Aerosol Generating Device with Battery Monitoring - Patent application

Abstract

An aerosol generating device configured to aerosolize an aerosol generating consumable is provided. The aerosol generating device comprises a battery (104) configured to provide power flow to a heater, and a controller (102) configured to determine a voltage level of the battery. The voltage level of the battery is determined as a measured voltage of the battery when an elapsed time after charge power flow to the battery is inhibited is equal to or greater than a time threshold. The voltage level of the battery is determined as a measured voltage of the battery after adjustment with a compensation factor when the elapsed time is less than the time threshold. The controller is further configured to control an indicator (108) to indicate a number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level.

Description

[Technical field]

[0001] The present invention relates to aerosol generating devices, and more particularly to power systems for aerosol generating devices. [Background technology]

[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 by an electronic heater to vaporize the product's ingredients for inhalation by the operator. In some examples, the product is a tobacco product similar to a traditional cigarette. Such devices are sometimes referred to as "heat-not-burn" devices in that they heat the product to the point of aerosolization without burning it.

[0004] Problems faced by such aerosol generating devices include providing an accurate indication of the charge level of the power system. Summary of the Invention

[0005] In a first aspect, there is provided an aerosol generation device configured to aerosolize an aerosol-generating consumable, the aerosol generation device comprising: a battery configured to provide a power flow to the heater; a controller configured to determine a voltage level of the battery, the voltage level of the battery being determined as a measured voltage of the battery when an elapsed time after charge power flow to the battery is inhibited is equal to or greater than a time threshold, and the voltage level of the battery being determined as a measured voltage of the battery adjusted by a compensation factor when the elapsed time is less than the time threshold; Equipped with The controller is further configured to control the indicator to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level.

[0006] In this way, an accurate and computationally efficient determination of the number of remaining aerosolization sessions that the battery can power is achieved. The measured battery voltage may be higher shortly after charging power flow to the battery is blocked than in a hibernating state, and the accuracy of the determination of the number of remaining aerosolization sessions is improved by accounting for an offset to the measured voltage after charging compared to the hibernating state using a compensation factor. This allows for an accurate and computationally efficient determination of the number of remaining aerosolization sessions that is consistent both immediately after charging the device and when the battery is in a hibernating state.

[0007] Adjusting the measured voltage of the battery may include compensating for a voltage overage in the measured voltage of the battery to determine a desired balanced battery voltage (i.e., a determined voltage level). The battery voltage (U BATT ) is U BATT =U EQUILIBRATED +U RELAXATION It can be defined as U RELAXATION is the voltage excess (negative for discharging, positive for charging). The controller calculates U as a function of time. RELAXATION Estimate and subtract this to get U EQUILIBRATED Then, U EQUILIBRATED (i.e., the determined voltage level) is used by the controller to calculate the measured battery voltage U BATT The energy content of the battery can be evaluated to determine the number of remaining aerosolization sessions that can be powered based on

[0008] Preferably, the device comprises a handpiece and a charging case connectable to the handpiece, the handpiece comprising a battery and a controller and configured to aerosolize the aerosol-generating consumable, and the charging case configured to charge a battery of the handpiece when the handpiece is connected to the charging case.

[0009] Such a two-part aerosol generating device advantageously enhances the consumer experience since the handpiece can be made smaller by being connectable to a separate charging case without compromising the number of aerosolization sessions that can be powered.

[0010] Preferably, the controller is configured to determine the time elapsed since charging power flow has been interrupted based on the time elapsed since the handpiece was disconnected from the charging case.

[0011] In this way, the controller can consider the effect on the measured battery voltage to determine that charging has ended when the handpiece is disconnected from the charging case.

[0012] Preferably, the indicator is configured to indicate a first number of remaining aerosolization sessions when the controller determines that the voltage level of the battery is greater than or equal to a first voltage threshold.

[0013] Preferably, the indicator is configured to indicate a second number of remaining aerosolization sessions when the controller determines that the voltage level of the battery is below a second voltage threshold, the second voltage threshold being lower than the first voltage threshold and the second number of remaining aerosolization sessions being less than the first number of remaining aerosolization sessions.

[0014] Preferably, the indicator is configured to indicate a third number of remaining aerosolization sessions when the controller determines that the voltage level of the battery is less than the first voltage threshold and greater than or equal to the second voltage threshold, the third number of remaining aerosolization sessions being less than the first number of aerosolization sessions and greater than the second number of aerosolization sessions.

[0015] In this manner, the use of a voltage threshold eliminates the requirement for costly current measurements and other additional components when determining the remaining number of aerosolization sessions that can be powered by a battery. Moreover, this approach takes into account the actual battery state-of-charge (SOC), making it robust and effective. It also allows for a more accurate determination of the number of aerosolization sessions that can be powered by a battery than, for example, counting how many aerosolization sessions have been performed.

[0016] Preferably, the controller controls the voltage level of the battery by: determining as the measured voltage of the battery a second elapsed time after the battery is at least partially discharged that is equal to or greater than a second time threshold; determining as the measured voltage of the battery after adjustment by a second compensation factor when the second elapsed time is less than a second time threshold; It is configured as follows.

[0017] The measured battery voltage may be lower shortly after discharge power flow from the battery (e.g., to the heater) is prevented than when in a hibernating state. Therefore, the accuracy of the determination of the number of remaining aerosolization sessions is further improved by offsetting the measured voltage after a heating load is applied to the battery compared to a hibernating state using a second compensation factor. This allows for an accurate and computationally efficient determination of the number of remaining aerosolization sessions that is consistent both immediately after the battery provides power to the heater and when the battery is in a hibernating state.

[0018] Preferably, the controller is further configured to determine whether the battery is fully charged and, when the battery is determined to be fully charged, indicate with the indicator a first number of remaining aerosolization sessions.

[0019] In this way, the processing overhead in the controller can be reduced because the controller does not need to determine the battery voltage when the battery is fully charged.

[0020] Preferably, the controller is further configured to determine whether the battery is fully charged by the charging case.

[0021] Preferably, the controller is configured to determine that the battery is fully charged by determining that the control parameter is set to a state indicative of fully charged.

[0022] Preferably, the battery is a lithium iron phosphate battery.

[0023] Lithium iron phosphate is a beneficial battery technology for use in aerosol generating devices due to its high power capability, long cycle life, high level of safety, thermodynamic stability, and flat voltage curve that allows it to deliver constant power over a wide range of states of charge without the need for the use of any compensation techniques.

[0024] Preferably, the aerosol generating device comprises a user input means operable in a first manner to trigger the aerosol generating device to aerosolize the aerosol generating consumable, and in a second manner to trigger the controller to determine a voltage level of the battery and control an indicator to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level.

[0025] In this manner, a single user input means can be utilized to both determine the remaining number of aerosolization sessions that can be powered and to trigger an aerosolization session, allowing for a more compact and simplified device arrangement, thereby improving the overall design of the device.

[0026] Preferably, the aerosol generating device further comprises a pulse width modulation module connected to the controller, the pulse width modulation module configured to convert the power flow from the battery to the heater into a pulse width modulated power flow.

[0027] In this way, a fixed power level can be output from the battery and then regulated before being supplied to the heater.

[0028] Preferably, the aerosol-generating consumable is a tobacco rod and the aerosol generating device is configured to generate the aerosol by heating, without burning, the tobacco rod during an aerosolization session.

[0029] In a second aspect, there is provided a method of operating an aerosol generating device configured to aerosolize an aerosol generating consumable, the aerosol generating device comprising a battery configured to provide a power flow to a heater, the method comprising: determining an elapsed time since charge power flow to the battery was interrupted; Determining a voltage level of a battery, comprising: Determining the voltage level of the battery includes determining the voltage level of the battery as a measured voltage of the battery when an elapsed time after charge power flow to the battery is inhibited is equal to or greater than a time threshold; determining a voltage level of the battery includes determining a voltage level of the battery as a measured voltage of the battery adjusted by a compensation factor when the elapsed time is less than a time threshold; controlling an indicator to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level; Includes.

[0030] In a third aspect, a controller configured for operation with an aerosol generation device configured to aerosolize an aerosol generation consumable, the aerosol generation device including a battery configured to provide a power flow to a heater, when executed by one or more processors of a controller configured for operation with an aerosol generation device configured to aerosolize an aerosol generation consumable, the aerosol generation device including a battery configured to provide a power flow to a heater, the controller comprising: using a timer to determine an elapsed time since charge power flow to the battery has been prevented; determining a voltage level of a battery using a voltage sensor of the aerosol generating device; Determining the voltage level of the battery includes determining the voltage level of the battery as a measured voltage of the battery when an elapsed time after charge power flow to the battery is inhibited is equal to or greater than a time threshold; determining a voltage level of the battery includes determining a voltage level of the battery as a measured voltage of the battery adjusted by a compensation factor when the elapsed time is less than a time threshold; controlling an indicator of the aerosol generating device to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level; A non-transitory computer readable medium is provided that stores instructions to cause the

[0031] The method of the second aspect and the non-transitory computer readable medium of the third aspect may be combined with preferred features of the first aspect as appropriate.

[0032] Embodiments of the invention will now be described, by way of example only, with reference to the drawings in which: [Brief description of the drawings]

[0033] [Figure 1A] FIG. 1 is a perspective view of a two-part aerosolization device having a handpiece and a charging case, the handpiece being stored within the charging case. [Figure 1B]FIG. 1 is a perspective view of a two-part aerosolization device with the handpiece partially separated from the charging case. [Diagram 2] FIG. 1 is a block diagram of a two-part aerosolization device. [Diagram 3] FIG. 1 is a circuit diagram of the handpiece electronics of a two-part aerosolization device. [Figure 4] 1 is a plot of state of charge versus open circuit voltage for charge and discharge cycles of an LFP battery configured to store enough energy to power an aerosol generation device for two aerosolization sessions. [Diagram 5] FIG. 1 is a process flow diagram of the processing steps performed by the controller of the aerosol generating device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] 1A and 1B show perspective views of a two-part aerosolization device having a handpiece 100 and a charging case 200. An aerosol generating device may also be referred to as a vapor generating device or an e-cigarette, and it will be understood that for purposes of this disclosure, the terms aerosol and vapor are interchangeable.

[0035] In Fig. 1A, the handpiece 100 is stored in a charging case 200, and in Fig. 1B, the handpiece is partially removed from the charging case. Fig. 2 shows a block diagram of the handpiece 100 and charging case 200 in a separated configuration.

[0036] The handpiece 100 is configured to aerosolize an aerosol-generating consumable. The handpiece 100 includes a battery 104, a controller 102, and a chamber 106 that can receive an aerosol-generating consumable 150 and heat it to generate an aerosol.

[0037] In one example, the heater can be disposed within the chamber 106. The chamber 106 is accessed through an opening in the handpiece 100. The chamber 106 is positioned to receive an associated aerosol-generating consumable 150.

[0038] The aerosol-generating consumable 150 may contain an aerosol-generating material, such as a tobacco rod containing tobacco. The tobacco rod may be similar to a conventional cigarette. The chamber has a cross-section approximately equal to the cross-section of the aerosol-generating consumable and a depth such that when the associated aerosol-generating consumable is inserted into the chamber, a first end of the aerosol-generating consumable reaches the bottom of the chamber (i.e., the end distal from the chamber opening) and a second end of the aerosol-generating consumable distal to the first end extends outward from the chamber. In this manner, a consumer may inhale the aerosol-generating consumable when it is inserted into the handpiece.

[0039] The heater can be disposed within the chamber 106 such that the aerosol-generating consumable 150 engages the heater when inserted into the chamber 106. The heater can be disposed as a tube within the chamber such that the heater substantially or completely surrounds the portion of the aerosol-generating consumable 150 within the chamber 106 when a first end of the aerosol-generating consumable 150 is inserted into the chamber. The heater can be a wire, such as a coiled wire heater, or a ceramic heater, or other suitable type of heater. The heater can comprise multiple heating elements disposed consecutively along the axial length of the chamber, which heating elements can be independently activated (i.e., powered) in sequence.

[0040] Alternatively, the heater can be positioned within the chamber as an elongated piercing member (e.g., in the form of a needle, rod, or blade) such that when the aerosol-generating consumable 150 is inserted into the chamber, the heater can penetrate the aerosol-generating consumable 150 and engage the aerosol-generating material.

[0041] Alternatively, the heater may be in the form of an induction heater. A heating element (i.e., a susceptor) may be provided within the consumable 150, which is inductively coupled to an inductive element (i.e., an induction coil) within the chamber when the consumable is inserted into the chamber. The induction heater then heats the heating element by induction.

[0042] The heater may be arranged to heat the aerosol-generating consumable 150 to a predetermined temperature in an aerosolization session to generate an aerosol. An aerosolization session may be considered to be when the device is operating to generate an aerosol from the aerosol-generating consumable. In an example where the aerosol-generating consumable 150 is a tobacco rod (such as the example of FIG. 2), the aerosol-generating consumable includes tobacco. The heater is arranged to heat the tobacco to generate an aerosol without burning the tobacco. That is, the heater heats the tobacco to a predetermined temperature below the combustion point of the tobacco such that a tobacco-based aerosol is generated. Those skilled in the art will readily appreciate that the aerosol-generating consumable does not necessarily have to include tobacco, and other substances that are particularly suitable for aerosolization (or vaporization) by heating without burning the substance may be used in place of tobacco.

[0043] Alternatively, the aerosol-generating consumable may be a vaporizable liquid, which may be contained in a cartridge receivable within the handpiece or may be stored directly within the handpiece.

[0044] The battery 104 in the handpiece 100 can have a charge capacity suitable for powering several aerosolization sessions. For example, the handpiece battery 104, when in a fully charged state, can have sufficient charge capacity to power an aerosolization session (such as to aerosolize two tobacco rods). In one example, the handpiece battery can be a lithium iron phosphate (LFP) battery. Lithium iron phosphate is a beneficial battery technology for use in the handpiece 100 due to its high power capability, long cycle life, high level of safety thermodynamic stability, and flat voltage curve that allows it to provide constant power over a wide range of charge states without the need to use any compensation techniques.

[0045] The handpiece 100 may include an indicator 108 positioned to indicate the number of remaining aerosolization sessions that can be powered by the handpiece battery 104 based on the determined voltage level of the battery 104. In one example, the indicator 108 may include multiple light sources (such as LEDs), with the number of LEDs that are illuminated corresponding to the number of remaining aerosolization sessions that can be powered by the handpiece battery 104. In another example, the indicator 108 may be a display screen that presents in a textual or visual manner the number of remaining aerosolization sessions that can be powered by the handpiece battery 104.

[0046] Handpiece controller 102 is configured to control the operation of handpiece 100, including the flow of power from handpiece battery 104 to the heater. Handpiece controller 102 can be at least one microcontroller unit that includes a memory having instructions stored therein for operating handpiece 100, including instructions for implementing operational modes and controlling power flow, and a processor or processors configured to execute the instructions.

[0047] The charging case 200 is connectable to the handpiece 100 and configured to charge the handpiece battery 104 when the handpiece 100 is connected to the charging case 200. The charging case 200 has a receiving area 220 to which the handpiece 100 is connected.

[0048] The charging case 200 includes a charging case battery 204. Typically, the battery 204 in the charging case 200 has a larger capacity than the handpiece battery 104 in the handpiece 100. In this way, when the handpiece battery 104 is depleted, it can be recharged by the charging case 200. For example, the handpiece battery 104 can store enough charge for two aerosolization sessions, and the charging case battery 204 can store enough charge to fully recharge the handpiece battery 104 ten times, so that the overall aerosol generating device (handpiece 100 and charging case 200) is capable of twenty aerosolization sessions. The charging case battery 204 can be recharged from an external power source, such as a wall adapter, a power bank, or a USB connector.

[0049] The charging case 200 may also include a charging case controller 202 configured to manage power flow from the charging case battery 204 to the handpiece battery 104.

[0050] The handpiece 100 may have a first connector 110 for power and / or data, and the charging case 200 may have a second connector 210 for power and / or data. The first connector 110 and the second connector 210 cooperate to allow power to flow from the charging case 200 to the handpiece 100 for charging the handpiece battery 104 from the charging case battery 204 when the handpiece 100 is held within the receiving area 220.

[0051] In use, the operator removes the handpiece 100 from the charging case 200 and inserts the aerosol-generating consumable 150 into the chamber 106. The operator can then operate the user input means to initiate an aerosolization session. In response, the handpiece controller 102 controls the flow of power from the handpiece battery 104 to the heater to preheat the heater to a predetermined aerosolization temperature. The handpiece controller 102 then controls the power flow to maintain the heater and aerosolization temperature for the aerosolization session. The operator utilizes an end of the aerosol-generating material 150 to inhale the generated aerosol. In one example, the aerosolization session continues for a predetermined period of time, after which the handpiece controller 102 blocks the flow of power from the handpiece battery 104 to the heater. This predetermined period of time can correspond to the amount of time it typically takes to aerosolize one consumable 150 (e.g., one tobacco rod). After completing an aerosolization session, the operator places the handpiece 100 in a receiving location 220 in the charging case 200 and power flow is initiated from the charging case battery 204 to the handpiece battery 104 to recharge the handpiece battery 104 for the next aerosolization session. In some examples, the handpiece battery 104 may be capable of powering multiple aerosolization sessions (e.g., two aerosolization sessions) before recharging. In this way, the operator does not need to reconnect the handpiece 100 to the charging case 200 between each aerosolization session.

[0052] 3 shows an example circuit diagram of the handpiece electronics. The handpiece electronics includes a handpiece battery 104, a handpiece controller 102, and a heater component 114. The handpiece electronics may further include a pulse width modulation (PWM) module 112 controlled by the handpiece controller 102. The PWM module 112 is configured to apply pulse width modulation to the power flow from the handpiece battery 104 to the heater component 114. The handpiece controller 102 may control the duty cycle of the pulse width modulation to control the power applied to the heater. For example, when preheating, a high duty cycle may be applied to rapidly heat the heater. When the heater is maintained at the aerosolization temperature, a lower duty cycle may be applied. The PWM module may include a switch, such as a transistor, controlled by the handpiece controller 102 to switch between an "on" state and an "off" state for each PWM period.

[0053] A temperature sensor 120 may be located in the heater or in the chamber 106 to monitor the heater temperature. The heater temperature is fed back to the handpiece controller 102. When the handpiece controller 102 determines that the heater temperature is above the aerosolization temperature, the power level applied to the heater may be decreased (e.g., by reducing the PWM duty cycle). Similarly, when the handpiece controller 102 determines that the heater temperature is below the aerosolization temperature, the power level applied to the heater may be increased (e.g., by increasing the PWM duty cycle).

[0054] A voltage sensor or voltage sensing circuit 118 can be connected to the handpiece battery 104 to function as a voltmeter and feed back the battery voltage to the handpiece controller 102 so that the handpiece controller 102 can monitor the state of charge of the handpiece battery 104 by determining the voltage level of the handpiece battery 104.

[0055] 3, the respective connections between the handpiece controller 102 and the voltage sensor 118, PWM module 112, and temperature sensor 114 are represented by arrows for simplicity, however, one skilled in the art will understand that typical electrical connections between the controller and these components may be used.

[0056] The handpiece controller 102 is configured to determine a voltage level of the handpiece battery 104 and, based on the determined voltage level, control the indicator 108 to indicate the number of remaining aerosolization sessions that can be powered by the handpiece battery 104.

[0057] The voltage level of the handpiece battery 104 corresponds to the number of aerosolization sessions that can be powered by the handpiece battery 104 .

[0058] The handpiece controller 102 can determine the number of remaining aerosolization sessions that can be powered by the handpiece battery 104 by comparing the determined voltage level of the handpiece battery 104 to one or more voltage thresholds, each voltage threshold calibrated to correspond to a minimum battery voltage level required by the handpiece battery 104 to power a number of aerosolization sessions. These voltage thresholds can be predetermined and stored in and accessed from storage associated with the handpiece controller 102.

[0059] In one example, the handpiece battery 104, when fully charged, is capable of powering two aerosolization sessions. When the determined voltage level of the handpiece battery 104 is equal to or greater than a first threshold, the charge level of the handpiece battery 104 may be deemed sufficient to power two aerosolization sessions (i.e., the number of remaining aerosolization sessions that can be powered by the handpiece battery 104 is two). When the determined voltage level of the handpiece battery 104 is less than a second threshold that is lower than the first threshold, the charge level of the handpiece battery 104 may be deemed insufficient to power an aerosolization session (i.e., the number of remaining aerosolization sessions that can be powered by the handpiece battery 104 is zero). When the determined voltage level of the handpiece battery 104 is less than the first voltage threshold and greater than or equal to the second voltage threshold (i.e., between the two thresholds), the charge level of the handpiece battery 104 can be deemed sufficient to power one aerosolization session (i.e., the number of remaining aerosolization sessions that can be powered by the handpiece battery 104 is one).

[0060] While the above uses the example of a handpiece battery 104 capable of powering two aerosolization sessions, one skilled in the art will appreciate that the number of aerosolization sessions need not be limited to two. For example, a handpiece battery 104 could power three aerosolization sessions and have three predefined thresholds that distinguish how many sessions can be completed based on the battery voltage level meeting or exceeding the thresholds. More generally, a handpiece battery 104 capable of powering N aerosolization sessions could have N predefined thresholds that distinguish how many of the N sessions can be completed based on the battery voltage level.

[0061] In other words, the handpiece controller 102 can determine that a first number of remaining aerosolization sessions (e.g., two aerosolization sessions) can be powered by the handpiece battery 104 when the handpiece controller 102 determines that the voltage level of the handpiece battery 104 is equal to or greater than a first voltage threshold. The indicator 108 is configured to indicate the first number of remaining aerosolization sessions when the handpiece controller 102 determines that the voltage level of the handpiece battery 104 is equal to or greater than the first voltage threshold. The handpiece controller 102 can determine that a second number of remaining aerosolization sessions (e.g., zero aerosolization sessions) can be powered by the handpiece battery 102 when the handpiece controller 102 determines that the voltage level of the handpiece battery 104 is less than a second voltage threshold, the second voltage threshold being lower than the first voltage threshold and the second number of remaining aerosolization sessions being less than the first number of remaining aerosolization sessions. Indicator 108 is configured to indicate a second number of remaining aerosolization sessions when handpiece controller 102 determines that the voltage level of handpiece battery 104 is less than a second voltage threshold. Handpiece controller 102 can determine that a third number of remaining aerosolization sessions (e.g., one aerosolization session) can be powered by handpiece battery 104 when handpiece controller 102 determines that the voltage level of handpiece battery 104 is less than the first voltage threshold and greater than or equal to the second voltage threshold, the third number of remaining aerosolization sessions being less than the first number of aerosolization sessions and greater than the second number of aerosolization sessions. Indicator 108 is configured to indicate a third number of remaining aerosolization sessions when handpiece controller 102 determines that the voltage level of handpiece battery 104 is less than the first voltage threshold and greater than or equal to the second voltage threshold.

[0062] FIG. 4 shows an exemplary plot of SOC 402 versus open circuit voltage (V) 404 for a charge cycle 406 and a discharge cycle 408 for a specific example of an LFP battery configured as a handpiece battery 104 capable of storing enough energy to power an aerosol generating device for two aerosolization sessions.

[0063] As can be seen from FIG. 4, LFP batteries have a flat voltage curve, which can pose a problem to exploit the aforementioned advantages of LFP batteries, meaning that precise and expensive voltage measurement solutions may be used to avoid large errors. For example, these may include applying current measurements to perform coulomb counting, which requires the implementation of measurement shunts or other sensors, which adds cost, complexity, and increased device size. In another example, this may include using custom battery fuel gauge integrated circuits, which also adds cost and complexity, and increases device size. LFP batteries are also characterized by a hysteresis effect, which can result in different voltage levels for the same SOC depending on whether there has been a short history of charging or discharging. This makes it impossible to build a simple relationship between battery voltage and charge level.

[0064] Comparing the measured voltage to a predetermined voltage threshold to determine the number of aerosolization sessions the battery can power, as described in this disclosure, overcomes these problems. The advantages of comparing the measured voltage to a predetermined voltage threshold to determine the number of aerosolization sessions the battery can power, as described in this disclosure, can be applied not only to LFP batteries, but also to other battery technologies to achieve an accurate and computationally efficient determination of the number of remaining aerosolization sessions the handpiece battery can power.

[0065] For this example battery, an open circuit voltage of 3.25V is predetermined as the minimum voltage required to power two aerosolization sessions, and an open circuit voltage of 3.19V is predetermined as the minimum voltage required to power one aerosolization session. Thus, in this example, the first threshold voltage 410 is 3.25V and the second threshold voltage 412 is 3.19V. For this battery, when the handpiece controller 102 determines that the battery's voltage level is equal to or greater than 3.25V (i.e., the first voltage threshold), the handpiece controller 102 determines that the battery has sufficient charge to power two aerosolization sessions. When the handpiece controller 102 determines that the battery's voltage level is less than 3.19V (i.e., the second voltage threshold), the handpiece controller 102 determines that the battery cannot power any more aerosolization sessions (i.e., the battery has sufficient charge to power zero aerosolization sessions). When the handpiece controller 102 determines that the battery voltage level is less than 3.25 V (i.e., the first voltage threshold) and greater than or equal to 3.19 V (i.e., the second voltage threshold), the handpiece controller 102 determines that the battery has sufficient charge to power one aerosolization session.

[0066] In addition to addressing the aforementioned problems associated with the use of LFP batteries, the voltage threshold technique of the present disclosure does not require costly current measurements or any additional components. Moreover, it is robust and effective and takes into account the actual battery state of charge. This allows for a more accurate determination of the number of aerosolization sessions a handpiece battery can power than, for example, counting how many aerosolization sessions have been activated.

[0067] The predetermined voltage threshold may be predetermined during a factory calibration phase and stored in storage associated with and accessible by the handpiece controller 102. In some examples, the voltage threshold may be based on an average value determined for multiple batteries of the same type. In other examples, the voltage threshold may be uniquely determined for each battery.

[0068] As described, the handpiece 100 can be configured to display an indication of the number of aerosolization sessions remaining in response to a user input. The user can trigger the handpiece controller 102 to determine the remaining number of aerosolization sessions that can be powered by the handpiece battery 102, for example by pressing a button. In response to the user input, the handpiece controller 102 can determine the battery voltage using the voltage sensor 118 and compare it to a predetermined voltage threshold to determine the remaining number of aerosolization sessions that can be powered by the handpiece battery 104. The handpiece controller 102 then controls the indicator 108 to display the number of aerosolization sessions remaining to the operator.

[0069] In some examples, the user input may be a button. For example, the user input may be a dedicated button for monitoring the charge status of the handpiece battery 104. In another example, the handpiece 100 may have a button that triggers different functions when pressed in different ways (e.g., half-pressing or fully pressing the button). The handpiece 100 may have a heater ignition button that triggers the start of an aerosolization session. When the button is operated in a first way (e.g., half-press or short press), it triggers the handpiece controller 102 to determine the battery voltage and display the number of remaining aerosolization sessions that the handpiece battery 104 can power. When the button is operated in a second way (e.g., full press or long press), it triggers the handpiece controller 102 to control the device to start an aerosolization session.

[0070] After a charging load (e.g., when the handpiece battery 104 is being charged) or a discharging load (e.g., when the handpiece battery 104 is powering a heater) is applied to the handpiece battery 104, the voltage level measured by the handpiece controller 102 using the voltage sensor 118 may not provide a true representation of the number of sessions that can be powered. For a period of time after a charging load (i.e., when the handpiece battery 104 is being charged) is applied to the handpiece battery 104, the measured voltage will be higher than the measured voltage of a rest battery (i.e., there is a positive voltage excess in the measured battery voltage). After the charging load is removed, over time the voltage level will drop to the rest battery state. Similarly, for a period of time after a discharging load (i.e., a heating load when the heater is being powered) is applied to the handpiece battery 104, the measured voltage will be lower than the measured voltage of a rest battery (i.e., there is a negative voltage excess in the measured battery voltage). That is, the measured battery voltage is lower than the balanced battery voltage or the battery voltage that recovers after a rest period. After the discharge load is removed, over time the voltage level rises to the rest battery condition.

[0071] As a result, immediately after the handpiece battery 104 is charged, the determined voltage level may be higher than in the resting state, thereby suggesting that more aerosolization sessions are available than the actual available charge. Similarly, immediately after the handpiece battery 104 applies power to the heater, the determined voltage level may be lower than in the resting state, thereby suggesting that fewer aerosolization sessions are available than the actual available charge. The handpiece controller 102 may apply a compensation factor to the measured voltage level to account for these discrepancies, thereby providing an accurate and consistent indication of the number of available aerosolization sessions immediately after charging and / or discharging the handpiece battery 104, as well as in the resting state.

[0072] After charging power flow to the handpiece battery 104 is interrupted (i.e., when the handpiece 100 is removed from the charging case 200 or when power flow from the charging case battery 204 to the handpiece battery 104 is interrupted), the handpiece controller 104 can adjust the measured handpiece battery voltage by a first compensation factor (or post-charge compensation factor) when the elapsed time after charging power flow is removed is less than a first time threshold. This elapsed time can be considered a first elapsed time, or post-charge time, and the first time threshold can be considered a post-charge time threshold. The first compensation factor can be considered a calibration factor applied to the battery voltage measured during the post-charge period to adjust the measured battery voltage to represent the resting battery voltage.

[0073] The handpiece controller 102 may start a post-charge timer to monitor the time after charge after detecting that charge flow to the handpiece battery 104 has been interrupted. Also, when the handpiece controller 102 determines the voltage level of the handpiece battery 104, the handpiece controller 102 compares the elapsed time after charge to a time after charge threshold.

[0074] If the handpiece controller 102 determines that the time since charge is greater than or equal to the time since charge threshold, the battery has had sufficient rest time after charging, the measured battery voltage represents a rest battery condition, and the first compensation factor is not applied. If the handpiece controller 102 determines that the time since charge is less than the time since charge threshold, the handpiece controller 102 adjusts the measured battery voltage by the first compensation factor. The first compensation factor may be predetermined and stored in a memory associated with and accessible by the handpiece controller 102.

[0075] The first compensation factor may be variable as a function of elapsed post-charge time. That is, the longer the elapsed time, the smaller the compensation factor as the handpiece battery 104 approaches a dormant state. For example, the handpiece controller 102 may access a lookup of compensation factors for various elapsed post-charge times and determine and apply a compensation factor for the elapsed time. In this manner, the measured voltage level may be precisely adjusted. In the alternative, the first compensation factor may be a fixed value rather than time-varying. This may reduce the processing burden compared to determining a time-varying compensation factor.

[0076] In other words, the first compensation factor can be subtracted from the measured battery voltage to provide an adjusted battery voltage that takes into account that the voltage after charging is blocked is higher than at rest. In one example, the first time threshold after charging is blocked can be 30 minutes.

[0077] After the heating load is removed from the handpiece battery 104 (i.e., when the battery stops supplying power to the heater), the handpiece controller 102 can adjust the measured battery voltage by a second compensation factor (or post-heat compensation factor) when the elapsed time after the heating load is removed is less than a second time threshold. This elapsed time can be considered a second elapsed time, or post-heat time, and the second time threshold can be considered an post-heat time threshold. The second compensation factor can be considered a calibration factor applied to the battery voltage measured during the post-heat period to adjust the measured battery voltage to represent the resting battery voltage.

[0078] The handpiece controller 102 may start an after-heat timer to monitor the after-heat time after detecting that the heating load has been removed from the handpiece battery 104. Also, when the handpiece controller 102 determines the voltage level of the handpiece battery 104, the handpiece controller 102 compares the elapsed after-heat time to an after-heat time threshold.

[0079] If the handpiece controller 102 determines that the after-heat time is equal to or greater than the after-heat time threshold, the handpiece battery 104 has had sufficient rest time after the heating load was applied, so the measured battery voltage represents a rest battery condition and the second compensation factor is not applied. If the handpiece controller 102 determines that the after-heat time is less than the after-heat time threshold, the handpiece controller 102 adjusts the measured battery voltage by the second compensation factor. The second compensation factor may be predetermined and stored in a memory associated with and accessible by the handpiece controller 102.

[0080] The second compensation factor may be variable as a function of elapsed post-heating time. That is, the longer the elapsed time, the smaller the compensation factor as the handpiece battery 104 approaches a dormant state. For example, the handpiece controller 102 may access a lookup of compensation factors for various elapsed post-heating times and determine and apply a compensation factor for the elapsed time. In this manner, the measured voltage level may be precisely adjusted. In the alternative, the second compensation factor may be a fixed value rather than time-varying. This may reduce the processing burden compared to determining a time-varying compensation factor.

[0081] In other words, a second compensation factor can be added to the measured battery voltage to provide an adjusted battery voltage that takes into account that the voltage after the heating load is removed is lower than at rest. In one example, the second time threshold after the heating load is removed from the handpiece battery can be 30 minutes.

[0082] When the handpiece battery 104 is fully charged by the charging case 200, a charge state control parameter in the handpiece controller 102 can be set to a state called “fully charged.” For example, firmware in the handpiece controller 102 can have a parameter that is set to a logic state of 1 when the handpiece battery 104 is fully charged (the “fully charged” state) and is set to a logic state of 0 when the handpiece battery 104 is not fully charged (the “not fully charged” state).

[0083] During the charging process, the charging case battery 204 provides charging to the handpiece battery 104 through the power connectors of power / data connectors 110 and 210 between the handpiece 100 and the charging case 200. When the charging case controller 202 determines that the handpiece battery 104 is fully charged, it blocks power flow from the charging case battery 204 to the handpiece battery 104. The charging case controller 202 can then also use the data connectors of power / data connectors 110 and 210 to set a charging state control parameter in the handpiece controller 102 to a “fully charged” state. Alternatively, the handpiece controller 102 can detect that the handpiece battery 104 is fully charged and set the charging state control parameter to a “fully charged” state.

[0084] When the handpiece battery 104 is subsequently (at least partially) discharged, for example, by applying a heating load to a heater, the handpiece controller 102 can switch the parameter to a "not full" state.

[0085] When the handpiece controller 102 is triggered to determine a voltage level to determine the number of remaining aerosolization sessions that can be powered by the handpiece battery 104, the handpiece controller 102 may first check the state-of-charge control parameter before determining the handpiece battery voltage level. When the state-of-charge control parameter is not set to indicate that the handpiece battery is fully charged (i.e., the state-of-charge control parameter is in the "not fully charged" state), the handpiece controller 102 proceeds to determine the voltage level of the handpiece battery 104 (e.g., using the voltage sensor 118) to determine the number of remaining aerosolization sessions that can be powered by the handpiece battery 104. When the state-of-charge control parameter is set to indicate that the handpiece battery 104 is fully charged (i.e., the state-of-charge control parameter is in the "fully charged" state), the handpiece controller 102 does not determine the voltage level of the handpiece battery 104. Instead, handpiece controller 102 determines that handpiece battery 104 has enough energy to power the maximum number of aerosolization sessions (two in the LFP battery example above) because the state-of-charge control parameter indicates that handpiece battery 104 is fully charged and has not yet been discharged or partially discharged. In this manner, processing overhead in handpiece controller 102 may be reduced by not having handpiece controller 102 determine the battery voltage when the battery is fully charged.

[0086] In light of the above discussion, it can be seen that the handpiece controller 102 can determine the number of aerosolization sessions for which the handpiece battery 104 has a sufficient charge level to power based on several criteria.

[0087] The handpiece controller 102 may determine that the handpiece battery 104 has a sufficient charge level to power a first number of aerosolization sessions (e.g., a maximum number of aerosolization sessions, or two aerosolization sessions in the previous example of an LFP battery capable of powering a maximum of two sessions) if the handpiece controller 102 determines at least one of the following: The charge state control parameter is set to indicate that the handpiece battery 104 is fully charged (i.e., the charge state control parameter is in the "Fully Charged" state). The elapsed time since charge is greater than or equal to a time since charge threshold and the measured battery voltage level is greater than or equal to a first voltage threshold. The elapsed post-charge time is less than a post-charge time threshold and the battery voltage level adjusted using the post-charge compensation factor is greater than or equal to a first voltage threshold. The elapsed post-heat time is greater than or equal to an post-heat time threshold and the measured battery voltage level is greater than or equal to a first voltage threshold. The elapsed after-heat time is less than an after-heat time threshold and the battery voltage level adjusted using the after-heat compensation factor is greater than or equal to a first voltage threshold.

[0088] The handpiece controller 102 can determine that the handpiece battery 104 has a sufficient charge level to power a second number of aerosolization sessions (e.g., zero aerosolization sessions) when the handpiece controller 102 determines at least one of the following: The elapsed time since charge is greater than or equal to a time since charge threshold and the measured battery voltage level is less than a second voltage threshold. The elapsed post-charge time is less than the post-charge time threshold and the battery voltage level adjusted using the post-charge compensation factor is less than the second voltage threshold. The elapsed post-heat time is greater than or equal to the post-heat time threshold and the measured battery voltage level is less than a second voltage threshold. The elapsed after-heat time is less than the after-heat time threshold and the battery voltage level adjusted using the after-heat compensation factor is less than the second voltage threshold.

[0089] The handpiece controller 102 can determine that the handpiece battery 104 has a sufficient charge level to power a third number of aerosolization sessions (e.g., an intermediate number of aerosolization sessions between the first and second numbers, or two aerosolization sessions in the previous example of an LFP battery capable of powering up to two sessions) when the handpiece controller 102 determines at least one of the following: the elapsed time since charge is greater than or equal to a time since charge threshold and the measured battery voltage level is less than a first voltage threshold and greater than or equal to a second voltage threshold. The elapsed post-charge time is less than a post-charge time threshold and the battery voltage level adjusted using the post-charge compensation factor is less than a first voltage threshold and greater than or equal to a second voltage threshold. the elapsed post-heat time is greater than or equal to an post-heat time threshold and the measured battery voltage level is less than a first voltage threshold and greater than or equal to a second voltage threshold; or The elapsed after-heat time is less than an after-heat time threshold and the battery voltage level adjusted using the after-heat compensation factor is less than the first voltage threshold and greater than or equal to a second voltage threshold.

[0090] FIG. 5 illustrates an exemplary process flow of steps performed by handpiece controller 102 in accordance with the foregoing description.

[0091] In step 503, the handpiece controller 102 determines the elapsed time (i.e., the first elapsed time) since charging power flow to the handpiece battery 104 was interrupted. Optionally, in step 504, the handpiece controller 102 determines a second elapsed time since the handpiece battery 104 was at least partially discharged (e.g., the elapsed time since power flow from the battery to the heater was terminated).

[0092] In step 505, the handpiece controller 102 determines a measured voltage level of the battery. In step 506, the handpiece controller 102 adjusts the measured voltage level by a compensation factor (i.e., a first compensation factor) when the elapsed time is less than a time threshold (i.e., a first time threshold). When the elapsed time is equal to or greater than the time threshold, the measured voltage level is not adjusted by the compensation factor.

[0093] Optionally, in step 507, the handpiece controller 102 adjusts the measured voltage level by the second compensation factor when the second elapsed time is less than the second time threshold, and does not adjust the measured voltage level by the second compensation factor when the second elapsed time is greater than or equal to the second time threshold.

[0094] In other words, the handpiece controller 102 can compensate for the voltage overshoot in the measured battery voltage to determine the desired balanced battery voltage. BATT ) is U BATT =U EQUILIBRATED +U RELAXATION It can be defined as U RELAXATION is the voltage excess (negative for discharging, positive for charging). The controller then calculates U as a function of time. RELAXATION Estimate and subtract this to get U EQUILIBRATED Then, U EQUILIBRATED , the measured battery voltage U BATT This can be used to estimate the energy content of the battery based on

[0095] If the handpiece controller 102 determines that the first elapsed time is less than the first time threshold (after charging) and the second elapsed time is less than the second time threshold (after heating), the handpiece controller 102 may adjust the measured voltage level by both the first compensation factor and the second compensation factor.

[0096] In step 508, the handpiece controller 102 controls the indicator 108 to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level.

[0097] Optionally, prior to step 503, handpiece controller 102 may determine whether handpiece battery 104 is fully charged by determining whether a control parameter is set to a state indicative of a full charge. When the control parameter is set to a state indicative of a full charge, the process may proceed to optional step 502, where handpiece controller 104 controls an indicator to indicate a maximum number of remaining aerosolization sessions that can be powered by handpiece battery 104. When the control parameter is not set to a state indicative of a full charge, the process may proceed to step 503.

[0098] Those skilled in the art will readily appreciate that the process steps described with reference to Figure 5 may be performed in any suitable order. In an alternative process flow similar to that of Figure 5, handpiece controller 102 may be configured to perform steps 504 and 507, with steps 503 and 506 being optional. In another alternative process flow similar to that of Figure 5, handpiece controller 102 may be configured to perform steps 501 and 502, with steps 503-507 being optional.

[0099] While the above discussion describes the handpiece controller 102 making the determination of the number of remaining aerosolization sessions that can be powered by the handpiece battery 104, these processing steps could alternatively be performed by the charging case controller 202 in communication with the handpiece 100 through data connectors 110 and 210 between the charging case 200 and the handpiece 100. In such an alternative example, the charging case 200 could also incorporate an indicator 108 that indicates the number of remaining aerosolization sessions.

[0100] While the above description describes the aerosol generating device as a two-part system including the handpiece 100 and the charging case 200, in alternative examples, the aerosol generating device can be a one-part system including only the handpiece. In such alternative examples, the handpiece can be charged from an external power source, such as a power bank or mains adapter, and the first elapsed time can be based on a period of time since the handpiece was disconnected from the external power source. In such alternative examples, a charge state control parameter can be set by the handpiece controller when the battery is determined to be fully charged. In some examples of such alternatives, the handpiece can be configured to power more than two aerosolization sessions when the battery is fully charged.

[0101] In the above description, the controller can store instructions for controlling the aerosol generating device and the power system in the manner described. Those skilled in the art will readily appreciate that the controller can be configured to perform any of the above manners in suitable combination with each other. The process steps described herein performed by the controller can be stored in a non-transitory computer readable medium, or storage device, associated with the controller. Computer readable media may include non-volatile media and volatile media. Volatile media may include semiconductor memory and dynamic memory, among others. Non-volatile media may include optical and magnetic disks, among others.

[0102] Those skilled in the art will readily understand that the preceding embodiments in the above description are not limiting, and that the features of each embodiment may be appropriately incorporated into other embodiments.

Claims

1. An aerosol generating device configured to aerosolize an aerosol generating consumable, the aerosol generating device comprising: a battery configured to provide an electric current to a heater; a controller configured to determine a voltage level of the battery, wherein the voltage level of the battery is determined as a measured voltage of the battery when an elapsed time after a charging current to the battery is blocked is equal to or greater than a time threshold, and the voltage level of the battery is determined as the measured voltage of the battery adjusted by a compensation factor when the elapsed time is less than the time threshold; and the controller is further configured to control an indicator to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level. An aerosol generating device.

2. The aerosol generating device according to claim 1, further comprising a handpiece and a charging case connectable to the handpiece, the handpiece comprising the battery and the controller and being configured to aerosolize the aerosol generating consumable, and the charging case being configured to charge the battery of the handpiece when the handpiece is connected to the charging case.

3. The aerosol generating device according to claim 2, wherein the controller is configured to determine the elapsed time after the charging current is blocked based on the elapsed time after the handpiece is disconnected from the charging case.

4. The aerosol generating device according to claim 1, wherein the indicator is configured to indicate a first number of remaining aerosolization sessions when the controller determines that the voltage level of the battery is equal to or greater than a first voltage threshold.

5. The aerosol generating device according to claim 4, wherein the indicator is configured to indicate a second number of remaining aerosolization sessions when the controller determines that the voltage level of the battery is less than a second voltage threshold, the second voltage threshold being lower than the first voltage threshold, and the second number of remaining aerosolization sessions being less than the first number of remaining aerosolization sessions.

6. The indicator is configured to indicate a third number of remaining aerosolization sessions when the controller determines that the voltage level of the battery is less than the first voltage threshold and greater than or equal to the second voltage threshold, and the third number of remaining aerosolization sessions is less than the first number of aerosolization sessions and greater than the second number of aerosolization sessions, the aerosol generating device according to claim 5.

7. The controller determines the voltage level of the battery when a second elapsed time after the battery is at least partially discharged is greater than or equal to a second time threshold, as the measured voltage of the battery, and when the second elapsed time is less than the second time threshold, determines it as the measured voltage of the battery adjusted by a second compensation factor the aerosol generating device according to claim 1, configured as such.

8. The controller determines whether the battery is fully charged, and when it is determined that the battery is fully charged, is further configured to indicate the first number of remaining aerosolization sessions by the indicator, the aerosol generating device according to claim 4.

9. The controller is configured to determine that the battery is fully charged by determining that a control parameter is set to a state indicating full charge, the aerosol generating device according to claim 8.

10. The battery is a lithium iron phosphate battery, the aerosol generating device according to claim 1.

11. The aerosol generating device comprises user input means operable in a first mode that triggers aerosolization of the aerosol generating consumable and in a second mode that triggers the controller to determine the voltage level of the battery and to control the indicator to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level, the aerosol generating device according to claim 1.

12. The aerosol generating device further comprises a pulse width modulation module connected to the controller, and the pulse width modulation module is configured to convert the power flow from the battery to the heater into a pulse width modulated power flow, the aerosol generating device according to claim 1.

13. The aerosol generating consumable is a tobacco rod, and the aerosol generating device is configured to generate an aerosol by heating the tobacco rod without burning it in an aerosolization session, the aerosol generating device according to claim 1.

14. A method of operating an aerosol generating device configured to aerosolize an aerosol generating consumable, the aerosol generating device comprising a battery configured to provide an electric current flow to a heater, the method comprising: determining an elapsed time since a charging current flow to the battery was blocked; determining a voltage level of the battery, wherein determining the voltage level of the battery includes determining the voltage level of the battery as the measured voltage of the battery when the elapsed time after the charging current flow to the battery is blocked is greater than or equal to a time threshold; wherein determining the voltage level of the battery includes determining the voltage level of the battery as the measured voltage of the battery adjusted by a compensation factor when the elapsed time is less than the time threshold; and controlling an indicator to indicate the number of remaining aerosolization sessions that can be powered by the battery based on the determined voltage level; A method including the above.

15. A non-transitory computer-readable medium, when executed by one or more processors of a controller configured for operation in an aerosol generating device configured to aerosolize an aerosol generating consumable and comprising a battery configured to provide an electric current flow to a heater, causes the one or more processors to: using a timer, determining an elapsed time since a charging current flow to the battery was blocked; determining a voltage level of the battery using a voltage sensor of the aerosol generating device, wherein determining the voltage level of the battery includes determining the voltage level of the battery as the measured voltage of the battery when the elapsed time after the charging current flow to the battery is blocked is greater than or equal to a time threshold; Determining the voltage level of the battery includes, when the elapsed time is less than the time threshold, determining the voltage level of the battery as the measured voltage of the battery after adjustment by a compensation factor, as a step; Based on the determined voltage level, controlling an indicator of the aerosol generator to indicate the number of remaining aerosolization sessions that can be powered by the battery; A non-transitory computer-readable medium storing a set of instructions for causing the above to be performed.

Images