Patent Description:
An e-vaping device includes a heater element which vaporizes a pre-vapor formulation to produce a "vapor.

The e-vaping device includes a power supply, such as a rechargeable battery, arranged in the device. The battery is electrically connected to the heater, such that the heater heats to a temperature sufficient to convert the pre-vapor formulation to a vapor. The vapor exits the e-vaping device through a mouthpiece including at least one outlet.

<CIT> discloses a cartridge for an aerosol delivery device, the cartridge comprising an atomizer comprising a liquid transport element and a heating element. The heating element may comprise a plurality of interconnected loops and may be at least partially bent around the liquid transport element in order to form the atomizer.

<CIT> discloses an input for production of atomizers and atomizers formed from a sheet of a material, and which may be employed in an aerosol delivery device such as a smoking article. The input may include a carrier and heating elements coupled thereto. The heating elements may include first and second ends and interconnected alternating loops disposed therebetween. The heating elements may be coupled to a liquid transport element by bending the interconnected loops at least partially around the liquid transport element.

<CIT> discloses a flexible insulated heater for surrounding pipes, the flexible insulated heater comprising a heater mat surrounded by an insulation jacket. The heat mat is formed with a curvature and size to fit snugly around the peripheral surface of the pipe that is to be heated. The heater mat includes a wire heating element which is configured in a serpentine, sinuous, or geometrical pattern.

<CIT> discloses a ceramic heating device in the form of cylindrical shape. The heating device comprises a heating element comprised of a plurality of heater tips of slim dovetail members having longer length in the longitudinal direction.

<CIT> discloses a heating device suitable for encasing a fluid-transporting conduit, comprising a first filiform electrical conductor, a second filiform electrical conductor, and a resistive wire crossing said first conductor and said second conductor several times such that a plurality of resistive connections are formed between said first and second conductors, an electrical contact being established at each intersection between the resistive wire and one of said first and second conductors.

<CIT> discloses a coated graphite heater. The heater may be a cylindrical body comprising an upper surface and has a configuration comprising a plurality of heating rungs having a major portion disposed parallel to an upper surface of the heater so that the major portion is disposed horizontally.

The invention is defined by the appended claims to which reference should be made. The invention relates to a method of making a heater of an electronic vaping device.

According to the invention, a method of making a heater assembly of an e-vaping device includes bending a wire to form a generally sinuous-shaped wire having a first set of lobes and a second set of lobes, and curling the first set of lobes towards the second set of lobes to form a curled heater having an opening therethrough. The method also includes threading a wick through the opening in the heater.

In at least one example embodiment, the method also includes curling the heater about a wick.

In at least one example embodiment, the wire is a nickel-chromium wire.

In at least one example embodiment, the method also includes attaching electrical leads to a first end and a second end of the heater.

In at least one example embodiment, each of the curves is generally U-shaped.

In at least one example embodiment, the first set of lobes is at a first side of the heater and the second set of lobes is at a second side of the heater. The first set of lobes is not in physical contact with the second set of lobes after the curling step.

Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.

Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.

It should be understood that when an element or layer is referred to as being "on," "connected to," "coupled to," or "covering" another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification.

It should be understood that, although the terms first, second, third, and so forth may be used herein to describe various elements, components, regions, layers or sections, these elements, components, regions, layers, or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or section. Therefore, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example embodiments.

Spatially relative terms (for example, "beneath," "below," "lower," "above," "upper," and the like) may be used herein for ease of description to describe one element or feature's relationship to another element or feature as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. Therefore, the term "below" may encompass both an orientation of above and below.

The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. It will be further understood that the terms "includes," "including," "comprises," and "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof.

Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of example embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques or tolerances, are to be expected. Therefore, example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

<FIG> is a side view of an e-vaping device containing a heater assembly formed according to at least one example embodiment of the method of the present invention.

As shown in <FIG>, an electronic vaping device (e-vaping device) <NUM> may include a cartridge (or first section) <NUM> and a battery section (or second section) <NUM>, which may be coupled together at a connector <NUM>. It should be appreciated that the connector <NUM> may be any type of connector, such as at least one of a threaded, snug-fit, detent, clamp, bayonet, or clasp.

The first section <NUM> may include a first housing <NUM> and the second section <NUM> may include a second housing <NUM>'. The e-vaping device <NUM> includes a mouth-end insert <NUM> at a first end <NUM> of the e-vaping device <NUM> and an end cap <NUM> at a second end <NUM> of the e-vaping device.

The first housing <NUM> and the second housing <NUM>' may each have a generally cylindrical cross-section. Alternatively, one or more of the first housing <NUM> and the second housing <NUM>' may have a generally triangular cross-section along one or more of the first section <NUM> and the second section <NUM>.

An air inlet <NUM> may extend through a portion of the connector <NUM>. Alternatively, the air inlet <NUM> may extend through the housing <NUM>, <NUM>'.

The air inlet <NUM> may be sized and configured such that the e-vaping device <NUM> has a resistance-to-draw (RTD) in the range of from about <NUM> millimetres of water to about <NUM> millimetres of water.

<FIG> is a cross-sectional view along line II-II of the e-vaping device of <FIG>.

As shown in <FIG>, the first section <NUM> may include a reservoir <NUM> configured to store a pre-vapor formulation and a heater <NUM> that may vaporize the pre-vapor formulation, which may be drawn from the reservoir <NUM> by a wick <NUM>.

The e-vaping device <NUM> may include the features set forth in <CIT>. Alternatively, the e-vaping device may include the features set forth in at least one of <CIT>, <CIT>, or <CIT>.

The pre-vapor formulation may be a material or combination of materials that may be transformed into a vapor. For example, the pre-vapor formulation may be at least one of a liquid, solid or gel formulation including, but not limited to, water, beads, solvents, active ingredients, ethanol, plant extracts, natural or artificial flavors, vapor formers such as glycerin and propylene glycol, and combinations thereof.

The first section <NUM> may include an inner tube (or chimney) <NUM> coaxially positioned within the housing <NUM>. The reservoir <NUM> may be established between the inner tube <NUM> and the housing <NUM>.

At a first end portion of the inner tube <NUM>, a nose portion <NUM> of a gasket (or seal) <NUM> may be fitted into the inner tube <NUM>, while an outer perimeter of the gasket <NUM> may provide a seal with an interior surface of the outer housing <NUM>. The gasket <NUM> may also include a central, longitudinal air passage <NUM>, which opens into an interior of the inner tube <NUM> that defines a central channel <NUM>.

As shown in <FIG>, a second gasket <NUM> may be inserted in a second end of the inner tube <NUM>. The second gasket <NUM> may include a second air passage <NUM> there through. The second air passage <NUM> may be in fluid communication with the central channel <NUM> of the inner tube <NUM>. An outer surface of the gasket <NUM> may form a tight seal between the gasket <NUM> and the housing <NUM>. A transverse channel <NUM> at a backside portion of the gasket <NUM> may intersect and communicate with the air passage <NUM> of the gasket <NUM>. This transverse channel <NUM> assures communication between the air passage <NUM> and a space <NUM> defined between the gasket <NUM> and a first connector piece <NUM>.

The first connector piece <NUM> may include a threaded section <NUM> for effecting the connection between the first section <NUM> and the second section <NUM>.

The space defined between the gaskets <NUM>, <NUM>, the housing <NUM>, and the inner tube <NUM> may establish the confines of the reservoir <NUM>. The reservoir <NUM> may store the pre-vapor formulation, and optionally include a storage medium (not shown) configured to store the pre-vapor formulation therein. The storage medium may include a winding of cotton gauze or other fibrous material about the inner tube <NUM>.

The reservoir <NUM> may be contained in an outer annulus between the inner tube <NUM> and the housing <NUM> and between the gaskets <NUM>, <NUM>. Therefore, the reservoir <NUM> may at least partially surround the central inner passage <NUM>. The heater <NUM>, the wick <NUM>, or both, may extend transversely across the central channel <NUM> between opposing portions of the reservoir 65Alternatively, the heater <NUM> may extend substantially parallel to a longitudinal axis of the central channel <NUM>.

The reservoir <NUM> may be sized and configured to hold enough pre-vapor formulation such that the e-vaping device <NUM> may be configured for vaping for at least about <NUM> seconds. Moreover, the e-vaping device <NUM> may be configured to allow each puff to last about <NUM> seconds or less.

The storage medium may be a fibrous material including at least one of cotton, polyethylene, polyester, rayon and combinations thereof. The fibers may have a diameter ranging in size from about <NUM> microns to about <NUM> microns (for example, about <NUM> microns to about <NUM> microns or about <NUM> microns to about <NUM> microns). The storage medium may be a sintered, porous or foamed material. Also, the fibers may be sized to be irrespirable and may have a cross-section which has a Y-shape, cross shape, clover shape or any other suitable shape. The reservoir <NUM> may include a filled tank lacking any storage medium and containing only pre-vapor formulation.

During vaping, pre-vapor formulation may be transferred from the reservoir <NUM>, storage medium, or both, to the proximity of the heater <NUM> via capillary action of the wick <NUM>. The wick <NUM> may include at least a first end portion and a second end portion, which may extend into opposite sides of the reservoir <NUM>. The heater <NUM> may at least partially surround a central portion of the wick <NUM> such that when the heater <NUM> is activated, the pre-vapor formulation in the central portion of the wick <NUM> may be vaporized by the heater <NUM> to form a vapor.

The wick <NUM> may include filaments (or threads) having a capacity to draw the pre-vapor formulation. For example, the wick <NUM> may be a bundle of glass (or ceramic) filaments, a bundle including a group of windings of glass filaments, and so forth, all of which arrangements may be capable of drawing pre-vapor formulation via capillary action by interstitial spacings between the filaments. The filaments may be generally aligned in a direction perpendicular (transverse) to the longitudinal direction of the e-vaping device <NUM>. The wick <NUM> may include one to eight filament strands, each strand comprising a plurality of glass filaments twisted together. The end portions of the wick <NUM> may be flexible and foldable into the confines of the reservoir <NUM>. The filaments may have a cross-section that is generally cross-shaped, clover-shaped, Y-shaped, or in any other suitable shape.

The wick <NUM> includes glass, ceramic- or graphite-based materials. The wick <NUM> may have any suitable capillarity drawing action to accommodate pre-vapor formulations having different physical properties such as density, viscosity, surface tension and vapor pressure. The wick <NUM> may be non-conductive.

The heater <NUM> includes a wire and at least partially surrounds the wick <NUM> as described in detail below with respect to <FIG>. The wire may be a metal wire. The heater <NUM> may extend fully or partially along the length of the wick <NUM>. The heater <NUM> may further extend fully or partially around the circumference of the wick <NUM>. In some example embodiments, the heater <NUM> may or may not be in contact with the wick <NUM>.

In at least one example embodiment, the heater <NUM> may be formed of any suitable electrically resistive materials. Examples of suitable electrically resistive materials may include, but not limited to, copper, titanium, zirconium, tantalum and metals from the platinum group. Examples of suitable metal alloys include, but not limited to, stainless steel, nickel, cobalt, chromium, aluminum-titanium-zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, stainless steel. For example, the heater <NUM> may be formed of nickel aluminide, a material with a layer of alumina on the surface, iron aluminide and other composite materials, the electrically resistive material may optionally be embedded in, encapsulated or coated with an insulating material or vice-versa, depending on the kinetics of energy transfer and the external physicochemical properties required. The heater <NUM> may include at least one material selected from the group consisting of stainless steel, copper, copper alloys, nickel-chromium alloys, super alloys and combinations thereof. In an example embodiment, the heater <NUM> may be formed of nickel-chromium alloys or iron-chromium alloys. The wire may have a diameter ranging from about <NUM> millimetres to about <NUM> millimetre (for example, about <NUM> millimetres to about <NUM> millimetres, about <NUM> millimetres to about <NUM> millimetres, about <NUM> millimetres to about <NUM> millimetres, or about <NUM> millimetres to about <NUM>). For example, the wire may have a diameter of about <NUM> millimetres.

The heater <NUM> may heat pre-vapor formulation in the wick <NUM> by thermal conduction. Alternatively, heat from the heater <NUM> may be conducted to the pre-vapor formulation by means of a heat conductive element or the heater <NUM> may transfer heat to the incoming ambient air that is drawn through the e-vaping device <NUM> during vaping, which in turn heats the pre-vapor formulation by convection.

The inner tube <NUM> may include a pair of opposing slots (not shown), such that the wick <NUM> and electrical leads <NUM>, <NUM> or ends of the heater <NUM> may extend out from the respective opposing slots. The provision of the opposing slots in the inner tube <NUM> may facilitate placement of the heater <NUM> and wick <NUM> into position within the inner tube <NUM> without impacting edges of the slots and the heater <NUM>.

The inner tube <NUM> may have a diameter of about <NUM> millimetres and each of the opposing slots (not shown) may have major and minor dimensions of about <NUM> millimetres by about <NUM> millimetres.

The first section <NUM> may be replaceable. In other words, once the pre-vapor formulation of the first section <NUM> is depleted, only the first section <NUM> may be replaced. An alternate arrangement may include an example embodiment where the entire e-vaping device <NUM> may be disposed once the reservoir <NUM> is depleted. For example, the e-vaping device <NUM> may be a single piece with no connector.

As shown in <FIG>, the mouth-end insert <NUM> may be inserted in the first end <NUM> of the e-vaping device <NUM>. The mouth-end insert <NUM> includes at least two outlets <NUM>, which may be located off-axis from the longitudinal axis of the e-vaping device <NUM>. The outlets <NUM> may be angled outwardly in relation to the longitudinal axis of the e-vaping device <NUM>. The outlets <NUM> may be substantially uniformly distributed about the perimeter of an end surface of the mouth-end insert <NUM> so as to substantially uniformly distribute vapor.

As shown in <FIG>, the second section <NUM> of the e-vaping device <NUM> may include a sensor <NUM> responsive to air drawn into the e-vaping device <NUM>. The second section <NUM> may also include a power supply <NUM>, a control circuit <NUM>, and a light <NUM>. The end cap <NUM> may be inserted in the housing <NUM>' at the second end <NUM>. A second connector piece <NUM> is configured to connect with the first connector piece <NUM> of the cartridge <NUM>.

The first electrical lead <NUM> extending from the heater <NUM> contacts a portion of the first connector piece <NUM>, which is mated with the second connector piece <NUM>. A lead <NUM> contacts a battery terminal and the second connector piece <NUM>. The second electrical lead <NUM> extending from the heater <NUM> contacts an inner post <NUM>. The inner post <NUM> contacts a second inner post <NUM> that extends through the second connector piece <NUM> and is electrically isolated therefrom by an insulator <NUM>. The second inner post <NUM> is in contact with the control circuit <NUM> via lead <NUM>. The control circuit is in contact with a second battery terminal via lead <NUM> to form the electrical connection between the heater <NUM> and the battery <NUM>.

The power supply <NUM> may include a battery arranged in the e-vaping device <NUM>. The power supply <NUM> may be a Lithium-ion battery or one of its variants, for example a Lithium-ion polymer battery. Alternatively, the power supply <NUM> may be a nickel-metal hydride battery, a nickel cadmium battery, a lithium-manganese battery, a lithium-cobalt battery or a fuel cell. The e-vaping device <NUM> may be vapable by an adult vaper until the energy in the power supply <NUM> is depleted or in the case of lithium polymer battery, a minimum voltage cut-off level is achieved.

The power supply <NUM> may be rechargeable. The battery section <NUM> may include circuitry configured to allow the battery to be chargeable by an external charging device. To recharge the e-vaping device <NUM>, an USB charger or other suitable charger assembly may be used as described below.

Furthermore, the sensor <NUM> is configured to generate an output indicative of a magnitude and direction of airflow in the e-vaping device <NUM>. The control circuit <NUM> receives the output of the sensor <NUM>, and determines if (<NUM>) the direction of the airflow indicates a draw on the mouth-end insert <NUM> (versus blowing) and (<NUM>) the magnitude of the draw exceeds a threshold level. If these activation conditions are met, the control circuit <NUM> electrically connects the power supply <NUM> to the heater <NUM>. Alternatively, the sensor <NUM> may indicate a pressure drop, and the control circuit <NUM> activates the heater <NUM> in response thereto.

The control circuit <NUM> may also include the light <NUM>, which is configured to glow when the heater <NUM> is activated. The light <NUM> may include a light-emitting diode (LED). Moreover, the light <NUM> may be arranged to be visible to an adult vaper during vaping, and may be positioned between the first end <NUM> and the second end <NUM> of the e-vaping device <NUM>. In addition, the light <NUM> may be utilized for e-vaping system diagnostics or to indicate that recharging is in progress. The light <NUM> may also be configured such that the adult vaper may activate, deactivate, or activate and deactivate the light <NUM> for privacy.

The control circuit <NUM> may supply power to the heater <NUM> responsive to the sensor <NUM>. The control circuit <NUM> may include a time-period limiter. In at least one example embodiment, the control circuit <NUM> may include a manually operable switch for an adult vaper to initiate the heater <NUM>. The time-period of the electric current supply to the heater <NUM> may be pre-set depending on the amount of pre-vapor formulation desired to be vaporized. The control circuit <NUM> may supply power to the heater <NUM> as long heater activation conditions are met.

The e-vaping device <NUM> may be about <NUM> millimetres to about <NUM> millimetres long and about <NUM> millimetres to about <NUM> millimetres in diameter. For example, the e-vaping device <NUM> may be about <NUM> millimetres long and may have a diameter of about <NUM> millimetres.

Upon completing the connection between the first section <NUM> and the second section <NUM> air may be drawn primarily into the first section <NUM> through the air inlet <NUM> in response to a draw on the mouth-end insert <NUM>. The air passes through the air inlet <NUM>, into the transverse channel <NUM> at the backside portion of the gasket <NUM> and into the air passage <NUM> of the gasket <NUM>, into the central channel <NUM>, and through the outlet <NUM> of the mouth-end insert <NUM>. If the control circuit <NUM> detects the activation conditions, the control circuit <NUM> initiates power supply to the heater <NUM>, such that the heater <NUM> heats pre-vapor formulation in the wick <NUM> to form a vapor. The vapor and air flowing through the central channel <NUM> combine and exit the e-vaping device <NUM> via the outlet <NUM> of the mouth-end insert <NUM>.

<FIG> is an enlarged view of the heater of <FIG> according to at least one example embodiment.

As shown in <FIG>, the heater <NUM> partially surrounds the wick <NUM>. The heater <NUM> includes a plurality of lobes <NUM>. A first set <NUM> of the lobes <NUM> may oppose a second set <NUM> of the lobes. The first set <NUM> of the lobes <NUM> is curled towards the second set <NUM> of the lobes <NUM>, such that the lobes <NUM> of each of the first set <NUM> and the second set <NUM> are adjacent, but are not in physical contact. In other example embodiments, the first set <NUM> and the second set <NUM> may be in physical contact (not shown). The first set <NUM> of lobes <NUM> may be about <NUM> millimetres to about <NUM> millimetre apart (for example, about <NUM> millimetres to about <NUM> millimetres, about <NUM> millimetres to about <NUM> millimetres, or about <NUM> millimetres to about <NUM>) from the second set <NUM> of lobes <NUM>. For example, the first set <NUM> of lobes <NUM> may be about <NUM> millimetres from the second set <NUM> of lobes <NUM>.

The wick <NUM> extends through the heater <NUM>, but the heater <NUM> is not coiled or wound about the wick <NUM>. The heater <NUM> may only partially surround the wick <NUM>. The wick <NUM> is inserted after forming the heater <NUM>. The wick <NUM> is rigid, which facilitates automated manufacture of the heater <NUM> and first section <NUM>.

In at least one example embodiment, the heater <NUM> may include about <NUM> to about <NUM> lobes <NUM> (for example, about <NUM> to about <NUM> or about <NUM> to about <NUM>) in each of the first set <NUM> and the second set <NUM>. Each of the lobes <NUM> may include an apex that is generally U-shaped. An inner width of the U-shaped portion of each of the lobes <NUM> may range from about <NUM> millimetres to about <NUM> millimetre apart (for example, about <NUM> millimetres to about <NUM> millimetres, about <NUM> millimetres to about <NUM> millimetres, or about <NUM> millimetres to about <NUM>). For example, a width of each of the lobes <NUM> may be about <NUM> millimetres. The inner width may be substantially uniform or may vary.

<FIG> are illustrations of a method of forming the heater of <FIG> according to at least one example embodiment.

In at least one example embodiment, as shown in <FIG>, a wire <NUM> is bent to form a first set <NUM> of lobes <NUM> and a second set <NUM> of lobes <NUM>. The number of lobes <NUM> in each set may be the same or different. Moreover, the number of lobes <NUM> in each set may vary depending on at least one of the size of the heater, the distance between adjacent lobes, or a desired heating profile. For example, a distance between adjacent lobes may range from about <NUM> millimetres to about <NUM> millimetre apart (for example, about <NUM> millimetres to about <NUM> millimetres, about <NUM> millimetres to about <NUM> millimetres, or about <NUM> millimetres to about <NUM>). For example, the distance between adjacent lobes may be about <NUM> millimetres.

In at least one example embodiment, as shown in <FIG>, the first set <NUM> of lobes <NUM> is curled towards the second set <NUM> to form a generally tubular heater having a heater channel <NUM> there through. For example, the first set <NUM> of lobes <NUM> may be rolled over a rod or mandrel having a desired outer diameter. The size of the rod or the mandrel may be chosen based on a desired inner diameter of the heater channel <NUM>. Use of a rod, mandrel, or both, helps ensure consistent heater channel <NUM> diameter from one heater to the next during manufacture.

In at least one example embodiment, as shown in <FIG>, the wick <NUM> is threaded through the heater channel <NUM>.

<FIG> is a diagram of a method of forming the heater of <FIG> according to at least one example embodiment.

In at least one example embodiment, as shown in <FIG>, the method of forming the heater of <FIG> may include bending <NUM> a wire of electrically resistive material to form a first lobe, bending <NUM> the wire to form a second lobe generally opposing the first lobe. The first lobe and the second lobe form a generally sinuously-shaped heater having a first set of lobes and a second set of lobes. A first apex of the first lobe is generally opposite a second apex of the second lobe. The bending step <NUM> may also include bending the wire to form a third lobe having a third apex, bending the wire to form a fourth lobe having a fourth apex, and bending the lobe to form a fifth lobe having a fifth apex. The third apex and the fifth apex are in the first set of lobes. The second apex and the fourth apex are in the second set of lobes.

Each of the first lobe and the second lobe may be generally U-shaped. In other example embodiments, each of the first lobe and the second lobe may be generally V-shaped or any other desired configured. The first lobe and the second lobe form a generally sinuously-shaped heater having a first set of lobes including the first lobe and a second set of lobes including the second lobe. The first lobe may be in the first set and the second lobe may be in the second set. The method may include forming additional lobes in each of the first and second sets.

In at least one example embodiment, the method also includes curling <NUM> the first set of lobes towards the second set of lobes to form a generally tubular heater having a channel there through.

In at least one example embodiment, the bending <NUM> and the bending <NUM> may include forming additional lobes of at least one of the first set and the second set. The method also includes threading a wick through the channel.

In at least one example embodiment, once curled, the first set of lobes is not in physical contact with the second set of lobes and the first apex of the first lobe is offset from the second apex of the second lobe. In other example embodiments, the first set of lobes may physically contact the second set of lobes.

Claim 1:
A method of making a heater assembly for an e-vaping device, the method comprising:
bending a wire (<NUM>) to form a generally sinuous-shaped wire having a first set of lobes (<NUM>) and a second set of lobes (<NUM>); and
curling the first set of lobes (<NUM>) towards the second set of lobes (<NUM>) over at least one of a rod and mandrel to form a curled heater (<NUM>) having an opening therethrough; and
threading a wick (<NUM>) through the opening in the heater (<NUM>).