# US 11,432,592 B2 · Method of forming heating elements that are coupled together to a voltage source > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,432,592 B2 - Document ID: US11432592B2 - Status: Granted - Kind: B2 - Application number: 16/404,055 - Filed: 2019-05-06 - Published: 2019-08-22 - Granted: 2022-09-06 - Earliest claimed: 2009-12-30 - Assignees: Philip Morris USA Inc. - Applicants: Philip Morris USA Inc. - Inventors: Olivier Greim; Felix Fernando; Charles Higgins - Web page: https://patentgrep.com/patent/US11432592B2 ## CPC - A24F 40/70: Manufacture - F24H 1/0018: {using electric energy supply} - H05B 3/0019: {Circuit arrangements} - H05B 3/46: heating conductor mounted on insulating base - A24F 40/20: Devices using solid inhalable precursors - A24F 40/46: Shape or structure of electric heating means - H05B 2203/017: Manufacturing methods or apparatus for heaters - A24F: SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES (inhaling appliances for medical purposes, shaped like cigars, cigarettes or pipes A61M15/06) - F24H: FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL (steam generation F22) - H05B: ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL ## Abstract A heater for heating an aerosol-forming substrate includes a plurality of elongate heating elements arranged in an elongate array. The elongate array has a support end with a first dimension, a heating end with a second dimension and a middle portion with a third dimension. The array is arranged to heat the substrate to form an aerosol. The third dimension is greater than the first dimension and greater than the second dimension. An electrically heated aerosol generating system can include the heater. ## Claims ### Claim 1 A method, comprising: flat stamping a heating element material to form heating elements, each of the heating elements including a first end and a second end that is opposite to the first end, the first end of each of the heating elements being connected to a linking element so that the heating elements are electrically and mechanically connected together, the linking element being substantially straight, respective portions of the heating elements being substantially parallel to each other; bending the linking element into a substantially circular shape; coupling opposing ends of the linking element together; coupling the second end of the heating elements to a collar element to establish an electrical connection between the heating elements and the collar element; and electrically coupling the collar element to a voltage source. ### Claim 2 (depends on 1) The method of claim 1, wherein the linking element extends substantially perpendicularly to the heating elements prior to the bending of the linking element. ### Claim 3 (depends on 1) The method of claim 1, further comprising: coupling the first end of each of the heating elements to the linking element, wherein the coupling of the first end of each of the heating elements includes spot welding each heating element to the linking element. ### Claim 4 (depends on 1) The method of claim 1, wherein the coupling of the opposing ends of the linking element includes, welding the opposing ends of the linking element together. ### Claim 5 (depends on 1) The method of claim 1, wherein the flat stamping includes, applying a stamp to a single sheet of the heating element material, the stamp being configured to form the heating elements to be substantially parallel to each other based on flat stamping the single sheet of the heating element material. ### Claim 6 (depends on 1) The method of claim 1, further comprising: coupling the first end of each of the heating elements to a common pin. ### Claim 7 (depends on 1) The method of claim 1, wherein the electrically coupling includes electrically coupling at least two of the heating elements in series to the voltage source. ### Claim 8 (depends on 1) The method of claim 1, further comprising: coupling the first end of each of the heating elements to the linking element, so that the heating elements are about equally spaced apart from each other along the linking element. ### Claim 9 A method, comprising: flat stamping a heating element material to form heating elements, each of the heating elements including a first end and a second end that is opposite to the first end, respective portions of the heating elements being substantially parallel to each other; and first coupling the second end of each of the heating elements to a voltage source, the first coupling causing the heating elements to be mechanically and electrically connected to each other, the first end of each of the heating elements being connected by a linking element. ### Claim 10 (depends on 9) The method of claim 9, further comprising: second coupling the first end of each of the heating elements to the linking element, the second coupling causing the heating elements to be substantially parallel to each other, the first coupling and the second coupling together causing the heating elements to be mechanically and electrically connected to each other. ### Claim 11 (depends on 9) The method of claim 9, wherein the first coupling includes electrically coupling at least two of the heating elements in series with the voltage source. ### Claim 12 (depends on 10) The method of claim 10, wherein the second coupling further includes extending the linking element substantially perpendicularly to the heating elements during the second coupling of the first end of each of the heating elements. ### Claim 13 (depends on 10) The method of claim 10, wherein the second coupling further includes spot welding the first end of each of the heating elements to the linking element. ### Claim 14 (depends on 10) The method of claim 10, further comprising: welding opposing ends of the linking element together. ### Claim 15 (depends on 9) The method of claim 9, wherein the flat stamping includes applying a stamp to a single sheet of the heating element material, the stamp configured to form the heating elements and the linking element on the first end of the heating elements, the flat stamping causing the heating elements to be substantially parallel to each other. ### Claim 16 (depends on 9) The method of claim 9, wherein the first coupling includes coupling the second end of each of the heating elements to a collar element; and electrically coupling the collar element to the voltage source. ### Claim 17 (depends on 9) The method of claim 9, further comprising: third coupling the second end of each of the heating elements to a common pin, the common pin extending at least between the first end of each of the heating elements and the second end of each of the heating elements. ### Claim 18 (depends on 10) The method of claim 10, wherein the first coupling and the second coupling can occur in any order or at a same time. ### Claim 19 (depends on 10) The method of claim 10, wherein the second coupling further includes coupling the first end of each of the heating elements to the linking element so that the heating elements are about equally spaced apart from each other along the linking element.