Multi-tab battery-powered aerosol generator

Abstract

The present invention relates to an aerosol generating device (2) comprising a battery (12), the battery (12) being configured to supply power for heating, the battery (12) comprising a cathode-anode unit (14), the cathode-anode unit (14) comprising a cathode (16) and an anode (17), at least one of the cathode (16) and the anode (17) being provided with at least two tabs (15), the at least two tabs (15) being arranged at a distance from each other.

Description

[Technical field]

[0001] The present invention relates to an aerosol generating device having a battery for providing power for heating. The present invention also relates to a method of operating the aerosol generating device and to the use of the aerosol generating device with enhanced rate capabilities of the battery. [Background technology]

[0002] Known handheld electrically operated smoking systems typically include an aerosol generating device that includes a battery, control electronics, and an electric heating element for heating an aerosol-generating article designed specifically for use with the aerosol generating device. In some embodiments, the aerosol-generating article includes an aerosol-forming substrate, such as a tobacco rod or tobacco plug, and the heating element contained within the aerosol generating device is inserted into or disposed around the aerosol-forming substrate when the aerosol-generating article is inserted into the aerosol generating device. In an alternative electrically operated smoking system, the aerosol-generating article may include a capsule that contains an aerosol-forming substrate, such as loose tobacco.

[0003] In prior art aerosol generating devices, single-tab batteries are used to allow for a compact design. However, the time required to heat the aerosol-forming substrate is relatively long because the current flow is limited by the single tab. Increasing the current flow will cause rapid deterioration of the battery. As a result, the user experience is poor due to slow heating or inaccurate temperature control, or the battery life is reduced.

[0004] It would be desirable to provide an aerosol generating device having a battery that is small enough for use in a very compact aerosol generating device, yet capable of delivering a significant amount of energy for a short period of time. Summary of the Invention

[0005] According to a first aspect of the present invention, there is provided an aerosol generating device comprising a battery, the battery being configured to provide power for heating. The battery comprises a cathode-anode unit. The cathode-anode unit comprises a cathode and an anode. At least one of the cathode and the anode is provided with at least two tabs. The at least two tabs may be disposed at a distance relative to each other.

[0006] Generally, tabs in the battery are provided on the anode or cathode to allow current flow to or from the anode or cathode. The tabs may be integrally formed with the anode or cathode or may be attached directly to the anode or cathode. At least two tabs may allow a significant amount of energy to be delivered in a short period of time to rapidly heat the heating element to an operating temperature. At least two tabs may allow for rapid compensation of temperature losses during intermittent aerosol generation. Nevertheless, the battery may be compact.

[0007] The battery may have an energy capacity of at least 1600 Joules to 2400 Joules, in particular 1800 Joules to 2200 Joules. The energy capacity of the battery may be limited to a predetermined number of intermittent aerosol generating operations. In particular, the energy capacity of the battery may be adapted to provide at least 2, preferably 2 to 5, in particular 2 to 3 aerosol generating cycles per one full charge of the battery. The aerosol generating cycles correspond to the consumption of the aerosol generating article with the aerosol generating device. Each aerosol generating cycle may include at least 5 to a maximum of 30, preferably at least 7 to a maximum of 20 intermittent aerosol generating operations, i.e. puffs of the consumer. The aerosol generating device may be adapted to allow only a specific number or a maximum number of aerosol generating operations by signaling the end of the aerosol generating cycle to the consumer or by only providing power for aerosol generating operations that do not exceed the specific number or the maximum number of aerosol generating operations as mentioned above.

[0008] In particular, the distance between the at least two tabs is an extension of the cathode or anode between the at least two tabs. The at least two tabs may be arranged to transfer power from the battery to an electrical circuit of the aerosol generating device. The at least two tabs may be arranged to transfer power from an external voltage source to the battery. The at least two tabs may be made of a material having conductive properties, in particular a metal or metal alloy, more particularly copper or aluminum.

[0009] To generate the aerosol, power may be drawn from a battery and provided to the heating element via power electronics that include a controller, which may be adapted to provide power to the heating element only when the temperature of the heating element or the aerosol-forming substrate falls below a threshold value.

[0010] The use of at least two tabs reduces the distance traveled by electrons in the cathode or anode to reach the tab. Thus, the cell rate capability is higher compared to single-tab designs. Even with high current loads, significant amounts of energy can be generated in a short period of time with the low polarization required for a heating discharge pulse.

[0011] The main extension direction of the battery, i.e. the direction in which the length of the battery is greatest, may be the longitudinal direction. The transverse direction may be perpendicular to the longitudinal direction. In an upright orientation of the aerosol generating device or battery, the longitudinal direction is the height direction and the transverse direction may be horizontal. The transverse direction may be perpendicular to the width direction of the aerosol generating device or battery. The designations below regarding "upper", "top", "lower" and "bottom" are relative to the longitudinal direction, which is the height direction.

[0012] The aerosol generating device may be adapted to be handheld. It may have a maximum side length of less than 20 centimeters, less than 15 centimeters, or less than 10 centimeters. It may have a maximum side length of more than 5 centimeters.

[0013] The battery may be a lithium iron phosphate (LFP) battery, and the negative electrode of the battery may include LFP. Additionally or alternatively, the negative electrode may include nickel manganese cobalt oxide (NMC), lithium cobalt oxide (LCO), nickel cobalt aluminum oxide (NCA), or any combination thereof.

[0014] The tabs may be provided at an end of the cathode. All of the tabs may be provided at the same end of the cathode.

[0015] In particular, the cathode-anode unit further comprises a separator, which is provided between the cathode and the anode, and which may comprise a polymer.

[0016] The battery may include a cap. The cap may provide a terminal for an electrical circuit of the aerosol generating device. The cap may have a cap end wall and a cap side wall. The cap may be electrically connected to the cathode or anode tabs.

[0017] The battery may comprise a shell. The shell may provide a cavity for the cathode anode unit. The cathode anode unit may be disposed entirely within the shell. The shell may provide terminals for an electrical circuit of the aerosol generating device.

[0018] The shell may comprise a shell sidewall and a shell endwall. The shell endwall may be electrically connected to the shell sidewall. The shell sidewall may have a larger surface than the cap sidewall. The shell sidewall may have a cylindrical shape.

[0019] The cap may be separate from the shell.

[0020] The shell may be electrically connected to the anode.

[0021] At least two tabs of the cathode may be attached to a cap, and the cap may be electrically connected to the cathode.

[0022] At least two tabs of the anode may be attached to the shell.

[0023] In particular, the battery has a housing, which in particular comprises a shell and a cap for closing the shell.

[0024] The at least two tabs may be folded and attached to the cap, in particular by welding or soldering.

[0025] At least two tabs or three or more tabs may form a stack of overlapping tabs. The stack may be formed with the overlapping tabs in layers. The stack may be stacked longitudinally.

[0026] Preferably, the battery may be a jellyroll battery. The cathode and anode of the cathode-anode unit may be provided to form a jellyroll having multiple windings. The cathode and anode may be wound about a longitudinal axis to form the jellyroll. Alternatively, the cathode and anode of the cathode-anode unit may form a pouch cell.

[0027] The cathode and anode may be wound around the longitudinal axis to form multiple windings. Optionally, at least one of the cathode and anode may be provided with a number of tabs less than the number of windings. This may reduce the stack height and allow more space for the cathode and anode compared to a battery having a tab for each winding. This may increase the energy capacity and volumetric energy density of the battery.

[0028] The plurality of windings may have a height of between 11 mm and 110 mm, preferably between 25 mm and 45 mm, in particular between 37 mm and 39 mm.

[0029] The plurality of windings may have a diameter of between 5 mm and 20 mm, in particular between 8 mm and 13 mm, in particular less than 10.5 mm.

[0030] The multiple windings may have a cylindrical shape.

[0031] The multiple windings may have a prismatic shape, which may increase the outer surface area of ​​the multiple windings and therefore reduce heat generation within the battery.

[0032] The battery may include a carbonate-based electrolyte.

[0033] The cathode anode unit or cell may have a height of 11 mm to 110 mm, preferably 25 mm to 45 mm, especially 37 mm to 39 mm.

[0034] The cathode anode unit or cell may have a diameter of 5 mm to 20 mm, in particular 8 mm to 13 mm, especially less than 10.5 mm.

[0035] At least one of the cathode and anode may be provided with only one tab per at least 2, at least 5, or at least 15 windings. At least one of the cathode and anode may be provided with at least one tab per 30, 25, or 15 windings.

[0036] At least one of the cathode and anode may be provided with at least three tabs.

[0037] At least one of the cathode and anode may be provided with two to eight tabs, particularly two to five tabs, more particularly two to four tabs.

[0038] At least two or three tabs may be provided on the cathode.

[0039] Both the cathode and the anode may be provided with at least two or three tabs, alternatively both the cathode and the anode may be provided with four tabs.

[0040] A cathode tab and an anode tab may be provided on opposite sides of the cell. The cathode tab and the anode tab may extend from opposite longitudinal ends of the cathode-anode unit.

[0041] If exactly two tabs are provided on one or each of the cathode and anode, the distance between the tabs of the anode may be 330 mm to 480 mm, preferably 380 mm to 480 mm, in particular 430 mm to 480 mm. The distance between the tabs of the cathode may be 200 mm to 400 mm, preferably 250 mm to 350 mm, in particular 280 mm to 320 mm. The two tabs may preferably be located at opposite ends of one end of the anode or cathode, in particular at two horizontal ends of the anode or cathode.

[0042] In case exactly three tabs are provided on one or each of the cathode and anode, the distance between the tabs of the anode may be 165 mm to 240 mm, preferably 190 mm to 240 mm, in particular 215 mm to 240 mm. The distance between the tabs of the cathode may be 100 mm to 200 mm, preferably 125 mm to 175 mm, in particular 140 mm to 160 mm. Two of the three tabs are preferably located at the opposite end of one end of the anode or cathode, and one tab is preferably located between two tabs on the same end. In particular, the tabs are located at the two horizontal ends and in the center of the anode or cathode.

[0043] If exactly four tabs are provided on one or each of the cathode and anode, the distance between the tabs on the anode may be 110 mm to 160 mm, preferably 125 mm to 160 mm, in particular 143 mm to 160 mm. The distance between the tabs on the cathode may be 65 mm to 130 mm, preferably 85 mm to 115 mm, in particular 92 mm to 107 mm.

[0044] When three or more tabs are provided on one of the anodes or cathodes, two tabs are located at opposite ends of one of the anodes or cathodes and an additional tab is located between two tabs on the same end.

[0045] The width of the tab may be from 1 mm to 5 mm, preferably from 2 mm to 4 mm, especially from 3 mm to 4 mm.

[0046] In particular, the cathode includes a cathode current collector and a cathode active material, and in particular, the anode includes an anode current collector and an anode active material.

[0047] The cathode may be formed of a multi-layer sheet material including a cathode current collector layer and a cathode active material layer. The cathode active material layer may be a coating on one side of the cathode current collector. The coating forming the cathode active material layer may have a thickness of 30 micrometers to 60 micrometers, preferably 40 micrometers to 50 micrometers. This thickness range may support high discharge currents of more than 1, 2, or 3 amps during heating while preventing cycle life from decreasing. This thickness range may provide energy to support two consecutive aerosol generation cycles, each including 7 to 18 consumer puffs. An aerosol generation cycle may require at least 700 Joules and less than 1500 Joules of energy from the battery, particularly at least 900 Joules, more particularly about 1000 Joules.

[0048] The anode may be formed of a multi-layer sheet material comprising an anode current collector layer and an anode active material layer. The anode active material layer may be a coating on one side of the anode current collector. The coating forming the anode active material layer may have a thickness of 20 micrometers to 50 micrometers, preferably 25 micrometers to 40 micrometers. This thickness range may prevent cycle life from decreasing while supporting a charge rate of 1 amp to 2 amps, preferably about 1.6 amps. This thickness range may support consistent and equal coverage.

[0049] At least one of the anode and cathode may include conductive and non-conductive regions extending in a horizontal direction of the multilayer sheet material, which may correspond to the main direction of extension of the multilayer sheet material, i.e., the direction in which the multilayer sheet material has its maximum length in an unrolled state.

[0050] The conductive areas may include areas with and without active material. The non-conductive areas may be provided with an adhesive tape to hold the cathode anode unit in place.

[0051] The conductive region of the anode may have a length of 350 mm to 500 mm, preferably 400 mm to 500 mm, in particular 450 mm to 500 mm. The conductive region of the anode may have a width of 25 mm to 40 mm, preferably 30 mm to 40 mm, in particular 30 mm to 35 mm.

[0052] The conductive region of the cathode may have a length of 350 mm to 450 mm, preferably 375 mm to 450 mm, in particular 400 mm to 450 mm. The conductive region of the cathode may have a width of 25 mm to 40 mm, preferably 30 mm to 40 mm, in particular 30 mm to 35 mm.

[0053] The at least two tabs may be integrally formed with the cathode current collector. The at least two tabs may be integrally formed with the anode current collector. The at least two tabs may be integrally formed with at least one of the cathode current collector and the anode current collector. This may reduce electrical resistance between the tabs and the current collectors. At least one of the cathode current collector and the anode current collector may be formed by cutting.

[0054] The cathode active material layer may include lithium iron phosphate, LiFePO4 (LFP). Alternatively, the cathode active material layer may include nickel manganese cobalt oxide (NCM). The use of an LFP cathode may improve the cycling stability of the battery and extend the life of the aerosol generator, especially in contrast to NCM batteries. The LFP cathode may have a low electrical conductivity compared to other cathode materials, such as NCM. Thus, applying at least two tabs on an LFP cathode may increase the battery rate capability even more than applying at least two tabs on an NCM cathode.

[0055] The anode active material layer may include graphite, silicon, and / or lithium titanate (LTO).

[0056] At least one of the at least two tabs may be attached to the cathode current collector, particularly by ultrasonic welding or resistance welding.

[0057] At least one of the at least two tabs may be attached to the anode current collector, in particular by ultrasonic welding or resistance welding. The at least one tab attached to the anode current collector may be made of nickel. The at least one tab attached to the cathode current collector may be made of aluminum.

[0058] The tabs may have a rectangular, trapezoidal, or needle shape. This may reduce the height of the stack of tabs compared to the height of a stack of tabs with a rectangular shape. More space may remain for the cathode-anode unit. This may increase the energy capacity and volumetric energy density of the battery. Tabs with a needle shape may increase the mechanical strength. Thus, the durability of the tabs for folding may increase.

[0059] The tabs may extend from the cathode or anode towards the periphery of the battery, which may reduce the stack height and allow more space for the cathode-anode unit compared to the stack height of a battery with the tabs folded towards the center of the battery, which may increase the energy capacity and volumetric energy density of the battery.

[0060] The tab may extend from the negative or positive electrode toward the center of the cell.

[0061] The tabs may be trapezoidal in shape and may be folded inwardly.

[0062] The tabs may be trapezoidal or rectangular in shape and may be folded outwardly.

[0063] The tabs may be needle-shaped and may be folded outwardly or inwardly.

[0064] The tab may preferably be needle-shaped, which increases the mechanical strength of the tab and therefore reduces the likelihood of the tab breaking, especially during folding.

[0065] Preferably, the negative electrode tab may be at least one of: rectangular in shape and folded outward away from the center of the cell; trapezoidal in shape and folded inward toward the center of the cell; trapezoidal in shape and folded outward away from the center of the cell; needle in shape and folded inward toward the center of the cell; or needle in shape and folded outward away from the center of the cell.

[0066] Alternatively or additionally, the anode tab may be at least one of rectangular in shape and folded inward toward the center of the cell, or trapezoidal in shape and folded inward toward the center of the cell.

[0067] The battery may be provided with a conductive structure having a connection port for the tab. The conductive structure allows for easy connection of the tab to the terminal of the battery. In particular, this facilitates the assembly of relatively small batteries. The conductive structure may allow the tab to be attached to the connection port instead of the cap. This may prevent a stack of tabs from being formed and allow more space for the cathode-anode unit. This may increase the energy capacity and volumetric energy density of the battery. Attaching the tab to the conductive structure may also reduce the number and angle of folds in the tab. Thus, the risk of the tab breaking during folding may be reduced.

[0068] The conductive structure may bridge the longitudinal distance between the cathode or anode and the battery terminal. The conductive structure may have a longitudinal extension of between 2 millimeters and 8 millimeters.

[0069] The terminals may be provided on a battery cap that is electrically isolated from the battery shell.

[0070] The conductive structure may electrically connect the tabs in parallel. The conductive structure may connect the tabs of the cathode.

[0071] Attaching the tabs to the connection ports may include soldering or welding.

[0072] The conductive structure may comprise a non-conductive structure for separating the tab from a terminal of the battery. The terminal may provide a potential different from that of the tab.

[0073] The conductive structure may be attached on the longitudinal end face of the cathode anode unit. The conductive structure may preferably be sealed to the shell so that the battery is fixed via its longitudinal end face. Prior art batteries have neck portions to hold the cathode anode unit in place. Attaching the conductive structure on the longitudinal end face of the cathode anode unit may overcome the requirement for such a neck portion. This allows more space for the cathode anode unit. This may increase the energy capacity and volumetric energy density of the battery.

[0074] The connection port of the conductive structure may be an opening for receiving the tab. The opening may be provided as a hole or a slot.

[0075] The size and shape of the opening may correspond to the size and shape of the tab. Holes may be provided when needle-shaped tabs are used. Slots may be provided when trapezoidal or rectangular shaped tabs are used.

[0076] The cathode tab may be provided with at least one of the following conductive structures: rectangular and folded outward away from the center of the battery; trapezoidal and folded inward toward the center of the battery; trapezoidal and folded outward away from the center of the battery; needle-shaped and folded inward toward the center of the battery; or needle-shaped and folded outward away from the center of the battery.

[0077] Alternatively, or in addition, the tab of the anode may be provided with at least one of a rectangular shape and folded inward toward the center of the cell, or a trapezoidal shape and folded inward toward the center of the cell, in a conductive structure.

[0078] The aerosol generating device may further comprise an aerosol generating means, in particular a heating element. The aerosol generating means or the heating element may be electrically connected to the battery.

[0079] The heating element may be an inductor coil.

[0080] The heating element may be an electrically resistive heating means.

[0081] The aerosol generating device may further include power electronics. The power electronics may be adapted to provide power from a battery for heating. The power electronics may be the electrical circuitry of the aerosol generating device. The power electronics may control the power provided to the heating element.

[0082] The power supply electronics may include a power converter, which may be electrically connected to the terminals of the battery.

[0083] The power converter may comprise a DC / AC inverter or a DC / DC converter.

[0084] The aerosol generating device may further comprise a sensor for acquiring the heating temperature, which may indicate the temperature of the heating element or the aerosol-forming substrate.

[0085] The aerosol generating device may further comprise a controller adapted to control power electronics for providing power from the battery for heating. The controller may comprise a controller in the form of a microcontroller, a field programmable gate array (FPGA), or an application specific integrated circuit (ASIC).

[0086] The controller may be operatively coupled to the sensor to obtain the heating temperature and the power converter in a feedback loop configuration.

[0087] The controller may be configured to receive a feedback signal indicative of the heating temperature from the sensor and to control the power converter to draw power from the battery in response to the received feedback signal.

[0088] The control device may comprise a bang-bang controller. In particular the bang-bang controller is adapted to turn the switch on when the feedback signal falls below a lower threshold and to turn the switch off when the feedback signal exceeds a higher threshold. The control device may form part of the power supply electronics.

[0089] The aerosol generating device may further comprise an aerosol-generating article receiving means adapted to receive the aerosol-generating article. The aerosol-generating article receiving means may be hollow.

[0090] According to a second aspect of the present invention there may be provided an aerosol generating system comprising an aerosol generating device according to the first aspect of the present invention. The aerosol generating system may also comprise an aerosol generating article.

[0091] The aerosol-generating article may comprise a susceptor.

[0092] The aerosol-generating article may include an aerosol-generating substrate.

[0093] The aerosol-generating substrate may be made from an aerosol-generating sheet material.

[0094] The aerosol-generating sheet material may be crimped, folded or cut.

[0095] The susceptor may be embedded within the aerosol-generating substrate.

[0096] According to a third aspect of the invention, there may be provided a method of manufacturing a battery for an aerosol generating device. The method may include providing a cathode anode unit with one or more tabs on a longitudinal end surface of the cathode anode unit. The method may also include disposing a conductive structure on the longitudinal end surface of the cathode anode unit such that the one or more tabs contact one or more connection ports of the conductive structure.

[0097] The cathode-anode unit may be provided with at least two tabs on its longitudinal end faces.

[0098] Providing the cathode-anode unit may include cutting the cathode or anode current collector layer to provide one or more tabs. Providing the cathode-anode unit may further include winding the cathode-anode unit with the cut cathode or anode current collectors about a longitudinal axis to form a jelly roll.

[0099] The conductive structure may be disposed on a longitudinal end surface of the cathode-anode unit such that the conductive structure is disposed entirely within the cell interior.

[0100] The step of disposing the conductive structure may include passing one or more tabs through one or more associated openings that form one or more ports in the conductive structure.

[0101] The step of providing the conductive structure may include attaching the conductive structure to the shell. The conductive structure may be sealed to the shell.

[0102] Preferably, a needle-shaped tab may be provided which may pass through the opening. The mechanical strength of the needle-shaped tab may allow it to easily pass through the opening.

[0103] The method may further include disposing the cathode-anode unit and the conductive structure within a shell. The method may further include closing the shell with a cap. The cap may be electrically connected to the one or more tabs via the conductive structure and may be electrically isolated from the shell.

[0104] The step of closing the cap may further include attaching a conductive structure to the cap, especially by soldering, ultrasonic welding, or resistance welding.

[0105] The step of disposing the conductive structure may include folding the one or more tabs towards the conductive structure. The step of disposing the conductive structure further includes attaching the one or more tabs to the conductive structure, particularly by soldering, ultrasonic or resistance welding.

[0106] According to a fourth aspect of the present invention, there may be provided an aerosol generating device comprising a battery. The battery may be configured to provide power for heating. The battery may comprise a cathode anode unit, the cathode anode unit may be provided with one or more tabs on a longitudinal end face of the cathode anode unit. The battery may further comprise a conductive structure. The conductive structure may be provided on a longitudinal end face of the cathode anode unit and may comprise one or more connection ports for the one or more tabs. The one or more connection ports may be in contact with the one or more tabs.

[0107] The conductive structure may bridge the longitudinal distance between the cathode anode unit and the battery terminal.

[0108] The conductive structures may have a longitudinal extension of between 3 millimeters and 8 millimeters.

[0109] The conductive structure may include a platform and a connector.

[0110] The platform may have a peripheral section that corresponds to the inner rim of the battery shell.

[0111] The platform may be disposed on a longitudinal end surface of the cathode-anode unit.

[0112] The platform may be made of conductive and non-conductive structures.

[0113] The conductive structure may include one or more connection ports in the form of one or more holes for receiving the one or more tabs. The one or more openings may be provided as holes. In other embodiments, one or more slots may be provided. The size and shape of the one or more openings may complement the size and shape of the one or more tabs. The conductive structure of the platform may be made of one or more of iron, copper, aluminum, nickel, most preferably nickel.

[0114] The non-conductive structure may be formed on a peripheral section of the conductive structure such that the conductive structure is electrically isolated from the shell. The platform may be attached to the shell such that the cathode-anode unit is fixed in a longitudinal position relative to the shell.

[0115] The thickness of the platform may be between 0.05 mm and 0.5 mm, preferably between 0.1 mm and 0.2 mm.

[0116] A connector may be provided between the platform and the cell's cap, the connector being capable of bridging the longitudinal distance between the cathode anode unit and the cap.

[0117] The connector may include a conductive structure for electrically connecting the tab to the cap and a non-conductive structure for separating the conductive material from the shell.

[0118] The conductive structure of the connector may have three connector sections, and at least one of the first connector section and the second connector section may be connected to the third connector section at an angle of 60 to 120 degrees, preferably 80 to 100 degrees. The first connector section and the second connector section may extend in the same lateral direction.

[0119] The first connector section may be attached to the cap, and the second connector section may be attached to a conductive structure of the platform. The conductive structure of the connector may be made from one or more of iron, copper, aluminum, nickel, most preferably aluminum or nickel.

[0120] Below are provided examples of tab designs where the tab is attached to a conductive structure.

[0121] The tab extension height may be between 1 millimeter and 5 millimeters, preferably between 2 millimeters and 4 millimeters. The tab extension height may correspond to the length of a portion of one or more tabs extending heightwise from the anode or cathode current collector layer.

[0122] If one or more rectangular shaped tabs are provided, the tab width may be from 1 mm to 5 mm, preferably from 2 mm to 4 mm, in particular from 3 mm to 4 mm. The thickness of the one or more rectangular shaped tabs may be about 0.1 mm.

[0123] If one or more trapezoidal shaped tabs are provided, the tab width on the current collector side may be 1 mm to 5 mm, preferably 2 mm to 4 mm, in particular 3 mm to 4 mm. The tab width on the distal side may be 1 mm to 4.5 mm, preferably 1 mm to 3.5 mm, in particular 1 mm to 2.5 mm. The thickness of the one or more trapezoidal shaped tabs may be about 0.1 mm. The distal side may correspond to the side of the tab that has the greatest distance to the current collector in the height direction.

[0124] Where one or more needle-shaped tabs are provided, the diameter of the one or more tabs may be from 0.5 mm to 3 mm, preferably from 0.5 mm to 2 mm, especially from 0.5 mm to 1 mm.

[0125] According to a fifth aspect of the present invention, there is provided a method of operating an aerosol generating device comprising the steps of detecting whether aerosol delivery is required by a consumer and delivering power from a battery to an aerosol generating means via at least two tabs in the battery, the tabs being arranged in parallel in an electrical circuit of which the battery forms part.

[0126] At least two tabs may be connected to or provided on the negative electrode of the battery. At least two tabs may be connected to or provided on the positive electrode of the battery. At least two tabs may be connected to or provided on both the negative and positive electrodes.

[0127] The step of detecting whether aerosol delivery is desired by a consumer may include detecting whether the consumer applies a pressure to the mouthpiece of the aerosol generating device that is less than ambient pressure.

[0128] The step of delivering power from the battery to the aerosol generating means via at least two tabs of the battery may comprise drawing a discharge current from the battery only when the heating temperature falls below a threshold level, which threshold level is preferably preset and stored in the memory of the aerosol generating device.

[0129] The discharge current drawn may be a pulsed current including at least one on cycle and at least one off cycle.

[0130] At least one of the on cycle and the off cycle may have a duration of from 0.5 seconds to 4 seconds, preferably from 0.75 seconds to 2 seconds, especially about 1 second.

[0131] At least one of the on cycle and the off cycle may have a duration of 0.01 seconds to 3 seconds, preferably 0.1 seconds to 2 seconds, especially about 0.3 seconds. Preferably, the on cycle and the off cycle may have substantially the same duration.

[0132] The discharge current may have a peak current of from 2 Amps to 5 Amps, preferably from 2.5 Amps to 4 Amps, especially about 3.15 Amps.

[0133] The method may be carried out at least in part by a controller of an aerosol generating device.

[0134] According to a sixth aspect of the present invention, there is provided the use of at least two tabs provided on the cathode or anode within the aerosol generating device to enhance the rate capability of the battery for intermittent heating.

[0135] Power may be drawn from the battery only when the temperature of the heating element drops below a threshold level.

[0136] An aerosol generating device according to the first or fourth aspect of the invention, and a system according to the second aspect of the invention may be operated according to the method of the fifth aspect of the invention.

[0137] An aerosol generating device according to the first or fourth aspect of the invention, and a system according to the second aspect of the invention may be manufactured according to the method of the third aspect of the invention. EXAMPLES

[0138] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples and embodiments. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0139] Example 1: An aerosol generating device comprising a battery, the battery being configured to supply power for heating, the battery comprising a cathode-anode unit, the cathode-anode unit comprising a cathode and an anode, at least one of the cathode and the anode being provided with at least two tabs, the at least two tabs being arranged at a distance from each other. Example 2: 2. An aerosol generating device as described in Example 1, wherein the battery has an energy capacity of at least 1600 Joules to 2400 Joules, in particular 1800 Joules to 2200 Joules. Example 3: An aerosol generating device according to any one of Examples 1 to 2, wherein the aerosol generating device is adapted to be handheld. Example 4: The aerosol generating device according to any one of Examples 1 to 3, wherein the battery is a lithium iron phosphate battery. Example 5: An aerosol generating device as described in any one of Examples 1 to 4, wherein a tab is provided on an end of the cathode. Example 6: The aerosol generating device according to any one of Examples 1 to 5, wherein the battery further comprises a separator, the separator being provided between the cathode and the anode. Example 7: An aerosol generating device as claimed in any one of Examples 1 to 6, wherein the battery is provided with a cap, the cap providing a terminal for an electrical circuit of the aerosol generating device. Example 8: 8. The aerosol generating device of example 7, wherein the cap is electrically connected to the cathode or anode tab. Example 9: An aerosol generating device as described in any one of Examples 7 to 8, wherein the battery further comprises a shell, the shell providing a cavity for the cathode-anode unit, and the shell providing a terminal for an electrical circuit of the aerosol generating device. Example 10: 10. The aerosol generating device of example 9, wherein the shell comprises a shell side wall and a shell end wall, the shell end wall being electrically connected to the shell side wall. Example 11: An aerosol generating device according to any one of Examples 9 to 10, wherein the cap is electrically isolated from the shell. Example 12: The aerosol generating device according to any one of Examples 9 to 11, wherein the cathode tab is attached to the cap. Example 13: The aerosol generating device according to any one of Examples 9 to 12, wherein the tab of the anode is attached to the shell. Example 14: An aerosol generating device according to any one of Examples 1 to 13, wherein at least two tabs or three or more tabs form a stack of overlapping tabs. Example 15: An aerosol generating device according to any one of Examples 1 to 14, wherein the cathode and anode are wound around the longitudinal axis to form a plurality of windings, and the number of tabs is less than the number of windings. Example 16: 16. An aerosol generating device as described in example 15, wherein the plurality of windings have a height of 11 mm to 110 mm, preferably 25 mm to 45 mm, in particular 37 mm to 39 mm. Example 17: An aerosol generating device according to any one of Examples 15 to 16, wherein the plurality of windings have a diameter of between 5 mm and 20 mm, in particular between 8 mm and 13 mm, in particular less than 10.5 mm. Example 18: The aerosol generating device according to any one of Examples 15 to 17, wherein the plurality of windings have a cylindrical shape. Example 19: The aerosol generating device according to any one of Examples 15 to 17, wherein the plurality of windings have a prismatic shape. Example 20: An aerosol generating device according to any one of Examples 1 to 19, comprising only one tab per at least 2, at least 5, or at least 15 windings. Example 21: An aerosol generating device according to any one of Examples 1 to 20, wherein at least one of the cathode and the anode is provided with at least three tabs. Example 22: An aerosol generating device according to any one of Examples 1 to 20, wherein at least two or three tabs are provided on the cathode. Example 23: An aerosol generating device according to any one of Examples 1 to 20, wherein both the cathode and the anode are provided with at least two or at least three tabs. Example 24: The aerosol generating device of any one of Examples 1 to 23, wherein a cathode tab and an anode tab are provided on opposite sides of the cell. Example 25: The cathode, a cathode current collector layer, and a cathode active material layer; The aerosol generating device according to any one of Examples 1 to 24, wherein the cathode active material layer is a coating on one side of the cathode current collector, and the coating forming the cathode active material layer has a thickness of 30 micrometers to 60 micrometers, preferably 40 micrometers to 50 micrometers. Example 26: 26. The aerosol generating apparatus of example 25, wherein the anode is formed of a multi-layer sheet material comprising an anode current collector layer and an anode active material layer, the anode active material layer being a coating on one side of the anode current collector, the coating forming the anode active material layer having a thickness of 20 micrometers to 50 micrometers, preferably 25 micrometers to 40 micrometers. Example 27: The aerosol generating device according to any one of Examples 25 to 26, wherein at least one of the at least two tabs is integrally formed with the cathode current collector. Example 28: The aerosol generating device according to any one of Examples 26 to 27, wherein at least one of the at least two tabs is integrally formed with the anode current collector. Example 29: The aerosol generating device according to any one of Examples 25 to 28, wherein the cathode active material layer comprises lithium iron phosphate, LiFePO4. Example 30: An aerosol generating device according to any one of Examples 25 to 29, wherein at least one of the at least two tabs is attached to the cathode current collector, in particular by ultrasonic welding or resistance welding. Example 31: An aerosol generating device according to any one of Examples 26 to 30, wherein at least one of the at least two tabs is attached to the anode current collector, in particular by ultrasonic welding or resistance welding. Example 32: An aerosol generating device according to any one of Examples 1 to 31, wherein the tab has a rectangular, trapezoidal, or needle shape. Example 33: The aerosol generating device according to any one of Examples 1 to 32, wherein the tab extends from the cathode or anode towards the periphery of the battery. Example 34: The cathode tab is Rectangular in shape, folded outwards away from the center of the battery, Trapezoidal in shape, folded inwards towards the centre of the battery, Trapezoidal in shape, folded outwards away from the centre of the battery, Needle-shaped and folded inwards towards the centre of the battery, or The aerosol generating device according to any one of Examples 1 to 33, which is at least one of: needle-shaped and folded outward away from the center of the battery. Example 35: The anode tab is Rectangular in shape and folded inwards towards the centre of the battery, or The aerosol generating device according to any one of Examples 1 to 34, which is at least one of: a trapezoidal shape, and folded inward towards the center of the battery. Example 36: An aerosol generating device as described in any one of Examples 1 to 35, wherein the battery further comprises a conductive structure having a connection port for a tab. Example 37: 37. An aerosol generating device as described in Example 36, wherein the conductive structure bridges the longitudinal distance between the cathode or anode and the terminal of the battery. Example 38: An aerosol generating device described in any one of Examples 36 to 37, wherein a terminal is provided on the cap of the battery, the cap being electrically isolated from the shell of the battery. Example 39: An aerosol generating device described in any one of Examples 36 to 38, wherein the conductive structure has a non-conductive structure for separating the tab from a terminal of the battery, and the terminal provides a potential different from the potential of the tab. Example 40: 40. The aerosol generating device according to any one of Examples 36 to 39, wherein the conductive structure electrically connects the tabs in parallel. Example 41: An aerosol generating device described in any one of Examples 36 to 40, wherein the connection port of the conductive structure is an opening, in particular a hole or slot, for receiving the tab. Example 42: The aerosol generating device according to any one of Examples 1 to 41, further comprising an aerosol generating means, in particular a heating element, the aerosol generating means being electrically connectable to the battery. Example 43: 43. The aerosol generating device of Example 42, wherein the heating element is an induction coil. Example 44: 43. The aerosol generating device of Example 42, wherein the heating element is an electrical resistance heating means. Example 45: An aerosol generating device described in any one of Examples 1 to 44, further comprising a power supply electronic circuit, the power supply electronic circuit adapted to supply power from a battery for heating. Example 46: An aerosol generating device as described in Example 45, wherein the power supply electronic circuitry includes a power converter electrically connected to the terminals of the battery. Example 47: 47. An aerosol generating device as described in Example 46, wherein the power converter comprises a DC / AC inverter or a DC / DC converter. Example 48: An aerosol generating device described in any one of Examples 1 to 47, further comprising a control device, the control device adapted to control a power supply electronic circuit for supplying power from a battery for heating. Example 49: The aerosol generating apparatus according to any one of Examples 1 to 48, further comprising a sensor for obtaining a heating temperature, the heating temperature indicating the temperature of the heating element. Example 50: The aerosol generating device according to any one of Examples 1 to 49, further comprising an aerosol-generating article receiving means, the aerosol-generating article receiving means being adapted to receive an aerosol-generating article. Example 51: 51. An aerosol generating device as described in Example 50, wherein the aerosol-generating article receiving means is hollow. Example 52: An aerosol generating system comprising the aerosol generating device according to any one of Examples 1 to 51 and an aerosol-generating article. Example 53: 53. The aerosol generating system of Example 52, wherein the aerosol generating article comprises a susceptor. Example 54: The aerosol-generating system according to any one of Examples 52 to 53, wherein the aerosol-generating article comprises an aerosol-generating substrate. Example 55: 55. The aerosol-generating system of Example 54, wherein the aerosol-generating substrate is made of an aerosol-generating sheet material. Example 56: 56. An aerosol-generating system as described in Example 55, wherein the aerosol-generating sheet material is crimped, folded, or cut. Example 57: The aerosol-generating system of Example 53, wherein the susceptor is embedded within the aerosol-generating substrate. Example 58: A method for manufacturing a battery for an aerosol generating device, comprising the steps of: providing a cathode-anode unit having one or more tabs on a longitudinal end surface of the cathode-anode unit; and disposing a conductive structure on a longitudinal end surface of the cathode-anode unit such that one or more tabs contact one or more connection ports of the conductive structure. Example 59: 59. The method of claim 58, wherein the cathode-anode unit is provided with at least two tabs on a longitudinal end surface. Example 60: providing a cathode-anode unit, cutting the cathode or anode current collector layer to provide one or more tabs; and winding the cathode-anode unit having the cut cathode or anode current collectors about a longitudinal axis to form a jelly roll. Example 61: The method according to any one of Examples 58 to 60, wherein the conductive structure is disposed on the longitudinal end surface of the cathode-anode unit such that the conductive structure is disposed completely inside the battery. Example 62: The method described in any one of Examples 58 to 61, wherein the step of disposing the conductive structure includes a step of passing one or more tabs through one or more associated openings that form one or more ports in the conductive structure. Example 63: In addition: disposing the cathode-anode unit and the conductive structure within a shell; and closing the shell with a cap; The method of any one of Examples 58 to 62, wherein the cap is electrically connected to the one or more tabs and electrically isolated from the shell via a conductive structure. Example 64: 64. The method of embodiment 63, wherein the step of closing the cap further comprises attaching a conductive structure to the cap, particularly by soldering, ultrasonic, or resistance welding. Example 65: The step of providing a conductive structure comprises: folding the one or more tabs toward the conductive structure; The method according to any one of Examples 58 to 64, further comprising attaching one or more tabs to the conductive structure, particularly by soldering, ultrasonic welding, or resistance welding. Example 66: An aerosol generating device, comprising: Equipped with a battery, a battery configured to provide power for heating; The battery, A cathode-anode unit, a cathode-anode unit provided with one or more tabs on a longitudinal end surface of the cathode-anode unit; 1. A conductive structure comprising: provided on a longitudinal end surface of the cathode-anode unit; one or more connection ports for one or more tabs; An aerosol generating device comprising: a conductive structure, the one or more connection ports being in contact with the one or more tabs. Example 67: 67. An aerosol generating device as described in Example 66, wherein the conductive structure bridges the longitudinal distance between the cathode anode unit and the terminal of the battery. Example 68: An aerosol generating device according to any one of Examples 66 to 67, wherein the conductive structure has a longitudinal extension of 2 millimeters to 8 millimeters. Example 69: A method of operating an aerosol generating device comprising the steps of detecting whether aerosol delivery is desired by a consumer and delivering power from a battery to an aerosol generating means via at least two tabs of the battery, the tabs being arranged in parallel in an electrical circuit of which the battery forms a part. Example 70: The method of Example 69, wherein the step of detecting whether aerosol delivery is desired by a consumer comprises detecting whether the consumer applies a pressure to the mouthpiece of the aerosol generating device that is less than ambient pressure. Example 71: A method described in any one of Examples 69 to 70, wherein the step of delivering power from the battery to the aerosol generating means via at least two tabs of the battery includes drawing current from the battery only when the heating temperature is below a threshold level. Example 72: The method according to any one of Examples 69 to 71, wherein the discharge current is a pulsed current having at least one on cycle and at least one off cycle. Example 73: The method according to example 72, wherein at least one of the on cycle and the off cycle has a duration of 0.01 seconds to 3 seconds, preferably 0.1 seconds to 2 seconds, in particular about 0.3 seconds. Example 74: The method of any one of Examples 72 to 73, wherein the on cycle and the off cycle have substantially the same duration. Example 75: The method according to any one of Examples 71 to 73, wherein the discharge current has a peak current of from 2 Amps to 5 Amps, preferably from 2.5 Amps to 4 Amps, in particular about 3.15 Amps. Example 76: The use of at least two tabs provided on the cathode or anode in an aerosol generating device to increase the rate capability of the battery for intermittent heating. Example 77: The use of example 76, wherein power is drawn from the battery only when the temperature of the heating element falls below a threshold level.

[0140] The embodiments will now be further described with reference to the figures. [Brief description of the drawings]

[0141] [Figure 1] FIG. 1 shows a schematic cross-sectional view of an embodiment of an aerosol generation system comprising an aerosol generation device according to an embodiment of the present invention. [Diagram 2] FIG. 2 shows a schematic perspective view of the cathode-anode unit used in the aerosol generating device of the first embodiment according to FIG. [Diagram 3] FIG. 3 shows a schematic partial perspective view of the cathode and anode of the cathode-anode unit according to FIG. 2 in the unrolled state. [Figure 4] FIG. 4 shows a schematic top view of an unrolled cathode current collector having multiple tabs that may be used in the cathode-anode unit according to FIGS. [Diagram 5] FIG. 5 shows a schematic perspective view of a battery for a second embodiment of the aerosol generation system according to FIG. [Figure 6] FIG. 6 shows a schematic perspective view of a cathode-anode unit used in a third embodiment of the aerosol generating device according to FIG. [Figure 7] FIG. 7 shows a schematic perspective view of a cathode-anode unit used in the fourth embodiment of the aerosol generating device according to FIG. [Figure 8] FIG. 8 shows a schematic perspective view of a cathode-anode unit used in the fifth embodiment of the aerosol generating device according to FIG. [Figure 9] FIG. 9 shows a schematic perspective view of a cathode-anode unit used in the sixth embodiment of the aerosol generating device according to FIG. [Figure 10] FIG. 10 shows a schematic perspective view of a battery for a seventh embodiment of the aerosol generating device according to FIG. [Figure 11] FIG. 11 shows a schematic perspective view of a battery for an eighth embodiment of the aerosol generating device according to FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0142] Figure 1 shows a schematic representation of an embodiment of an aerosol generating system 1. It comprises an aerosol generating device 2 according to an embodiment of the invention and an aerosol-generating article 3 for use in the aerosol generating device 2. The aerosol-generating article 3 comprises an aerosol-forming substrate 9 which is heated to form an inhalable aerosol.

[0143] The aerosol-generating article 3 is a rod-shaped consumable with four elements arranged contiguously in a coaxial alignment: an aerosol-forming rod segment 4, a support element 5 having a central air passage, an aerosol-cooling element 6, and a mouthpiece element 7 including a filter. The aerosol-forming rod segment 4 is arranged at the distal end of the article 3 and includes a strip-shaped susceptor 8 and a heated aerosol-forming substrate 9. The mouthpiece element 7 is arranged at the proximal end of the article 3 and allows the consumer to puff on it. The support element 5 and the aerosol-cooling element 6 are arranged therebetween. Each of the four elements is a substantially cylindrical element, all of which have substantially the same diameter. The four elements are surrounded by an outer wrapper 10 to hold the four elements together and maintain the desired circular cross-sectional shape of the rod-like article 3. The wrapper 10 is preferably made of paper.

[0144] The aerosol-generating device 2 comprises a cylindrical receiving cavity defined in a proximal portion 1 of the device 2, in which at least a distal portion of the article 3 is received. The device 2 further comprises a heating element 11 including an inductor for generating a high-frequency alternating magnetic field. In this embodiment, the inductor is a helical coil circumferentially surrounding the cylindrical receiving cavity. In an alternative embodiment, the heating element may be an electrical resistance heating means. The coil is arranged such that the susceptor 8 of the aerosol-generating article 3 is exposed to the alternating magnetic field as the article 3 engages with the device 2. Thus, upon actuation of the heating element 11, the susceptor 8 is heated by eddy currents and hysteresis losses induced by the alternating electromagnetic field, depending on the magnetic and electrical properties of the susceptor 8. The susceptor 8 is heated until it reaches an operating temperature sufficient to vaporize the aerosol-forming substrate 9 surrounding the susceptor 8 in the article 3. Within the distal portion, the aerosol generating device 2 further comprises a battery 12 and power electronics 13 for providing power and controlling the heating process.

[0145] In use of the aerosol-generating system 1, when a consumer draws a puff on the mouthpiece element 7 of the article 3, air is drawn into the receiving cavity at the rim of the cavity. The airflow extends further towards the distal end of the cavity through a passageway formed between the inner surface of the cylindrical cavity and the outer surface of the article 3. At the distal end of the cavity, the airflow enters the aerosol-generating article 3 through the base element 4, passes further through the support element 5, the aerosol cooling element 6, and the mouthpiece element 7, and finally exits the article 3. At the base element 4, vaporized material from the aerosol-forming substrate 9 is entrained into the airflow. Thereafter, as it passes through the support element 5, the cooling element 6, and the mouthpiece element 7, the airflow containing the vaporized material is cooled to form an inhalable aerosol that exits the article 3 through the mouthpiece element 7.

[0146] In a first embodiment of the aerosol generating device 2, the battery 12 includes a cathode anode unit 14, as shown in FIG. 2. The cathode anode unit 14 is shown in an upright orientation with its longitudinal axis extending vertically. The cathode anode unit 14 has a jelly roll configuration. The cathode anode unit 14 includes a plurality of tabs 15. The plurality of tabs 15 extend from an upper longitudinal end surface of the cathode anode unit 14.

[0147] 2, any number of tabs, at least two, may be provided on the upper longitudinal end surface of the cathode-anode unit 14. Preferably, the number of tabs may be two or three.

[0148] 2, one or more tabs are provided on the opposing bottom longitudinal end faces of the cathode-anode unit 14. The number of tabs on both longitudinal ends of the cathode-anode unit 14 may be equal.

[0149] Figure 3 shows the cathode-anode unit 14 according to Figure 2 in an unrolled state. The cathode-anode unit 14 comprises two electrodes, a cathode 16 and an anode 17.

[0150] Cathode 16 is formed of a multi-layer sheet material. The cathode multi-layer sheet material includes a cathode current collector layer 18. Cathode current collector layer 18 is formed of a sheet material and has two opposing large surfaces. Cathode current collector layer 18 is coated on both sides with a cathode active material such that a cathode active material layer 19 is formed on both sides of cathode current collector layer 18. In some embodiments, only one surface of cathode current collector layer 18 may be coated with cathode active material.

[0151] Similar to the cathode 16, the anode 17 is formed of a multi-layer sheet material. The multi-layer sheet material of the anode 17 includes an anode current collector layer 21. The anode current collector layer 21 is formed of a sheet material and includes two opposing large surfaces. The anode current collector layer 21 is coated on both sides with anode active material such that an anode active material layer 22 is formed on both sides of the anode current collector layer 21. In some embodiments, only one surface of the anode current collector layer 21 may be coated with anode active material.

[0152] The cathode-anode unit 14 further comprises a separator 24. The separator 24 is formed of a sheet material. The separator is provided between the cathode and the anode.

[0153] An example of a cathode current collector layer 18 is shown in top view in Figure 4. The vertical extension of the cathode current collector layer 18 shown in Figure 4 corresponds to the height of the cathode-anode unit 14 shown in Figure 2. The horizontal extension of the cathode current collector layer 18 corresponds to the length of the cathode current collector layer 18 and is perpendicular to the vertical extension.

[0154] The anode current collector layer 21 may be formed with a structure similar or equal to that of the cathode current collector layer 18 .

[0155] 2 are provided at a distance from one another on the ends of the cathode current collector layer 18. This distance is the extension between the tabs 15 relative to the horizontal extension of the cathode current collector layer 18 in the unrolled state.

[0156] A plurality of tabs 15 are provided on the edge such that the plurality of tabs 15 extend from the edge of the current collector layer 18 having a tab extension height 25 .

[0157] The electron is shown diagrammatically as a black bullet point in FIG. 4. The electron is one of many that form part of the cathode current collector layer 18. Because the length of the current collector layer 18 is long, the electron must travel a long distance when a single tab design is used. In contrast, when multiple tabs are provided, the travel distance is short, thus increasing the cell rate capability. The use of multiple tabs allows the cell 12 to produce a significant amount of energy in a short period of time with little polarization, even under high current loads.

[0158] As further shown in FIG. 4, each of the plurality of tabs 15 has a rectangular shape.

[0159] In a second embodiment of the aerosol generating device 2, the battery 12 has a tab mounting design as shown in Figure 5. The battery 12 comprises the cathode-anode unit 14 according to Figure 2, a separator structure 26 and a housing having two terminals 27, 28 for connecting the electrical circuit of the aerosol generating device 2.

[0160] The upper terminal 27 is connected to the cathode to provide a positive terminal (+) and the lower terminal 28 is connected to the anode to provide a negative terminal (-). The battery 12 has a cylindrical shape. Alternatively, the polarity of the terminals 27, 28 may be reversed, the battery 12 may have a cylindrical shape and both terminals 27, 28 may be provided on the same longitudinal end face of the battery, or the battery 12 may have a terminal configuration and arrangement similar to the well-known "9V block battery."

[0161] The housing comprises a shell 29 and a cap 30 for closing the shell 29 .

[0162] The shell 29 includes a shell sidewall, an upper shell opening for receiving the cathode-anode unit 14 during manufacture, and a lower shell end wall. The shell sidewall may be in the form of a cylindrical section extending longitudinally to provide a cavity for the cathode-anode unit 14. The shell end wall forms the bottom of the shell 29.

[0163] Both the shell end wall and the shell side wall are made of a conductive material, such as aluminum. The shell end wall and the shell side wall are electrically connected to provide the same electrical potential. The shell end wall functions as the negative terminal (-).

[0164] The cap 30 has a round shape with a bump in the middle that serves as the positive terminal (+). The cap 30 closes the shell opening. A second separator structure (not shown) is provided that separates the cap 30 from the shell 29. The second separator structure may be provided on the cap 30 or on the shell 29.

[0165] The shell 29 further includes a neck portion 31 for holding the cathode-anode unit 14 in place longitudinally. The neck portion 31 forms part of the cylindrical portion of the shell 29. The neck portion 31 is located above an upper longitudinal end face of the cathode-anode unit 14 and corresponds to a taper on the cylindrical portion of the shell 29.

[0166] Provided between the neck portion 31 and the cathode anode unit 14 is a separator structure 26 which separates a plurality of tabs 15 extending from an upper longitudinal end face of the cathode anode unit 14 from the shell 29. As shown, the separator structure 26 includes a central hole for receiving the plurality of tabs 15.

[0167] The tabs 15 are attached to the cap 30. The tabs 15 are preferably welded or soldered to the cap 30. As shown in Figures 5 and 6, the tabs 15 are folded inwardly toward the center of the cell 12 before they pass through a central hole in the separator structure 26 and into the cap 30, creating a longitudinally extending stack of overlapping tabs.

[0168] Because the size of the battery 12 used in the handheld aerosol generating device 2 is limited, the space required by the overlapping tabs reduces the space available for the cathode-anode unit 14 and therefore reduces the energy capacity of the battery 12.

[0169] In the embodiment of the aerosol generating device 2 having a cathode-anode unit or battery according to Figures 7-11, the overlapping space 32 caused by the use of multiple tabs 15 can be reduced.

[0170] In a fourth embodiment of the aerosol generating device 2, the battery 12 includes a cathode-anode unit 14, as shown in Fig. 7. According to the fourth embodiment, the tabs 15 are folded outward. Thus, the overlapping space 32 caused by the tabs 15 after folding can be reduced.

[0171] In the fifth and sixth embodiments of the aerosol generating device 2, the battery 12 comprises a cathode-anode unit 14, as shown in Figs.

[0172] In contrast to the cathode-anode unit 14 shown in Fig. 2, the tabs 15 according to Fig. 8 have a trapezoidal shape. The width of the tabs 15 decreases with increasing distance to the longitudinal end face of the cathode-anode unit 14. Thus, the overlapping space 104 caused by the tabs 15 after folding is reduced.

[0173] In contrast to the cathode-anode unit 14 shown in Fig. 2, the tabs 15 according to Fig. 9 have a needle shape, thus reducing the overlapping space 104 caused by the tabs 15 after folding.

[0174] Referring to FIG. 5, an embodiment of a method for manufacturing a battery 12 for an aerosol generating device 2 may include one or more of the following steps.

[0175] First, a cathode-anode unit 14 is provided. The cathode-anode unit 14 includes three tabs 15 extending from an upper longitudinal end face of the cathode-anode unit 14.

[0176] Second, the cathode-anode unit 14 is disposed within the shell 29. The cathode-anode unit 14 may be disposed so as to abut against an end wall of the shell.

[0177] Third, the three tabs 15 extending from the lower end surface of the cathode-anode unit 14 are attached to the bottom shell end wall. The three tabs extending from the lower end surface of the cathode-anode unit 14 are preferably attached by welding the three tabs 15 to the bottom shell end wall. For example, a welding needle passes through the center of the cathode-anode unit 14 to weld the three tabs 15 on the shell end wall.

[0178] Fourth, the shell 29 is at least partially filled with an electrolyte.

[0179] Fifth, the separator structure 26 is disposed above the cathode-anode unit 14 such that the three tabs 15 pass through a central hole in the separator structure 26. The fifth step further includes folding the three tabs 15 according to one of the techniques discussed with respect to Figures 6 and 7.

[0180] Sixth, the three tabs 15 are attached to the cap 30 by welding or soldering.

[0181] Typically, the three tabs 15 are long enough to facilitate easy installation. For example, the tab extension height 25 for a battery of 11390 design may range from 14 mm to 16 mm.

[0182] In the seventh and eighth embodiments of the aerosol generating device 2, the battery 12 has a tab mounting design as shown in Figures 10 and 11. Insofar as the battery 12 has the same or similar features as the battery 12 according to Figure 4, the same reference numbers are used.

[0183] Instead of attaching the tabs 15 directly to the cap 30, the battery 12 according to Figs. 10 and 11 comprises a conductive structure 33 having connection ports 34 for the tabs 15. Essentially, the conductive structure 33 allows the tabs 15 to be attached to the connection ports 34 instead of the cap 30, thereby reducing their length and thus reducing space consumption. The conductive structure 33 may also reduce folding and therefore breakage of the tabs. Finally, the conductive structure 33 allows the neck portion 31 to be removed.

[0184] The conductive structure 33 comprises a platform 35 and a connector 36. The platform 35 has a periphery that fits the inner rim of the shell 29. The platform 35 is disposed on a longitudinal end face of the cathode-anode unit 14. The platform 35 is made of a conductive structure 37 and a non-conductive structure 38. The conductive structure 37 includes connection ports 34 in the form of a number of holes for receiving a number of tabs 15. The number of connection ports 34 is equal to the number of tabs 15. The openings are provided as holes. In other embodiments, slots may be provided.

[0185] Slots are provided when rectangular shaped tabs are used, as shown in Figure 10. Similarly, slots may be provided when trapezoid shaped tabs are used.

[0186] Holes are provided when needle-shaped tabs are used, as shown in Figure 11. During manufacture, the tabs 15 pass through the openings, fold inwards or outwards, and are then welded or soldered to the conductive structure 37. The mechanical strength of the needles allows the tabs 15 to easily pass through the openings without cracking.

[0187] A non-conductive structure 38 is formed around the conductive structure 37 such that the conductive structure 37 is electrically isolated from the shell 29. The platform replaces the separator structure 26 shown in FIG.

[0188] The platform 35 is attached to the shell 29 such that the cathode anode unit 14 is fixed in longitudinal position relative to the shell 29. In particular, the non-conductive structure 26 is sealed to the shell sidewall. This allows the cathode anode unit 14 to be held in place longitudinally and eliminates the need for the neck portion 31. This allows for an increase in space for the cathode anode unit 14 and therefore the volumetric energy density of the battery 12.

[0189] A connector 36 is provided between the platform 35 and the cap 30. The connector 36 bridges the longitudinal distance between the cathode-anode unit 14 and the cap 30. The connector 36 includes a conductive structure 39 for electrically connecting the plurality of tabs 15 to the cap 30 and a non-conductive structure 40 for separating the conductive structure 39 from the shell 29.

[0190] The conductive structure 39 of the connector 36 has a "U" shape. In particular, the connector has three connector sections, with a first connector section and a second connector section each connected to a third connector section at a 90 degree angle. The first connector section and the second connector section extend in the same lateral direction. The first connector section is attached to the cap 30. The second connector section is attached to the conductive structure 37 of the platform 35.

[0191] Referring to the manufacturing method of the battery 12 according to FIG. 4, the manufacturing method of the battery 12 according to FIG. 10 and FIG. 11 may also include the first to fourth steps.

[0192] Instead of the fifth step of disposing the separator structure 26 and the sixth step of attaching the plurality of tabs 15 to the cap 30, the method of manufacturing the battery 12 according to FIGS. 10 and 11 includes one or more of the following steps.

[0193] Fifth, the conductive structure 33 is disposed on the longitudinal end surface of the cathode-anode unit 14 such that the three tabs 15 contact the three connection ports 34 of the conductive structure 33. The fifth step further includes one of the following steps.

[0194] Each of the three tabs 15 passes through a corresponding one of the three holes that form the three connection ports 34 .

[0195] A conductive structure 33 is attached to the shell 29. The conductive structure 33 is preferably sealed to the shell sidewall.

[0196] The three tabs 15 are folded inwards or outwards and attached to the conductive structure 33 .

[0197] Sixth, the conductive structure 33 is attached to the cap 30. The conductive structure 33 is preferably welded or soldered to the cap 30.

Claims

1. An aerosol generating device, comprising: Equipped with a battery, the battery is configured to provide power for heating; the battery comprises a cathode-anode unit; the cathode-anode unit comprises a cathode and an anode; At least one of the cathode and anode is provided with at least two tabs; The at least two tabs are disposed at a distance from each other.

2. 2. The aerosol generating device of claim 1, wherein the cathode and the anode are wound about a longitudinal axis to form a plurality of windings, and the number of tabs is less than the number of windings.

3. 3. An aerosol generating device as claimed in claim 1 or 2, comprising only one tab per at least 2, at least 5, or at least 15 windings.

4. The cathode is a cathode current collector layer, and a cathode active material layer; 4. An aerosol generating device according to claim 1, wherein the cathode active material layer is a coating on one side of the cathode current collector, the coating forming the cathode active material layer having a thickness of from 30 micrometers to 60 micrometers, preferably from 40 micrometers to 50 micrometers.

5. 5. The aerosol generating device according to claim 4, wherein at least one of the at least two tabs is attached to the cathode current collector, in particular by ultrasonic welding or resistance welding.

6. 6. An aerosol generating device according to claim 1, wherein the tab extends from the cathode or the anode towards the periphery of the battery.

7. 7. The aerosol generating device according to claim 1, wherein the battery further comprises a conductive structure having a connection port for the tab.

8. 8. The aerosol generating device of claim 7, wherein the conductive structure bridges the longitudinal distance between the cathode or anode and a terminal of the battery.

9. 9. An aerosol generating device as claimed in claim 7 or 8, wherein the connection port of the conductive structure is an opening, in particular a hole or a slot, for receiving the tab.

10. 1. A method of operating an aerosol generating device, comprising: detecting whether aerosol delivery is desired by a consumer; delivering power from the battery to the aerosol generating means via at least two tabs of the battery; The method wherein the tabs are disposed in parallel in an electrical circuit of which the battery forms a part.

11. 11. The method of claim 10, wherein the step of delivering power from the battery to the aerosol generating means via the at least two tabs within the battery includes drawing current from the battery only when a heating temperature is below a threshold level.

12. 12. The method of claim 11, wherein the discharge current is a pulsed current having at least one on cycle and at least one off cycle.

13. 13. The method of claim 12, wherein at least one of the on cycle and the off cycle has a duration of 0.01 seconds to 3 seconds, preferably 0.1 seconds to 2 seconds, in particular about 0.3 seconds.

14. A method according to any of claims 11 to 13, wherein the discharge current has a peak current of between 2 Amps and 5 Amps, preferably between 2.5 Amps and 4 Amps, in particular about 3.15 Amps.

15. The use of at least two tabs provided on the cathode or anode in an aerosol generating device to increase the rate capability of the battery for intermittent heating.

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