Aerosol-generating device and aerosol delivery system

Abstract

An aerosol-generating device for generating an inhalable aerosol from an aerosol-forming substrate is provided. The aerosol-generating device includes a lithium ion battery pack. The battery pack includes an electrolyte and at least one pair of electrodes. The electrode pairs are spaced apart from each other in the electrolyte. One of the electrode pairs defines the anode and contains an anode active material. The other electrode of the pair of electrodes defines the cathode and contains a cathode active material. The electrolyte includes a halogenated carbonate. Also provided is an aerosol delivery system comprising such an aerosol-generating device and an aerosol-generating article comprising an aerosol-forming substrate wherein the aerosol-generating device is configured to receive the aerosol-generating article.

Description

[0001] The present disclosure relates to aerosol generating devices and aerosol delivery systems.

[0002] Aerosol generating devices configured to generate aerosols from aerosol-forming substrates (such as tobacco-containing substrates) are known in the art. In order to provide portability, it is known that such aerosol generating devices include their own onboard power supplies, such as battery packs. It is known that such aerosol generating devices use heat as a mechanism for emitting volatile compounds from aerosol-forming substrates, wherein the battery pack provides the electric energy required for driving the heating process. The temperature required for emitting volatile compounds from aerosol-forming substrates may exceed 300 degrees Celsius. In the case where the aerosol-forming substrate is in liquid form, it is also known that aerosols are generated by contacting the substrate with a vibrating membrane, wherein the battery pack provides the energy required for generating a drive signal that causes vibration. The use process of consumable aerosol-generating articles containing aerosol-forming substrates is limited, typically about a few minutes. Whether using heat or vibration as a mechanism for generating aerosols from aerosol-forming substrates, the battery pack for providing the electric energy required for driving the aerosol generation process needs to deliver a large amount of energy in a short time. It is also desirable that the battery pack has a capacity sufficient to meet the energy demand of the aerosol generating device in at least one use process. Portable aerosol generating devices may also be used in a variety of different environments and temperatures. Low temperature environments are known to adversely affect the performance of known battery packs.

[0003] It would therefore be desirable to provide an aerosol generating device having an improved battery pack.

[0004] According to a first aspect of the present disclosure, there is provided an aerosol generating device for generating an inhalable aerosol from an aerosol-forming substrate. The aerosol generating device comprises a lithium ion battery pack. The battery pack comprises an electrolyte and at least one pair of electrodes. The electrode pairs are spaced apart from each other in the electrolyte. One electrode in the electrode pair defines an anode and comprises an anode active material. The other electrode in the electrode pair defines a cathode and comprises a cathode active material. The electrolyte comprises a halogenated carbonate.

[0005] Lithium-ion batteries are particularly suitable for aerosol generating devices due to their high energy density and low self-discharge characteristics. The use of halogenated carbonates may help the battery have improved performance at low temperatures. Preferably, the battery may be a rechargeable battery. In the case where the battery is rechargeable, the use of halogenated carbonates may help the battery have an improved cycle life. "Improved cycle life" means that after a predetermined number of charging cycles, the battery retains a higher maximum capacity (as a percentage of the initial capacity of the battery in a "new" state) than a battery without the halogenated carbonate. "Charge cycle" means the period of use of a battery from full charge to full discharge and then full charge again; the term "charge / discharge cycle" may be used instead of the term "charge cycle". When referring to the capacity of a battery, the term "capacity" is a measure of the charge stored by the battery; the capacity is usually expressed in ampere-hours (Ah).

[0006] The electrode pairs and electrolyte may form components of discrete cells of a battery. A battery may include a single cell or a plurality of cells.

[0007] The halogenated carbonate may include one or more of fluoroethylene carbonate (FEC), difluoroethylene carbonate (DFEC), trifluoropropylene carbonate (TFPC), 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolane-2-one (HFEEC), 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolane-2-one (NFPEC), bis(2,2,2-trifluoroethyl) carbonate (TFEC), and 2,2,3,4,4,4-hexafluorobutylmethyl carbonate (HFBMC). Advantageously, the halogenated carbonate may include or consist of fluoroethylene carbonate (FEC). As will be discussed in more detail in the specific description, it has been found that using FEC as a constituent of the electrolyte provides an improved life cycle for the battery pack compared to a battery pack that is identical in all respects except that there is no FEC in the electrolyte.

[0008] The halogenated carbonate may be present in the electrolyte at a concentration of 0.05 wt % to 15 wt % of the electrolyte, or between 0.05 wt % to 10 wt % of the electrolyte, or between 0.05 wt % to 5 wt % of the electrolyte, or between 0.1 wt % to 2 wt % of the electrolyte.

[0009] Advantageously, the electrolyte may include a lithium salt. The lithium salt may serve as a lithium ion source for the battery. The lithium salt may include one or more of LiPF6, LiBF4, LiSbF6, LiAsF6, LiClO4, LiCF3SO3, LiN(SO2CF3)2, LiN(SO2C2F5)2, LiC(SO2CF3)3, LiN(SO3CF3)2, LiC4F9SO3, LiAlO4, LiAlCl4, LiCl and LiI. Preferably, the lithium salt may include or consist of LiPF6. In addition to the lithium salt, the electrolyte may also include a solvent. The solvent serves as a medium for transferring ions associated with the electrochemical reactions that occur in the battery during use. The solvent may be an aqueous solvent or a non-aqueous solvent. LiPF6 has the characteristics of being dissolved in a solvent and having high ionic conductivity. The solvent may include a non-aqueous organic solvent, the non-aqueous organic solvent including one or more of propylene carbonate (PC), ethylene carbonate (EC) and ethyl methyl carbonate (EMC).

[0010] The anode active material may comprise one or more of carbon, an allotrope of carbon, lithium titanate oxide, and silicon. Preferably, the allotrope of carbon comprises or consists of graphite. The graphite may be natural graphite or synthetically produced. Graphite is preferred as the anode active material because it has high electrical conductivity and the ability to reversibly place lithium ions between its constituent layers, and this ability is maintained after thousands of charging cycles.

[0011] The anode may also include an anode current collector. A coating comprising an anode active material may be applied to the anode current collector. The coating may be applied to the anode current collector by a baking operation. The anode current collector may include copper. Alternatively, the anode current collector may include nickel. The anode current collector may be in the form of a foil. The anode current collector may have a mesh configuration.

[0012] The cathode active material may include one or more of lithium iron phosphate, lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide and lithium sulfur. Preferably, the cathode active material includes or consists of lithium iron phosphate. Lithium iron phosphate has the characteristics of thermal stability and long cycle life.

[0013] The cathode may also include a cathode current collector. A coating comprising a cathode active material may be applied to the cathode current collector. The coating may be applied to the cathode current collector by a baking operation. The cathode current collector may include aluminum. In a similar manner to the anode current collector, the cathode current collector may be in the form of a foil and / or have a mesh configuration.

[0014] The coating applied to the anode current collector and the coating applied to the cathode current collector may each further include a binder, a conductive agent and a stabilizer. The binder, the conductive agent and the stabilizer may be mixed with a solvent, and the solvent may be aqueous or non-aqueous. The solvent may include one or more of N-methyl-2-pyrrolidone (NMP), dimethylformamide (DMF), dimethylacetamide, N,N-dimethylaminopropylamine, ethylene oxide and tetrahydrofuran (THF).

[0015] The binder can help to mix the components of the coating into a paste or slurry. The binder can also help to adhere the coating material to the anode or cathode current collector. The binder can include polyvinylidene fluoride (PVDF), polyhexafluoropropylene-polyvinylidene fluoride copolymer, poly (vinyl acetate), polyvinyl alcohol, polyethylene oxide (PEO), polyvinyl pyrrolidone (PVP), alkylated polyethylene oxide, polyvinyl ether (PVE), poly (methyl methacrylate) (PMMA), poly (ethyl acrylate), polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyacrylonitrile (PAN), polyvinyl pyridine, styrene-butadiene rubber (SBR) and acrylonitrile-butadiene rubber One or more. The binder can be present in the corresponding coating at a concentration of 0.1% to 30% by weight of the coating or preferably 1% to 10% by weight of the coating.

[0016] The conductive agent may include one or more of a graphite agent, a carbon black agent, a metal and a metal compound agent. In the case where the conductive agent includes a graphite agent, the graphite agent may include one or more of artificial graphite and natural graphite. In the case where the conductive agent includes a carbon black agent, the carbon black agent may include one or more of acetylene black, ketjen black, denka black, thermal black and channel black. In the case where the conductive agent includes a metal or metal compound agent, the metal or metal compound agent may include one or more of Sn, SnO2, SnPO4, TiO2, KTiO3, LaSrCoO3 and LaSrMnO3. The conductive agent may be present in the coating at a concentration of 0.1 wt % to 10 wt % of the coating. In terms of energy density per unit weight, it may be beneficial to limit the concentration of the conductive agent to no more than 10 wt % of the coating. Maintaining the concentration of the conductive agent at not less than 0.1 wt % of the coating may be beneficial to enhance the electrochemical properties of the coating.

[0017] The stabilizer may include one or more of carboxymethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose. The stabilizer may be selected to adjust the viscosity of the anode active material / cathode active material slurry for forming the coating.

[0018] Preferably, the battery pack may also include a permeable barrier configured to allow lithium ions to pass therethrough, the permeable barrier being located in the electrolyte between the anode and cathode. The permeable barrier helps prevent short circuits between the anode and cathode while also allowing passage of ionic charge carriers between the anode and cathode during the use of the battery pack. Conveniently, the permeable barrier is formed by a polymer material. The permeable barrier may include one or more layers. The permeable barrier may have a porous structure. The permeable barrier may be formed by any one or more of a multilayer membrane, a microporous membrane, a woven fabric, and a nonwoven fabric. The material selected for the permeable barrier will preferably be a material that does not chemically react with the electrolyte and / or ions released from the anode and cathode during the use of the battery pack.

[0019] In an advantageous embodiment, the halogenated carbonate may comprise fluoroethylene carbonate (FEC). Preferably, the cathode active material may comprise lithium iron phosphate. Preferably, the electrolyte may comprise LiPF6.

[0020] Conveniently, the cathode active material may comprise one or more of lithium iron phosphate, lithium nickel manganese cobalt oxide and lithium cobalt oxide.The anode active material may comprise graphite.

[0021] The battery pack may provide power to support the function of the aerosol generating device to generate an inhalable aerosol from an aerosol-forming substrate.

[0022] In the case of using heating of an aerosol-forming substrate to generate an aerosol from the substrate, the aerosol generating device may also include an electric heating device and control electronics configured to control the supply of energy from a battery pack to the heating device. The heating device may take various forms. In one example, the electric heating device may include a resistive heating element. In another example, the electric heating device may include an inductor configured to induce eddy currents in a susceptor. The susceptor may form part of the heating device. Alternatively, the susceptor may form part of an aerosol-generating article for use with the aerosol generating device, the article containing the aerosol-forming substrate. The susceptor may be embedded in the aerosol-forming substrate.

[0023] In the case where vibration of the membrane is used to generate an aerosol from a substrate, the aerosol generating device may further comprise a membrane for releasing an aerosol from an aerosol-forming substrate by vibration of the membrane. The actuator may be coupled to the membrane. The aerosol generating device may further comprise control electronics configured to control the supply of energy from the battery pack to the actuator to drive the vibration of the membrane.

[0024] Preferably, the aerosol-generating device is configurable to receive an aerosol-generating article comprising an aerosol-forming substrate.

[0025] Preferably, the aerosol generating device is configured in size and mass to be hand-held.Conveniently, the aerosol generating device is generally elongate; for example, the aerosol generating device may be generally cylindrical.

[0026] According to another aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol generating device according to any of the above variations. The aerosol delivery system may further comprise an aerosol generating article comprising an aerosol-forming substrate. The aerosol generating device may be configured to receive the aerosol generating article.

[0027] As used herein, the term "aerosol generating device" is used to describe a device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol. Preferably, the aerosol generating device is a smoking device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol that can be inhaled directly into the lungs of a user through the user's mouth. The aerosol generating device may be a holder for a smoking article.

[0028] Preferably, the aerosol-generating article is a smoking article that generates an aerosol that is directly inhalable into the smoker's lungs through the smoker's mouth. More preferably, the aerosol-generating article is a smoking article that generates a nicotine-containing aerosol that is directly inhalable into the user's lungs through the user's mouth.

[0029] As used herein, the term "aerosol-forming substrate" means a substrate consisting of or comprising an aerosol-forming material which is capable of releasing volatile compounds to generate an aerosol when heated.

[0030] As used herein, the term "aerosol-forming material" refers to a material that is capable of releasing volatile compounds to generate an aerosol when heated. The aerosol-forming substrate may comprise or consist of an aerosol-forming material.

[0031] As used herein, the terms "upstream" and "downstream" are used to describe the relative position of elements or portions of elements of a heated aerosol-generating article relative to the direction in which a user draws on the aerosol-generating article during use of the aerosol-generating article.

[0032] Preferably, the aerosol-forming substrate is a solid aerosol-forming substrate. However, the aerosol-forming substrate may comprise both a solid component and a liquid component. Alternatively, the aerosol-forming substrate may be a liquid aerosol-forming substrate.

[0033] Preferably, the aerosol-forming substrate comprises nicotine. More preferably, the aerosol-forming substrate comprises tobacco. Alternatively or in addition, the aerosol-forming substrate may comprise a tobacco-free aerosol-forming material.

[0034] If the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate may include, for example, one or more of a powder, granules, pellets, shreds, strips, ribbons or sheets comprising one or more of herb leaves, tobacco leaves, tobacco ribs, expanded tobacco and homogenized tobacco.

[0035] Optionally, the solid aerosol-forming substrate may contain tobacco volatile flavor compounds or non-tobacco volatile flavor compounds, which are released when the solid aerosol-forming substrate is heated. The solid aerosol-forming substrate may also contain one or more capsules, which for example include additional tobacco volatile flavor compounds or non-tobacco volatile flavor compounds, and such capsules may melt during the heating of the solid aerosol-forming substrate.

[0036] Alternatively, the solid aerosol-forming substrate can be arranged on or embedded in a heat-stable carrier. The carrier can take the form of a powder, granule, pellet, fragment, filament, strip or sheet. The solid aerosol-forming substrate can be deposited on the surface of the carrier in the form of, for example, a sheet, foam, gel or slurry. The solid aerosol-forming substrate can be deposited on the entire surface of the carrier, or alternatively, can be deposited in a certain pattern to provide uneven fragrance delivery during use.

[0037] In preferred embodiments, the aerosol-forming substrate comprises homogenised tobacco material.As used herein, the term "homogenised tobacco material" refers to material formed by agglomerating particulate tobacco.

[0038] Preferably, the aerosol-forming substrate comprises a gathered sheet of homogenised tobacco material. As used herein, the term "sheet" refers to a laminar element whose width and length are significantly greater than its thickness. As used herein, the term "gathered" is used to describe a sheet that is rolled, folded or compressed or tightened substantially transversely to the longitudinal axis of the aerosol-generating article.

[0039] Preferably, the aerosol-forming substrate comprises an aerosol former. As used herein, the term "aerosol former" is used to describe any suitable known compound or mixture of compounds that facilitates the formation of an aerosol in use and is substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article.

[0040] Suitable aerosol formers are known in the art and include, but are not limited to: polyols such as propylene glycol, triethylene glycol, 1,3-butylene glycol and glycerol; esters of polyols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Preferred aerosol formers are polyols or mixtures thereof, for example propylene glycol, triethylene glycol, 1,3-butylene glycol and most preferably glycerol.

[0041] The aerosol-forming substrate may comprise a single aerosol-forming agent. Alternatively, the aerosol-forming substrate may comprise a combination of two or more aerosol-forming agents.

[0042] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0043] Example Ex1: An aerosol generating device for generating an inhalable aerosol from an aerosol-forming substrate, the aerosol generating device comprising:

[0044] Lithium-ion battery pack;

[0045] wherein the battery comprises an electrolyte and at least one pair of electrodes spaced apart from one another in the electrolyte, one electrode of the pair defining an anode and containing an anode active material, and the other electrode of the pair defining a cathode and containing a cathode active material;

[0046] The electrolyte includes a halogenated carbonate.

[0047] Example Ex2: An aerosol generating device according to Ex1, wherein the halogenated carbonate comprises one or more of fluoroethylene carbonate, difluoroethylene carbonate, trifluoropropylene carbonate, 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolan-2-one, 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolan-2-one, bis(2,2,2-trifluoroethyl) carbonate and 2,2,3,4,4,4-hexafluorobutyl methyl carbonate.

[0048] Example Ex3: An aerosol generating device according to any one of Ex1 or Ex2, wherein the halogenated carbonate is present in the electrolyte at a concentration of 0.05 wt % to 15 wt % of the electrolyte, or between 0.05 wt % and 10 wt % of the electrolyte, or between 0.05 wt % and 5 wt % of the electrolyte, or between 0.1 wt % and 2 wt % of the electrolyte.

[0049] Example Ex4: An aerosol generating device according to any one of Ex1 to Ex3, wherein the electrolyte comprises a lithium salt.

[0050] Example Ex5: An aerosol generating device according to Ex4, wherein the lithium salt comprises one or more of LiPF6, LiBF4, LiSbF6, LiAsF6, LiClO4, LiCF3SO3, LiN(SO2CF3)2, LiN(SO2C2F5)2, LiC(SO2CF3)3, LiN(SO3CF3)2, LiC4F9SO3, LiAlO4, LiAlCl4, LiCl and LiI.

[0051] Example Ex6: An aerosol generating device according to any one of Ex1 to Ex5, wherein the anode active material comprises one or more of carbon, an allotrope of carbon, lithium titanate oxide, and silicon.

[0052] Example Ex7: An aerosol generating device according to Ex6, wherein the allotrope of carbon comprises graphite.

[0053] Example Ex8: An aerosol generating device according to any one of Ex1 to Ex7, wherein the anode further comprises an anode current collector, wherein a coating comprising the anode active material is applied to the anode current collector.

[0054] Example Ex9: An aerosol generating device according to Ex8, wherein the anode current collector comprises copper.

[0055] Example Ex10: An aerosol generating device according to any one of Ex1 to Ex9, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide and lithium sulfur.

[0056] Example Ex11: An aerosol generating device according to any one of Ex1 to Ex10, wherein the cathode further comprises a cathode current collector, wherein a coating comprising the cathode active material is applied to the cathode current collector.

[0057] Example Ex12: An aerosol generating device according to Ex11, wherein the cathode current collector comprises aluminum.

[0058] Example Ex13: An aerosol generating device according to any one of Ex8 or Ex11, wherein the coating applied to the anode current collector and the coating applied to the cathode current collector further comprise a binder, a conductive agent and a stabilizer.

[0059] Example Ex14: An aerosol generating device according to Ex13, wherein the binder comprises one or more of polyvinylidene fluoride, polyhexafluoropropylene-polyvinylidene fluoride copolymer, poly(vinyl acetate), polyvinyl alcohol, polyethylene oxide, polyvinyl pyrrolidone, alkylated polyethylene oxide, polyethylene ether, poly(methyl methacrylate), poly(ethyl acrylate), polytetrafluoroethylene, polyvinyl chloride, polyacrylonitrile, polyvinyl pyridine, styrene-butadiene rubber and acrylonitrile-butadiene rubber.

[0060] Example Ex15: An aerosol generating device according to Ex14, wherein the binder is present in the respective coating at a concentration of 0.1 wt % to 30 wt % of the coating, or 1 wt % to 10 wt % of the coating.

[0061] Example Ex16: An aerosol generating device according to any one of Ex13 to Ex15, wherein the conductive agent comprises one or more of a graphite agent, a carbon black agent, a metal, and a metal compound agent.

[0062] Example Ex17: An aerosol generating device according to Ex16, wherein the graphite agent comprises one or more of artificial graphite and natural graphite.

[0063] Example Ex18: An aerosol generating device according to any one of Ex16 or Ex17, wherein the carbon black agent comprises one or more of acetylene black, Ketjen black, Denka black, thermal black and channel black.

[0064] Example Ex19: An aerosol generating device according to any one of Ex16 to Ex18, wherein the metal or metal compound agent comprises one or more of Sn, SnO2, SnPO4, TiO2, KTiO3, LaSrCoO3 and LaSrMnO3.

[0065] Example Ex20: An aerosol generating device according to any one of Ex16 to Ex19, wherein the conductive agent is present in the coating at a concentration of 0.1 wt % to 10 wt % of the coating.

[0066] Example Ex21: An aerosol generating device according to any one of Ex1 to Ex20, wherein the battery pack further comprises a permeable barrier configured to allow lithium ions to pass therethrough, the permeable barrier being located in the electrolyte between the anode and the cathode.

[0067] Example Ex22: An aerosol generating device according to Ex1, wherein the halogenated carbonate comprises fluoroethylene carbonate, preferably wherein the cathode active material comprises lithium iron phosphate.

[0068] Example Ex23: An aerosol generating device according to Ex22, wherein the electrolyte comprises LiPF6.

[0069] Example Ex24: An aerosol generating device according to any one of Ex22 or Ex23, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel manganese cobalt oxide, and lithium cobalt oxide.

[0070] Example Ex25: An aerosol generating device according to any one of Ex22 to Ex24, wherein the anode active material comprises graphite.

[0071] Example Ex26: An aerosol generating device according to any one of Ex1 to Ex25, wherein the lithium-ion battery is a rechargeable battery.

[0072] Example Ex27: An aerosol generating device according to any one of Ex1 to Ex26, wherein the aerosol generating device further comprises:

[0073] Electrically powered heating devices; and

[0074] Control electronics are configured to control the supply of energy from the battery pack to the heating device.

[0075] Example Ex28: An aerosol generating device according to Ex27, wherein the electric heating device comprises a resistive heating element.

[0076] Example Ex29: An aerosol generating device according to Ex27, wherein the electrically powered heating device comprises an inductor configured to induce eddy currents in the susceptor.

[0077] Example Ex30: An aerosol generating device according to Ex29, wherein the electric heating device further comprises a susceptor.

[0078] Example Ex31: An aerosol generating device according to any one of Ex1 to Ex30, wherein the aerosol generating device further comprises:

[0079] a membrane for releasing an aerosol from an aerosol-forming substrate by vibration of the membrane;

[0080] an actuator coupled to the membrane; and

[0081] Control electronics configured to control the supply of energy from the battery pack to the actuator to drive vibration of the membrane.

[0082] Example Ex32: An aerosol-generating device according to any one of Ex1 to Ex31, wherein the aerosol-generating device is configured to receive an aerosol-generating article comprising an aerosol-forming substrate.

[0083] Example Ex33: An aerosol delivery system comprising an aerosol generating device according to any one of Ex1 to Ex32 and an aerosol generating article comprising an aerosol-forming substrate, wherein the aerosol generating device is configured to receive the aerosol generating article.

[0084] Several examples will now be further described with reference to the accompanying drawings, in which:

[0085] Figure 1 illustrates a schematic diagram of an aerosol generating device and an aerosol delivery system according to a first embodiment of the present disclosure;

[0086] Figure 2 illustrates a schematic diagram of an aerosol generating device and an aerosol delivery system according to a second embodiment of the present disclosure;

[0087] Figure 3 illustrates a schematic diagram of an aerosol generating device and an aerosol delivery system according to a third embodiment of the present disclosure;

[0088] Figure 4 A schematic diagram of a lithium-ion battery pack according to the present disclosure is shown, which is suitable for use in Figures 1 to 3 an aerosol generating device;

[0089] Figure 5 For use as a battery pack (such as Figure 4 Schematic diagram of the chemical structures of seven different halogenated carbonates that are additives to the electrolyte of the battery pack shown in FIG.

[0090] Figure 6 A graph showing the maximum capacity of lithium-ion batteries containing fluoroethylene carbonate (FEC) and corresponding batteries without FEC as a function of the number of charge cycles is provided.

[0091] Figure 1 An exemplary aerosol generating device 10 is shown. The aerosol generating device 10 is a handheld aerosol generating device and has an elongated shape in the form of a substantially cylindrical shape defined by a housing 11. The housing 11 houses a lithium-ion battery pack 12, control electronics 13, and an electrically powered heating element 14. A blind cavity 15 is located at a proximal end 16 of the housing 11 for receiving an aerosol generating article 20. The heating element 14 extends longitudinally along the cavity from a closed end 17 of the cavity 15. The heating element 14 is a resistive heating element. The combination of the aerosol generating device 10 and the aerosol generating article 20 forms an aerosol delivery system 100.

[0092] The aerosol-generating article 20 has the form of a cylindrical strip formed by a combination of an aerosol-forming substrate 21 and a filter element 22. The aerosol-forming substrate 21 and the filter element 22 are axially aligned and enclosed in a wrapper 23 of cigarette paper. The aerosol-forming substrate 21 is a solid aerosol-forming substrate containing tobacco. However, in alternative embodiments, the aerosol-forming substrate 21 may be a liquid aerosol-forming substrate instead or formed by a combination of a liquid and a solid aerosol-forming substrate. The filter element 22 acts as a mouthpiece for the aerosol-generating article 20. The aerosol-generating article 20 has a diameter substantially equal to the diameter of the cavity 15 of the device 10 and has a length that is longer than the depth of the cavity. When the aerosol-generating article 20 is received in the cavity 15 of the device 10, the portion of the article containing the filter element 22 extends outside the cavity and can be smoked by the user in a manner similar to a conventional cigarette.

[0093] The lithium-ion battery pack 12 acts as a power source to support the operation of the aerosol generating device 10. The control electronics 13 is configured to control the supply of energy from the battery pack 12 to the resistive heating element 14 during use of the device 10 within the use process. The control electronics 13 includes a memory module 13a or is connected to the memory module. In use, the control electronics 13 controls the supply of energy from the lithium-ion battery pack 12 to the resistive heating element 14 according to the instructions and data stored in the memory module 13a. The memory module 13a contains instructions and data that manage when power is supplied from the battery pack 12 to the heating element 14 and the duration of power supplied from the battery pack to the heating element. The instructions and data may include a target thermal curve for the heating element 14 within the use process. The target thermal curve defines a target operating temperature of the heating element 14. The target operating temperature may be defined as a function of the time elapsed during a given use process, or as a function of the number of puffs applied to the device 10 during a given use process, or a combination thereof. The duration of a use session may be defined by the first occurrence of a use session that has lasted for a predetermined maximum duration and a number of puffs applied to the aerosol-generating article 20 that has reached a predetermined maximum number of applied puffs. For example, the predetermined maximum duration is 6 minutes and the predetermined maximum number of applied puffs is 14.

[0094] Figure 2 Shows Figure 1 An alternative embodiment of the aerosol generating device 10. Figure 1 The resistive heating element 14 of the device 10, Figure 2The aerosol generating device 10 of the embodiment of the present invention has an induction coil 141 disposed within the housing 11 and surrounding a tubular wall that defines the cavity 15. For the illustrated embodiment, the susceptor 241 is embedded within the aerosol-forming substrate 21 of the aerosol-generating article 20. However, in an alternative embodiment, the susceptor may instead form part of the aerosol generating device 10; for example, the susceptor may define the tubular wall of the cavity 15. In use, the susceptor 241 is embedded within the aerosol-forming substrate 21 of the aerosol-generating article 20. Figure 1 In a manner similar to the method described in the embodiment of the present invention, the control electronics 13 controls the supply of energy from the lithium-ion battery pack 12 to the induction coil 141 according to the instructions and data stored in the memory module 13a. When the aerosol generating article 20 is fully inserted into the cavity 15, the susceptor 241 is located within the induction coil 141. The current passing through the induction coil 141 induces eddy currents, which pass through and thus heat the susceptor 241.

[0095] Figure 3 Shows Figure 1 and Figure 2 An alternative embodiment of a heat-related aerosol generating device. Figure 3 The aerosol generating device 10 generates an aerosol from an aerosol-forming substrate by vibration of a membrane in contact with the substrate rather than by heating of the substrate. Figure 1 and Figure 2 The aerosol generating device 10 is the same as that of Figure 3The aerosol generating device 10 has a housing 11, which contains a lithium-ion battery pack 12 and a control electronic device 13. The housing 11 has a first housing portion 11a and a second housing portion 11b. The first housing portion 11a is in the form of a cylindrical tube and is connected to the second housing portion 11b. The second housing portion 11b defines a mouthpiece of the aerosol generating device 10, and an opening is provided at one end of the mouthpiece. A replaceable / disposable barrel 200 is located in the housing 11. The barrel 200 contains a reservoir 201 of a liquid aerosol-forming matrix. A feed assembly 212 is fluidly connected to the barrel 200 and is located downstream of the barrel. The feed assembly 212 can be a passive structure, such as a wicking element. Alternatively, the feed assembly 212 can be an active feed assembly (such as a pump or similar assembly) powered by the battery pack 12. A vibration aerosolization module 142 is provided downstream of the feed assembly 212. The aerosolization module 142 includes an actuator assembly 142a coupled to a perforated membrane 142b. The actuator assembly 142a is coupled to the battery pack 12 via control electronics 13. In use, the control electronics 13 controls the supply of energy from the lithium-ion battery pack 12 to the actuator assembly 142a according to instructions and data stored in the memory module 13a. The control electronics 13 provides a drive signal to the actuator assembly 142a, wherein the actuator assembly causes a vibration response of the membrane 142b. The feed assembly 212 feeds a liquid aerosol-forming substrate 201 from the cartridge 200 to one side of the membrane 142b. The vibration of the membrane 142b causes the substrate 201 to be ejected through the perforated membrane and dispersed as a spray of aerosol droplets through the opening in the mouthpiece 11b - e.g. Figure 3 As shown schematically in FIG.

[0096] for Figures 1 to 3 In all three embodiments of the aerosol generating device 10, the lithium-ion battery 12 is used as an electrical energy source to facilitate the generation of an inhalable aerosol from the aerosol-forming substrate 21, 201 - whether by heating (e.g. Figure 1 and Figure 2 in) or by vibration (such as Figure 3 The aerosol generating device 10 has a size and mass that enables it to be hand-held by a user. The battery pack 12 provides a high energy level for a short, limited period of time, specifically, during a session. The battery pack 12 has only enough capacity to complete a predetermined number of sessions. Upon completion of the predetermined number of sessions, the battery pack 12 is recharged. The predetermined number of sessions may be a single session or two or more sessions.

[0097] The following paragraphs describe an exemplary configuration of the battery 12 and describe how the use of certain forms of additives in the battery's electrolyte may help enhance the battery's maximum capacity at a fully charged state over thousands of charging cycles.

[0098] Figure 4 Shown as Figures 1 to 3 Schematic diagram of the lithium-ion battery pack 12 used in the aerosol generating device 10. Figure 4 Also included is the presentation of an external circuit formed by connecting the battery pack to the control electronics 13 and other electrical loads of the aerosol generating device 10. Other electrical loads would include Figure 1 The resistance heating element 14, Figure 2 The induction coil 141 and Figure 3 The control electronics 13 and these other electrical loads are provided by the actuator assembly 142a of the vibrating aerosolization module 142. Figure 4 The reference symbol "L" indicates.

[0099] Figure 4 A single cell of the lithium-ion battery 12 is shown. The cell of the lithium-ion battery 12 has a pair of electrodes in the form of an anode 121 and a cathode 122. The anode and cathode are spaced apart from each other in an electrolyte 123. A separator 124 is located between the anode 121 and the cathode 122 in the cell. It should be understood that in other embodiments, the battery 12 may include multiple cells.

[0100] Anode 121 has anode current collector 1211 formed of copper foil. Anode current collector 1211 is coated with anode active material 1212. Anode active material 1212 is formed of graphite. Cathode 122 has cathode current collector 1221 formed of aluminum foil. Cathode current collector 1221 is coated with cathode active material 1222. Cathode active material 1222 is formed of lithium iron phosphate.

[0101] In other embodiments, the anode active material is formed of a material other than graphite, such as silicon, lithium titanate oxide, or an allotrope of carbon other than graphite. In addition, in other embodiments, the cathode active material is formed of a material other than lithium iron phosphate, such as one or more of lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide, and lithium sulfur.

[0102] The electrolyte 123 is formed of a non-aqueous organic solvent, a lithium salt and a halogenated carbonate additive. For the described embodiment, the halogenated carbonate is fluoroethylene carbonate (FEC) and the lithium salt is LiPF6, wherein FEC is present in the electrolyte at a concentration of 0.1 wt % to 2 wt % of the electrolyte. FEC is dissolved in the non-aqueous organic solvent of the electrolyte. In other embodiments, the halogenated carbonate is other than FEC, such as one or more of difluoroethylene carbonate (DFEC), trifluoropropylene carbonate (TFPC), 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolan-2-one (HFEEC), 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolan-2-one (NFPEC), bis(2,2,2-trifluoroethyl) carbonate (TFEC), and 2,2,3,4,4,4-hexafluorobutyl methyl carbonate (HFBMC). Figure 5 Schematic diagrams of six alternative forms of halogenated carbonates that can be used instead of FEC are provided. Similarly, in other embodiments, the lithium salt is other than LiPF6, such as one or more of LiBF4, LiSbF6, LiAsF6, LiClO4, LiCF3SO3, LiN(SO2CF3)2, LiN(SO2C2F5)2, LiC(SO2CF3)3, LiN(SO3CF3)2, LiC4F9SO3, LiAlO4, LiAlCl4, LiCl and LiI. In other embodiments, the concentration of FEC or other halogenated carbonates in the electrolyte is between 0.05 wt% and 15 wt% of the electrolyte, or between 0.05 wt% and 10 wt% of the electrolyte, or between 0.05 wt% and 5 wt% of the electrolyte.

[0103] When the battery is discharged (e.g., when providing power to the control electronics 13 and other electrical loads of the aerosol generating device 10 described previously), lithium ions will flow from the cathode 122 through the electrolyte 123 and the separator 124 to the anode 121 (e.g., Figure 4 In addition, the electrons flow from the anode 121 to the cathode 122 via the external circuit and its component L. When the battery pack 12 is charged, the traveling direction of the ions is reversed, that is, flowing from the anode 121 to the cathode 122.

[0104] Figure 6 The percentage of the maximum capacity of the battery (relative to its initial capacity) is shown as a function of the number of charging cycles for two different batteries, which differ only in whether they contain FEC as an additive in the electrolyte. The two batteries were manufactured as follows:

[0105] First, a mixture of lithium iron phosphate as a cathode active material, polyvinylidene fluoride (PVDF) as a binder, and carbon as a conductive agent is provided in a relative weight ratio between 94:3:3 and 96:2:2. These components are mixed together in a non-aqueous solvent N-methyl-2-pyrrolidine (NMP) to form a cathode active slurry. The slurry is then coated on an aluminum foil current collector with a thickness between 10 and 40 microns, then dried and rolled up to produce a cathode.

[0106] Secondly, a mixture of synthetic graphite as an anode active material, styrene-butadiene rubber (SBR) as a binder, and carboxymethyl cellulose as a stabilizer is provided in a relative weight ratio between 92:4:4 and 94:3:3. These components are mixed together in water to produce an anode active slurry. The slurry is then coated on a copper foil current collector having a thickness between 10 and 30 microns, and then dried and rolled to produce an anode.

[0107] Each battery pack uses an anode and a cathode made according to the above paragraph. The anode and cathode are placed in an electrolyte, wherein the electrolyte is prepared by dissolving LiPF6 in a non-aqueous organic solvent. A separator formed of polyethylene having a thickness of 7 to 12 microns is located between the anode and the cathode. For the first battery pack, 0.1 to 0.2 weight percent of fluoroethylene carbonate (FEC) is added to the electrolyte solution; the weight percentage of FEC is relative to the weight of the non-aqueous organic solvent alone. For the second battery pack, FEC is not added to the electrolyte solution.

[0108] The two battery packs were then charged at 6C / 3.65V constant current and constant voltage for 0.1 hour at 25 degrees Celsius, and then discharged at 10 to 20C pulse current and 2.55V as the lower limit voltage. "C" is the multiplier of the charge or discharge rate of the battery pack; a rate of 1C is equivalent to charging the battery pack from 0 to 100% in one hour, and a rate of 2C reaches the same charge level in half the time (i.e., 30 minutes). The above charge / discharge cycle was repeated for about 10,000 cycles, and the maximum capacity of the battery pack was calculated as a percentage of the initial capacity of the battery pack. Figure 6 A graphical representation is provided of how the introduction of FEC into the electrolyte significantly improves the maximum capacity of the battery pack after the number of charge / discharge cycles exceeds about 6,000. More specifically, when considering the percentage of maximum capacity remaining at cycle 10,560, it can be seen that the maximum capacity of the battery pack without FEC drops below 75%, while the maximum capacity of the battery pack containing FEC is still above 85% of the initial capacity of the battery pack.

[0109] The same two battery packs discussed above (one with FEC added to the electrolyte and one without) were also tested to determine if each pack could deliver 170 mAh when discharged from a fully charged state at a temperature of 5 degrees C. It was found that the pack containing FEC was able to achieve a 100% pass rate, while the pack without FEC was only able to achieve a 40% pass rate.

[0110] For the purpose of this specification and the appended claims, unless otherwise stated, all numbers representing amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed in this article. Therefore, in this article, the number "A" is understood to be "A" ± 10% of "A". In this article, the number "A" can be considered to be included in the numerical value within the general standard error of the measurement of the property modified by the number "A". In certain cases used in the appended claims, the number "A" may deviate from the percentages listed above, provided that the amount of "A" deviation will not substantially affect the basic characteristics and novel features of the invention claimed for protection. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed in this article.

Claims

1. An aerosol generating device for generating an inhalable aerosol from an aerosol-forming substrate, the aerosol generating device comprising: Lithium-ion battery pack; wherein the battery comprises an electrolyte and at least one pair of electrodes spaced apart from one another in the electrolyte, one electrode of the pair defining an anode and containing an anode active material, and the other electrode of the pair defining a cathode and containing a cathode active material; The electrolyte includes a halogenated carbonate.

2. An aerosol generating device according to claim 1, wherein the halogenated carbonate comprises one or more of fluoroethylene carbonate, difluoroethylene carbonate, trifluoropropylene carbonate, 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolan-2-one, 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolan-2-one, bis(2,2,2-trifluoroethyl) carbonate and 2,2,3,4,4,4-hexafluorobutyl methyl carbonate.

3. An aerosol generating device according to any one of claims 1 or 2, wherein the halogenated carbonate is present in the electrolyte at a concentration of 0.05 wt % to 15 wt % of the electrolyte, or between 0.05 wt % and 10 wt % of the electrolyte, or between 0.05 wt % and 5 wt % of the electrolyte, or between 0.1 wt % and 2 wt % of the electrolyte.

4. An aerosol generating device according to any one of claims 1 to 3, wherein the electrolyte comprises a lithium salt.

5. An aerosol generating device according to claim 4, wherein the lithium salt comprises one or more of LiPF6, LiBF4, LiSbF6, LiAsF6, LiClO4, LiCF3SO3, LiN(SO2CF3)2, LiN(SO2C2F5)2, LiC(SO2CF3)3, LiN(SO3CF3)2, LiC4F9SO3, LiAlO4, LiAlCl4, LiCl and LiI.

6. An aerosol generating device according to any one of claims 1 to 5, wherein the anode active material comprises one or more of carbon, an allotrope of carbon, lithium titanate oxide and silicon.

7. An aerosol generating device according to claim 6, wherein the carbon allotrope comprises graphite.

8. An aerosol generating device according to any one of claims 1 to 7, wherein the anode further comprises an anode current collector, wherein a coating comprising the anode active material is applied to the anode current collector.

9. An aerosol generating device according to claim 8, wherein the anode current collector comprises copper.

10. An aerosol generating device according to any one of claims 1 to 9, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide and lithium sulfur.

11. An aerosol generating device according to claim 1, wherein the halogenated carbonate comprises fluoroethylene carbonate, preferably wherein the cathode active material comprises lithium iron phosphate.

12. An aerosol generating device according to claim 11, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel manganese cobalt oxide and lithium cobalt oxide.

13. An aerosol generating device according to any one of claims 1 to 12, wherein the lithium ion battery is a rechargeable battery.

14. An aerosol-generating device according to any one of claims 1 to 13, wherein the aerosol-generating device is configured to receive an aerosol-generating article comprising an aerosol-forming substrate.

15. An aerosol delivery system comprising an aerosol generating device according to any one of claims 1 to 14 and an aerosol generating article comprising an aerosol-forming substrate, wherein the aerosol generating device is configured to receive the aerosol generating article.

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