Aerosol generating device with battery monitoring arrangement

Abstract

To provide an aerosol generating device that can reliably detect any physical expansion of a rechargeable battery.SOLUTION: An aerosol generating device 10 comprises: a housing 16 defining a cavity 18 for receiving an aerosol-generating substance 26; a controller 22; and a rechargeable battery 20 positioned in the housing 16. The controller 22 is configured to detect expansion of the rechargeable battery 20 in the housing 16.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates generally to aerosol generating devices, and more particularly to aerosol generating devices for heating an aerosol-generating substance to generate an aerosol for inhalation by a user. [Background technology]

[0002] In recent years, devices that heat, rather than burn, aerosol-generating materials to produce aerosols for inhalation have become popular with consumers. Such devices can provide heat to the aerosol-generating material using one of several different techniques.

[0003] One approach is to provide an aerosol generating device that employs a resistive heating system, in which a resistive heating element is provided to heat an aerosol-generating substance to generate a vapor, which typically cools and condenses to form an aerosol for inhalation by a user of the device.

[0004] Another approach is to provide an aerosol-generating device that employs an induction heating system. Such devices include an induction coil and a susceptor. When a user activates the device, electrical energy is supplied to the induction coil, which in turn generates an alternating electromagnetic field. The susceptor couples with the electromagnetic field, generating heat, which is transferred, for example by conduction, to the aerosol-generating material, generating vapor, which typically cools and condenses to form an aerosol for inhalation by the user of the device.

[0005] Whichever approach is used to heat the aerosol-generating material, it may be preferable for the aerosol-generating device to include a rechargeable battery to provide the necessary power to the resistive heating element or induction coil. However, the use of rechargeable batteries may have certain drawbacks, which the present disclosure seeks to mitigate. Summary of the Invention [Means for solving the problem]

[0006] According to a first aspect of the present disclosure, there is provided an aerosol generating device, the aerosol generating device comprising: a housing defining a cavity for receiving an aerosol-generating material; A controller; a rechargeable battery disposed within the housing; The controller is configured to detect swelling of the rechargeable battery within the housing.

[0007] The aerosol generating device is adapted to heat the aerosol generating substance without burning it to volatilize at least one component of the aerosol generating substance, thereby generating a vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol generating device.

[0008] Generally speaking, a vapor is a substance that is in the gas phase below its critical temperature, meaning that the vapor can be condensed into a liquid by increasing the pressure without decreasing the temperature. An aerosol, on the other hand, is a suspension of fine solid particles or liquid droplets in air or another gas. However, the terms "aerosol" and "vapor" are used interchangeably herein, particularly with respect to the form of inhalable medium that is generated for inhalation by a user. Note that we obtain

[0009] Detection of physical swelling of the rechargeable battery is easily achieved by the controller, thereby avoiding possible damage to the aerosol generating device, for example, by allowing the device to be taken out of use and / or by taking action to replace the rechargeable battery and / or by allowing the controller to change how the rechargeable battery is charged and / or discharged.

[0010] The aerosol generating device may include a conductive component having electrical properties that vary in response to expansion of the rechargeable battery within the housing. The conductive component may be disposed within the housing such that expansion of the rechargeable battery within the housing causes deformation of the conductive component. The variation in the electrical properties of the conductive component provides a reliable indication that there is physical expansion of the rechargeable battery.

[0011] The electrical properties of the conductive components may change based on the deformation of the conductive components. Thus, the degree of physical expansion of the rechargeable battery can be determined based on the variations in the electrical properties. For example, a small variation in the electrical properties may indicate a small physical expansion of the rechargeable battery, which may indicate no reason for intervention or replacement, while a large variation in the electrical properties may indicate a large physical expansion of the rechargeable battery, which may indicate a reason for intervention or replacement.

[0012] The controller may be configured to detect swelling of the rechargeable battery based on variations in the detected electrical properties of the conductive components. Thus, the controller can reliably detect any physical swelling of the rechargeable battery based on variations in the electrical properties of the conductive components.

[0013] A rechargeable battery may include one or more rechargeable cells contained within a battery housing. The battery housing may have any suitable shape, such as a substantially cylindrical shape, a substantially button- or coin-shaped shape, or a substantially rectangular shape. It will be apparent to those skilled in the art that these housing shapes are provided purely by way of example, and that other housing shapes may be used and are fully within the scope of the present disclosure.

[0014] The electrical characteristic may include an electrical resistance of the conductive component, and the controller may be configured to monitor the electrical resistance of the conductive component, whereby the controller may be configured to detect physical expansion of the rechargeable battery based on a detected change in the electrical resistance of the conductive component.

[0015] The electrical characteristic may include the conductivity of the conductive components, and the controller may be configured to detect a discontinuity in the conductivity. For example, the conductive components may be configured to mechanically fail under tension when the rechargeable battery swells. In this configuration, the controller may be configured to detect physical expansion of the battery based on the detected discontinuity in the conductivity of the conductive components.

[0016] The conductive component may extend around at least a portion of the exterior surface of the rechargeable battery.The structure of the aerosol generating device may be simplified.

[0017] The conductive component may extend substantially along the entire periphery (e.g., perimeter) of the rechargeable battery, which may allow any swelling of the rechargeable battery to be reliably detected.

[0018] The conductive component may extend around the exterior surface of the rechargeable battery over a distance greater than the circumference (e.g., periphery) of the rechargeable battery. The ends of the conductive component may be displaced relative to each other in the axial direction of the rechargeable battery. In one example, the conductive component may be wrapped diagonally or spirally around the rechargeable battery. In another example, one or more portions of the conductive component may extend substantially in the axial direction of the rechargeable battery. These configurations allow the conductive component to cover a larger surface area of the rechargeable battery, thereby enabling more reliable detection of swelling of the rechargeable battery.

[0019] The conductive component may be provided on the exterior surface of the rechargeable battery. For example, the conductive component may be coated, glued, printed, deposited, or otherwise fabricated on the exterior surface of the rechargeable battery. Direct, intimate contact between the conductive component and the exterior surface of the rechargeable battery may facilitate detection of swelling of the rechargeable battery and may allow for a simplified construction of the aerosol generating device.

[0020] The conductive component may be disposed adjacent to an exterior surface of the rechargeable battery. In this example, the conductive component may be an integral component part of the aerosol generating device. For example, the conductive component may be provided on the housing of the aerosol generating device.

[0021] The conductive components may comprise conductive tracks or conductive strips.

[0022] The controller may be configured to generate an alert upon detecting a swelling of the rechargeable battery, which may enable a user of the aerosol generating device to take appropriate action, for example by ceasing use of the device and possibly removing and replacing the rechargeable battery.

[0023] The aerosol generating device may include a heater electrically connected to the rechargeable battery and configured to heat the aerosol-generating material disposed within the cavity, and the controller may be configured to electrically disconnect the heater from the rechargeable battery upon detecting expansion of the rechargeable battery. Further use of the device and anticipated further physical expansion of the rechargeable battery may be prevented, thereby minimizing the risk of physical damage to the aerosol generating device by preventing continued use.

[0024] The heater may comprise a resistive heater. The resistive heater may include a resistive heating element. The resistive heating element may include an electrically resistive material. Examples of suitable electrically resistive materials include, but are not limited to, metals, metal alloys, conductive ceramics such as tungsten and its alloys, and composite materials including metallic and ceramic materials.

[0025] The heater may comprise an induction coil configured to generate an alternating current electromagnetic field for inductively heating the inductively heatable susceptor. The induction coil may comprise Litz wire or Litz cable; however, it will be understood that other materials may be used. The induction coil may extend around the cavity.

[0026] The induction coil may be substantially helical in shape. The circular cross-section of a helical induction coil may facilitate insertion of the aerosol-generating material, or an aerosol-generating article, for example, including the aerosol-generating material, and optionally one or more inductively heatable susceptors, into the cavity and ensure uniform heating of the aerosol-generating material.

[0027] The inductively heatable susceptor may include one or more of aluminum, iron, nickel, stainless steel, and alloys thereof, such as nickel chromium or nickel copper. Without limitation, application of an electromagnetic field in the vicinity of a susceptor can cause the susceptor to generate heat due to eddy currents and magnetic hysteresis losses resulting in electromagnetic-to-thermal energy conversion.

[0028] The induction coil may be configured, in use, to operate with a varying electromagnetic field having a magnetic flux density of between about 20 mT and about 2.0 T at its highest density point.

[0029] The controller may include electronic circuitry. The rechargeable battery and electronic circuitry may be configured to operate at high frequencies. The rechargeable battery and electronic circuitry may be configured to operate at frequencies of about 80 kHz to 500 kHz, optionally about 150 kHz to 250 kHz, optionally about 200 kHz. The rechargeable battery and electronic circuitry may be configured to operate at higher frequencies, for example in the MHz range, depending on the type of inductively heatable susceptor used.

[0030] The aerosol-generating material can be any type of solid or semi-solid material. Exemplary types of aerosol-generating solids include powders, granules, pellets, shreds, strands, particles, gels, strips, loose-leaf, cut-leaf, cut-filler, porous materials, foam materials, or sheets. The aerosol-generating material may include plant-derived materials, particularly tobacco. The plant-derived material may advantageously include reconstituted tobacco.

[0031] The aerosol-generating material may be surrounded by a wrapping paper and thus embodied as an aerosol-generating article. The aerosol-generating article may be substantially rod-shaped. The aerosol-generating article may include a filter, for example, comprising cellulose acetate fibers. The filter may be coaxially disposed adjacent to the aerosol-generating material.

[0032] The aerosol-generating material may be configured within a shell and thus embodied as an aerosol-generating article. The shell may be a breathable shell or may comprise an electrically insulating, non-magnetic material. The shell may comprise a breathable material, e.g., a porous material. This material may have high breathability, allowing air to flow through it, along with resistance to high temperatures. Examples of suitable breathable materials include cellulose fibers, paper, cotton, and silk. The breathable material may also function as a filter. Alternatively, the shell may comprise a material that is not breathable, e.g., a non-porous material, but includes perforations or openings to allow air to pass through the shell.

[0033] The aerosol-generating material may include an aerosol-forming agent. Examples of aerosol-forming agents include polyhydric alcohols, such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-generating material may contain about 5% to about 50% aerosol-forming agent by dry weight. In some embodiments, the aerosol-generating material may contain about 10% to about 20% aerosol-forming agent by dry weight, and in some cases about 15% by dry weight.

[0034] In another example, the aerosol-generating substance may be the aerosol-forming agent itself. Thus, the aerosol-generating substance may be a liquid. In this case, the aerosol-generating device may include a liquid transfer element (e.g., a wick) associated with a heater, which allows the liquid to be vaporized by the heater, forming a vapor that can be expelled / emitted from the liquid transfer element, and the vapor then cools and condenses to form an aerosol suitable for inhalation by a user of the aerosol-generating device.

[0035] Upon heating, the aerosol-generating material may release volatile compounds, which may include flavor compounds such as nicotine or tobacco flavorings. [Brief explanation of the drawings]

[0036] [Figure 1] 1 is a schematic cross-sectional view of an example of an aerosol generating device including a rechargeable battery and a conductive component extending around the exterior of the battery. [Figure 2] 2 is a schematic cross-sectional view taken along line AA in FIG. 1 showing the rechargeable battery in an unexpanded state. [Figure 3] 2 is a schematic cross-sectional view taken along line AA in FIG. 1 showing the rechargeable battery in an expanded state. [Figure 4] 3 is a schematic diagram similar to FIG. 2 of an alternative embodiment in which the conductive component extends around a portion of the exterior surface of the rechargeable battery. [Figure 5]4 is a schematic diagram similar to FIG. 3 of an alternative embodiment in which the conductive component extends around a portion of the exterior surface of the rechargeable battery. [Figure 6] 2 is a schematic cross-sectional view similar to FIG. 1 showing only the rechargeable battery and the conductive component spiraling around the exterior surface of the rechargeable battery. DETAILED DESCRIPTION OF THE INVENTION

[0037] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0038] 1-3, an example aerosol generation system 1 is shown schematically. The aerosol generation system 1 comprises an aerosol generation device 10 and an example aerosol-generating article 24. The aerosol generation device 10 comprises a housing 16 having a proximal end 12 and a distal end 14 and defining a cavity 18. The housing 16 includes one or more air inlets 19 for supplying air to the cavity 18. The aerosol generation device 10 further comprises a power source in the form of a rechargeable battery 20, and a controller 22. Although only one rechargeable battery 20 is shown in FIG. 1, it will be understood that the power source may comprise multiple rechargeable batteries 20, and that the or each rechargeable battery 20 may be inductively rechargeable, for example.

[0039] The aerosol-generating device 10 is generally cylindrical, and the cavity 18 defined by the housing 16 is also cylindrical and takes the form of a cylindrical heating section. The cavity 18 is configured to receive a correspondingly shaped, generally cylindrical or rod-shaped aerosol-generating article 24 containing an aerosol-generating material 26. The aerosol-generating article 24 is a disposable article and may contain, for example, tobacco as the aerosol-generating material 26. The aerosol-generating article 24 has a first end 28 and a second end 30 and includes a paper wrapper 32 surrounding the aerosol-generating material 26. The aerosol-generating article 24 also includes a filter 34 at the first end 28, which is coaxially disposed adjacent to the aerosol-generating material 26 and the paper wrapper 32. The filter 34 functions as a mouthpiece and includes a breathable plug, for example, comprising cellulose acetate fibers. Both the paper wrapper 32 and the filter 34 are enclosed in an outer wrapper 36, typically comprising tipping paper. In an alternative embodiment not shown, the filter 34 can be omitted and the aerosol generating device 10 can instead include an integral mouthpiece.

[0040] The aerosol generating device 10 includes a heater 37 for heating the aerosol generating material 26 without burning the aerosol generating material 26. In the illustrated embodiment, the heater 37 comprises a resistive heating element 38 disposed radially outward of and extending around the cavity 18.

[0041] During operation of the aerosol-generating system 1, an electric current is supplied to the resistive heating element 38, causing the resistive heating element to heat up. Heat from the resistive heating element 38 is transferred, for example, by conduction, radiation, and convection, to the aerosol-generating material 26 disposed within the cavity 18, causing the aerosol-generating material Heating the substance 26 generates a vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol-generating system 1. Vaporization of the aerosol-generating substance 26 is aided by adding air from the surrounding environment through the air inlet 19.

[0042] The aerosol generating device 10 includes a conductive component 40 in the form of a conductive track 42. In the example shown in FIGS. 1-3 , the rechargeable battery 20 is substantially circular in cross section, and the conductive track 42 extends circumferentially around substantially the entire circumference of the outer surface 20 a of the rechargeable battery 20. As is evident from the cross-sectional view of FIG. 2 , which shows the rechargeable battery 20 in an unexpanded state, the conductive track 42 is disposed adjacent to the outer surface 20 a of the rechargeable battery 20. More specifically, the conductive track 42 is disposed on the housing 16 within the battery compartment in which the rechargeable battery 20 is disposed. In another example (not shown), the conductive track 42 may be disposed on the outer surface 20 a of the rechargeable battery 20 by, for example, coating, adhering, printing, depositing, or otherwise manufacturing the conductive track 42 on the outer surface 20 a of the rechargeable battery 20. In either case, the conductive track 42 is configured such that the conductive track 42 remains intact and conductive when the rechargeable battery 20 is in the unexpanded state shown in FIG. 2 .

[0043] 1-3, the conductive track 42 is formed of a substantially non-extensible material. Thus, if the rechargeable battery 20 expands by a predetermined amount or beyond a predetermined threshold, the conductive track 42 will be subjected to tension and will pull apart and become disconnected, for example at point A in FIG. 3, resulting in a discontinuity in the conductivity of the conductive track 42. The controller 22 may be configured to detect the discontinuity in the conductivity of the conductive track 42, thereby detecting expansion of the rechargeable battery 20 within the housing 16.

[0044] In another example, shown in Figures 4 and 5, the conductive track 42 extends around only a portion of the outer surface 20a of the rechargeable battery 20. The conductive track 42 comprises an extensible material that mechanically stretches under tension when the rechargeable battery 20 expands within the housing 16. The stretching of the conductive track 42 due to the expansion of the rechargeable battery 20 is apparent from a comparison of Figures 4 and 5. The conductive track 42 has a resistance that changes (e.g., increases or decreases) as it deforms, and in particular as it stretches. The controller 22 can be configured to detect the change in resistance of the conductive track 42, thereby detecting the expansion of the rechargeable battery 20 within the housing 16.

[0045] In some embodiments, the controller 22 may be configured to generate an alert upon detecting swelling of the rechargeable battery 20, e.g., based on a detected discontinuity in the conductivity of the conductive track 42 ( FIGS. 2 and 3 ) or a detected change in the resistance of the conductive track 42 ( FIGS. 4 and 5 ). The alert may notify a user of the aerosol generating device 10 that swelling of the battery 20 has been detected, thereby enabling the user to, for example, discontinue use of the device 10 and / or replace the rechargeable battery 20. Alternatively or additionally, the controller 20 may be configured, upon detecting physical swelling of the rechargeable battery 20, to electrically disconnect the resistive heating element 38 from the rechargeable battery 20 and / or to modify the charge and / or discharge characteristics of the rechargeable battery 20, e.g., to minimize the rate of further swelling and extend the useful life of the rechargeable battery 20.

[0046] 6, an alternative embodiment of a conductive track 42 that extends spirally around the exterior surface 20a of the rechargeable battery 20 is shown. In this alternative embodiment, the conductive track 42 extends around the exterior surface 20a for a total distance that is greater than the circumference of the rechargeable battery 20. As mentioned above, a configuration in which the conductive track 42 extends around the exterior surface 20a of the rechargeable battery 20 for a distance that is greater than the circumference of the rechargeable battery 20 is referred to as a conductive track 42. 2 covers a larger surface area of the rechargeable battery 20, which may allow swelling of the rechargeable battery 20 to be detected more reliably.

[0047] While exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications can be made to these embodiments without departing from the scope of the appended claims, and therefore, the breadth and scope of the claims should not be limited to the exemplary embodiments described above.

[0048] Any combination of the above-described features in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or clearly contradicted by context.

[0049] Unless the context clearly dictates otherwise, throughout this specification and the claims, the words "comprises," "including," "comprises," and the like are to be construed in an inclusive sense, i.e., "including but not limited to," rather than in an exclusive or exhaustive sense.

Claims

1. An aerosol generating device (10), comprising: a housing (16) defining a cavity (18) for receiving an aerosol-generating material (26); a controller (22); a rechargeable battery (20) disposed within the housing (16); The aerosol generating device (10), wherein the controller (22) is configured to detect expansion of the rechargeable battery (20) within the housing (16).

2. 2. The aerosol generating device of claim 1, wherein the aerosol generating device includes a conductive component having electrical characteristics that vary in response to expansion of the rechargeable battery within the housing.

3. 3. The aerosol generating device of claim 2, wherein the conductive component (40) is arranged within the housing (16) such that expansion of the rechargeable battery (20) within the housing (16) causes deformation of the conductive component (40).

4. 4. The aerosol generating device of claim 3, wherein the electrical properties of the conductive component (40) vary based on the deformation of the conductive component (40).

5. 5. The aerosol generating device of claim 2, wherein the controller is configured to detect expansion of the rechargeable battery based on a detected variation in the electrical characteristic of the conductive component.

6. An aerosol generating device as described in any one of claims 2 to 5, wherein the electrical characteristic includes an electrical resistance of the conductive component (40), and the controller (22) is configured to monitor the electrical resistance of the conductive component (40).

7. An aerosol generating device as described in any one of claims 2 to 6, wherein the electrical characteristics include the conductivity of the conductive component (40), and the controller (22) is configured to detect a break in the conductivity.

8. 8. An aerosol generating device according to any one of claims 2 to 7, wherein the conductive component (40) extends around at least a portion of the outer surface (20a) of the rechargeable battery (20).

9. 9. An aerosol generating device according to any one of claims 2 to 8, wherein the conductive component (40) extends along substantially the entire periphery of the rechargeable battery (20).

10. 9. An aerosol generating device according to any one of claims 2 to 8, wherein the conductive component (40) extends around the outer surface (20a) of the rechargeable battery (20) over a distance greater than the circumference of the rechargeable battery (20).

11. 11. The aerosol generating device of claim 10, wherein the ends of the conductive component (40) are displaced relative to each other in the axial direction of the rechargeable battery (20).

12. 12. The aerosol generating device according to any one of claims 2 to 11, wherein the conductive component (40) is provided on an outer surface (20a) of the rechargeable battery (20).

13. 12. The aerosol generating device according to any one of claims 2 to 11, wherein the conductive component (40) is arranged adjacent to an outer surface (20a) of the rechargeable battery (20).

14. 14. The aerosol generating device according to any one of claims 1 to 13, wherein the controller (22) is configured to generate an alert when it detects swelling of the rechargeable battery (20).

15. 15. The aerosol generating device of claim 1, wherein the aerosol generating device (10) includes a heater (37) electrically connected to the rechargeable battery (20) and configured to heat the aerosol-generating material (26) disposed in the cavity (18), and the controller (22) is configured to electrically disconnect the heater (37) from the rechargeable battery (20) when it detects expansion of the rechargeable battery (20).

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