Heater for an aerosol delivery device and methods of formation thereof

Abstract

The present disclosure relates to aerosol delivery devices, methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure provides a heating member that can be formed of a heating element conformed to a heater substrate configured as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size. In some embodiments, the disclosure provides methods of forming an aerosol delivery device, which can include providing a shell, providing a heating member formed of a heating element conformed to a substrate, configuring the heating member as a truncated cone (or similar shape) having a first end of a first size and a second end of greater size, and inserting the heating member within the shell.

That which is claimed is: 
     
         1 . A method of forming an aerosol delivery device comprising:
 providing a shell;   providing a heating member formed of a heating element conformed to a substrate;   configuring the heating member as a truncated cone having a first end of a first size and a second end of greater size; and   inserting the heating member within the shell.   
     
     
         2 . The method according to  claim 1 , further comprising providing a porous transport element configured for passage of an aerosol precursor composition along a length thereof, the porous transport element having a first end and a second opposing end, and configuring the first end thereof in a heating arrangement with the heating member. 
     
     
         3 . The method according to  claim 2 , further comprising contacting the second end of the porous transport element with the aerosol precursor composition. 
     
     
         4 . The method according to  claim 2 , wherein the truncated cone includes a central passage therethrough, and wherein configuring the first end of the porous transport element in a heating arrangement with the heating member comprises inserting the first end of the porous transport element into the central passage at the second, greater sized end of the heating member. 
     
     
         5 . The method according to  claim 2 , wherein the first end of the porous transport element comprises a central opening therein, and wherein configuring the first end of the porous transport element in a heating arrangement with the heating member comprises inserting the first, lesser sized end of the heating member into the central opening in the first end of the porous transport element. 
     
     
         6 . The method according to  claim 1 , wherein providing the heating member comprises forming the heating member on the substrate by printing an electrically conductive ink thereon. 
     
     
         7 . A method of forming an aerosol delivery device comprising:
 providing a shell;   providing a heating member formed of a heating element conformed to a substrate, wherein providing the heating member comprises forming the heating member on the substrate by printing an electrically conductive ink thereon;   configuring the heating member as a truncated cone having a first end of a first size and a second end of greater size, wherein the truncated cone includes a central passage therethrough;   providing a porous transport element configured for passage of an aerosol precursor composition along a length thereof, the porous transport element having a first end and a second opposing end;   configuring the first end the porous transport element in a heating arrangement with the heating member, wherein configuring the first end of the porous transport element in a heating arrangement with the heating member comprises inserting the first end of the porous transport element into the central passage at the second, greater sized end of the heating member; and   inserting the heating member within the shell.