Aerosol generating device power system

Abstract

An aerosol-generating device power system (300) is provided. The power system includes a first power module (104) and a second power module (106). A first voltage converter (310) is configured to be connected between the first power module and a heater component (108) of an aerosol-generating device to boost a voltage of a power flow from the first power module to the heater component. A second voltage converter (312) is connected between the second power module and the first power module.

Description

Technical Field

[0001] The present invention relates to an aerosol generating device, and more particularly to an aerosol generating device power system. Background Art

[0002] Aerosol-generating devices, such as e-cigarettes and other aerosol inhalers or vaporizers, are becoming increasingly popular consumer products.

[0003] Heating devices for vaporization or aerosolization are known in the art. Such devices typically include a heating chamber and a heater. In operation, an operator inserts the product to be aerosolized or vaporized into the heating chamber. The product is then heated with an electric heater to vaporize its components for inhalation. In some instances, the product is a tobacco product similar to a traditional cigarette. Such devices are sometimes referred to as "heat-not-burn" devices because the product is heated to the point of aerosolization without burning.

[0004] Problems faced by known aerosol-generating devices include providing efficient power management and heating. Summary of the Invention

[0005] In a first aspect, an aerosol generating device power system is provided, which includes a first power module, a second power module, a first voltage converter, and a second voltage converter, wherein the first voltage converter is configured to be connected between the first power module and a heater component of the aerosol generating device to boost the voltage of the power flow from the first power module to the heater component, and the second voltage converter is connected between the second power module and the first power module.

[0006] In this manner, by boosting the voltage from the first power module, a smaller first power module can be utilized in the power system while achieving continuous power delivery to the heater component. This, in turn, can reduce the overall size of the aerosol-generating device, including the power system. The first voltage converter allows for the use of a lower voltage, which helps stabilize power delivery and improves the quality of the aerosolization process.

[0007] Preferably, the second voltage converter is controlled by input current control.

[0008] Preferably, the second voltage converter supplies substantially constant power from each of the second power module and the first power module to the heater according to a change in the voltage of the first power module using input current control.

[0009] In this way, the second power module provides continuous power flow independent of the voltage of the first power module. This stabilizes the power system and reduces losses at the first power module as the voltage of the first power module decreases. Consequently, higher energy efficiency is achieved, especially at low voltages, helping to use more of the energy stored in the first power module and allowing for reduced component size.

[0010] Preferably, the aerosol generating device power system is connectable to an auxiliary power supply, and input current control at the second voltage converter controls power flow from the auxiliary power supply to the heater to perform the aerosolisation process.

[0011] In this way, by using input current control at the second voltage converter, other power sources (including external power supplies) can be used instead of the second power module. This increases the flexibility of the power system.

[0012] Preferably, the second power module is configured to recharge the first power module.

[0013] In this way, the first power module can power the aerosolization process for a longer period of time and / or be fully charged for a subsequent aerosolization process. This improves power usage in the power system.

[0014] Preferably, the second voltage converter is configured to boost a voltage of power flowing from the second power module to the first power module when the first power module is recharged from the second power module.

[0015] In this way, a lower voltage second power module can be used.

[0016] Preferably, the first power module is a supercapacitor module including one or more supercapacitors, or the first power module is a battery module including one or more high-power batteries.

[0017] A high-power battery is a battery with a high discharge rate that can provide high power.

[0018] Preferably, the first power module may include one or more electrochemical double layer capacitors.

[0019] Preferably, the first power module is capable of providing a high power / discharge rate, for example greater than or equal to 10 W / Wh, or more preferably greater than or equal to 40 W / Wh. A discharge rate greater than or equal to 40 W / Wh during the preheating period is particularly preferred.

[0020] In this way, energy can be quickly transferred from the first power module to the heater component by using supercapacitors or high power batteries.

[0021] Preferably, the second power module is a battery module comprising at least one battery, or wherein the second power module is a supercapacitor module comprising one or more supercapacitors, or wherein the second power module is a supercapacitor module comprising one or more hybrid supercapacitors.

[0022] In this way, high energy content can be stored in the second power module to recharge the first power module and / or power the heater component.

[0023] In a second aspect, there is provided an aerosol-generating device comprising the aerosol-generating device power system of the first aspect.

[0024] Preferably, the aerosol-generating device comprises a heating chamber configured to receive the aerosol-generating consumable and to heat the aerosol-generating consumable without burning the aerosol-generating consumable to generate the aerosol during the aerosolisation process.

[0025] In this way, the consumer can perform an aerosolization process that provides an experience similar to traditional smoking.

[0026] Preferably, the heating chamber has a substantially circular cross-section and defines a substantially cylindrically shaped cavity for receiving the aerosol-generating consumable.

[0027] In this way, an aerosol-generating rod-shaped consumable can be used for an aerosolization process that provides the operator with an experience similar to traditional smoking.

[0028] Preferably, the aerosol-generating consumable is a tobacco rod.

[0029] In this way, the tobacco rod can be used in an aerosolization process that provides the operator with an experience similar to traditional smoking.

[0030] Preferably, the heating chamber has a substantially rectangular cross-section and defines a substantially cubically shaped cavity for receiving the aerosol-generating consumable.

[0031] In this way, the heating chamber may have a compact configuration, thereby reducing the size of the entire device.

[0032] Preferably, the aerosol-generating consumable is substantially planar in shape.

[0033] In this way, the aerosol-generating substrate is compact, thereby allowing the overall device to be smaller in size.

[0034] Preferably, the aerosol-generating consumable comprises tobacco. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0036] Figure 1 is a block diagram of components of an aerosol generating device;

[0037] Figure 2 is a flow chart of the steps of the aerosolization process;

[0038] Figure 3 is a circuit diagram of the power system of the aerosol generating device;

[0039] Figure 4 is a graph of heater temperature versus time, wherein the first data set represents a first voltage converter comprising Figure 3 The heater temperature of the power system changes with time, and the second data set represents Figure 3 a temporal variation of a heater temperature of the power system excluding the first voltage converter;

[0040] Figure 5 Is the warm-up time Figure 3 A graph showing a change in a current limit value of a second voltage converter of the power system;

[0041] Figure 6A is used in the second voltage converter Figure 3 A graph showing power versus supercapacitor voltage in a power system with output current control;

[0042] Figure 6B is used in the second voltage converter Figure 3 A graph showing power versus supercapacitor voltage in a power system with input current control;

[0043] Figure 7 is a graph showing supercapacitor loss versus supercapacitor voltage;

[0044] Figure 8A yes Figure 3 a graph of heater voltage versus time for an electrical power system of FIG. 1 , wherein input current limiting is not used at the second voltage converter;

[0045] Figure 8B yes Figure 3 a graph of heater voltage versus time for a power system of FIG. 1 , wherein input current limiting is used at the second voltage converter;

[0046] Figure 9A yes Figure 3 a graph of a current measured at a second power module versus time for an electric power system of the invention, wherein input current limiting is not used at the second voltage converter;

[0047] Figure 9B yes Figure 3 a graph of a current measured at a second power module versus time of an electric power system of the invention, wherein input current limiting is used at the second voltage converter;

[0048] Figure 10A yes Figure 3 a graph of a voltage measured at a first power module versus time for an electric power system of the invention, wherein input current limiting is not used at a second voltage converter;

[0049] Figure 10B yes Figure 3 a graph of a voltage measured at a first power module versus time for an electric power system of the invention, wherein input current limiting is used at a second voltage converter;

[0050] Figure 11A yes Figure 3 a graph of a current measured at the first power module versus time for an electric power system of the invention, wherein input current limiting is not used at the second voltage converter;

[0051] Figure 11B yes Figure 3 a graph of a current measured at a first power module versus time for an electric power system of the invention, wherein input current limiting is used at a second voltage converter;

[0052] Figure 12A It is a flat graphic representation of an aerosol-generating consumable;

[0053] Figure 12B is inserted into the heating chamber Figure 12A a graphic representation of the aerosol-generating consumables; and

[0054] Figure 12C is included Figure 12B Illustration of the mouthpiece region of an aerosol-generating device with a heating chamber, the heating chamber being configured to receive Figure 12A Flat aerosol-generating consumables. DETAILED DESCRIPTION

[0055] Figure 1 A block diagram showing components of an aerosol-generating device 100 or vapour-generating device (also known as an electronic cigarette).For the purposes of this specification, it should be understood that the terms "vapour" and "aerosol" are interchangeable.

[0056] The aerosol-generating device 100 has a body portion 112 containing a controller 102, and a power system including a first power module 104 and a second power module 106. Figure 3 Discuss the power system in more detail.

[0057] Only one first power module 104 and one second power module 106 are mentioned herein; however, those skilled in the art will understand that the power system may include one or more first power modules and one or more second power modules as appropriate.

[0058] As will be described subsequently, the controller 102 is configured to control the power flow of the first power module 104 and the second power module 106 based on an operating mode of the aerosol-generating device.

[0059] The controller 102 may be at least one microcontroller unit comprising: a memory storing instructions for operating the aerosol generating device 100 , including instructions for executing selectable operating modes and instructions for controlling power flow; and one or more processors configured to execute these instructions.

[0060] In an example, the heater 108 (or heater component) is contained within the body portion 112. In such an example, Figure 1 As shown, the heater 108 is disposed in a heating chamber 110 or cavity in the body portion 112. The heating chamber 110 is accessed through an opening 110A in the body portion 112. The heating chamber 110 is arranged to receive an associated aerosol-generating consumable 114. The aerosol-generating consumable may comprise an aerosol-generating material, such as a tobacco rod comprising tobacco. The tobacco rod may be similar to a conventional cigarette. The heating chamber 110 may have a substantially cross-sectional shape, thereby defining a substantially cylindrical cavity for receiving the aerosol-generating consumable 114.

[0061] The cross-section of the heating chamber 110 is substantially equal to the cross-section of the aerosol-generating consumable 114 and its depth is such that when the associated aerosol-generating consumable 114 is inserted into the heating chamber 110, a first end portion 114A of the aerosol-generating consumable 114 reaches a bottom portion 110B of the heating chamber 110 (that is, the end portion 110B of the heating chamber 110 remote from the heating chamber opening 110A) and a second end portion 114B of the aerosol-generating consumable 114 remote from the first end portion 114A extends outwardly from the heating chamber 110. In this way, when the aerosol-generating consumable 114 is inserted into the aerosol-generating device 100, the consumer can inhale over the aerosol-generating consumable. Figure 1 In the example of , the heater 108 is arranged in the heating chamber 110 such that the aerosol-generating consumable 114 engages the heater 108 when inserted into the heating chamber 110. Figure 1In the example of FIG. 1 , the heater 108 is arranged as a tube in the heating chamber so that when the first end portion 114A of the aerosol-generating consumable is inserted into the heating chamber, the heater 108 substantially or completely surrounds the portion of the aerosol-generating consumable 114 within the heating chamber 110. The heater 108 can be a wire, such as a coiled heating wire, or a ceramic heater, or any other suitable type of heater. The heater 108 can include a plurality of heating elements arranged sequentially along the axial length of the heating chamber, and these heating elements can be independently activated (i.e., energized) in sequence.

[0062] In an alternative embodiment (not shown), the heater may be arranged as an elongated piercing member (e.g. in the form of a needle, rod or blade) within the heating chamber; in such an embodiment, the heater may be arranged to penetrate the aerosol-generating consumable and engage with the aerosol-generating material when the aerosol-generating consumable is inserted into the heating chamber.

[0063] In another alternative embodiment (not shown), the heater may be in the form of an induction heater. In this embodiment, a heating element (i.e., a susceptor) may be disposed within the consumable, and when the consumable is inserted into the heating chamber, the heating element inductively couples with an inductive element (i.e., an induction coil) within the heating chamber. The induction heater then heats the heating element via induction.

[0064] The heater 108 is arranged to heat the aerosol-generating consumable 114 to a predetermined temperature to generate an aerosol during an aerosolization process. The aerosolization process can be considered to be the process by which the device is operated to generate an aerosol from the aerosol-generating consumable 114. In the example where the aerosol-generating consumable 114 is a tobacco rod, the aerosol-generating consumable 114 comprises tobacco. The heater 108 is arranged to heat the tobacco without burning it to generate the aerosol. In other words, the heater 108 heats the tobacco to a predetermined temperature below the combustion point of the tobacco, thereby generating a tobacco-based aerosol. A skilled person will readily appreciate that the aerosol-generating consumable 114 does not necessarily need to comprise tobacco, and any other substance suitable for aerosolization (or vaporization) (particularly by heating the substance without burning it) can be used in place of tobacco.

[0065] In an alternative, the aerosol-generating consumable may be a vaporizable liquid. The vaporizable liquid may be contained in a cartridge receivable in an aerosol-generating device, or may be deposited directly into the aerosol-generating device.

[0066] The controller 102 is arranged to control the power flow of the first power module 104 and the second power module 106 based on the selected operating mode of the aerosolization process. The operating mode of the aerosolization process may include a preheating mode and a heating mode. The progression from the preheating mode to the heating mode in the aerosolization process may be determined from the Figure 2 Understand in.

[0067] In preheating mode 202, the heater 108 associated with the aerosol-generating device 100 is heated to a predetermined temperature for generating aerosol from the aerosol-generating consumable 114. The preheating phase can be considered the time during which the preheating mode is executed, for example, the time it takes for the heater 108 to reach the predetermined temperature. The preheating mode occurs during a first time period of the aerosolization process. In one example, the first time period can be a fixed predetermined time period. In other examples, the first time period can vary, corresponding to the length of time required to heat the heater 108 to the predetermined temperature.

[0068] When the heater reaches the predetermined temperature, the controller 102 ends the preheating mode 202 and controls the power system to execute the heating mode 204. In the heating mode 204, the controller 102 controls the power flow from the power system to substantially maintain the heater 108 at the predetermined temperature, thereby generating an aerosol for inhalation by the consumer. The heating phase can be considered the time during which the heating mode is executed, for example, the time during which the heater 108 aerosolizes an aerosol-generating consumable 114 (or at least a portion thereof) after the preheating phase. The controller 102 can control the power system to operate in the heating mode for a second time period during the aerosolization process. The second time period can be predetermined and stored by the controller 102.

[0069] In both preheat and heating modes, the controller 102 can control the power flow from the power system to the heater so that the power flow is pulse-width modulated power flow having one or more pulse-width modulation cycles. The pulse-width modulated power flow includes one or more pulse-width modulation (PWM) cycles (also referred to as pulse-width modulation switching cycles). A single PWM cycle or switching cycle includes one PWM cycle "on period" D and one PWM cycle "off period" 1-D. The combination of the PWM cycle on period D and the PWM cycle off period 1-D forms the total PWM cycle or switching cycle.

[0070] During the PWM-on period of a PWM cycle, power is applied to the heater; that is, the heater's power line is closed by the PWM-controlled switch. During the PWM-off period, no power is applied to the heater; that is, the heater's power line is disconnected by the PWM-controlled switch. Thus, one pulse-width modulation cycle involves switching the power between the on and off states once, so the pulse-width modulated power flow includes continuously powering the heater with power flow that rapidly switches between the PWM-on and off periods at a certain duty cycle.

[0071] The pulse-width modulation duty cycle corresponds to the on-period (D) that is a fraction of the total period of the cycle (D + (1-D)) (i.e., the combination of the "on-period" and "off-period" of the switching cycle). The pulse-width modulated power flow, comprising multiple PWM cycles, continuously powers the heater at an average power across the PWM on-period and PWM off-periods, based on the duty cycle. Controlling the duty cycle controls the amount of power delivered to the heater. A higher duty cycle of the pulse-width modulated power flow delivers a higher average power; a lower duty cycle of the pulse-width modulated power flow delivers a lower average power. That is, for a higher duty cycle, a greater portion of the cycle is the "on-period," D, compared to a lower duty cycle. In this way, by controlling the duty cycle of the pulse-width modulated power flow, careful control of the power level applied to the heater can be achieved.

[0072] In heating mode, controller 102 is configured to control the power system to apply a pulse-width modulated power flow to the heater at a first duty cycle schedule to substantially maintain the heater at a predetermined aerosol-generating temperature. In preheat mode, controller 102 is configured to control the power system to apply a pulse-width modulated power flow to the heater at a second duty cycle schedule, different from the first duty cycle schedule, to heat the heater to the aerosol-generating temperature. The second duty cycle schedule can have a higher duty cycle than the first duty cycle schedule, such that a greater amount of power is applied to the heater to quickly heat it to the predetermined temperature, while a lesser amount of power is used to maintain the heater at the predetermined temperature. The first duty cycle schedule includes one or more PWM cycles with a first duty cycle D1, and the second duty cycle schedule includes one or more PWM cycles with a second duty cycle D2. The relationship between D1 and D2 can be considered as D2 = D1*K, where K is a coefficient that is >> 1 and can be selected as per the implementation. The theoretical maximum duty cycle is 1, i.e., no off period, or close to but less than 1, i.e., with a very short off period. In an example, the first duty cycle scheme includes one or more duty cycles with a duty cycle much less than 1, and the second duty cycle scheme includes one or more duty cycles with a duty cycle close to but less than 1. In other examples, the first duty cycle scheme includes one or more duty cycles with a duty cycle << 0.5, and the second duty cycle scheme includes one or more duty cycles with a duty cycle ≥ 0.5. In another example, the first duty cycle is configured such that < 3 W is applied in heating mode, and the second duty cycle is configured such that approximately 16 W is applied in preheat mode. More generally, 2 W to 6 W may be applied during heating mode, and 10 W to 30 W may be applied during preheat mode.

[0073] Figure 3 Presented in reference Figure 1 1 is a circuit diagram of a power system 300 for use in the described aerosol-generating device, or any other suitable type of aerosol-generating device.

[0074] Figure 3 The power system 300 includes a first power module 104 and a second power module 106 .

[0075] The first power module 104 can be implemented as an ultracapacitor module including one or more ultracapacitors. Such multiple ultracapacitors can be connected in series for use in the first power module 104. Connecting multiple smaller ultracapacitors in series rather than using a single larger ultracapacitor is advantageous in allowing for greater design flexibility. In another example, the first power module 104 can be implemented as a battery module including one or more high-power batteries, such as lithium titanate (LTO) batteries, that discharge at a high power rate.

[0076] In a specific example, the first power module 104 can be implemented as an ultracapacitor module including two ultracapacitors connected in series. These ultracapacitors can be conventional ultracapacitors and can each have a voltage of 2.5V, thereby providing a total voltage of 5V to the first power module 104. In another such example, the ultracapacitors can each have a voltage of 3V, thereby providing a total voltage of 6V to the first power module 104. In another such example, the ultracapacitors can each have a voltage of 3.3V, thereby providing a total voltage of 6.6V to the first power module 104. More generally, the ultracapacitors can each have a voltage of 2.5V to 3.3V, thereby providing a total voltage of 5V to 6.6V to the first power module 104. In other examples, multiple ultracapacitors can be connected in series to meet the voltage requirements required to power the heater 108.

[0077] Due to the high power nature of such components, it is beneficial to use one or more supercapacitors or high power batteries as the first power module 104 to power the energy intensive preheating phase of the aerosolization process. This allows preheating to be achieved quickly.

[0078] The second power module 106 can be implemented as a battery module including one or more batteries. These batteries can be high-energy batteries that store a large amount of energy, such as batteries using lithium-ion technology, aluminum-ion technology, or zinc-ion technology, or any other suitable type of battery. Alternatively, the second power module 106 can be implemented as one or more hybrid supercapacitors.

[0079] In a specific example, the second power module 106 may be implemented as a battery module including a lithium-ion battery. Such a battery may have a voltage of 3.7 V.

[0080] Due to the high energy storage capacity, the use of one or more high-energy batteries or hybrid supercapacitors as the second power module 106 is beneficial for powering multiple aerosolization processes. In particular, the high energy storage capacity allows the second power module 106 to both supplement the power flow from the first power module 104 and recharge the first power module 104 (as will be discussed).

[0081] The first power module 104 may be connected to the heater 108, for example, in a parallel configuration. The heater 108 itself need not be a component of the power system 300, but rather powered by the power system 300.

[0082] The first voltage converter 310 is disposed between the first power module 104 and the heater 108. The first voltage converter 310 may be a DC / DC voltage converter having a low minimum voltage input and may be arranged to step up or boost the voltage of the first power module 104 to enable power flow from the first power module 104 to the heater 108.

[0083] If the first voltage converter 310 is not included in the power system 300, the first power module 104 may have limited usable energy content because, as the voltage drops, the required power can no longer be delivered to the heater 108. Consequently, continuous power delivery may not be possible. This may negatively impact the quality of the aerosolization process. The energy content issue can be addressed by increasing the size of the first power module 104 to have a higher energy content. However, this results in a larger aerosol-generating device, which may be disadvantageous to consumers. These issues are avoided by including the first voltage converter 310 between the first power module 104 and the heater 108 to boost the voltage of the power flow from the first power module 104 to the heater 108. In other words, the first voltage converter 310 is beneficial because, by boosting the voltage from the first power module 104, a smaller first power module 104 can be utilized in the power system while achieving continuous power delivery to the heater 108. This, in turn, can reduce the overall size of the aerosol-generating device, including the power system. The first voltage converter 310 allows the use of a lower voltage, which helps stabilize power delivery and improves the quality of the aerosolization process.

[0084] This is due to Figure 4 As shown, the figure shows a graph 400 of heater temperature 402 versus time 404, which includes a first data set 406 and a second data set 408. The first data set 406 represents the change in heater temperature over time of the power system 300 including the first voltage converter 310 (as shown in FIG. Figure 3 For comparison purposes, a second data set 408 shows the heater temperature variation over time for the same power system, but without the first voltage converter 310. With the inclusion of the first voltage converter, the heater temperature for the first data set 406 increases more quickly, reaching the target temperature of 210° C. in approximately 27.5 seconds (compared to approximately 40 seconds for the second data set 408) and stabilizing at this temperature in approximately 55 seconds (compared to approximately 85 seconds for the second data set).

[0085] Furthermore, by including the first voltage converter 310 , the warm-up time of the aerosolization process is independent of the current limit value of the second voltage converter 312 (the second voltage converter 312 will be discussed later). Figure 5Graph 500 shows preheating time 502 as a function of current limit 504 of second voltage converter 312. As can be seen, preheating time 504 remains approximately constant at around 22 seconds regardless of the varying current limit 504 of second voltage converter 312. This provides improved control during preheating, thereby improving the aerosolization process.

[0086] return Figure 3 The first power module 104 and the second power module 106 are connected to each other in the power system, for example, in a parallel configuration. The second power module 106 can be configured to charge the first power module 104.

[0087] The controller 102 can control the second power module 106 to recharge the first power module 104. The controller 102 can control the power flow from the second power module 106 to the first power module 104 after the aerosolization process to recharge the first power module 104. In this way, the first power module 104 is fully charged between the aerosolization processes to power the power-intensive preheating phase of the subsequent aerosolization process. Alternatively or additionally, the controller 102 can control the power flow from the second power module 106 to the first module during the aerosolization process. In this way, the first power module 104 is recharged during the aerosolization process so that it can power the aerosolization process for a longer time. How to achieve this control will be discussed later.

[0088] The second voltage converter 312 is disposed between the first power module 104 and the second power module 106. The second voltage converter 312 may be configured to boost the voltage of power flowing from the second power module 106 to the first power module 104 when recharging the first power module 104 from the second power module 106. The second voltage converter 312 may be a DC / DC voltage converter and may be arranged to boost or increase the voltage of the second power module 106 in order to charge the first power module 104 from the second power module 106.

[0089] When powering a heater with both the first power module 104 and the second power module 106, the first voltage converter 310 can boost the voltage of the power flow from each of the first and second power modules 104, 106. The power flow from the second power module 106 can be boosted by the second voltage converter 312 and then boosted again by the first voltage converter 310. The second power module 106 can provide constant current support. Therefore, the second voltage converter 312 controls the power flow in such a way that the input current from the second power module 106 to the second voltage converter 312 is constant. Depending on the state of the first power module 104, this can mean boosting the voltage on the second voltage converter 312 (if the first power module 104 is relatively fully loaded) or bucking the voltage (if the first power module 104 is relatively unloaded and does not require a very high current charge). The first voltage converter 310 can manage the power flow to the heater 108. A very small portion of the current from the second power module 106 can flow to the heater 108 (while the majority of the current recharges the first power module 104). The resistance of the heater 108 will increase during the aerosolization process, so the first voltage converter 310 will need to continually step up the voltage.The power delivery can be varied by varying the duty cycle (low power, low duty cycle).

[0090] The first switching device 320 (or first switch) is disposed between the power system (i.e., the first power module 104 and the second power module 106) and the heater 108. The first switching device 320 can be configured to switch power flow from the power system to the heater 108 such that power flows to the heater 108 when the first switching device 320 is in a closed state, and power does not flow to the heater 108 when the first switching device 320 is in an open state. The first switching device 320 can be used to turn off the heater 108 or to control power flow to the heater 108 using PWM to control heater temperature.

[0091] A second switching device 322 (or second switch) can optionally be disposed between the second power module 106 and the second voltage converter 312. The second switching device 322 can be configured to control the flow of power from the second power module 106 to the first power module 104 to charge the first power module 104. In instances where the second power module 106 helps power the heater 108, the second switching device 322 can also be configured to control the flow of power from the second power module 106 to the heater 108. In some instances, the second switching device 322 need not be included because, for example, size considerations of the second power module 106 and the first power module 104 mean that the second power module 106 can always support the first power module 104.

[0092] The first switching device 320 and the second switching device 322 may be transistors connected to the controller 102 ( Figure 5 not shown in A).

[0093] As already mentioned, the second power module 106 may be configured and controlled to recharge the first power module 104 .

[0094] In some examples, the second power module 106 can be controlled to recharge the first power module 104 after the aerosolization process. This can be achieved by: the controller 102 controls the first switching device 320 to be open so that power does not flow to the heater 108, and controls the second switching device 322 to be closed so that power flows from the second power module 106 to the first power module 104, thereby recharging the first power module 104.

[0095] In other examples, in addition to or instead of charging the first power module 104 between aerosolization processes, the second power module 106 may be controlled using PWM control to recharge the first power module 104 during the aerosolization process.

[0096] In a first example in which the second power module 106 charges the first power module 104 during the aerosolization process, the second power module 106 charges the first power module 104 during both the preheat mode and the heating mode. During the PWM cycle-on period of the PWM power flow to the heater 108, the first power module 104 (or both the first power module 104 and the second power module 106) powers the heater 108. During the PWM cycle-off period of the PWM power flow to the heater 108, the second power module 106 recharges the first power module 104. In a second example in which the second power module 106 charges the first power module 104 during the aerosolization process, the second power module 106 charges the first power module 104 during the heating mode, as described in the previous example. However, the second power module 106 does not charge the first power module 104 during the preheat mode. Not charging the first power module 104 during the preheat mode reduces system complexity due to the higher duty cycle used in the preheat mode.

[0097] An exemplary approach for achieving such charging during the aerosolization process can involve the controller 102, the first switching device 320, and the second switching device 322 controlling heating and charging. During the on-period of the PWM cycle of the pulse-width modulated power flow, the controller 102 controls the first switching device 320 to close and the second switching device 322 to open. In this manner, during the on-period of the PWM cycle, power flows from the first power module 104 to the heater 108, while the second power module 106 is isolated from the first power module 104 and the heater 108. During the off-period of the PWM cycle of the pulse-width modulated power flow, the controller 102 controls the first switching device 320 to open and the second switching device 322 to close. In this manner, power flows from the second power module 106 to the first power module 104 to recharge the first power module 104, while the first power module 104 is isolated from the heater 108. As such, during pulse width modulated power flow, rapid switching occurs between powering the heater 108 during the on-period of the PWM cycle and recharging the first power module 104 during the off-period of the PWM cycle.

[0098] In some examples, the heater 108 is powered by the first power module 104 only during the aerosolization process. In such examples, the second power module 106 is isolated from the heater 108 while power flows from the first power module 104 to the heater 108 (e.g., using the second switching device 322), and the first switching device 320 is controlled to switch the power flow from the first power module 104 to the heater 108. In such examples, the second power module 106 is used to recharge the first power module 104 between or during multiple aerosolization processes, as already discussed.

[0099] However, in other examples, the heater 108 can be powered by both the first power module 104 and the second power module 106 during the aerosolization process. In such examples, the second power module 106 supports the first power module 104 during the preheating phase and / or the heating phase. The second voltage converter 312 can advantageously be configured to improve the support provided by the second power module 106 to the first power module 104. This can be achieved by controlling the second voltage converter 312 using input current control (also known as input current limiting). Input current control controls the current limit at the input of the second voltage converter 312, rather than output current control, which controls the output current of the voltage converter.

[0100] To understand the beneficial effects of controlling the second voltage converter 312 by input current control compared to output current control, refer to Figure 6A and Figure 6B .exist Figure 6A and Figure 6B In the example of FIG, the first power module 104 can be considered as an ultracapacitor and the second power module 106 can be considered as a battery. However, the same teachings can apply to the first power module 104 as any other example described herein, and the second power module 106 as any other example described herein.

[0101] Controlling the second voltage converter 312 via input current control allows the second power module 106 to be a less robust or powerful energy source by design. The limitation from the input current control helps protect the second power module 106, for example, so that the second power module never draws a higher current than allowed. It also protects alternative energy sources for the second power module, such as a USB port, AA batteries, or a power adapter. The first power module 104 can be inherently more robust and powerful, and therefore it does not require such protection.

[0102] Figure 6A A graph 600A of power 602A versus supercapacitor voltage 604A is shown, where the second voltage converter 312 uses output current control. A first data set 606A corresponds to the power output of the supercapacitor (i.e., the first power module 104) as a function of the supercapacitor voltage (i.e., the first power module voltage). A second data set 608A corresponds to the power output of the second voltage converter 312 as a function of the supercapacitor voltage (i.e., the first power module voltage). If the voltage at the output of the second voltage converter 312 drops, for example due to a drop in the voltage on the battery or the second power module 106, the power also drops. The output current needs to remain constant, so P 输出 = I 输出 (constant) * V 输出 (It decreases linearly because the discharge curve of the ultracapacitor is also linear.) In this case, because some power is needed at the heater and the second power module 106 and the second voltage converter 312 cannot deliver this power, more power is drawn from the ultracapacitor or the first power module 104, resulting in a higher voltage and higher power output from the ultracapacitor or the first power module 104. This is further facilitated by the low internal resistance of the ultracapacitor.

[0103] Figure 6BGraph 600B shows power 602B versus supercapacitor voltage 604B, where input current control is used for the second voltage converter 312. A first data set 606B corresponds to the power output of the supercapacitor (i.e., the first power module 104) as a function of the supercapacitor voltage (i.e., the first power module voltage). A second data set 608B corresponds to the power output of the second voltage converter 312 as a function of the supercapacitor voltage (i.e., the first power module voltage). Due to input current control, the power output of the second voltage converter 312 (i.e., the power of the battery or second power module 106) is constant. This is because input current control forces the battery or second power module 106 to continuously support the power supply to the heater 108 by continuously providing the maximum power required by the battery or second power module 106. Consequently, the supercapacitor (i.e., the first power module) also provides a constant output, allowing the desired power to be directed to the heater 108. This stabilizes the power system and reduces losses on the supercapacitor.

[0104] Regarding reducing losses, Figure 7 A graph 700 shows supercapacitor losses 702 for a supercapacitor with an internal resistance of 10 mΩ as a function of supercapacitor voltage 704. A first data set 706 shows supercapacitor losses as a function of supercapacitor voltage when an input current control limit of 3 A is used at the second voltage converter 312. A second data set 708 shows supercapacitor losses as a function of supercapacitor voltage when an output current control limit of 2 A is used at the second voltage converter 312. As can be seen, significantly lower supercapacitor losses occur when input current control is used at the second voltage converter 312.

[0105] As a result, higher energy efficiency is achieved, especially for low voltages, helping to use more of the energy stored in the supercapacitor. This allows for a reduced supercapacitor size. Input current control allows power distribution to be independent of the supercapacitor voltage.

[0106] Further advantages of controlling the second voltage converter 312 using input current control are discussed with reference to FIG. 8 to FIG. 11 .

[0107] Figure 8A Graph 800A shows the change in heater voltage 802A over time 804A of the power system 300 if input current limiting is not used at the second voltage converter 312 . Figure 8B Graph 800B shows the change in heater voltage 802B over time 804B of the power system 300 if input current limiting is used at the second voltage converter 312. As can be seen, applying input current control does not affect the voltage across the heater 108.

[0108] Figure 9A Graph 900A shows current 902A measured at the second power module 106 of the power system 300 versus time 904A if input current limiting is not used at the second voltage converter 312 . Figure 9A Graph 900B shows how current 902B measured at the second power module 106 of the power system 300 changes over time 904B if input current limiting is used at the second voltage converter 312. As can be seen, by applying input current limiting, the current level of the second power module 106 is more consistent and can be controlled to not exceed a maximum specified current range. This places less stress on the second power module 106, thereby increasing its life expectancy.

[0109] Figure 10A Graph 1000A shows voltage 1002A measured at first power module 104 of power system 300 versus time 1004A if input current limiting is not used at second voltage converter 312 . Figure 10B Graph 1000B shows the voltage 1002B measured at the first power module 104 of the power system 300 over time 1004B if input current limiting is used at the second voltage converter 312. By applying input current limiting, a lower voltage drop is seen across the first power module 104. This results in lower losses and improved stability.

[0110] Figure 11A Graph 1100A shows current 1102A measured at the first power module 104 of the power system 300 versus time 1104A if input current limiting is not used at the second voltage converter 312 . Figure 11B Graph 1100B shows the current 1102B measured at the first power module 104 of the power system 300 over time 1104B if input current limiting is used at the second voltage converter 312. As can be seen, by applying input current limiting, the current at the first power module 104 is more consistent, thereby placing less stress on the first power module 104.

[0111] Therefore, the benefit of the second voltage converter 312 is twofold. First, when charging the first power module 104, the second voltage converter 312 can advantageously boost the voltage of the power flow from the second power module 106 to the first power module 104, thereby allowing the use of a lower voltage second power module 106. Second, by input-controlling the power flow from the second power module 106 at the second voltage converter 312, losses and stresses at the first power module 104 are reduced, and stresses at the second power module 106 are reduced.

[0112] The use of input current control also allows for the use of an external or auxiliary power source, for example, if the energy level at the second power module 106 is depleted, or in place of the second power module 106. In a first example, a low-cost power adapter with a low maximum current (e.g., up to 3A, 5V) can be used as an external power source to perform the aerosolization process without requiring power from the second power module 106. In a second example, a USB connector, such as from a power bank, a car cigarette lighter socket, a portable PC, a stationary PC, etc., can be used in a manner similar to the first example. In a third example, primary batteries (e.g., three or four AA batteries) can be used as a backup battery in place of the second power module 106 to perform the aerosolization process.

[0113] return Figure 3 The power system 300 may further include a temperature sensor 332 or a temperature sensing subcircuit configured to monitor the temperature of the first power module 104. The power system may also include a temperature sensor 334 or a temperature sensing subcircuit configured to monitor the temperature of the second power module 106. An additional temperature sensor 330 or a temperature sensing subcircuit may be included at the heater 108 to measure the heater temperature or the heating chamber temperature. The above-mentioned temperature sensors may be controlled by the controller 102.

[0114] The power system 300 may further include a voltage sensor 342 or a voltage sensing subcircuit configured to monitor the voltage of the first power module 104. The power system may also include a voltage sensor 344 or a voltage sensing subcircuit configured to monitor the voltage of the second power module 106. An additional voltage sensor 340 or a voltage sensing subcircuit may be included at the heater 108 to measure the heater voltage. The voltage sensors described above may be controlled by the controller 102.

[0115] The power system 300 may further include a current sensor 352 or current sensing subcircuit configured to monitor the current output by the first power module 104. The power system may also include a current sensor 354 or current sensing subcircuit configured to monitor the current output by the second power module 106. An additional current sensor 540 or current sensing subcircuit may be included at the heater 108 to measure the heater current. The above-mentioned current sensors may be controlled by the controller 102.

[0116] The power system 300 can be connected to an external power source, such as a mains power source, a battery, a power bank, etc. The external power source can be connected at a connection node 370. The controller 102 can use a third switching device 324 (or third switch) between the power system and the connection node 370 to control the charging of the second power module 106 and / or the first power module 104. In an example, the third switching device 324 can be a transistor switch controlled by the controller 102.

[0117] Although reference has been made to the Figure 1 The aerosol generating device 100 of FIG. 1 is described herein, but alternative arrangements of aerosol generating devices may be readily adapted with reference to FIG. Figure 3 The power system 300 described herein is used in conjunction with the power system 300 described herein. 12A to 12C An example of an aerosol-generating device configured with an alternative heating chamber 1210 for use with an alternative aerosol-generating consumable 1214 is presented.

[0118] In such alternative embodiments, the aerosol-generating consumable 1214 may be substantially flat or planar in shape. 12A to 12C A diagrammatic representation of an arrangement of a planar aerosol-generating consumable 1214 and corresponding heating chamber 1210 is shown by which such a planar aerosol-generating consumable 1214 and corresponding heating chamber 1210 may be implemented. Figure 12A is a diagram of a flat aerosol generating consumable 1214, and Figure 12B is an illustration of an aerosol-generating consumable 1214 inserted into a heating chamber 1210 . Figure 12C 1 is an illustration of the mouthpiece region of an aerosol-generating device comprising a heating chamber 1210 configured to receive such a planar aerosol-generating consumable 1214, with a mouthpiece 1260 mounted therein. The power system 300 as described herein, and the operation and control of the aerosol-generating device as already described, may be used with this embodiment of the aerosol-generating device, and for the sake of brevity these details will not be repeated.

[0119] refer to Figure 12A The shape of the aerosol-generating consumable 1214 can be planar or flat, for example in the form of a flat rectangular parallelepiped. In a specific example, the length of the consumable 1214 along the consumable axis is substantially 33 mm, and the width and depth are substantially 12 mm and 1.2 mm, respectively. That is, the shape of the consumable 1214 can be considered planar because it has a depth that is much shorter than its length and width. However, in other examples, the aerosol-generating consumable 1214 and the corresponding heating chamber 1210 can have other suitable shapes or sizes.

[0120] The aerosol-generating consumable 1214 may include a heating portion 1239 and a mouthpiece portion 1238. The heating portion 1239 is received in the heating chamber 1210, and the mouthpiece portion 1238 is received in the mouthpiece 1260. That is, the heating portion 1239 defines an abutting end of the consumable 1214, which can abut or be close to the bottom 1250 of the heating chamber 1210, and the mouthpiece portion 1238 defines a mouth end of the consumable 1214.

[0121] The heating portion 1239 is configured to be heated by the heater 1208 in the heating chamber 1210 and includes an aerosol-generating material. The aerosol-generating material may be, for example, a material including nicotine or tobacco and an aerosol-forming agent. The tobacco may take the form of a variety of different materials, such as cut tobacco, granulated tobacco, leaf tobacco, and / or reconstituted tobacco. Suitable aerosol-forming agents include polyols such as sorbitol, glycerol, and diols (such as propylene glycol or triethylene glycol); non-polyols (such as monohydric alcohols), acids (such as lactic acid), glycerol derivatives, and esters (such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin, or vegetable glycerin). In some embodiments, the aerosol-generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The consumable 1214 may further include at least one of a gelling agent, a binder, a stabilizer, and a humectant. When the aerosol-generating material is heated, an aerosol or vapor is formed.

[0122] The mouthpiece portion 1238 is intended to be received within the interior of the mouthpiece 1260. The mouthpiece portion 1238 includes a core 1264 that can provide a filtering function. In some examples, the core 1264 can be foam or filled with fiber strands. The mouthpiece portion 1238 can have a plurality of vents 1262 arranged on the wall of the consumable 1214 to allow fresh air to enter the interior of the consumable 1214 to achieve a specific puffing / tasting effect.

[0123] refer to Figure 12C , the mouthpiece 1260 has a through hole that is designed to receive the mouthpiece portion 1238 of the aerosol-generating consumable 1214. The through hole can have the same cross-sectional shape as the aerosol-generating consumable 1214, wherein the inner dimension is slightly larger than the outer dimension of the mouthpiece portion 1238 of the aerosol-generating consumable 1214. As can be seen, the mouthpiece 1260 fits over the mouthpiece portion 1238 of the aerosol-generating consumable 1214 extending from the heating chamber 1210, such that the opening in the mouthpiece 1260 coincides with the end of the aerosol-generating consumable 1214, through which the generated aerosol is drawn when the operator inhales on the mouthpiece 1260.

[0124] In some cases, the consumable 1214 may not include a vent 1262; in such cases, air can flow into the consumable 1214 by being drawn through the abutment end. For example, air can be drawn into the device through an inlet 1266 in the nozzle 1260 or a side wall of the device to offset the pressure drop caused by the operator sucking on the nozzle 1260.

[0125] Steering Figure 12B The heating chamber 1210 can be cup-shaped, having an open end 1248 and an opposite sealed end 1250 into which the aerosol-generating consumable 1214 is inserted. The heating chamber 1210 receives the heating portion 1239 of the aerosol-generating consumable 1214. The heating chamber 1210 has substantially the same cross-sectional shape as the aerosol-generating consumable 1214. That is, the heating chamber 1210 can have a substantially rectangular cross-section that defines a substantially cubical cavity for receiving the planar aerosol-generating consumable 1214.

[0126] The walls of the heating chamber 1210 may include therein or thereon one or more heating elements of the heater 1208. Each of the walls, or one or more of the walls, of the heating chamber 1210 may have a heating element therein or thereon.

[0127] The walls of the heating chamber 1210 may be ceramic with heater wires or tracks embedded therein or thereon. In an example, the heating element may be arranged to contact one of the heating chamber walls outside the heating chamber 1210. Figure 12B In the example depicted, the heating element is arranged on the outer surface of the chamber wall. Similarly, a second heating element can be arranged on the outer surface of an opposing chamber wall (not shown). Thus, the chamber wall transfers heat from the heating element to the aerosol generating consumable 1214. In other examples, the heating element can be embedded within the chamber wall. In another example, the heating element can be on the chamber wall inside the heating chamber 1210. As explained, the chamber wall can be a ceramic material with heater tracks or wires therein or thereon. In the alternative, each heating element can include a polyimide film heater that extends along substantially the entire area of ​​the outer surface of the corresponding heating wall or along only a portion of this surface.

[0128] In a preferred embodiment, the heating chamber 1210 has two major inner surfaces corresponding to the relatively wider surfaces of the planar aerosol-generating consumable 1214, and two minor inner surfaces corresponding to the relatively narrower surfaces of the planar aerosol-generating consumable 1214. The minor inner surfaces may be perpendicular to and connected to the major inner surfaces. The walls of the heating chamber 1210 corresponding to the major inner surfaces may be arranged with heater wires or tracks embedded therein or thereon, thereby forming two ceramic heaters. In some embodiments, the walls of the heating chamber 1210 corresponding to the minor inner surfaces may also be ceramic. Such ceramic heaters can provide a compact heating chamber 1210 with well-distributed heat directed to the planar aerosol-generating consumable 1214. However, such ceramic heaters may require considerably more power to heat (e.g., >10 W and / or >1600 J) than heaters of aerosol-generating devices configured to receive more traditional cigarettes or cigarette-like consumables. Thus, such heaters greatly benefit from heating power management utilizing one or more supercapacitors or high power batteries, as described herein.

[0129] In other examples, each of these walls may comprise a heat conducting material, such as metal, in particular stainless steel. Additionally, at least some of these walls or all of these walls may form a single piece.

[0130] The interior dimensions of the heating chamber 1210 can be defined such that an airflow channel is formed between the walls of the heating chamber 1210 and the aerosol-generating consumable 1214 when the aerosol-generating consumable 1214 is inserted into the heating chamber. In other words, when the heating portion 1239 of the aerosol-generating consumable 1214 is inserted into the heating chamber 1210, an airflow channel is formed along the axial length of the consumable 1214.

[0131] The skilled person will readily appreciate that the aforementioned embodiments in the foregoing description are not limiting; the features of each embodiment may be incorporated into other embodiments as appropriate.

[0132] In the foregoing examples, the processing steps described herein as performed by the controller 102 or control electronics may be stored in a non-transitory computer-readable medium or storage device associated with the corresponding controller or control electronics. Computer-readable media may include non-volatile media and volatile media. Volatile media may include, in particular, semiconductor memory and dynamic memory. Non-volatile media may include, in particular, optical and magnetic disks.

Claims

1. An aerosol generating device power system, the power system comprising: a first power module; a second power module; a first voltage converter configured to be connected between the first power module and a heater component of an aerosol-generating device to step up the voltage of power flowing from the first power module to the heater component; and A second voltage converter is connected between the second power module and the first power module.

2. The aerosol generating device power system according to claim 1, wherein: The second voltage converter is controlled by input current control.

3. The aerosol generating device power system according to claim 2, wherein: The second voltage converter uses the input current control to provide substantially constant power from each of the second power module and the first power module to the heater according to changes in the voltage of the first power module.

4. An aerosol generating device power system according to claim 2 or claim 3, wherein: The aerosol generating device power system is connectable to an auxiliary power supply, and input current control at the second voltage converter controls power flow from the auxiliary power supply to the heater to perform the aerosolisation process.

5. An aerosol-generating device power system according to any preceding claim, wherein: The second power module is configured to recharge the first power module.

6. The aerosol generating device power system according to claim 5, wherein: The second voltage converter is configured to boost a voltage of power flowing from the second power module to the first power module when the first power module is recharged from the second power module.

7. An aerosol-generating device power system according to any preceding claim, wherein: The first power module is an ultracapacitor module including one or more ultracapacitors, or the first power module is a battery module including one or more high-power batteries.

8. An aerosol-generating device power system according to any preceding claim, wherein: The second power module is a battery module comprising at least one battery, or wherein the second power module is a supercapacitor module comprising one or more supercapacitors, or wherein the second power module is a supercapacitor module comprising one or more hybrid supercapacitors.

9. An aerosol-generating device comprising an aerosol-generating device power system as claimed in any preceding claim.

10. The aerosol generating device according to claim 9, wherein: The aerosol-generating device comprises a heating chamber configured to receive an aerosol-generating consumable and to heat the aerosol-generating consumable without burning the aerosol-generating consumable to generate an aerosol in an aerosolization process.

11. The aerosol generating device according to claim 10, wherein: The heating chamber has a substantially circular cross-section and defines a substantially cylindrically shaped cavity for receiving the aerosol-generating consumable.

12. The aerosol generating device according to claim 11, wherein The aerosol-generating consumable is a tobacco rod.

13. The aerosol generating device according to claim 10, wherein: The heating chamber has a substantially rectangular cross-section and defines a substantially cubic-shaped cavity for receiving the aerosol-generating consumable.

14. The aerosol generating device according to claim 13, wherein: The aerosol generating consumable is substantially planar in shape.

15. The aerosol generating device according to any one of claims 10 to 14, wherein: The aerosol-generating consumable product comprises tobacco.

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