Charging assembly for an aerosol generation device, aerosol generation device and method of using a charging assembly

Abstract

A charging assembly (12) for an aerosol generation device is described. The charging assembly (12) comprises an electrically conductive tubular receiving coil for wireless inductive charging of an energy storage device. The coil (20) has a first end (20a) defining a fluid inlet and a second end (20b) defining a fluid outlet. The first and second ends (20a, 20b) are electrically connectable to the energy storage device by means of a charging circuit. An air-cooled heat exchanger comprises a tubular heat transfer member (32) arranged in a heat transfer space (40) adapted to receive air (or another secondary heat transfer fluid). The heat transfer member (32) has a first end defining a fluid inlet and a second end defining a fluid outlet. The fluid inlet of the heat transfer member (32) is fluidly connected to the fluid outlet of the coil (20) and the fluid outlet of the heat transfer member (32) is fluidly connected to the fluid inlet of the coil (20) to define a closed loop heat transfer circuit. A primary heat transfer fluid is circulated around the closed loop heat transfer circuit by natural convection.

Description

Technical Field

[0001] This disclosure generally relates to a charging assembly for an aerosol generating device, and more particularly to an apparatus suitable for heating aerosol generating materials to generate an aerosol for inhalation by a user. The charging assembly can be used to wirelessly charge an energy storage device (e.g., a rechargeable battery) of the aerosol generating device. This disclosure also generally relates to a method of using the charging assembly to transfer heat from the coil of the charging assembly and / or from any heat-generating component thermally coupled to the coil.

[0002] This disclosure also relates generally to an aerosol generating device. This disclosure is particularly suitable for portable (handheld) aerosol generating devices. Background Technology

[0003] In recent years, devices that generate inhaled aerosols by heating rather than burning aerosol-generating materials have become increasingly popular with consumers. Commonly used risk-reducing or risk-modifying devices are heated aerosol-generating devices, or so-called heated-material non-burning devices. This type of device generates aerosols or vapors by heating the aerosol-generating material to a temperature typically in the range of 150°C to 300°C. This temperature range is quite low compared to regular cigarettes. Heating the aerosol-generating material to this temperature range without burning or combusting it produces vapor, which typically cools and condenses to form an aerosol for the user to inhale.

[0004] Aerosol generating materials can be solid or liquid. For example, an aerosol generating article may include a solid or semi-solid matrix of plant-derived material (such as tobacco), or it may include a wick and a heater to generate vapor from a liquid aerosol stored in a capsule or reservoir. When a user operates the aerosol generating device, the liquid immersed in the wick is heated by the heater to generate vapor, which is then cooled and condensed to form an aerosol that can be subsequently inhaled. An aerosol generating article (sometimes called a pod or cartridge) may be incorporated into the aerosol generating device and may include a liquid reservoir, a liquid delivery element (e.g., a wick), and a heater. Electrical contacts may provide an electrical connection between the heater and an energy storage device of the aerosol generating device. The energy storage device may be a rechargeable battery that can be charged from an external power source via a charging assembly of the aerosol generating device. A stick-shaped object that resembles a regular cigarette can also be used as an aerosol generating article.

[0005] The charging assembly may include an inductive receiving coil suitable for wirelessly charging the battery. Specifically, the wireless external power source (such as a wireless charger) will include an inductive transmitting coil that generates an electromagnetic field when current flows through it. The inductive transmitting coil and the inductive receiving coil may also be referred to as the primary coil and secondary coil, respectively. When the receiving coil of the charging assembly of the aerosol generating device is placed close to the wireless charger, the electromagnetic field generates a current in the receiving coil of the charging assembly, which can be supplied to the charging circuitry and used to charge the battery. Wireless charging is a convenient way to charge batteries without requiring a charging cable to be physically and / or mechanically connected to the aerosol generating device. New entry protection standards may also mean that wired charging assemblies (e.g., those that may include a plug and socket (such as a USB socket) for receiving a Universal Serial Bus (USB) charging cable (plug) and therefore require an opening in the housing) may no longer be suitable for aerosol generating devices. Using wireless charging also avoids the need for users to carry or use a separate charging cable. However, there may be limitations on the size of the receiving coil that can be positioned within the housing of the aerosol generating device, and high current may be required to meet the expected charging time. This can lead to excessive heat generation in the receiving coil and related components during charging. This heat should not be completely dissipated into the housing to improve device safety. The housing will typically be made of plastic because conductive material cannot be positioned between the receiving coil of the charging assembly and the transmitting coil of the external wireless charger if a wireless connection is to be established between them. This could make heat dissipation even more difficult, as the thermal conductivity and heat capacity of plastic materials are generally lower than those of conductive materials (e.g., metals). Excessive heat generation within the housing can accelerate the degradation of other internal components of the aerosol generation device. Therefore, an improved charging assembly is needed that can improve the transfer of heat generated during wireless charging away from the receiving coil. Summary of the Invention

[0006] According to a first aspect of this disclosure, a charging assembly for an aerosol generating apparatus is provided, the charging assembly comprising:

[0007] A conductive tubular receiving coil for wireless inductive charging of an energy storage device (e.g., a rechargeable battery for an aerosol generating device, such as a lithium-ion secondary battery), the coil including a first end defining a fluid inlet and a second end defining a fluid outlet, wherein the first end and the second end can be electrically connected to the energy storage device by means of a charging circuit.

[0008] A heat exchanger includes a tubular heat transfer member arranged in a heat transfer space adapted to receive a secondary heat transfer fluid. The heat transfer member includes a first end defining a fluid inlet and a second end defining a fluid outlet, wherein the fluid inlet of the heat transfer member is fluidly connected to a fluid outlet of a coil, and the fluid outlet of the heat transfer member is fluidly connected to a fluid inlet of the coil, to define a closed-loop heat transfer circuit; and

[0009] The primary heat transfer fluid in this closed-loop heat transfer circuit.

[0010] Circulating the primary heat transfer fluid around a closed-loop heat transfer circuit transfers heat away from the coil during wireless charging. More specifically, the heat generated by the coil during wireless charging is transferred to the circulating primary heat transfer fluid, thereby cooling the coil. The heat is then transferred from the primary heat transfer fluid to the secondary heat transfer fluid via a heat exchanger, further cooling the primary heat transfer fluid. Finally, the heat is removed from the interior of the aerosol generation device's housing (i.e., the housing in which the charging assembly and energy storage device are located) via the secondary heat transfer fluid. The charging assembly allows for faster wireless charging of the energy storage device because the receiving coil is less likely to overheat. It also reduces heat dissipation into the housing, thus protecting other internal components from overheating. Furthermore, if the temperature of the receiving coil changes significantly, the coil's impedance and resistance may also change, potentially leading to a decrease in wireless charging efficiency. Therefore, the charging assembly is beneficial because it minimizes temperature variations in the receiving coil and helps maintain high efficiency during wireless charging.

[0011] The charging assembly can also be used to remove heat from any heat-generating component thermally coupled to the coil. The coil can be directly thermally coupled to the heat-generating component or indirectly thermally coupled by means of suitable thermally conductive components, adhesives, or potting materials. Such materials include resins, silicones, etc. (which may include additives such as metal particles (e.g., copper or aluminum) or particles of other suitable materials (e.g., silica, alumina, etc.)). For example, the coil can be thermally coupled to the energy storage device of an aerosol generating device. During normal operation of the aerosol generating device, heat generated by the heat-generating component (e.g., the energy storage device) can be removed from the heat-generating component by circulating a primary heat transfer fluid around a closed-loop heat transfer circuit. More specifically, the heat generated by the heat-generating component is transferred to the coil and the circulating primary heat transfer fluid, thereby cooling the component. The heat is then transferred from the primary heat transfer fluid to the secondary heat transfer fluid via a heat exchanger, thereby cooling the primary heat transfer fluid. Finally, the heat is removed from the interior of the aerosol generating device housing via the secondary heat transfer fluid. The charging assembly can allow the heat-generating component to have better performance because the component is less likely to overheat. It also reduces heat dissipation into the housing, protecting other internal components from overheating. The charging assembly can be used to transfer heat away from the heat-generating component when the coil is not used for wireless charging (i.e., when the coil itself does not generate heat). The charging assembly can also be used to transfer heat away from the heat-generating component when the coil is used for wireless charging (i.e., when both the coil and the heat-generating component generate heat simultaneously). This is possible, for example, if the heat-generating component is an energy storage device that is charged by the charging assembly.

[0012] The primary heat transfer fluid can circulate around a closed-loop heat transfer circuit via natural convection (or “free convection”), where the movement of the primary heat transfer fluid is generated solely by density differences due to temperature gradients, rather than by any fluid propulsion mechanism such as a pump. More specifically, locally heated primary heat transfer fluid decreases in density and expands, thus propelling downstream primary heat transfer fluid through the coil toward the fluid outlet. This ultimately causes the primary heat transfer fluid to circulate around the closed-loop heat transfer circuit. Circulation can occur even when the coils are arranged substantially horizontally, as might happen during wireless charging, for example. Natural convection provides a simple and reliable way to circulate the primary heat transfer fluid around a closed-loop heat transfer circuit without requiring additional components such as pumps. The natural convection mechanism can also be considered in terms of the heat generated by the coils and / or heat-generating components that act as an energy source for circulating the primary heat transfer fluid. Because no additional kinetic and / or electrical energy is required, natural convection is unrestricted and, for example, it is not dependent on any specific operating conditions of the aerosol generating device.

[0013] The primary heat transfer fluid can be a dielectric fluid. For example, using a dielectric fluid means that the primary heat transfer fluid will not affect the wireless charging process when current is generated in the coil. For example, the primary heat transfer fluid can be a food-grade fluid. For example, the primary heat transfer fluid can be a liquid (such as propylene glycol, deionized water) or a suitable oil (such as natural oil, synthetic oil, or mineral oil). For example, the primary heat transfer fluid can be a gas, such as air or another suitable gas.

[0014] For example, the secondary heat transfer fluid can be ambient air, and the heat exchanger can be an air-cooled heat exchanger. Ambient air can pass through the heat exchange space and the tubular heat transfer member, allowing heat to be exchanged between the primary heat transfer fluid and the ambient air. This heat exchange cools the primary heat transfer fluid in the heat transfer member. The cooled primary heat transfer fluid flows to the fluid outlet of the heat transfer member and then into the receiving coil through the fluid inlet of the coil.

[0015] The coil can be made of a copper alloy containing about 0.015 wt% to about 0.040 wt% phosphorus, with the balance being copper (i.e., a "phosphorus-deoxidized, high-residue" copper alloy (UNS C12200)). This copper alloy has good electrical and thermal properties. However, the coil can be made of any other suitable metal or metal alloy.

[0016] The heat transfer element can be made of a conductive material. In this arrangement, it is generally important to electrically isolate the heat transfer element from the coil, as the current generated by the coil during wireless charging would otherwise flow through the heat transfer element. This could reduce the efficiency of wireless charging. The fluid outlet of the heat transfer element can be fluidly connected to the fluid inlet of the coil via a non-conductive tubular first fluid connector. The fluid inlet of the heat transfer element can be fluidly connected to the fluid outlet of the coil via a non-conductive tubular second fluid connector. This means that the fluid inlet (or first end) of the coil is not directly and physically connected to the fluid outlet (or second end) of the heat transfer element, and vice versa. The first and second fluid connectors can be made of, for example, plastic or synthetic polymer materials and serve as electrical insulators. The first and second fluid connectors can be flexible, which allows for relative movement due to thermal expansion of the coil and / or the heat transfer element. The first and second fluid connectors can also act as pressure relief valves in case of excessive pressure in the closed-loop heat transfer circuit. For example, the first and second fluid connectors can make the charging components easier to assemble compared to using a completely rigid connection between the coil and the heat transfer component.

[0017] For example, the first fluid connector and the second fluid connector can be connected to the fluid inlet and fluid outlet (or the first end and the second end) of the coil and the heat transfer component using a suitable adhesive (such as food-grade silicone adhesive).

[0018] The heat transfer components can be made of a copper alloy containing approximately 0.001 wt% oxygen and the balance copper (i.e., an "oxygen-free" copper alloy (UNS C10200)) or approximately 0.04 wt% oxygen and the balance copper (i.e., an "electrolytically tough copper" alloy (UNSC11000)). This copper alloy exhibits good heat transfer properties. However, the heat transfer components can be made of any suitable metal or metal alloy.

[0019] Heat exchange between the primary and secondary heat transfer fluids depends on the heat transfer member. Therefore, enhancing heat transfer through the walls of the tubular heat transfer member is important for improving the cooling of the primary heat transfer fluid. If the heat transfer member is made of a suitable metal or metal alloy with high thermal conductivity, good heat exchange will exist between the primary and secondary heat transfer fluids; however, if current is allowed to flow through the heat transfer member, the efficiency of wireless charging may be reduced. Using a first fluid connector and a second fluid connector allows the heat transfer member to be made of a metal or metal alloy with high thermal conductivity, while also providing electrical isolation from the receiving coil, thus maintaining high efficiency in wireless charging.

[0020] The heat transfer component can be made of a non-conductive material. For example, it can be made of plastic or synthetic polymer. In this case, the current generated by the coil during wireless charging will not flow through the heat transfer component, so the coil can be directly connected to it. Specifically, the fluid inlet (or first end) of the coil can be directly and physically connected to the fluid outlet (or second end) of the heat transfer component, and vice versa. This allows for a reduction in the number of components in the charging assembly, for example, because the first and second fluid connectors can be omitted.

[0021] The coil and heat transfer components can have wall thicknesses ranging from about 0.05 mm to about 0.4 mm. For example, a wall thickness of about 0.2 mm is likely preferred for both the coil and the heat transfer components. A smaller wall thickness in the coil will result in better heat transfer to the primary heat transfer fluid and will also help reduce the skin effect when current is generated in the coil during wireless charging. A smaller wall thickness in the heat transfer components will result in better heat transfer from the primary heat transfer fluid to the secondary heat transfer fluid within the heat transfer space. It should be understood that wall thickness is also important for maintaining mechanical strength. The ranges suggested above provide good heat transfer while still maintaining sufficient mechanical strength and stiffness in both the coil and the heat transfer components.

[0022] The inner diameter of the coil can be smaller than the inner diameter of the heat transfer element. This means the heat transfer element will have a larger surface area than the coil, but the coil can have better thermal conductivity. The larger surface area provides improved heat exchange between the primary and secondary heat transfer fluids within the heat exchanger. This also means the inner diameter of the closed-loop heat transfer circuit decreases at the point where the cooled primary heat transfer fluid enters the coil through the fluid inlet. This reduction in inner diameter facilitates the circulation of the primary heat transfer fluid; that is, the Venturi effect increases the fluid velocity of the primary heat transfer fluid through the coil portion of the closed-loop heat transfer circuit. This change in fluid velocity is described by Bernoulli's principle.

[0023] For example, a coil can have an inner diameter of about 0.8 mm and an outer diameter of about 1.0 mm.

[0024] The heat transfer member can extend along a serpentine path and may include multiple bends or turns. These bends or turns may be spaced apart. This can increase the surface area of ​​the portion of the heat transfer member located within the heat transfer space and improve the efficiency of heat transfer from the primary heat transfer fluid to the secondary heat transfer fluid. Between the fluid inlet and the fluid outlet, the heat transfer member can define one or more paths for the flow of the primary heat transfer fluid. For example, a single flow path (defined by a single tubular member) may exist between the fluid inlet and the fluid outlet, or two or more parallel flow paths may exist between the fluid inlet and the fluid outlet, which may be defined by corresponding tubular members. For example, the fluid inlet and fluid outlet may be arranged as a manifold. Each tubular member can extend along a serpentine path and may include multiple bends or turns.

[0025] The charging component may further include:

[0026] - A first electrical connector having a collar fixedly connected around a first end of a coil and optionally including an open solder pad, and

[0027] - A second electrical connector having a collar fixedly connected around a second end of a coil and optionally including an open solder pad.

[0028] The first and second electrical connectors provide a reliable means of electrical connection to the first and second ends of the coil. Specifically, one end of the wire can be received through an optional opening in each connector and then soldered to a corresponding pad, or simply soldered to a pad. The other end of each wire can be electrically connected to a printed circuit board assembly (PCBA). Specifically, the PCBA may include a printed circuit board and a charging circuit having a first charging terminal and a second charging terminal, the charging circuit including one or more electronic components mounted on the printed circuit board. For example, the PCBA may include a charging integrated circuit (IC). An energy storage device can also be electrically connected to the PCBA (e.g., a pair of energy storage device terminals on the printed circuit board) such that the current generated by the coil during wireless charging can be supplied to the charging circuit (e.g., the charging IC) and then used to charge the energy storage device.

[0029] The coil between the first and second ends preferably includes a plurality of bends arranged substantially in a common plane. The heat transfer element is preferably not arranged substantially in the common plane. For example, the heat transfer element may be arranged substantially in a plane substantially perpendicular to the common plane of the coil. This will ensure that no current is generated in the heat transfer element during wireless charging.

[0030] According to a second aspect of this disclosure, an aerosol generating apparatus is provided, comprising:

[0031] The charging components described above;

[0032] A charging circuit, electrically connected to a first and second terminal of the coil of the charging assembly; and

[0033] An energy storage device (e.g., a rechargeable battery) is electrically connected to a charging circuit.

[0034] The coil can be arranged adjacent to the energy storage device and can be thermally coupled to the energy storage device. This means that the coil of the charging assembly can also be used to transfer heat generated by the energy storage device during charging and during normal operation of the aerosol generating device. Therefore, the energy storage device can be cooled by the charging assembly, as described in more detail above.

[0035] The aerosol generating device may further include a housing, within which a charging assembly and an energy storage device are located. The housing may include at least one air opening in fluid communication with the heat transfer space. In this case, the secondary heat transfer fluid is air, and the heat exchanger is an air-cooled heat exchanger. Therefore, air can flow into and out of the heat transfer space through at least one air opening. Heat is transferred from the primary heat transfer fluid flowing through the tubular heat transfer member to the air in the heat transfer space, and then the heated air can flow out of the heat transfer space, i.e., out of the housing, through at least one air opening. The heated air can be replaced by cooler air from outside the housing. In this way, heat generated within the housing by the coil during wireless charging or by any other heat-generating component thermally coupled to the coil (e.g., an energy storage device) can be removed from the housing by the air-cooled heat exchanger. The housing may include two or more air openings. For example, heated air can flow out of the heat transfer space through one air opening, while cooler air can flow into the heat transfer space through another air opening. Therefore, air can circulate through or flow through the heat transfer space and over the heat transfer components to effectively remove heat generated inside the housing of the aerosol generating device. In one arrangement, at least one air opening may be located at one end of the housing and may be spaced apart from the heat transfer space.

[0036] The heat transfer space can be sealed from the rest of the housing interior. For example, the heat transfer space can be enclosed by a wall sealed to the housing, thus separating the heat transfer space from the rest of the housing interior. This wall can define at least one air opening or be aligned with at least one air opening, i.e., the wall can open to the outside. For example, the wall can be sealed to the housing using adhesive sealant or O-rings. This means that heated air or other secondary heat transfer fluids in the heat transfer space cannot flow into the housing interior. This also means preventing water, dust, etc., from entering the housing interior through the heat transfer space. The wall can be generally tubular or define a generally tubular member in which at least a portion of the heat transfer member is located and supported. Multiple portions of the heat transfer member (e.g., a first end and a second end) can be located outside the tubular member (i.e., outside the heat transfer space). For example, the wall can be made of a plastic material.

[0037] At least one air opening can be sealed by a breathable covering (such as a hydrophobic membrane or the like). The breathable covering will allow heated air to flow out of the heat transfer space and allow cooler air to flow into the heat transfer space, but will prevent water, dust, etc. from entering. If water or dust enters and subsequently remains in the heat transfer space, it will interfere with the airflow through the heat transfer space, thereby reducing heat exchange efficiency.

[0038] The housing may include a first end and a second end opposite to the first end, the first end being adapted to receive an aerosol-generating article with a mouthpiece through which the user inhales the aerosol. A heat exchanger may be located between the coil and the second end. This means that when the aerosol generating device is held upright by the user, the heat exchanger is located below the coil, i.e., the first end points upward. This can help improve the natural convection of the primary heat transfer fluid around the closed-loop heat transfer circuit, as the heated primary heat transfer fluid will flow upward as its density decreases. It should be understood that the coil is not typically used for wireless charging when the aerosol generating device is in this particular orientation, but if the coil is thermally coupled to other components, such as an energy storage device, the charging assembly can be used to transfer the heat generated by those components. Therefore, positioning the heat exchanger below the coil when the aerosol generating device is held upright by the user can help improve natural convection when other thermally coupled components generate heat, for example, when the energy storage device supplies power to generate the aerosol for the user to inhale. Improving the natural convection of the primary heat transfer fluid around the closed-loop heat transfer circuit will allow heat to be transferred to the outside of the shell more efficiently.

[0039] According to a third aspect of this disclosure, an aerosol generating apparatus is provided, comprising a charging assembly including a first electrical connector and a second electrical connector. The first electrical connector has a collar fixedly connected around a first end of a coil and a solder tab optionally including an opening. The second electrical connector has a collar fixedly connected around a second end of a coil and a solder tab optionally including an opening. The aerosol generating apparatus further includes:

[0040] Energy storage devices; and

[0041] Printed circuit board assembly (or PCBA), the printed circuit board assembly including:

[0042] A printed circuit board, the printed circuit board including a first charging terminal and a second charging terminal, a first energy storage device terminal and a second energy storage device terminal, and

[0043] A charging circuit, comprising one or more electronic components mounted to the printed circuit board, wherein the charging circuit is electrically connected to the first charging terminal and the second charging terminal, as well as the first energy storage device terminal and the second energy storage device terminal;

[0044] The first electrical connector is electrically connected to the first charging terminal via a first wire electrically connected to a solder pad of the first electrical connector (e.g., received in an opening of the solder pad), and the second electrical connector is electrically connected to the second charging terminal via a second wire electrically connected to a solder pad of the second electrical connector (e.g., received in an opening of the solder pad); and

[0045] The energy storage device is electrically connected to the first energy storage device terminal and the second energy storage device terminal.

[0046] The collar of the first electrical connector can clamp around the first end of the coil. The collar of the second electrical connector can clamp around the second end of the coil. This provides a reliable electrical and physical connection between the first and second electrical connectors and the ends of the coil.

[0047] The first wire can be physically and electrically connected to the solder pads of the first electrical connector by either receiving one end through the opening and soldering it in place or simply soldering it to a solder pad. The second wire can be physically and electrically connected to the solder pads of the second electrical connector by either receiving one end through the opening and soldering it in place or simply soldering it to a solder pad. The other end of each wire can be soldered to a corresponding solder point on the printed circuit board (e.g., at a corresponding charging terminal).

[0048] It should be understood that during wireless charging, the current generated in the coil and supplied to the first and second charging terminals via the first and second conductors will be alternating current. The first and second conductors may include litz wire to mitigate the skin effect.

[0049] The energy storage device can be electrically connected to a first energy storage device terminal and a second energy storage device terminal via a pair of wires. One end of each wire can be soldered to a corresponding solder point on a printed circuit board (e.g., at the corresponding energy storage device terminal).

[0050] According to a fourth aspect of this disclosure, a method is provided to transfer heat from the coil and / or from any heat-generating component thermally coupled to the coil by circulating a heat transfer fluid around a closed-loop heat transfer circuit of the aforementioned charging assembly via natural convection. For example, such a heat-generating component may be an energy storage device, such as a rechargeable lithium-ion secondary battery.

[0051] Aerosol generating devices are suitable for receiving aerosol-generated products during use.

[0052] For example, the aerosol generating article may be housed within the body or housing of the aerosol generating device. The aerosol generating article may be removably housed within the body or housing. The aerosol generating article may be of any suitable type and may include an aerosol generator adapted to heat the aerosol generating material to generate an aerosol for inhalation by a user. The aerosol generator may include a heater. The heater may alternatively be part of the aerosol generating device.

[0053] Aerosol generators can be adapted to heat aerosol-generating materials. The aerosol-generating material can be a liquid that can be stored in an aerosol-generating article. The liquid aerosol-generating material can be immersed in a wick (e.g., a cotton wick) and then heated by a heater to generate vapor. The vapor cools and condenses to form an aerosol, which can then be drawn in. In some cases, the wick can be omitted, and the liquid aerosol-generating material can be stored directly in the cavity of the aerosol-generating article. The aerosol-generating article can be formed as an integrated component (or “pod”) including a liquid reservoir, a liquid transfer element or wick, and a heater. One or more electrical contacts can also be provided to establish an electrical connection between the heater and the energy storage device.

[0054] Aerosol generating materials can include any type of solid or semi-solid material. Exemplary types of aerosol generating solids include powders, microparticles, pellets, fragments, strands, granules, gels, strips, loose leaves, chopped fillers, porous materials, foam materials, or sheets. Aerosol generating materials can include plant-derived materials, and in particular, can include tobacco. Aerosol generating materials may advantageously include reconstituted tobacco, for example, comprising tobacco and any one or more of cellulose fibers, tobacco stem fibers, and inorganic fillers. Solid or semi-solid aerosol generating materials can be heated by a heater configured as part of an aerosol generating article or aerosol generating apparatus, for example, the heater being arranged adjacent to a heating space or chamber of the aerosol generating apparatus adapted to receive the aerosol generating article during use.

[0055] Aerosol generating materials may include aerosol forming agents. Examples of aerosol forming agents include polyols and mixtures thereof, such as glycerol or propylene glycol. Typically, aerosol generating materials may include an aerosol forming agent content of about 5% to about 50% based on dry weight. In some embodiments, aerosol generating materials may include an aerosol forming agent content of about 10% to about 22% based on dry weight, possibly up to about 15% based on dry weight.

[0056] The aerosol generating device may be adapted to heat, rather than burn, the aerosol generating material or matrix to cause at least one component of the aerosol generating material to volatilize, thereby generating heated vapor that is cooled and condensed to form an aerosol for inhalation by a user of the aerosol generating device. Volatile compounds released from the aerosol generating material may include nicotine or flavor compounds such as tobacco flavorings.

[0057] Generally speaking, vapor is a substance that is in the gaseous phase at a temperature below its critical temperature, meaning that vapor can condense into a liquid by increasing its pressure without lowering the temperature, while aerosols are suspensions of fine solid particles or liquid droplets in air or another gas. However, it should be noted that the terms "aerosol" and "vapor" are used interchangeably in this specification, particularly with respect to the form of the inhalable medium produced for the user to inhale.

[0058] When the aerosol generating material is exhausted, the aerosol generating article can be removed from the aerosol generating device, and a new article can be inserted.

[0059] Aerosol-generating articles may include a mouthpiece through which the generated aerosols can be inhaled. Attached Figure Description

[0060] Figure 1 It is a schematic view of an aerosol generation system having an aerosol generation device and an aerosol generation product;

[0061] Figure 2 yes Figure 1 A schematic view of the aerosol generation system without a housing;

[0062] Figure 3 This is a schematic view of the charging components;

[0063] Figures 4 to 7 yes Figure 3 A detailed diagram of the charging components;

[0064] Figure 8 yes Figure 3 A schematic view of a portion of the charging assembly, in which the tubular wall does not define the heat transfer space;

[0065] Figure 9A yes Figure 3 A front view of the charging assembly in the case of a tubular wall;

[0066] Figure 9B yes Figure 9A A schematic side view of the charging component;

[0067] Figure 9C yes Figure 9A A top view of the charging components; and

[0068] Figure 10 This is a schematic view of an alternative aerosol generating device, in which an air opening is provided at the bottom of the device housing. Detailed Implementation

[0069] Embodiments of this disclosure will now be described by way of example only and with reference to the accompanying drawings.

[0070] First refer to Figure 1 and Figure 2 An example of an aerosol generating system 1 is illustrated. The aerosol generating system 1 includes an aerosol generating device 2 and an aerosol generating article 4 for use with the aerosol generating device 2. The aerosol generating device 2 includes a body or housing 6, and its size is determined so that it can be comfortably held by a user with one hand without assistance.

[0071] The aerosol generating device 2 includes a printed circuit board assembly (PCBA) 8, an energy storage device (e.g., a rechargeable battery 10), and a charging component 12.

[0072] The aerosol generating article 4 includes an aerosol generator 14, which is adapted to heat an aerosol generating material (not shown) to generate an aerosol for inhalation by a user. The user can inhale the aerosol through the nozzle 16 of the aerosol generating article 4.

[0073] The aerosol generating article 4 is received in the opening 18 at the upper end of the body or housing 6.

[0074] exist Figure 1 and Figure 2 In this diagram, the aerosol generating article 4 is shown as a cartridge (or "pod"). In another arrangement, for example, the aerosol generating article may be a stick-shaped object that resembles a conventional cigarette. The aerosol generator may be attached to or embedded in such a stick-shaped aerosol generating article, or may be formed as part of an aerosol generating device.

[0075] refer to Figures 3 to 8 and Figures 9A to 9C The charging assembly 12 includes a tubular coil 20 made of a conductive material (such as a copper alloy). The coil 20 is a receiving coil for wireless inductive charging of the battery 10.

[0076] The coil 20 has a first end 20a defining a fluid inlet and a second end 20b defining a fluid outlet. The first end 20a and the second end 20b can be electrically connected to the battery 10 by means of a charging circuit.

[0077] The charging circuitry is implemented by one or more electronic components mounted on a printed circuit board of the charging PCBA 22. Specifically, a charging integrated circuit (IC) 22a may be mounted on the printed circuit board and electrically connected to both the coil 20 and the battery 10. The printed circuit board includes a pair of charging terminals U+, U- and a pair of battery terminals B+, B-, which are electrically connected to the charging IC 22a via one or more conductive paths formed on one or more surfaces of the printed circuit board. Alternatively, the charging IC 22a may be mounted on another surface of the charging PCBA 22. For example, the charging IC 22a may be integrated with one or more other electronic components, such as a microcontroller unit, to form a single “chip.”

[0078] The charging assembly 12 includes a first electrical connector 24 and a second electrical connector 26. The first electrical connector 24 is located in... Figure 5 and Figure 6 The coil 20 is shown in more detail and includes a collar 24a and a solder tab 24b, the collar being fixedly connected (i.e., by clamping) around the first end 20a of the coil 20, the solder tab including an opening 24c. A second electrical connector 26 is formed in the same manner and has a collar and a solder tab, the collar being fixedly connected (i.e., by clamping) around the second end 20b of the coil 20, the solder tab including an opening. One end of a first wire 28 is received through the opening 24c of the first electrical connector 24 and soldered to the solder tab 24b. One end of a second wire 30 is received through the opening of the second electrical connector 26 and soldered to the solder tab. The other ends of the first wire 28 and the second wire 30 are electrically connected to corresponding charging terminals U+ and U-. The first wire 28 and the second wire 30 may be Litz wires to mitigate the skin effect. Although not shown, the battery 10 is electrically connected to battery terminals B+ and B- via a pair of wires. Therefore, the current generated by the coil 20 during wireless charging can be supplied to the charging IC 22a and then used to charge the battery 10. As shown in the figure, the first wire 28 and the second wire 30 are electrically connected to the first electrical connector 24 and the second electrical connector 26 by means of corresponding openings in the solder pads. In other words, the first wire 28 and the second wire 30 are electrically connected to the first electrical connector 24 and the second electrical connector 26 using through-hole mounting technology. Alternatively, surface mount technology can be used, in which at least one of the first wire 28 and the second wire 30 is directly connected to the surface of the corresponding electrical connector without openings; for example, the wires are simply soldered to the solder pads.

[0079] The charging assembly 12 includes a tubular heat transfer member 32 arranged in a serpentine path with multiple bends or turns. Each individual bend or turn also extends along the serpentine path as shown. The heat transfer member 32 is made of a conductive material (such as a copper alloy), and its serpentine configuration maximizes the surface area available for heat transfer.

[0080] The heat transfer member 32 has a first end 32a defining a fluid inlet and a second end 32b defining a fluid outlet. The fluid outlet of the heat transfer member 32 is fluidly connected to the fluid inlet of the coil 20 via a tubular first fluid connector 34. The fluid outlet of the coil 20 is fluidly connected to the fluid inlet of the heat transfer member 32 via a tubular second fluid connector 36. The first fluid connector 34 and the second fluid connector 36 are made of, for example, plastic or synthetic polymer material and serve as electrical insulators. Although Figure 7 Only the first fluid connector 34 is shown in detail. It should be understood that the second fluid connector 36 has a similar construction, but is longer due to the greater distance between the fluid outlet of the coil 20 and the fluid inlet of the heat transfer member 32. The first fluid connector 34 and the second fluid connector 36 are flexible, allowing for relative movement due to thermal expansion of the coil 20 and / or the heat transfer member 32. The first fluid connector 34 and the second fluid connector 36 can also act as pressure relief valves in case of excessive pressure in the closed-loop heat transfer circuit. The first fluid connector 34 and the second fluid connector 36 also make it easier to assemble or manufacture the charging assembly 12 and to assemble the charging assembly 12 into the aerosol generating device 2. For example, the first fluid connector 34 and the second fluid connector 36 are connected to the coil 20 and the heat transfer member 32 using a suitable adhesive (such as food-grade silicone adhesive).

[0081] If the heat transfer component 32 is made of a non-conductive material, the first fluid connector 34 and the second fluid connector 36 can be omitted. In this case, the ends 20a and 20b of the coil 20 can be directly connected to the ends 32a and 32b of the heat transfer component 32.

[0082] The coil 20, located between the first end 20a and the second end 20b, includes a plurality of bends arranged substantially in a common plane. This in Figure 9B The most clearly visible feature is that heat transfer component 32 is not arranged in this common plane. Figure 9B and Figure 9C The bending or turning portion of the heat transfer member 32 is shown to be arranged in a plane substantially perpendicular to the common plane of the coil 20. In other words, the bending or turning portion of the heat transfer member 32 is spaced apart in a direction substantially normal to the common plane of the coil 20. This ensures that no current is generated in the heat transfer member 32 during wireless charging of the coil 20.

[0083] The bends or turns of the heat transfer member 32 extend through the tubular wall 38 that defines the heat transfer space 40. The tubular wall 38 is made of plastic. The inner wall divides the heat transfer space 40 into multiple channels, as shown in the figure. The inner wall is also made of plastic.

[0084] The open end of the tubular wall 38 is aligned with the air opening 42 provided in the housing 6 of the aerosol generating device 2. Figure 1 An air opening 42 is shown; it should be understood that another air opening is formed on the opposite side of the housing 6. The tubular wall 38 is sealed or otherwise fixedly connected to the housing 6, separating the heat transfer space 40 from the rest of the housing interior. For example, the tubular wall 38 can be sealed to the housing 6 using adhesive or an O-ring. Heated air in the heat transfer space 40 does not flow into the housing interior. Water, dust, etc., are also prevented from entering the housing interior through the heat transfer space 40.

[0085] exist Figure 8 as well as Figures 9A to 9C In the image, the tubular wall 38 is omitted, allowing the heat transfer component 32 to be seen more clearly.

[0086] The primary heat transfer fluid (e.g., propylene glycol or other suitable dielectric liquid) circulates around a closed-loop heat transfer circuit defined by coil 20, heat transfer member 32, and first fluid connector 34 and second fluid connector 36. As described above, the primary heat transfer fluid circulates via natural convection (or “free convection”).

[0087] During wireless charging, a primary heat transfer fluid is circulated around a closed-loop heat transfer circuit to transfer heat away from coil 20. More specifically, the heat generated in coil 20 during wireless charging is transferred to the primary heat transfer fluid, thereby cooling coil 20. The heat is then transferred from the primary heat transfer fluid to the air in the heat transfer space 40, thereby cooling the primary heat transfer fluid. The heated air will pass through an air opening (e.g., Figure 1 The air opening 42 shown exits the heat transfer space 40, and cold air from outside the housing 6 will flow out through the same air opening or another air opening (e.g., Figure 1 An air opening (not shown but formed on the other side of the housing 6) flows into the heat transfer space 40. Therefore, air can flow through the heat transfer space 40, past the bends or curves of the heat transfer member 32, for efficient heat exchange. In this way, heat is removed from the interior of the housing 6 of the aerosol generating device 2. This allows for faster wireless charging of the battery 10 because the coil 20 is less likely to overheat. The electrical parameters of the coil (e.g., impedance) are kept within a preferred range; it should be understood that these parameters vary with temperature, and a significant increase in coil temperature could reduce wireless charging efficiency. Heat dissipated into the housing 6 is also reduced.

[0088] Coil 20 is thermally coupled to battery 10. For example, coil 20 is positioned adjacent to battery 10, such as... Figure 2 and Figure 10As shown. During normal operation of the aerosol generating device 2, the heat generated by the battery 10 can be transferred away from the battery 10 by circulating the primary heat transfer fluid around a closed-loop heat transfer circuit. More specifically, the heat generated by the battery 10 is transferred to the coil 20 and the primary heat transfer fluid, thereby cooling the battery 10. The heat is then transferred from the primary heat transfer fluid to the air in the heat transfer space 40 via the heat transfer member 32, thereby cooling the primary heat transfer fluid. This allows the battery 10 to have better performance and can extend battery life. The heat dissipated into the housing 6 is also reduced.

[0089] The charging component 12 can be used to transfer heat from the battery 10 when the coil 20 is not used for wireless charging (i.e., when the coil 20 itself does not generate heat). The charging component 12 can also be used to transfer heat from the battery 10 when the coil 20 is used for wireless charging (i.e., when both the coil 20 and the battery 10 generate heat at the same time).

[0090] It should be noted that no external kinetic or electrical energy is required to operate the heat exchanger of the charging assembly 12. As described above, the density difference of the primary heat transfer fluid caused by the temperature gradient causes the primary heat transfer fluid to circulate around the closed-loop heat transfer circuit. Once a temperature gradient is caused by localized heating of the primary heat transfer fluid in the coil 20, the primary heat transfer fluid will automatically circulate around the closed-loop heat transfer circuit through natural convection. Therefore, whenever heat is generated inside the housing of the aerosol generating device 2, the coil 20 and any components thermally coupled to the coil 20 will automatically cool down without requiring any additional kinetic or electrical energy.

[0091] The heat transfer element 32 is located between the coil 20 and the bottom of the housing. This means that when the aerosol generator 2 is held upright by the user (i.e., with the nozzle 16 pointing upwards), the heat transfer element 32 is positioned below the coil 20. This can help improve the natural convection of the primary heat transfer fluid around the closed-loop heat transfer circuit, as the heated primary heat transfer fluid will flow upwards as its density decreases. Therefore, positioning the heat transfer element 32 below the coil 20 when the aerosol generator 2 is held upright by the user can help improve natural convection when the battery 10 generates heat (i.e., when the battery 10 supplies power to generate the aerosol for the user to inhale). Gravity can contribute to natural convection. Improved natural convection of the primary heat transfer fluid around the closed-loop heat transfer circuit will allow heat to be transferred to the outside of the housing 6 more efficiently.

[0092] Air openings (e.g., air opening 42) can be sealed by a breathable covering (e.g., a hydrophobic membrane or the like). The breathable covering will allow heated air to flow out of the heat transfer space 40 and cooler air to flow into the heat transfer space 40, but will prevent water, dust, etc., from entering. If water or dust enters and subsequently remains in the heat transfer space 40, it will interfere with airflow through the heat transfer space 40, thereby reducing heat exchange efficiency.

[0093] Figure 10 An alternative aerosol generating device is shown, wherein an air opening 44 is provided at the bottom end of the housing 6. A heat transfer member 32 is also visible, located in a heat transfer space 40, which is fluidly connected to the air opening 44 via the interior of the housing 6. Heated air can flow from the heat transfer space 40 and out of the housing 6 through the air opening 44. Cooler air can flow from the outside of the housing 6 into the heat transfer space 40.

[0094] While exemplary embodiments have been described in the foregoing paragraphs, it should be understood that various modifications may be made to these embodiments without departing from the scope of the appended claims. Therefore, the breadth and scope of the claims should not be limited to the exemplary embodiments described above.

[0095] Unless otherwise stated herein or the context clearly contradicts it, this disclosure covers any combination of all possible variations of the above features.

[0096] Unless the context clearly requires otherwise, throughout the specification and claims, the words “comprise”, “comprising”, etc., shall be interpreted in a sense of inclusion rather than exclusion or exhaustion; that is, in the sense of “including but not limited to”.

Claims

1. A charging assembly (12) for an aerosol generating device (2), the charging assembly (12) comprising: A conductive tubular receiving coil (20) for wireless inductive charging of an energy storage device (10) includes a first end (20a) defining a fluid inlet and a second end (20b) defining a fluid outlet, wherein the first end and the second end (20a, 20b) can be electrically connected to the energy storage device (10) by means of a charging circuit. A heat exchanger comprising a tubular heat transfer member (32) arranged in a heat transfer space (40) adapted to receive a secondary heat transfer fluid, the heat transfer member (32) comprising a first end (32a) defining a fluid inlet and a second end (32b) defining a fluid outlet, wherein the fluid inlet of the heat transfer member (32) is fluidly connected to the fluid outlet of the coil (20), and the fluid outlet of the heat transfer member (32) is fluidly connected to the fluid inlet of the coil (20) to define a closed-loop heat transfer circuit; and The primary heat transfer fluid in this closed-loop heat transfer circuit.

2. The charging assembly (12) according to claim 1, wherein, The heat transfer component (32) is made of a conductive material, and wherein the fluid outlet of the heat transfer component (32) is fluidly connected to the fluid inlet of the coil (20) via a non-conductive tubular first fluid connector (34), and the fluid inlet of the heat transfer component (32) is fluidly connected to the fluid outlet of the coil (20) via a non-conductive tubular second fluid connector (36).

3. The charging assembly (12) according to claim 1, wherein, The heat transfer component is made of a non-conductive material.

4. The charging assembly (12) according to any of the preceding claims, wherein, The inner diameter of the coil (20) is smaller than the inner diameter of the heat transfer component (32).

5. The charging assembly (12) according to any of the preceding claims, wherein, The heat transfer component (32) extends along a serpentine path.

6. The charging assembly (12) according to any of the preceding claims further comprises: A first electrical connector (24) having a collar (24a) fixedly connected around a first end (20a) of the coil (20) and a solder pad (24b) optionally including an opening (24c); and a second electrical connector (26) having a collar fixedly connected around a second end (20b) of the coil (20) and a solder pad optionally including an opening.

7. The charging assembly (12) according to any of the preceding claims, wherein, The coil (20) located between the first end and the second end (20a, 20b) includes a plurality of bends that are substantially arranged in a common plane, wherein the heat transfer member (32) is not substantially arranged in the common plane.

8. An aerosol generating device (2), comprising: The charging component (12) according to any of the preceding claims; A charging circuit electrically connected to the first and second terminals (20a, 20b) of the coil (20) of the charging assembly (12); and Energy storage device (10) is electrically connected to the charging circuit.

9. The aerosol generating device (2) according to claim 8, wherein, The coil (20) is arranged adjacent to the energy storage device (10) and is thermally coupled to the energy storage device (10).

10. The aerosol generating device (2) according to claim 8 or claim 9, further comprising a housing (6) in which the charging assembly (12) and the energy storage device (10) are located, and wherein, The housing (6) includes at least one air opening (42; 44) in fluid communication with the heat transfer space (40).

11. The aerosol generating device (2) according to claim 10, wherein, The heat transfer space (40) is sealed to the rest of the interior of the housing.

12. The aerosol generating apparatus (2) according to claim 10 or claim 11, wherein, The at least one air opening (42; 44) is sealed by a breathable covering.

13. The aerosol generating apparatus (2) according to any one of claims 10 to 12, wherein, The housing (6) includes a first end and a second end opposite to the first end, the first end being adapted to receive an aerosol generating article (4) having a nozzle (16) in use, through which the user inhales the aerosol, and wherein the heat exchanger is located between the coil (20) and the second end.

14. An aerosol generating device (2), comprising: The charging assembly (12) according to claim 6; Energy storage device (10); as well as Printed circuit board assembly (22), the printed circuit board assembly comprising: A printed circuit board, the printed circuit board including a first charging terminal and a second charging terminal, a first energy storage device terminal and a second energy storage device terminal, and A charging circuit, comprising one or more electronic components mounted to the printed circuit board, wherein the charging circuit is electrically connected to the first charging terminal and the second charging terminal, as well as the first energy storage device terminal and the second energy storage device terminal; The first electrical connector (24) is electrically connected to the first charging terminal via a first wire (28) electrically connected to the solder pad (24b) of the first electrical connector (24), and the second electrical connector (26) is electrically connected to the second charging terminal via a second wire (30) electrically connected to the solder pad of the second electrical connector (26); and The energy storage device (10) is electrically connected to the first energy storage device terminal and the second energy storage device terminal.

15. A method of transferring heat from the coil (12) and / or from any heat-generating component (10) thermally coupled to the coil (20) by means of a charging assembly (12) according to any one of claims 1 to 7, through natural convection to circulate the primary heat transfer fluid around the closed-loop heat transfer circuit.

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