an external shell housing internal components of the device body 10. Similarly, the consumable 30 includes an external shell housing internal components of the consumable 30.

In this example, the body 10 includes the power supply 4. The body may additionally include any one or more of electrical circuitry 12, a memory 14, a wireless interface 16, one or more other components 18. Components such as the power supply 4, the electrical circuitry 12, the memory 14 and the wireless interface 16 may correspond to internal components of the device body 10.

The electrical circuitry 12 may include a processing resource for controlling one or more operations of the body 10 and consumable 30, e.g. based on instructions stored in the memory 14.

The wireless interface 16 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

The other component(s) 18 may include one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 3).

The consumable 30 includes a storage portion implemented here as a tank 32 which stores the liquid precursor 6 (e.g. e-liquid). The consumable 30 also includes a heating system 34, one or more air inlets 36, and a mouthpiece 38. The consumable 30 may include one or more other components 40. Components such as the tank 32, and the heating system 34 may correspond to internal components of the consumable 30.

The body 10 and consumable 30 may each include a respective electrical interface (not shown) to provide an electrical connection between one or more components of the body 10 with one or more components of the consumable 30. In this way, electrical power can be supplied to components (e.g. the heating system 34) of the consumable 30, without the consumable 30 needing to have its own power supply.

In use, a user may activate the aerosol generating apparatus 1 when inhaling through the mouthpiece 38, i.e. when performing a puff. The puff, performed by the user, may initiate a flow through a flow path in the consumable 30 which extends from the air inlet(s) 34 to the mouthpiece 38 via a region in proximity to the heating system 34.

Activation of the aerosol generating apparatus 1 may be initiated, for example, by an airflow sensor in the body 10 which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the mouthpiece), or by actuation of an actuator included in the body 10. Upon activation, the electrical circuitry 12 (e.g. under control of the processing resource) may supply electrical energy from the power supply 2 to the heating system 34 which may cause the heating system 32 to heat liquid precursor 6 drawn from the tank to produce an aerosol which is carried by the flow out of the mouthpiece 38.

In some examples, the heating system 34 may include a heating filament and a wick, wherein a first portion of the wick extends into the tank 32 in order to draw liquid precursor 6 out from the tank 32, wherein the heating filament coils around a second portion of the wick located outside the tank 32. The heating filament may be configured to heat up liquid precursor 6 drawn out of the tank 32 by the wick to produce the aerosol.

In this example, the aerosol generating unit 4 is provided by the above-described heating system 34 and the delivery system 8 is provided by the above-described flow path and mouthpiece 38.

In variant embodiments (not shown), any one or more of the precursor 6, heating system 34, air inlet(s) 36 and mouthpiece 38, may be included in the body 10. For example, the mouthpiece 36 may be included in the body 10 with the precursor 6 and heating system 32 arranged as a separable cartomizer.

Figs. 3A and 3B show an example implementation of the aerosol generating device 1 of Fig. 2. In this example, the consumable 30 is implemented as a capsule/pod, which is shown in Fig. 3A as being physically coupled to the body 10, and is shown in Fig. 3B as being decoupled from the body 10.

In this example, the body 10 and the consumable 30 are configured to be physically coupled together by pushing the consumable 30 into an aperture in a top end 11 the body 10, with the consumable 30 being retained in the aperture via an interference fit.

In other examples (not shown), the body 10 and the consumable 30 could be physically coupled together in other ways, e.g. by screwing one onto the other, through a bayonet fitting, or through a snap engagement mechanism, for example.

The body 10 also includes a charging port (not shown) at a bottom end 13 of the body 10. The body 10 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a light 15, which may e.g. be configured to illuminate when the apparatus 1 is activated. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

In this example, the consumable 30 has an opaque cap 31 , a translucent tank 32 and a translucent window 33. When the consumable 30 is physically coupled to the body 10 as shown in Fig. 3A, only the cap 31 and window 33 can be seen, with the tank 32 being obscured from view by the body 10. The body 10 includes a slot 15 to accommodate the window 33. The window 33 is configured to allow the amount of liquid precursor 6 in the tank 32 to be visually assessed, even when the consumable 30 is physically coupled to the body 10.

Fig. 4 shows an implementation of the apparatus 1 of Fig. 1 , where the aerosol generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.

In this example, the apparatus 1 includes a device body 50 and a consumable 70. The device body 50 includes an external shell housing internal components of the device body 50.

In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62. Components such as the power supply 4, the heating system 52, the electrical circuitry 56, the memory 58 and the wireless interface 60 may correspond to internal components of the device body 10.

The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58.

The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 5).

The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid precursor 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

Fig. 5 shows an example implementation of the aerosol generating device 1 of Fig. 4.

In this example, the body 50 is coupled to a cap 51 . In use the cap 51 is engaged at a top end 53 of the body 50. The cap 51 includes an external shell housing internal components of the cap 51. Although not apparent from Fig. 5, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.

As depicted in Fig. 5, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end 53 of the cap 51 , which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6.

The consumable 70 includes the solid precursor 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid precursor 6 may be a reconstituted tobacco formulation.

In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. Other heating element shapes are possible, e.g. the at least one heating element may be blade-shaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile).

The body 50 also includes an actuator 55 on an outer surface of the body 50. In this example, the actuator 55 has the form of a button.

The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and/or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

The body may also include an airflow sensor which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.

In this example, the consumable 70 includes a flow path which transmits aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable.

In this example, the aerosol generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.

An aerosol generating apparatus according to the present disclosure comprises an external shell 100 housing an internal component 102.

An example of an external shell 100 detached from an aerosol generating apparatus is shown in Fig. 6. Fig. 7 shows an example of an aerosol generating apparatus without its external shell 100, such that internal components of the aerosol generating apparatus can be seen.

In the cases of Figs. 6 and 7, the aerosol generating apparatus is a HNB aerosol generating apparatus, which may correspond to the HNB device discussed above with reference to Figs. 4 and 5. The external shell 100 is an external shell 100 of a cap of the HNB aerosol generating apparatus, which may correspond to the cap discussed above with reference to Fig. 5.

An internal component 102 of the aerosol generating apparatus is a shell liner 102, which couples to, and which covers other internal components of the apparatus, such as a rotatable door 110 of the cap, and coupling arms 101 of the device body 103 of the aerosol generating apparatus. The shell liner includes two slots 105 (one of which is visible in Fig. 7) into which respective coupling arms 101 of the device body 103 extend. The slots 105 are longer along the longitudinal axis of the aerosol generating apparatus than the portion of the coupling arms 101 which extend into the slots 105 to enable the cap to be moveable with respect to the device body 103 along the longitudinal axis of the aerosol generating apparatus. The device body 103 may correspond to the device body discussed above with reference to Fig. 5.

The external shell 100 is formed of a rigid material which can be deep drawn, such as aluminium.

As will be appreciated from Figs. 6 and 7, the external shell 100 sleeves the shell liner 102. During manufacture, the external shell 100 slides onto the shell liner 102 along a longitudinal axis of the aerosol generating apparatus. A transverse cross-sectional shape of the inner surface 104 of the external shell 100 is complementary to a transverse cross-sectional shape of the outer surface 107 of the shell liner 102. Both the external shell and the shell liner have a generally obround transverse cross-sectional shape. Thus, transverse movement, and rotational movement of the shell liner 102 relative to the external shell 100 may be inhibited.

As can be seen in Fig. 6, the external shell 100 comprises an inner surface 104 which includes a retention recess 106. In the example of Fig. 6, the retention recess 106 takes the form of a groove. The groove 106 extends circumferentially along a longer side of the obround shape of the inner surface 104 of the external shell 100. In a central region of the groove 106 the cross-sectional shape of the groove 106 is generally rectangular. Towards each lateral end of the groove 106, the depth of the groove 106 tapers so that a base of the groove 106 meets the surrounding inner surface 104. Thus, the depth of the groove 106 tapers towards each lateral end of the groove. The groove 106 is longitudinally offset from an open base 112 of the shell through which the internal component is inserted. The groove 106 is configured to engage with a corresponding retention protrusion 108 of the shell liner 102.

As shown in Fig. 7, the shell liner 102 comprises an outer surface 107 which includes a retention protrusion 108. In the example of Fig. 7, the retention protrusion 108 takes the form of a pip 108, which extends from a flexible arm 116 of the shell liner 102. The retention protrusion 108 extends circumferentially along a longer side of the obround shape of the outer surface 107 of the shell liner 102. The pip 108 has a sloped upper surface 109 which is sloped downwards with respect to the longitudinal axis of the internal component 102. The retention protrusion 108 is longitudinally offset from a base of the shell liner, where the shell liner meets the device body 103. The pip 108 is configured to engage with the groove 106 of the external shell 100 when the internal component 102 is inserted into the external shell 100 through its open base 1 12.

Thus, due to the engagement of the pip 108 and the groove 106, the external shell 100 may be inhibited from separating from the shell liner 102 when the cap is pulled away from the device body 103. The retention pip 108 and the groove 106 extending circumferentially provides a sufficiently large retention force holding the pip 108 within the groove 106.

Due to the pip 108 being coupled to the flexible arm 116, the pip 108 is resiliently biased. In particular, the flexible arm 116 is resiliently biased to align with a longitudinal axis of the aerosol generating apparatus. As such, the pip 108, which extends outward from the flexible arm 116, is resiliently biased towards the groove 106 when the external shell 100 is fitted to the shell liner 102.

As such, when the external shell 100 is fitted to the shell liner 102, the flexible arm 116 may be pushed inwards to enable the external shell to slide onto the shell liner 102. Then, when the groove 106 and the pip 108 are aligned, the flexible arm may relax, moving the pip 108 into the groove 106.

In addition, as mentioned above, the upper surface 109 of the pip 108 is sloped downwards, which facilitates the fitting of the external shell 100 to the shell liner 102, as the sloped surface 109 may provide for a gradual engagement between the pip 108 and the inner surface 104 of the external housing 100.

Further, although not visible in Fig. 7, a lower surface of the pip 108 may be transverse to the longitudinal axis of the aerosol generating apparatus. As such, the lower surface of the pip 108 may form a pip abutment surface. The pip abutment surface is configured to abut a corresponding groove abutment surface, which is also transverse to the longitudinal axis of the aerosol generating apparatus, at a lower end of the groove 106.

In this way, there is a strong retention of the external shell to the shell liner when a user exerts a force along a longitudinal axis of the aerosol generating apparatus by pulling the cap away from the device body 103, as the groove abutment surface abuts the pip abutment surface.

In summary then, when the external shell 100 is fitted to the shell liner 102 by sliding the external shell 100 onto the shell liner 102 along a longitudinal axis of the aerosol generating apparatus, the flexible arm 116 is pushed inwards, by the pip 108 engaging with the inner surface of the external housing. Due to the sloped upper surface 109 of the pip, the pip 108 gradually engages with the inner surface 104 of the external housing. When the groove 106 and the pip 108 are aligned, the flexible arm 116 relaxes and the pip 108 moves into the groove. With the pip 108 engaged with the groove 106, the pip abutment surface on a lower side of the pip abuts a groove abutment surface on a lower side of the groove. Thus, when the user pulls the cap away from the device body 103, abutment of the pip abutment surface and the groove abutment surfaces inhibits the external housing disengaging from the shell liner. Advantageously then, manufacture of the aerosol generating apparatus may be facilitated.

Additionally, due to the fixed coupling being achieved by the pip 108 and the groove 106, there is no need for the aerosol generating apparatus to include a fixing means for fixing the external shell 100 to the shell liner 102 which requires a through-hole in the external shell 100, such as a screw. Thus, an outer surface 111 of the external shell 100 can be unbroken at the engagement location of the pip 108 and the groove 106, and the retention means can be inaccessible to an end user of the product.

Accordingly, the only interruptions in the outer surface of the external shell 100 shown in Fig. 6, are a consumable-receiving aperture (not visible in Fig. 6), and an open base 112 for coupling to the cap to the device body. As such, the outer surface 111 of the circumferential wall 114 of the external shell 100 is continuous, or unbroken, the circumferential wall 114 being the portion of the external shell 100 with a constant diameter of its outer surface.

Such a continuous outer surface 111 may be achieved due to the external shell 100 being integrally formed by deep drawing, with the retention recess 106 being formed using a slot cutter.

Although a groove 106 can only be seen as part of the inner surface 104 on one side of the external shell 100, the inner surface 104 includes another groove 106 on the other side of the external shell 100, opposing the visible retention recess 106. Similar is true for the visible pip 108. The outer surface 107 of the shell liner 102 includes another pip 108 on the other side of the shell liner 102, along the same radial line as the visible retention protrusion 108.

In this way, a more effective engagement of the external shell and the shell liner is achieved, as the retention force can be applied more evenly across the cap, and across a larger surface area.

Fig. 8 shows another example of an external shell 200 of an HNB aerosol generating apparatus. In the example shown in Fig. 8, the external shell 200 is an external shell 200 of a device body of the aerosol generating apparatus, which may correspond to the device body discussed above with reference to Figs. 4 and 5.

As shown in Fig. 8, the external shell 200 has a generally obround shape. An inner surface of the external shell 200 includes a plurality of retention recesses 206, two extending circumferentially along respective longer sides of the obround shape of the inner surface of the external shell 200, and two extending circumferentially along respective shorter sides of the obround inner surface of the external shell 200, each retention recess 206 configured to engage with a corresponding protrusion of an internal component (not shown in Fig. 8) at least partially housed within the external shell 200. Similarly to the retention recess 106 of the external shell 100 shown in Fig. 6, the retention recesses 206 of the external shell 200 shown in Fig. 8 takes the form of a groove.

The grooves 206 shown in Fig. 8 are at different longitudinal positions to one another. Advantageously, such an arrangement of grooves (and the corresponding retention protrusions on the internal component) may provide a stronger engagement of the internal component with the external shell, because a surface area across which a retention force may be applied may be increased. Similarly to the external shell 100 of the cap shown in Fig. 6, the external shell 200 of the device body shown in Fig. 8 has been integrally formed by deep drawing, with the grooves 206 being formed using a slot cutter.

Fig. 9 shows an alternative example of an external shell 300 of an HNB aerosol generating apparatus. Again, in the example shown in Fig. 9, the external shell 300 is an external shell 300 of a device body of the aerosol generating apparatus, which may correspond to the device body discussed above with reference to Figs. 4 and 5.

However, in the external shell 300 shown in Fig. 9, the external shell 300 is made up of a front shell portion 300a and a back shell portion 300b. A cross-section of each shell portion 300a/b, taken axially along the longitudinal axis of the aerosol generating apparatus, has a generally obround shape.

These portions are shown separated in Fig. 9 for clarity, but in the manufactured aerosol generating apparatus, the front shell portion 300a and the back shell portion 300b are fixedly coupled to one another, to form a generally obround external shell 300. For example, a transverse cross section of the external shell 300 has a generally obround shape. Each of the shell portions 300a/b is formed individually by deep drawing.

Each shell portion 300a/b includes a lip 301 extending from a main portion 303 of the shell portion 300a/b. When the front shell portion 300a and the back shell portion 300b are fixedly coupled to one another, a gap is defined between the lip of each portion, into which a cap of the aerosol generating apparatus may be slotted.

The back shell portion 300b of the aerosol generating apparatus has an inner surface 304 which includes retention recesses 306a/b, each taking the form of a groove and configured to engage with a corresponding protrusion of an internal component (not shown in Fig.9) housed within the external shell 300. A first groove 306a is within the main portion and a second groove is within the lip 301 . The first groove 306a extends along sides of the obround shape of the axial cross-section of the back shell portion 300b, that is, along a first longer side, along a first shorter side, and along a second longer side. The second groove 306a also extends along sides of the obround shape of the axial crosssection, that is, along a first longer side, along a second shorter side, and along a second longer side. Although they cannot be seen in Fig. 9, the front shell portion 300a of the aerosol generating apparatus may also include retention recesses.

Claims

1. An aerosol generating apparatus comprising: an external shell (100, 200, 300) and an internal component (102), the external shell (100, 200, 300) housing the internal component (102), wherein the external shell (100, 200, 300) comprises an inner surface (104) including one or more retention recesses (106, 206, 306), wherein the internal component (102) comprises an outer surface (107) including one or more retention protrusions (108), and, wherein each retention recess is engaged with at least one of the retention protrusions (108) to thereby couple the internal component (102) to the external shell (100, 200, 300).

2. An aerosol generating apparatus according to claim 1 , wherein each retention recess (106) is engaged with at least one of the retention protrusions (108) to inhibit movement of the internal component (102) relative to the external shell (100, 200, 300) along a longitudinal axis of the aerosol generating apparatus.

3. An aerosol generating apparatus according to any of the preceding claims, wherein a cross-sectional shape of the outer surface (107) of the internal component (102) is complementary to a cross-sectional shape of the inner surface (104) of the external shell (100, 200, 300).

4. An aerosol generating apparatus according to claim 3, wherein a transverse cross-sectional shape of the outer surface (107) of the internal component (102) is complementary to a transverse cross- sectional shape of the inner surface (104) of the external shell (100, 200, 300) at an engagement location where one of the retention recesses (106, 206, 306) is engaged with a retention protrusion (108).

5. An aerosol generating apparatus according to any of the preceding claims, wherein the one or more retention recesses (106, 206, 306) includes a plurality of retention recesses (106, 206, 306), wherein the one or more retention protrusions (108) includes a plurality of retention protrusions (108).

6. An aerosol generating apparatus according to claim 5, wherein one or more of the retention recesses (106, 206, 306) are at different longitudinal positions to one another relative to a longitudinal axis of the aerosol generating apparatus.

7. An aerosol generating apparatus according to claim 5 or claim 6, wherein the plurality of retention recesses (106, 206, 306) includes two opposing recesses disposed across the longitudinal axis from one another.

8. An aerosol generating apparatus according to any of the preceding claims, wherein each of the retention protrusions (108) is resiliently biased into the retention recess (106, 206, 306) with which the retention protrusion is engaged.

9. An aerosol generating apparatus according to any of the preceding claims, each of the retention recesses (106, 206, 306) is at least partially defined by a respective recess abutment surface, the recess abutment surface being transverse to a longitudinal axis of the aerosol generating apparatus.

10. An aerosol generating apparatus according to claim 9, wherein each of the retention protrusions (108) comprises a protrusion abutment surface transverse to the longitudinal axis of the aerosol generating apparatus, wherein each protrusion abutment surface abuts a corresponding recess abutment surface.

11. An aerosol generating apparatus according to any of the preceding claims, wherein the external shell (100, 200, 300) includes a circumferential wall (114), the circumferential wall (114) having an outer surface which has a constant diameter along a longitudinal axis of the aerosol generating apparatus, and wherein an outer surface (107) of the circumferential wall (114) is continuous.

12. An aerosol generating apparatus according to any of the preceding claims, wherein each of the retention recesses (106, 206, 306) extends circumferentially along a portion of the inner surface (104).

13. A method of manufacturing an aerosol generating apparatus according to any of the preceding claims, wherein the method comprises: forming the one or more retention recesses (106, 206, 306) by machining.

14. A method of manufacturing according to claim 13, wherein the method comprises: forming a primary form of the external shell (100, 200, 300) by deep drawing; and, forming the one or more retention recesses (106, 206, 306) by machining the primary form of the external shell (100, 200, 300).

15. A method of manufacturing according to either of claims 13 or 14, wherein the method comprises: sliding the internal component (102) into the external shell (100, 200, 300) along a longitudinal axis of the aerosol generating apparatus to thereby engage each retention protrusion (108) of the internal component (102) with a corresponding retention recess (106, 206, 306) of the external shell (100, 200, 300).