KR20250160461A - Heaters for non-combustion heating devices - Google Patents

Abstract

A heating assembly (10) for a non-combustion heating device (100) comprises: a heating substrate (110) having a substantially flat surface (118); a heating track (120) formed on the surface (118) of the heating substrate (110); an electrical contact (140) positioned on the surface (118) of the heating substrate (110); a wire (150) connected to the electrical contact (140), the wire (150) extending from the heating substrate (110); and an insulating layer (50) positioned on the surface (118) of the heating substrate (110), the insulating layer (50) configured to provide an opening through which the wire (150) extends.

Description

Heaters for non-combustion heating devices

The present invention relates to a heater for an aerosol generating device, more particularly for a non-combustion heating device.

Typically, a heater for a non-combustion heating device includes a cavity into which a consumable is inserted. The cavity may be formed by one or more walls, each wall comprising a substrate with heating tracks formed thereon. When electrical energy is supplied to the heating tracks via electrical contacts, heat is transferred to the consumable, generating an aerosol for the user to inhale.

One problem with these devices is their limited efficiency. Because the substrate may have a large thermal mass, significant energy is required to reach the desired temperature, resulting in poor responsiveness to heater control signals. Because electrical connections and wires must be connected to the heating track, insulating the heater from the rest of the non-combustion-heated device can be challenging. Insufficient insulation means that not all of the generated heat is delivered to the consumables within the cavity, further reducing efficiency.

Therefore, the purpose of the present invention is to solve the problems discussed above.

According to one aspect of the present invention, a non-combustion heating type heater is provided, comprising: a substrate; a heating track formed on the substrate; and at least one electrical contact positioned between a first point on the heating track and a second point on the heating track on the substrate.

In this manner, the imaginary line connecting the first point and the second point along the surface of the substrate preferably passes through the location of at least one electrical contact. The at least one electrical contact is located in a "heating area" of the substrate occupied (or "filled") by the heating track. Advantageously, this allows the heating track to fill the substrate without requiring protrusions or spaces near the edges where the electrical contacts could be located. This allows the substrate size to be reduced without reducing the size of the heating track, thereby improving the overall efficiency of the heater without affecting its performance. During use, the aerosol-forming material may be positioned adjacent to the surface of the substrate, such that the heat generated by the heating track is transferred to the aerosol-forming material.

The substrate may have a base portion configured to provide a base of the heating cavity and a top portion configured to provide a top portion of the heating cavity. The heating track preferably has a first portion adjacent the base portion of the substrate and a second portion adjacent the top portion of the substrate.

In this way, the heating track can extend to both the top and the base of the heating cavity, eliminating the need to maintain space adjacent to the top or base portion of the substrate to provide at least one electrical contact. This reduces the required substrate size and improves the efficiency of the heater.

The substrate may have a first side and a second side extending between a base portion and a top portion of the substrate, respectively, and the heating track may have a third portion adjacent the first side of the substrate and a fourth portion adjacent the second side of the substrate.

In this way, the heating track can extend to both sides of the heating cavity without the need to maintain space to provide at least one electrical contact. This reduces the required size of the substrate and improves the efficiency of the heater. The substrate may be substantially rectangular, with four edges corresponding to the base portion, the top portion, the first side, and the second side. Preferably, the heating track substantially follows the perimeter of the substrate (i.e., the heating zone extends to the perimeter) in portions other than the first portion, the second portion, the third portion, and the fourth portion. It will be appreciated that the heater may also be provided using a non-rectangular substrate. In such a case, the heating zone preferably extends to the perimeter of the substrate.

Preferably, at least one electrical contact is located in the central region of the substrate. In this way, at least one electrical contact can be provided substantially in the center of the heating region of the substrate.

Preferably, the substrate is substantially flat, providing a plane on which the heating tracks are formed. In this manner, the heater can be readily manufactured from a flat sheet material. The substrate may be a ceramic substrate. The substrate may provide the walls of the heating cavity. Other such substrates may provide other walls of the cavity, for example, two parallel walls forming a thin rectangular heating cavity therebetween. It will be appreciated that the substrate may not be flat, but instead have a curved profile, for example.

Preferably, at least one electrical contact comprises a pair of electrical contacts for supplying power to the heating track. This eliminates the need for additional electrical contacts elsewhere to supply power to the heating track, which can reduce the size of the substrate and improve the efficiency of the heater.

The heater may further include a temperature sensor positioned on the substrate. The temperature sensor may monitor the temperature within the heating cavity. The temperature sensor may be connected to a feedback loop to control the temperature of the heater.

Preferably, the temperature sensor is located in the central region of the substrate. Preferably, the temperature sensor is also located in the center of the heating zone. In this way, the temperature sensor can more accurately monitor the heat supplied to the aerosol-forming material inserted adjacent to the heater.

At least one electrical contact may include a pair of electrical contacts connected to a temperature sensor.

The heater may further include at least one wire extending from at least one electrical contact, preferably extending from the substrate in a direction perpendicular to the substrate. This may facilitate connection to other components of the non-combustion heating device, such as a power supply (for connection to the heating track) and/or a processor or control circuit (for receiving the output of the temperature sensor).

Preferably, at least a portion of one wire is bent in a direction parallel to the substrate.

An insulating layer (or "insulating plate") may be positioned on or adjacent to a surface of the substrate. The insulating layer may be positioned on the surface of the substrate opposite the surface to which the aerosol-forming material is positioned during use. The combination of the insulating layer and the heater may be referred to as a "heating assembly." The term "insulating" preferably indicates that the layer is thermally insulating, but it will be appreciated that the layer may also be electrically insulating. In this way, heat flow away from the aerosol-forming material is inhibited, thereby increasing the amount of heat supplied to the aerosol-forming material. The insulating layer may comprise Superwool® or Finesulight®. The thickness of the insulating layer may be from about 1 mm to about 3 mm.

The substrate may be a first substrate, and the heater may further include a second substrate arranged parallel to the first substrate, such that a heating cavity is provided between the first and second substrates. This provides a heater having a substantially rectangular shape. The second substrate is preferably similar to the first substrate, and thus includes a second heating track formed on the second substrate, and at least one electrical contact positioned on the substrate as described above and herein. Any of the optional features set forth above may also be applied to the second substrate.

According to another aspect of the present invention, a non-combustion heating device is provided comprising a heater as described above and also as described herein.

According to another aspect of the present invention, a heating assembly for a non-combustion heating device is provided, the heating assembly comprising: a heating substrate having a substantially flat surface; a heating track formed on a surface of the heating substrate; an electrical contact positioned on the surface of the heating substrate; a wire connected to the electrical contact and extending from the heating substrate; and an insulating layer positioned on the surface of the heating substrate, the insulating layer being configured to provide an opening through which the wire extends.

In this way, the insulating layer (or insulating plate) can be positioned on the flat (planar) surface of the heating substrate while also allowing wires to pass through it and be connected to other components of the non-combustion heating device. It will be appreciated that other components of the heating substrate other than the surface need not necessarily be flat. The insulating layer can be positioned directly in contact with the surface of the heating substrate. Alternatively, a small gap or air layer can be provided between the insulating layer and the surface of the heating substrate. The insulating layer can comprise Superwool® or Finesulight®. The thickness of the insulating layer can be from about 1 mm to about 3 mm.

Preferably, the wire extends from the heating substrate in a direction substantially perpendicular to the surface of the heating substrate. This can reduce the size of the opening in the insulating layer and simplify the structure of the opening.

The heating assembly may further include a plurality of electrical contacts arranged on the surface of the heating substrate, each electrical contact being connected to a corresponding wire.

The insulating layer may include a first portion and a second portion positioned over the heating substrate and having a gap providing an opening therebetween. The first portion and the second portion may be translated or slidable over the surface of the heating substrate, for example, to position the first portion and the second portion from the top or bottom of the heating substrate. The first portion and the second portion may be translated until they contact a wire connected to an electrical contact. If there are multiple electrical contacts, they are preferably collinear, which allows the insulating layer to be simply divided into the first portion and the second portion along a straight line. It will be appreciated that the boundary between the first portion and the second portion may have a different shape to accommodate electrical contacts that are not collinear and/or to fill a space between the electrical contacts.

The opening may be provided by a slot in the insulating layer extending to the edge of the insulating layer, wherein the insulating layer is positioned by translational movement of the insulating layer over the surface of the heating substrate as the wire passes through the slot. If multiple electrical contacts are present, they are preferably colinear, which allows the slot to be made straight (making manufacturing easier) and allows the insulating layer to be easily slid and positioned along a single direction.

The opening may be provided by at least one hole in the insulating layer, wherein the insulating layer is positioned over the surface of the heating substrate by passing the end of a wire through the at least one hole. In this way, the hole prevents the insulating layer from sliding over the surface of the heating substrate, and the area of the heating substrate not covered by the insulating layer is reduced.

The insulation layer may include multiple holes, each corresponding to a separate wire. This further reduces the area of the heating substrate not covered by the insulation layer, as each hole only needs to be large enough to accommodate a single wire. Preferably, each hole wraps around a corresponding wire. Alternatively, more than one wire may pass through a single hole in the insulation layer.

Preferably, the portion of the wire extending through the opening is bent in a direction parallel to the insulating layer, and secured so that the insulating layer is in contact with the surface of the heating substrate.

The heating substrate may be a first heating substrate, and the heating assembly may further include a second heating substrate arranged parallel to the first heating substrate to provide a heating cavity therebetween. This provides a heater having a substantially rectangular shape. The second heating substrate is preferably similar to the first heating substrate, and has electrical contacts positioned on a surface of the second heating substrate, wires connected to the electrical contacts, and an insulating layer positioned on the surface of the second heating substrate. The insulating layer covering the second heating substrate may be a separate insulating layer from the insulating layer covering the first heating substrate, or the heating substrates may be covered by the same insulating layer. Any of the optional features set forth above may also be applied to the second heating substrate.

According to another aspect of the present invention, a method of manufacturing a heating assembly for a non-combustion heating device is provided, the method comprising the steps of: providing a heating substrate; positioning an electrical contact on a substantially flat surface of the heating substrate; connecting a wire to the electrical contact; and positioning an insulating layer over the surface of the heating substrate such that the wire extends through an opening provided by the insulating layer.

According to another aspect of the present invention, a heating assembly for a non-combustion heating device is provided, comprising: a heater disposed around an interior heating cavity having an opening configured to receive a consumable; and an insulating layer curved about a first axis around the heater, the insulating layer covering at least a first (e.g., outer) surface of the heater and a second (e.g., outer) surface of the heater, the second surface being opposite the first surface; the insulating layer curved about a second axis perpendicular to the first axis, the insulating layer covering a third (e.g., outer) surface of the heater connecting the first surface to the second surface; and the insulating layer is sealed to form a wrapping around the heater.

The insulating layer can be wrapped around a first axis to cover the first and second surfaces, with the third surface of the heater initially in an unfolded state. Subsequently, the insulating layer can be bent around a second axis to cover the third surface, thereby providing a pouch-shaped piece of insulating material containing the heater, the (main) opening of the pouch being aligned with the opening of the heating cavity. In this manner, the wrap is formed by self-sealing a single piece of insulating material without requiring another component (e.g., a separate base) to cover the third surface of the heater. Advantageously, this reduces the number of parts required to provide the insulating layer and simplifies manufacturing. The first surface, the second surface, and the third surface are preferably outer surfaces of the heater. As used herein, the term "opposing" preferably indicates that the second surface is located opposite the first surface of the heater. The first and second surfaces may be parallel to each other. In this case, the third surface may be perpendicular to both the first surface and the second surface (e.g., in the case of a rectangular heater). Alternatively, the first surface and the second surface may be curved or angled surfaces located on opposite sides of the heater. The third surface may also be curved or angled with respect to the first surface and/or the second surface.

The insulating layer may have at least one edge that protrudes above the third surface after being bent about the first axis, such that the insulating layer can be bent about the second axis to cover the third surface. The at least one edge may protrude above the third surface from the first surface and the second surface. Preferably, the heater is at least partially in contact with the bend of the insulating layer, such that the heater is relatively tightly wrapped by the insulating layer. The seal may be a crimp seal. Preferably, the insulating layer is sealed over the third surface of the heater. The seal may include a fold in the insulating layer. The insulating layer may comprise Superwool® or Finesulight®.

Preferably, the first surface, the second surface, and the third surface are each substantially flat or planar. Preferably, the first surface, the second surface, and the third surface are connected by straight edges. Preferably, the heater has a rectangular parallelepiped shape. In this way, the insulation layer can be wrapped around the edges to cover each surface of the heater, while also reducing the amount of folding and/or wrinkling of the insulation layer. Furthermore, wrapping is particularly advantageous when used with a rectangular parallelepiped heater, because a rectangular parallelepiped heater (having a flat surface) has a larger surface area than a heater having a curved surface (e.g., a cylindrical heater) and is therefore particularly advantageous in reducing heat loss from the rectangular parallelepiped heater.

Alternatively, the heater may have a different shape, such as a cylinder. Thus, the first, second, and third surfaces need not necessarily be connected by edges, but may instead be connected by smooth surfaces. In this case, the insulation layer may still be curved about the first and second axes to cover the first, second, and third surfaces of the heater, and the insulation layer may still include additional folds or creases to relatively tightly wrap around the heater. In this manner, the wrapping can be used to provide insulation for heaters of different shapes.

Preferably, the third surface of the heater is on the base of the heater opposite the opening of the heating cavity. In this configuration, the first axis corresponds to the bending of the insulation layer around the longitudinal axis of the heater, and the second axis corresponds to the bending of the insulation layer under the base around an axis perpendicular to the longitudinal axis.

Alternatively, the third surface may be a side surface of the heater, wherein the first axis corresponds to the bending of the insulation layer under the base, and the second axis corresponds to the bending of the insulation layer around at least one side of the heater before a seal is formed along the side surface of the heater.

The heater assembly may further include one or more additional insulating layers, each of which is curved to cover at least the first surface and the second surface of the heater, and at least one of the insulating layers is curved and sealed about a second axis to cover a third surface of the heater. Preferably, all of the insulating layers are sealed, providing a plurality of overlapping insulating pouches.

Preferably, the thickness of the (or each) insulating layer is less than 1 mm. The heater may include at least one corner where the insulating layer is bent (about the first or second axis). For example, the heater may be a rectangular parallelepiped with the corner forming a 90 degree angle. A thinner insulating layer (e.g., a layer less than 1 mm thick) may be more sharply wrapped (folded) around the edge or corner of the heater. When multiple insulating layers are used, the overall thickness may be about 3 mm.

The heating assembly may further include a wire extending from the outer surface of the heater, and the insulation layer may include an opening through which the wire extends. The opening may be different from the main opening, which is aligned with the opening of the cavity. The opening may be a hole, through which the wire passes before wrapping the insulation layer around the heater (i.e., before bending the insulation layer, preferably about the first or second axis). Alternatively, the opening may be a slot, through which the wire may be positioned, for example, by sliding or folding the insulation layer during the wrapping process. Preferably, the size of the opening is minimized to a dimension that fits around the wire, thereby forming a seal around the wire. Additional wires may be provided that can supply electricity to the heating element of the heater (e.g., a heating track) and/or connect to a temperature sensor adjacent to the heating cavity. The wires may be connected on different sides of the heater.

Preferably, the portion of the wire extending through the opening is bent so as to contact the outer surface of the insulation layer. This secures the insulation layer against the surface of the heater. This also allows the wire to be connected to other components of the device (e.g., a power supply or control electronics) located around the periphery of the heating assembly without having to be located directly over the wire.

Preferably, an air layer is provided between the insulation layer and the heater. Advantageously, the air layer provides additional insulation due to the low specific heat of air. It will be appreciated that the air layer may be filled with another insulating material. For example, the air layer may be provided between the insulation layer and the third surface of the heater. In other words, the insulation layer is not sealed while being bent about the second axis and then directly contacting the third surface, thereby forming an air pocket between them. By providing the air pocket, the insulation of the third surface (e.g., the base) of the heater is improved, thereby increasing the efficiency of the heater.

Alternatively or additionally, the air gap may be provided by positioning a wire between the insulation layer and the heater. In this manner, a separate spacer to maintain the air gap is not required. Preferably, the wire is bent between the first and second insulation layers, thereby providing an air gap therebetween. When wrapping an additional insulation layer around the heater, the wire may be bent to separate any adjacent pairs of insulation layers. If multiple wires are present, the wires may be bent between different pairs of insulation layers, thereby providing multiple air gaps. At least one wire may be bent over the outer surface of the outermost insulation layer.

Preferably, the openings in the first insulation layer are covered by the second insulation layer. For example, if a wire extends through a slot in the first insulation layer, the same wire may extend through a hole in the second insulation layer (or vice versa). If the wires extend from opposite sides of the heater, each wire may pass through the slot and hole alternately. In some scenarios, a hole tightly sealed around the wire may provide better insulation than the slot (uncovered area), meaning that all sides of the heater are covered by at least one layer of insulation.

The heater may include a first heating substrate providing a first (e.g., outer) surface of the heater, and a second heating substrate disposed parallel to the first heating substrate, wherein the second heating substrate may provide a substantially planar heating cavity between the second (e.g., outer) surface of the heater and the first and second heating substrates. This provides a rectangular heater in which the insulation layer is curved over substantially straight edges, allowing the heater to be covered without substantial wrinkling of the insulation layer. Conversely, if the heater is curved (e.g., cylindrical), the insulation layer may be wrinkled when bent to cover the base. If additional folds or pleats are used to tightly wrap the insulation layer around the heater, additional seals (e.g., between different folds of the insulation layer) may be used to secure the insulation layer in the wrapped state.

According to another aspect of the present invention, a non-combustion heating device is provided comprising a heating assembly as described above and herein.

According to another aspect of the present invention, a method of manufacturing a heating assembly for a non-combustion heating device is provided, the method comprising: providing a heater disposed around an interior heating cavity having an opening arranged to receive a consumable; bending an insulating layer about a first axis around the heater to cover at least a first (e.g., outer) surface of the heater and a second (e.g., outer) surface of the heater, the second surface of the heater being opposite the first surface; bending the insulating layer about a second axis perpendicular to the first axis to cover a third (e.g., outer) surface connecting the first and second surfaces of the heater; and sealing the insulating layer of the heater to wrap around the heater.

The method may further comprise the step of bending one or more additional insulating layers around the heater to cover at least the first surface and the second surface, wherein at least one of the insulating layers is bent about the second axis to cover and seal the third surface of the heater.

The method may further include the steps of connecting a wire to an outer surface of the heater, and placing the wire through an opening in the insulating layer before bending the insulating layer about the first axis or the second axis.

Preferably, the opening in the first insulating layer is covered by the second insulating layer.

It will be appreciated that any of the features of any of the embodiments described and defined herein may be provided in any suitable combination. Furthermore, optional or preferred features of any one of the embodiments described above may be incorporated into any of the other embodiments. Those skilled in the art will appreciate that any device feature described herein may be provided as a method feature, and vice versa. Furthermore, it will be appreciated that specific combinations of the various features described and defined in any of the embodiments described herein may be implemented and/or provided and/or used independently.

It is also to be understood that the present invention has been described purely for illustrative purposes and that details may be modified within the scope of the invention.

One or more embodiments will now be described, purely by way of example, with reference to the accompanying drawings.
Figure 1a illustrates one embodiment of an aerosol generating device.
Figure 1b illustrates a cross-sectional view of an aerosol generating device showing a heating assembly including a heating substrate.
Figure 2a illustrates an example of a conventional heating substrate having heating tracks and electrical contacts positioned toward the base of the substrate.
Figure 2b illustrates a consumable located inside a heater formed with a conventional heating substrate of Figure 2a.
FIG. 3A illustrates one embodiment of a heater that may form part of a heating assembly, the heater having a heating substrate having electrical contacts positioned on the substrate.
Figure 3b illustrates the heating substrate of Figure 3a with wires extending from electrical contacts.
Figure 4 illustrates a first example of an insulating layer that may form part of a heating assembly, the insulating layer having one or more holes.
Figures 5a to 5c illustrate a method of positioning the insulating layer of Figure 4 on a heating substrate of a heater.
Figures 6a and 6b illustrate a second example of an insulating layer having slots and a method of positioning the insulating layer over a heating substrate of a heater.
Figures 7a and 7b illustrate a third example of an insulating layer having a first portion and a second portion, and a method of positioning the insulating layer on a heating substrate of a heater.
Figures 8a to 8d illustrate a fourth example of an insulating layer having both holes and slots, and a method of positioning the insulating layer by wrapping the insulating layer around the heater.
Figures 9a to 9d illustrate an example of a heating assembly in which multiple insulating layers surround a heater.
Figures 10a to 10d illustrate examples of heating assemblies in which the insulating layer is bent and sealed to form a wrap.

Figure 1a illustrates an external view of an aerosol generating device (1), and Figure 1b illustrates a cross-sectional view of the aerosol generating device (1). The device (1) includes an outer casing (2) in which a heating assembly (10) is arranged. In this specific example, the heating assembly (10) is connected to a mouthpiece (4) through which a user can inhale the aerosol. It will be appreciated that the device (1) may have other components and functions (e.g., a display and control circuitry) not described in detail herein.

As illustrated in FIG. 1B, the heating assembly (10) includes a heater (100). Although not illustrated in FIG. 1B, the heating assembly (10) includes an insulating layer (50) around the heater (100), which will be described in more detail with reference to FIGS. 4 to 10. The heater (100) includes a first wall provided by a first heater substrate (110a) and a second wall provided by a second heater substrate (110b). In this example, the heater substrate (110) is formed of a ceramic material. The heater substrate (110) has a substantially flat or planar surface (118). The first heater substrate (110a) is arranged parallel to the second heater substrate (110b). In this manner, the heater (100) has a substantially rectangular parallelepiped shape, and a substantially flat cavity (105) is formed between the substrates (110a, 110b). Accordingly, a substantially planar consumable (5) can be accommodated in the cavity (105). During use, the consumable (5) is heated by the heater (100) to generate an aerosol. The consumable (5) includes an aerosol-forming material and can be configured as a non-combustion heating consumable (5). Since the heater (100) has a rectangular parallelepiped shape formed from planar substrates (110a, 110b), it has a larger surface area than other types of heaters, such as cylindrical heaters. Therefore, it is particularly important to improve the energy efficiency of the heater (100).

The heater (100) comprises a base (101) and side walls (103, 104) (as shown in FIG. 3A). In this manner, the edge of the cavity (105) is sealed, so that the consumable (5) is fixed at a fixed position within the cavity (105). The top portion (102) of the heater (100) is kept substantially open so that the consumable (5) can be inserted into the cavity (105). That is, the top portion (102) provides an opening in the cavity (105). The mouthpiece (4) can be detachably connected to the top portion (102) of the heater (100)/heating assembly (10) via an interface connection (not shown), thereby allowing easier access to the cavity (105) (e.g., for inserting or cleaning the consumable (5)). Alternatively, the consumable (5) can be inserted into the cavity (105) through the mouthpiece (4).

A heating track (120) is formed on each substrate (110) (i.e., on the plane (118) of each substrate (110). The heating track (120) follows a winding path on the surface (118) of the substrate (110). The heating track (120) is configured to receive electrical energy from a battery or power source (not shown) of the device (1) and generate heat to produce an aerosol from the consumable (5) when the consumable (5) is inserted into the cavity (105) of the heater (100). An electrical connection between the heating track (120) and the battery is provided by at least one electrical contact (140) located on the substrate, each electrical contact (140) being connected to a corresponding wire (150).

A conventional heater substrate (110') will now be described with reference to FIGS. 2A and 2B. As illustrated, a heating track (120') is formed on the substrate (110'). Electrical contacts (140') are positioned at an end of the substrate (110') (in this case, near the base (111'), and wires (150') extend from the base (111') in a direction substantially parallel to the plane of the substrate (110'). This allows for a simple electrical connection to the heating track (120'), and allows other components to be positioned around the heater (100') without being obstructed by the electrical contacts (140') or wires (150'). However, the area near the base (111') cannot be used to heat the consumable (5') during use. As a result, as illustrated in FIG. 2b, the consumable (5') is not fully inserted into the cavity (105') between the substrates (110a', 110b') because the area near the base (111') does not generate sufficient heat to form an inhalable aerosol. However, especially when using ceramic for the substrate (110'), the area near the base (111') still increases the thermal mass of the heater (100'), which means a longer heating time and an overall increase in the size of the heater (100') and the device (1). Although FIGS. 2a and 2b illustrate the electrical contact (140') near the base (111'), it will be appreciated that the same problem exists even if the electrical contact is near any of the edges, such as the side or top, of the substrate (110').

The heater (100) will now be described in detail with reference to FIGS. 3A and 3B. FIG. 3A illustrates a heater substrate (110) installed on a heater (100) having a base (101), a top portion (102), and side walls (103, 104). FIG. 3B illustrates a heater substrate (110) of the heater (100) connected to a wire (150). It will be appreciated that all features provided in the following description may be applied to the first heater substrate (110a) and/or the second heater substrate (110b). It will also be appreciated that the first heater substrate (110a) and the second heater substrate (110b) need not be identical, for example, the heating tracks (120) provided on each substrate (110) may have different paths and/or the electrical contacts (140) may be located at different locations on the substrate (110). Alternatively, the opposite wall of the cavity (105) provided by the unheated substrate or insulating substrate may be provided by a single heater substrate (110). However, this example has two substrates (110a, 110b) to heat the consumable (5) from both sides.

As illustrated in FIG. 3A, the substrate (110) is substantially rectangular having a base portion (111), a top portion (112), a first side (113), and a second side (114). In this manner, the first side (113) and the second side (114) extend between the base portion (111) and the top portion (112). The base (101), the first side (113), and the second side (114) provide surfaces of a heater that couple the first substrate (110a) and the second substrate (110b), respectively. Alternatively, the substrate (110) may have another shape (e.g., not rectangular). The heating track (120) is formed on the planar surface (118) of the substrate (110). The heating track (120) follows a winding path on the substrate (110). A first electrical contact (140-1) and a second electrical contact (140-2) are connected to the heating track (120) to supply power to the heating track (120). In this example, the heating track (120) forms a closed loop, with the track (120) having two paths connecting the first electrical contact (140-1) and the second electrical contact (140-2). It will be appreciated that an open loop, such as a single path between the first electrical contact (140-1) and the second electrical contact (140-2), may also be used. Additionally, multiple winding paths may form the heating track (120), and additional electrical contacts (140) may be used.

The heating track (120) is formed within a heating zone (115) on the substrate (110). For purposes of illustration, the boundary of the heating zone (115) is depicted in dashed lines in FIG. 3A, but it will be appreciated that this boundary is typically not visible. In this example, since both the cavity (105) and the consumable (5) are rectangular, the heating zone (115) has a correspondingly rectangular shape. The heating zone (115) may have a shape other than rectangular (which may be suitable for non-rectangular cavities (105) and/or consumables (5). Generally, for any path of the heating track (120), the heating zone (115) is defined as a convex shape (e.g., a convex polygon) having a minimum area that surrounds the entire heating track (120). The heating zone (115) substantially corresponds in size and shape to the consumable (5) when inserted into the cavity (105). This means that the entire heating track (120) is used to heat the consumable (5) and the entire consumable (5) is heated by a portion of the heating track (120). This reduces wasted energy (e.g., by heating components other than the consumable (5)) and reduces wastage of the consumable (5) (e.g., by using components that are not sufficiently heated to generate an aerosol).

The substrate (110) has a central region, which is defined as a region adjacent to the center of the substrate (110) and/or a region adjacent to the center of the heating region (115). The center of the substrate (110) and/or the heating region (115) may be defined as the average position or center of mass of the substrate (110) and/or the heating region (115).

A temperature sensor (130) is provided on the substrate (110). In this way, the amount of heat supplied to the consumable (5) can be monitored. This allows for optimal vaporization and/or prevents overheating (which may lead to unwanted vapor generation). The temperature sensor (130) has corresponding third and fourth electrical contacts (140) (not shown), each electrical contact being connected to a corresponding wire (150). This allows the temperature measured by the temperature sensor (130) to be transmitted to other components of the device (1), such as a control unit. For example, the temperature sensor (130) may be connected to the power supply and the heating track (120) in a feedback loop. To better monitor the temperature, the temperature sensor (130) (and its electrical contacts (140)) is located within the central region of the substrate (110).

The electrical contact (140) is positioned between the first point and the second point of the heating track (120) on the substrate (110). In this way, a line (straight line) connecting the first point and the second point along the substrate (110) passes through the position of at least one electrical contact (140). The first point and the second point do not necessarily need to be unique for each electrical contact (140), as long as a pair of such points can be found. That is, when the heating zone (115) is defined in the above-described manner, at least one electrical contact (140) is positioned within the heating zone (115). As described above, the electrical contact (140) includes electrical contacts (140-1, 140-2) for supplying power to the heating track (120) and includes electrical contacts (140) (e.g., a pair) for connecting to a temperature sensor (130).

On the other hand, in the substrate (110') described with reference to FIGS. 2a and 2b, there cannot be a straight line between two points on the heating track (120') passing through one of the electrical contacts (140'), because they are adjacent to the edge of the substrate (110') (in this case, the base portion (111')). That is, the electrical contact (140') is located outside the heating area (115') of the heating track (120').

Advantageously, by positioning the electrical contact (140) between the first point and the second point on the heating track (120), the heating track (120) can fill the substrate (110) without requiring a space or protrusion near the edge for the electrical contact (140). In the rectangular heating area (115) illustrated in FIG. 3A, the heating track (120) has a first portion (121) adjacent to the base portion (111) of the substrate (110) and a second portion (122) adjacent to the top portion (112) of the substrate (110). That is, the heating track (120) extends to both the top and the base of the heating cavity (105), eliminating the need to maintain space adjacent to the top portion (112) or the base portion (111) of the substrate (110) to provide at least one electrical contact (140). This reduces the size of the substrate (110) and improves the efficiency of the heater (100). As used herein, the term "adjacent" indicates that a portion (121, 122) of a heating track (120) enters an area within 20%, more preferably within 10%, and even more preferably within 5% of the length of the substrate (110) from the top portion (112) or the base portion (111).

The heating track (120) has a third portion (123) adjacent to the first side (113) of the substrate (110) and a fourth portion (124) adjacent to the second side (114) of the substrate (110). That is, the heating track (120) extends to both sides of the heating cavity (105), eliminating the need to maintain space for providing at least one electrical contact (140). This allows for a further reduction in the size of the substrate (110) without reducing the size of the heating track (120), which improves the overall efficiency of the heater (100) without affecting its performance. As used herein, the term "adjacent" indicates that a portion (123, 124) of the heating track (120) enters an area within 20%, more preferably within 10%, and even more preferably within 5% of the width of the substrate (110) from the first side (113) or the second side (114).

Preferably, the heating track (120) substantially follows the perimeter of the substrate (110) in other portions in addition to the first, second, third, and fourth portions described above (i.e., the heating zone (115) extends around the perimeter of the substrate (110). That is, the portions (121, 122, 123, 124) illustrated in FIG. 3A are not the only portions adjacent to each side of the substrate and are merely shown by way of example. For both rectangular and non-rectangular substrates (110), the heating zone (115) preferably extends around the perimeter of the substrate (110) (i.e., when the boundary of the heating zone (115) is adjacent to the perimeter of the substrate (110), the term “adjacent” is defined as described above).

As illustrated in FIG. 3B, at least one wire (150) extends from at least one electrical contact (140). More specifically, a first wire (150-1) extends from a first electrical contact (140-1), a second wire (150-2) extends from a second electrical contact (140-2), and a third wire (150-3) and a fourth wire (150-4) extend from an electrical contact (140) of a temperature sensor (130). As described in more detail below, the wire (150) preferably extends in a direction perpendicular to a surface (118) of the substrate (110), with a portion of the wire (150) being bent in a direction parallel to the surface (118) of the substrate (110). This allows the wire (150) to be connected to other components of the device (1), such as a power supply or a control circuit. In this example, all of the wires (150) are bent to extend over the base (101) of the heater (100), but it will be appreciated that the wires (150) may be bent to extend in other directions or may not be bent at all.

Advantageously, the energy efficiency of the heater (100) is improved by providing electrical contacts (140) within the heating zone (115). The energy consumed is generally proportional to the area of the substrate (110). In the conventional heater (100I) illustrated in FIGS. 2A and 2B, the surface area is 329 mm ² , and approximately 3 kJ of energy is required per session. In the case of the heater (100) illustrated in FIGS. 3A and 3B , the surface area is reduced to 263 mm ² , and only approximately 2.6 kJ of energy is required per session. This represents an approximately 20% improvement in energy efficiency while still maintaining the performance of the device (1).

To further improve the efficiency of the device (1), it is desirable to maximize the amount of heat transferred from the heating track (120) to the cavity (105) and minimize any heat leakage to other locations. This can improve the battery life of the device (1) and reduce heating of the exterior of the device (1) during use without affecting the performance of the heater (100). To achieve this, the heating assembly (10) includes an insulating layer (50) positioned over the surface (118) of the substrate (110). The insulating layer (50) may also be referred to herein as an insulating plate (50).

As illustrated in FIG. 4, the insulating layer (50) may be a substantially rectangular material. The material may have a thickness of about 3 mm, but as described below, multiple insulating layers (50) may be used so that the total thickness is about 3 mm, with each layer preferably having a thickness of about 1 mm or less. The insulating layer (50) may have a nanoporous structure and may include a material such as Superwool® or Finesulight®.

As mentioned above, since the wire (150) extends from the central region of the surface (118) of the substrate (110), how to effectively insulate the heater (100) while still allowing the wire (150) to be connected to other components of the device (1) can be a challenge. In contrast, in the configuration illustrated in FIGS. 2A and 2B, an insulating layer can be easily provided over the heating zone (115') without being obstructed by the electrical contacts (140') or the wires (150'). To address this issue in this example, the insulating layer (50) is positioned to provide an opening through which the wires (150) extend. As illustrated in FIG. 4, the insulating layer (50) includes at least one hole or perforation (52), more specifically, a hole (52) corresponding to each wire (150). In this example, the first hole (52-1) and the second hole (52-2) correspond to the first wire (150-1) and the second wire (150-2) connected to the heating track (120). The third hole (52-3) and the fourth hole (52-4) correspond to the third wire (150-3) and the fourth wire (150-4) connected to the temperature sensor (130).

Figures 5a to 5c illustrate manufacturing steps of a heating assembly (10). In Figure 5a, the end of each wire (150) passes through a corresponding hole (52). In Figure 5b, the insulating layer (50) is positioned to contact the surface (118) of the substrate (110), with the wire (150) moving through the hole (52). The size of each hole (52) is such that it tightly seals around the corresponding wire (150), meaning that no portion of the surface (118) is covered by the insulating layer (50). Preferably, the insulating layer (50) contacts the surface (118) of the substrate (110), although alternatively, an air layer may be provided therebetween to provide additional insulation.

As illustrated in FIG. 5c, the portion of each wire (150) extending through the hole (52) is bent parallel to the insulating layer (50). This secures the insulating layer (50) while bringing it into contact with the surface (118) of the heating substrate (110). Although FIGS. 5a through 5c only illustrate a single insulating layer (50) positioned over the first heating substrate (110a), it will be appreciated that the same process may be applied to the second heating substrate (110b) so that both sides of the heater (100) are insulated. Additionally, another heating layer may be provided to cover the base (101) and side walls (103, 104) of the heater (100). As will be described in more detail below, the insulating layer (50) may be bent (folded or wrapped) to cover the base (101) and side walls (103, 104).

The opening may be provided in other ways. As illustrated in FIGS. 6A and 6B, the insulating layer (50) may include a slot (54) extending to an edge of the insulating layer (50). In this manner, the insulating layer (50) may be positioned by translation of the wire (150) over the surface (118) of the substrate (110) extending through the slot (54). Since the electrical contacts (140) are preferably collinear, the slot (54) may be straight, so that the insulating layer (50) can be easily slid into place along a single direction (as indicated by the arrows). While a straight slot (54) may be more easily manufactured, it will be appreciated that other shaped slots (54) may be used to accommodate other (e.g., non-linear) configurations of the electrical contacts (140). When a slot (54) is used, the wire (150) may be bent parallel to the insulating layer (50) and secured while bringing the insulating layer (50) into contact with the heating substrate (110), which may be performed before or after the insulating layer (50) is positioned on the substrate (110), but is preferably performed after.

As another alternative for providing an opening, FIGS. 7A and 7B illustrate an insulating layer (50) having a first portion (50-1) and a second portion (50-2) positioned over a substrate (110) and having a gap (56) therebetween providing an opening. As illustrated by the arrows in FIG. 7A, the first portion (50-1) and the second portion (50-2) can be translated (slid) over the surface (118) of the heating substrate (110) to position them. In FIG. 7B, the first portion (50-1) and the second portion (50-2) have slid to contact a wire (150) connected to an electrical contact (140). Since the electrical contacts (140) are preferably colinear, the insulating layer (50) can be simply divided into the first portion (50-1) and the second portion (50-2) along the straight line. Although a straight gap (56) (boundary) is easier to manufacture, it will be appreciated that other shaped gaps (56) may be used, such as to handle electrical contacts (140) that are not on the same line and/or to fill the space between electrical contacts (140).

Figures 8a to 8d illustrate an alternative method of providing an opening in the insulating layer (50), wherein the insulating layer (50) surrounds the heater (100). As shown in Figure 8a, the insulating layer (50) includes a hole (52) corresponding to that already described with respect to Figure 4. However, the insulating layer (50) is also wider and has slots (54-1, 54-2) on the sides.

As illustrated in FIG. 8b, a first set of wires (150a) extends from a first substrate (110a), and a second set of wires (150b) extends from a second substrate (110b). In a similar manner to FIG. 5a, an end of each wire (150a) passes through a corresponding hole (52) so as to position the insulating layer (50) so as to contact the surface (118) of the first substrate (110a), as illustrated in FIG. 8b.

In FIG. 8c, the insulating layer (50) is bent (i.e., wrapped/wrapped or folded) around the side walls (103, 104) of the heater (100) so as to position the insulating layer (50) so as to contact the surface (118) of the second substrate (110b). The insulating layer (50) is bent about the longitudinal axis of the heater (100), which is an axis extending between the base (101) of the heater (100) and the mouthpiece (4). The insulating layer (50) may be sealed to itself and/or to the heater (100) to prevent subsequent unraveling. Since the heater (100) is a rectangular parallelepiped, the insulating layer (50) may be bent over a 90 degree corner of the heater (100) without substantially wrinkling.

As illustrated in FIG. 8d, the slots (54-1, 54-2) allow the second set of wires (150b) to extend through the insulation layer (50). In this example, the insulation layer (50) is wrapped around the side walls (103, 104) of the heater (100), but it will be appreciated that the insulation layer (50) could be wrapped under the base (101) of the heater (100), which may require a different configuration of the holes (52) and slots (54) or a different shape of the insulation layer (50). It will also be appreciated that the first set of wires (150a) could instead pass through the slots (54) and the second set of wires (150b) could instead pass through the holes (52) of the insulation layer (50).

Any of the features of the aforementioned insulating layers (50) may be combined in any suitable manner. For example, instead of providing a slot (54) on the side of the insulating layer (50) in FIG. 8A, the insulating layer (50) may be slightly narrowed so that when the insulating layer (50) is folded around the heater (100), the wires instead extend through the gap.

As will now be described with reference to FIGS. 9A to 9D , multiple insulating layers (50) can be wound on top of each other. In FIG. 9A , a first insulating layer (50a) is wrapped around the heater (100) in a manner similar to that described with reference to FIGS. 8A to 8D . A first set of wires (150a) extends through holes (52a) in the first insulating layer (50a), and a second set of wires (150b) extends through slots (54a) in the first insulating layer (50a). While the first insulating layer (50a) covers most of the heater (100), the slots (54a) mean that components of the second substrate (110b) near the second set of wires (150b) (e.g., between adjacent wires (150)) are not covered by the first insulating layer (50a).

In Fig. 9b, the second insulating layer (50b) is wrapped around the heater (100) over the first insulating layer (50a) in a similar manner as described above. Preferably, the second insulating layer (50b) is wrapped so as to cover the opening of the first insulating layer (50a). More specifically, the slot (54a) of the first insulating layer (50a) is covered by the second insulating layer (50b). This is achieved by passing the second set of wires (150b) through the opening (52b) of the second insulating layer (50b) and passing the first set of wires (150a) through the slot (54b) of the second insulating layer (50b). That is, if a particular wire (150) extends through the slot (54a) of the first insulating layer (50a), the same wire (150) can extend through the hole (52b) of the second insulating layer (and vice versa). The hole (52) (preferably tightly sealed around the wire (150)) has better insulation than the slot (54) (the uncovered area), which means that all sides of the heater (100) are covered by at least one insulating layer (50).

Preferably, as illustrated in FIG. 9c, the third insulating layer (50c) surrounds the heater (100). As described above, the third insulating layer (50c) surrounds at least one opening of the first or second insulating layer (50a, 50b). In particular, the slot (54b) of the second insulating layer (50b) is covered by the third insulating layer (50c). Accordingly, it will be appreciated that the third insulating layer (50c) surrounds in a similar manner to the first insulating layer (50a), but the third insulating layer (50c) may surround differently from one or both of the first and second insulating layers (50a, 50b).

FIG. 9d illustrates an enlarged view of FIG. 9c. As shown, the wire (150) passes alternately through the slot (54) and the hole (52). Wrapping the heater (100) in this manner allows for substantially covering the entire heater (100) while still providing an opening for the wire (150) to extend through. Another advantage of having multiple layers of insulation (50) is that each layer can be made thinner, allowing for a tighter wrap around the 90-degree corners of the heater (100). For example, a total thickness of about 3 mm may be required to provide sufficient insulation, and by providing this thickness using three layers, each 1 mm thick, each insulation layer (50) can be bent at a sharper angle (smaller bend radius) around the corners of the heater (100).

The aforementioned insulating layer (50) provides insulation to the substrate (110) and sidewalls (103, 104) of the heater (100), but the base (101) of the heater (100) is typically not covered. Typically, a separate material may be used to insulate the base (101). However, as will now be described with respect to the cross-sectional views of FIGS. 10A through 10F, the insulating layer (generally designated by reference numeral 50) is preferably bent to form a wrapping (generally designated by reference numeral 55) that substantially surrounds the heater (100). This wrapping (55) may be referred to as an insulating pouch (55).

FIG. 10A illustrates a heating assembly (10) in which an insulating layer (50a) is wrapped around a heater (100) in a manner similar to that described above. More specifically, the insulating layer (50a) is bent about a first axis to cover a first substrate (110a), an opposite second substrate (110b), and side walls (103, 104). The first axis corresponds to the longitudinal axis of the heater (100). As illustrated in FIG. 10A, the base (101) is not initially covered or wrapped by the insulating layer (50a) after being bent about the first axis. The insulating layer (50a) has a height greater than the insulating layers described above, such that the lowermost edge of the insulating layer (50a) extends beyond (i.e., protrudes) the base (101).

Next, as illustrated in FIG. 10b, the insulating layer (50a) is bent about a second axis perpendicular to the first axis to cover the base (101). The second axis corresponds to an axis perpendicular to the longitudinal axis, e.g., an axis passing through opposing surfaces of the cavity (105). Once bent to cover the base (101), the insulating layer (50a) is sealed over the base (101) to form a wrapping (55a) having a sealing portion (56a). The sealing portion (56a) is preferably a crimp seal, but other types of sealing portions (56a) may be used to connect the insulating layer (50a) to itself over the base (101), such as by using one or more folds in the insulating layer (50a). The wrapping (55a) has a main opening that is aligned with the opening of the heating cavity (105). By forming the wrapping (55a) in this manner, the heater (100) can be more faithfully insulated using a single insulating material, without the need for a separate material to insulate the base (101) or the side walls (103, 104). In addition, an air pocket (58) is formed between the base (101) and the sealing portion (56a). Since air has a low specific heat, this further reduces heat loss from the heater (100) through the base (101). Optionally, the air pocket (58) may be filled with an insulating material.

It will be appreciated that the wrapping (55a) has another opening (different from the main opening) through which the wire (150) extends, such as the hole (52) or slot (54) already described above. It will also be appreciated that the first and second axes can be defined using different directions.

Preferably, the wrapping (55a) is a first wrapping (55a), and one or more additional insulating layers are wrapped around the heater (100). As shown in FIG. 10c, the second insulating layer (50b) is bent around a first axis around the heater (100), such that the lowermost edge of the second insulating layer (50b) protrudes above the base (101) of the heater (100). In FIG. 10d, the second insulating layer (50b) is bent around a second axis to cover the base (101), and is sealed to form a second wrapping (55b) having a sealing portion (56b). This provides a pair of overlapping wrappings (55a, 55b), thereby improving the insulation of the heater (100).

As illustrated in FIG. 10e, the third insulating layer (50c) is bent around the first axis around the heater (100) so that the lowermost edge of the third insulating layer (50c) protrudes above the base (101) of the heater (100). In FIG. 10f, the third insulating layer (50c) is sealed by being bent around the second axis so as to cover the base (101), thereby forming a third wrapping (55c) having a sealing portion (56c). This provides a plurality of overlapping wrappings (55a, 55b, 55c), thereby further improving the insulation of the heater (100).

It will be appreciated that any number of wrappings (55), for example, four or more, can be provided using a corresponding number of insulating layers (50). By using multiple wrappings (55), each wrapping can be formed of a thinner material (e.g., less than about 1 mm), which means that each insulating layer (50) can bend more sharply around the edge of the heater (100). On the other hand, if only one wrapping (55) having a thickness of about 3 mm is provided, the insulating layer (50) cannot bend sharply around the edge of the heater (100) due to the limited bend radius of the thick material.

Although FIG. 10f illustrates all insulating layers (50) being sealed to form a wrapping (55), it will be appreciated that not all insulating layers (50) are necessarily sealed. Furthermore, sealing need not necessarily be performed before the wrapping of the additional insulating layers (50) is completed; for example, sealing of all three insulating layers (50) may be performed simultaneously. Furthermore, the wrapping (55) may be combined with other configurations of the insulating layers (50) described above.

When multiple wrappings (55) are provided, the wire (150) passes through the layers in a manner similar to that already described above with respect to FIGS. 9a to 9d, wherein the openings alternate between holes (52) and slots (54). In addition, the wire (150) is bent parallel to the heater (100) to secure the insulating layer (50) to the substrate (110) and is connected to other components of the device (1), such as a power supply or control circuit.

To further improve the insulating properties of the heater assembly (10), an air layer is provided that separates at least one of the insulating layers (50) from the heater (100). More specifically, adjacent pairs of the insulating layers (50) are spaced apart from each other to form an air layer therebetween. Since air has a low specific heat, providing the air layer further improves the insulating properties around the heater (100). The air layer is provided in addition to the air layer (58) described above.

As illustrated in FIG. 10d, the air layer is provided by separating the first insulating layer (55a) from the second insulating layer (55b) using a first wire (150-1) extending from the first substrate (110a). The first wire (150-1) is bent while contacting the outer surface of the first wrapping (55a) before wrapping the second insulating layer (50b) over the first insulating layer (50a). As a result, once the second insulating layer (50b) is bent around the heater (100), an air layer is formed adjacent to the first wire (150-1). Since the first wire (150-1) is bent parallel to the surface (118) of the substrate (110), the opening of the second insulating layer (55b) through which the first wire (150-1) extends is provided toward the base of the second wrapping (55b) adjacent to the sealing portion (56b).

As illustrated in FIG. 10d, the second wire (150-2) is instead bent over the outer surface of the second insulating layer (50b). Accordingly, the second wire (150-2) extends through the opening of the second insulating layer (50b) in the manner described above with respect to FIGS. 9a to 9d. As illustrated in FIG. 10f, the second wire (150-2) is also bent over the outer surface of the third (outermost) insulating layer (50c), so that no air layer is formed between the second insulating layer (50b) and the third insulating layer (50c). Alternatively, the second wire (150-2) may separate the second insulating layer (50b) from the third insulating layer (50c) to form an air layer.

While the air layer has been described above with respect to the first wire (150-1) and the second wire (150-2) extending from the first substrate (110a) of the heater (100), it will be appreciated that any other wire (150) extending from either of the substrates (110a, 110b) may also be used for this purpose. That is, any adjacent pair of insulating layers (50) may be spaced apart using any of the wires (150). Since the heating assembly (10) has multiple wires (150), multiple air layers may be formed using different wires (150). Additionally, although not described above, the wire (150) may be bent directly between the heater (100) and the first insulating layer (50a).

While the above describes exemplary embodiments of the present invention, it will be understood that the present invention is described herein by way of example only, and that modifications in detail are possible within the scope of the present invention. Furthermore, those skilled in the art will understand that the present invention is not limited by the embodiments disclosed herein or any details depicted in the accompanying drawings that are not specifically described herein or defined in the claims. In fact, such unnecessary features may be removed from the drawings without detracting from the essence of the present invention.

Furthermore, other and further embodiments of the present invention will be apparent to those skilled in the art in view of this specification and may be contemplated without departing from the basic scope of the present invention as determined by the claims below.

Claims (10)

As a heating assembly for a non-combustion heating device,
A heating substrate having a substantially flat surface;
A heating track formed on the surface of the heating substrate;
An electrical contact positioned on the surface of the heating substrate;
A wire connected to the electrical contact, the wire extending from the heating substrate; and
A heating assembly comprising an insulating layer positioned on a surface of the heating substrate, the insulating layer configured to provide an opening through which the wire extends. A heater in claim 1, wherein the wire extends from the heating substrate in a direction substantially perpendicular to the surface of the heating substrate. A heater according to claim 1 or 2, further comprising a plurality of electrical contacts arranged on the surface of the heating substrate, each electrical contact being connected to a corresponding wire. A heater according to any one of claims 1 to 3, wherein the insulating layer comprises a first part and a second part positioned on the heating substrate with a gap providing the opening therebetween. A heater according to any one of claims 1 to 4, wherein the opening is provided by a slot in the insulating layer extending to an edge of the insulating layer, and the insulating layer is positioned by translational movement of the insulating layer over the surface of the heating substrate together with the wire extending through the slot. A heater according to any one of claims 1 to 5, wherein the opening is provided by at least one hole in the insulating layer, and the insulating layer is positioned above the surface of the heating substrate by passing an end of the wire through the at least one hole. A heater in claim 6, wherein the insulating layer includes a plurality of holes, each hole corresponding to a separate wire. A heater according to any one of claims 1 to 7, wherein a portion of the wire extending through the opening is bent in a direction parallel to the insulating layer, thereby holding the insulating layer against the surface of the heating substrate. A heater according to any one of claims 1 to 8, wherein the heating substrate is a first heating substrate, and the heater further includes a second heating substrate arranged parallel to the first heating substrate to provide a heating cavity therebetween. A method for manufacturing a heating assembly for a non-combustion heating device,
A step of providing a heating substrate;
A step of positioning an electrical contact on a substantially flat surface of the heating substrate;
a step of connecting a wire to the electrical contact; and
A method comprising the step of positioning an insulating layer over a surface of the heating substrate so that the wire extends through an opening provided by the insulating layer.