Aerosol Generator

Abstract

An aerosol generating device (100, 800) is provided that includes a holding unit (10, 810) configured to receive and aerosolize an aerosol-generating substrate (12, 812) and a charging unit (50, 850) connectable to the holding unit. The holding unit includes a heater component (47, 847) and a first charge storage module (11, 811) that provides power to the heater component. The charging unit includes a second charge storage module (51, 851) that provides power to the heater component when the charging unit is connected to the holding unit. A controller (43, 843) is configured to direct a first power flow from the first charge storage module in a first pre-heating manner to pre-heat the heater component when the holding unit is not connected to the charging unit, and to direct a second power flow from the second charge storage module in a second pre-heating manner to pre-heat the heater component when the holding unit is connected to the charging unit.

Description

[Technical field]

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

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

[0003] Heating devices for vaporization or aerosolization are known in the art. Such devices typically include a heating chamber and a heater. In operation, an operator inserts the product to be aerosolized or vaporized into the heating chamber. The inserted product is heated by an electronic heater, vaporizing the product's ingredients, which are inhaled by the operator. In some instances, the product is a tobacco product similar to a traditional cigarette. Such devices are sometimes referred to as "non-combustion heat-to-vapor" devices, since they heat the product to the point of aerosolization without burning it.

[0004] Challenges facing known aerosol generating devices include providing effective power management as well as enhancing ease of use. Summary of the Invention [Problem to be solved by the invention]

[0005] The object of the present invention is, inter alia, to address the problem of achieving effective power management as well as increasing ease of use. [Means for solving the problem]

[0006] In a first aspect, there is provided an aerosol generating device comprising: a holding unit configured to receive and aerosolize an aerosol-generating substrate; and a charging unit connectable to the holding unit; the holding unit includes a heater component configured to aerosolize the aerosol-generating substrate and a first charge storage module configured to provide power to the heater component; the charging unit includes a second charge storage module configured to provide power to the heater component when the charging unit is connected to the holding unit; The aerosol generating device further includes a controller, the controller comprising: preheating the heater component to a predetermined temperature for an aerosolization session by directing a first power flow from the first charging storage module to the heater component in a first preheating manner when the holding unit is not connected to the charging unit; preheating the heater component to a predetermined temperature for the aerosolization session by directing a second power flow from the second charging storage module to the heater component in a second preheating manner when the holding unit is connected to the charging unit. It is structured as follows.

[0007] In this way, an operator of the aerosol generating device has flexible power management with respect to whether to use a first charging storage module of the holding unit to power the pre-heating phase when the holding unit is disconnected from the charging unit, or to use a second charging storage module of the charging unit to power the pre-heating phase when the holding unit is connected to the charging unit.

[0008] Preferably, the first pre-heating strategy includes directing a first power flow from a first charge storage module to a heater component for a first predetermined time period; A second pre-heating strategy includes directing a second power flow from a second charge storage module to the heater component for a second predetermined time period.

[0009] Preferably, the first predetermined time is longer than the second predetermined time and the first power flow is lower power than the second power flow.

[0010] In this way, the operator of the aerosol generating device has flexible power management with respect to whether to use only the first charging storage module to power the pre-heating phase for a longer period of time when the holding unit is disconnected from the charging unit, or to use the second charging storage module of the charging unit to power the pre-heating phase for a shorter period of time when the holding unit is connected to the charging unit.

[0011] Preferably, the controller when the holding unit is connected to the charging unit, directing power flow from the second charging storage module to the heater component to maintain the predetermined temperature during a heating phase of the aerosolization session after the heater component has been preheated; When the holding unit is not connected to the charging unit, directing power flow from the first charge storage module to the heater component to maintain the predetermined temperature during a heating phase of the aerosolization session after the heater component has been preheated. It is structured as follows.

[0012] In this way, an operator of the aerosol generating device has flexible power management with respect to whether to use a first charging storage module of the holding unit to power the heating phase when the holding unit is disconnected from the charging unit, or to use a second charging storage module of the charging unit to power the heating phase when the holding unit is connected to the charging unit.

[0013] Preferably, the controller further comprises: When the holding unit is connected to the charging unit, the holding unit directs a power flow from the second charging storage module to the first charging storage module to charge the first charging storage module. It is structured as follows.

[0014] In this way, the second charge storage module of the charging unit is used to recharge the first charge storage module of the holding unit, which helps ensure that the first charge storage module has a sufficient charge level in case the holding unit is disconnected from the charging unit, thereby enhancing overall power management.

[0015] Preferably, the holding unit is configured to be received within the charging unit when connected to the charging unit.

[0016] Preferably, the holding unit includes a cavity, and the aerosol-generating substrate is insertable into the cavity for heating by the heater component to generate the aerosol.

[0017] Preferably, the holding unit includes a cavity, the aerosol-generating substrate is insertable into the cavity for heating by the heater component to generate an aerosol, and the cavity is accessible for receiving the aerosol-generating substrate when the holding unit is housed within the charging unit.

[0018] In this way, the operator can perform aerosolization when the holding unit is connected to the charging unit.

[0019] Preferably, the cavity is configured to accommodate a substantially planar aerosol-generating substrate. Preferably, the cavity configured to accommodate a substantially planar aerosol-generating substrate comprises two major internal surfaces facing each other, the aerosol-generating substrate being configured to be accommodated between the opposing major internal surfaces, each of the major internal surfaces being associated with a heating element of the heater component. Preferably, the major internal surfaces comprise a ceramic material, and the heating element is disposed on or embedded within the ceramic material.

[0020] Alternatively, the cavity is configured to accommodate a rod-shaped aerosol-generating substrate. Preferably, the aerosol-generating substrate is a tobacco rod.

[0021] Preferably, the second charge storage module has a greater charge storage capacity than the first charge storage module.

[0022] In this way, a physically smaller charge storage module may be housed in the holding unit for improved comfort and safety.

[0023] Preferably, the first charge storage module may be one or more batteries, supercapacitors, or a combination thereof. Preferably, the second charge storage module may be one or more batteries, supercapacitors, or a combination thereof.

[0024] Preferably, the aerosol generating device is configured to perform a first aerosolization session followed consecutively by a second aerosolization session, each aerosolization session including a preheating phase in which a heater component is preheated to a predetermined temperature and a heating phase in which the heater component is preheated and then maintained at the predetermined temperature.

[0025] In this manner, the power management of the device is provided to provide the operator with the flexibility to have one operator aerosolize two substrates sequentially, or to have a first operator aerosolize one substrate and then a second operator aerosolize a second substrate using the same aerosol generating device.

[0026] Preferably, both the pre-heating phase of the first aerosolization session and the pre-heating phase of the second aerosolization session are performed when the holding unit is connected to the charging unit, and the controller is configured to direct a second power flow from the second charging storage module to the heater component in a second pre-heating manner during the pre-heating phase of the first aerosolization session and the pre-heating phase of the second aerosolization session; Both the heating phase of the first aerosolization session and the heating phase of the second aerosolization session are performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charging storage module to the heater component during the heating phase of the first aerosolization session and the heating phase of the second aerosolization session.

[0027] In this way, the operator only has to hold the more convenient holding unit during the heating phase, while still enjoying the short-term pre-heating advantages of a larger or more powerful second charge storage module.

[0028] Preferably, both the pre-heating phase of the first aerosolization session and the pre-heating phase of the second aerosolization session are performed when the holding unit is connected to the charging unit, and the controller is configured to direct a second power flow from the second charging storage module to the heater component in a second pre-heating manner during the pre-heating phase of the first aerosolization session and the pre-heating phase of the second aerosolization session; a heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charge storage module to the heater component during the heating phase of the first aerosolization session; The heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct power flow from the second charging storage module to the heater component during the heating phase of the second aerosolization session.

[0029] In this manner, a minimal size charge storage module may be used in the holding unit because the first charge storage module only needs to store charge for the heating phase of one aerosolization session (e.g., the first aerosolization session) and still be able to power the aerosol generation device for successive aerosolization sessions.

[0030] Preferably, the controller is configured to direct the second power flow and the power flow from the first charge storage module to the heater component during a pre-heating phase of the first aerosolization session and during a pre-heating phase of the second aerosolization session.

[0031] In this manner, the second charge storage module may be used to boost power flow to the heater component by combining with the power flow from the first charge storage module.

[0032] Preferably, the pre-heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct a first power flow from the first charging storage module to the heater component in a first pre-heating manner during the pre-heating phase of the first aerosolization session; a heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charge storage module to the heater component during the heating phase of the first aerosolization session; The pre-heating phase of the second aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct a first power flow from the first charging storage module to the heater component in a first pre-heating manner during the pre-heating phase of the second aerosolization session; The heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct power flow from the second charging storage module to the heater component during the heating phase of the second aerosolization session.

[0033] In this manner, the second charge storage module can power the heater component during the heating phase of the second aerosolization session. Thus, a smaller charge storage module can be used as the first charge storage module, which improves ease of use and safety. By using the second charge storage module to power the heating phase of the second aerosolization session, the charge level of the first charge storage module can be conserved for a subsequent aerosolization session.

[0034] Preferably, the pre-heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct a first power flow from the first charging storage module to the heater component in a first pre-heating manner during the pre-heating phase of the first aerosolization session; a heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charge storage module to the heater component during the heating phase of the first aerosolization session; A pre-heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct a second power flow from the second charging storage module to the heater component in a second pre-heating manner during the pre-heating phase of the second aerosolization session; The heating phase of the second aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charging storage module to the heater component during the heating phase of the second aerosolization session.

[0035] In this manner, the second charge storage module can power the heater component during the pre-heating phase of the second aerosolization session. Thus, a smaller charge storage module can be used as the first charge storage module, which improves ease of use and safety. By using the second charge storage module to power the pre-heating phase of the second aerosolization session, the charge level of the first charge storage module can be conserved in preparation for the heating phase of the second aerosolization session.

[0036] Preferably, the pre-heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct a first power flow from the first charging storage module to the heater component in a first pre-heating manner during the pre-heating phase of the first aerosolization session; a heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charge storage module to the heater component during the heating phase of the first aerosolization session; A pre-heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct a second power flow from the second charging storage module to the heater component in a second pre-heating manner during the pre-heating phase of the second aerosolization session; The heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct power flow from the second charging storage module to the heater component during the heating phase of the second aerosolization session.

[0037] In this way, the first charge storage module only needs to have the capacity to power the first aerosolization session, which means that a smaller charge storage module may be used as the first charge storage module, thereby improving ease of use and safety, and also allowing the size of the holding unit to be reduced by making the first charge storage module smaller while still allowing successive aerosolization sessions to be performed.

[0038] Preferably, the pre-heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct a first power flow from the first charging storage module to the heater component in a first pre-heating manner during the pre-heating phase of the first aerosolization session; a heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charge storage module to the heater component during the heating phase of the first aerosolization session; The pre-heating phase of the second aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct a first power flow from the first charging storage module to the heater component in a first pre-heating manner during the pre-heating phase of the second aerosolization session; The heating phase of the second aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct power flow from the first charging storage module to the heater component during the heating phase of the second aerosolization session.

[0039] In this manner, the operator is provided with the flexibility to perform two aerosolization sessions without relying on a charging unit.

[0040] Preferably, the pre-heating phase of the first aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct a second power flow from the second charging storage module to the heater component in a second pre-heating manner during the pre-heating phase of the first aerosolization session; a heating phase of the first aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct power flow from the second charging storage module to the heater component during the heating phase of the first aerosolization session; A pre-heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct a second power flow from the second charging storage module to the heater component in a second pre-heating manner during the pre-heating phase of the second aerosolization session; The heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct power flow from the second charging storage module to the heater component during the heating phase of the second aerosolization session.

[0041] In this way, the charge stored in the first charge storage module can be preserved for a subsequent aerosolization session, thereby allowing flexibility in power management. Additionally, if the second charge storage module is more powerful than the first charge storage module, shorter pre-heat times can be achieved.

[0042] In a second aspect, there is provided an aerosol generating system comprising an aerosol generating device of the first aspect, wherein an aerosol-generating substrate is housed in a holding unit of the aerosol generating device.

[0043] In a third aspect, there is provided a method of operating an aerosol generating device, the aerosol generating device comprising: a holding unit configured to receive and aerosolize an aerosol-generating substrate; and a charging unit connectable to the holding unit, the holding unit including a heater component configured to aerosolize the aerosol-generating substrate and a first charge storage module configured to provide power to the heater component, the charging unit including a second charge storage module configured to provide power to the heater component when the charging unit is connected to the holding unit; The method is: preheating the heater component to a predetermined temperature for an aerosolization session by directing a first power flow from the first charging storage module to the heater component in a first preheating manner when the holding unit is not connected to the charging unit; preheating the heater component to a predetermined temperature for an aerosolization session by directing a second power flow from the second charging storage module to the heater component in a second preheating manner when the holding unit is connected to the charging unit; Includes.

[0044] The method of the third aspect may, where appropriate, include preferred features of the aerosol generating device of the first aspect.

[0045] In a fourth aspect, there is provided a non-transitory computer readable medium storing instructions executable by one or more processors of an aerosol generating device, the aerosol generating device comprising: a holding unit configured to receive and aerosolize an aerosol-generating substrate; and a charging unit connectable to the holding unit, the holding unit including a heater component configured to aerosolize the aerosol-generating substrate and a first charge storage module configured to provide power to the heater component, the charging unit including a second charge storage module configured to provide power to the heater component when the charging unit is connected to the holding unit; The instructions are sent to one or more processors: preheating the heater component to a predetermined temperature for an aerosolization session by directing a first power flow from the first charging storage module to the heater component in a first preheating manner when the holding unit is not connected to the charging unit; preheating the heater component to a predetermined temperature for an aerosolization session by directing a second power flow from the second charging storage module to the heater component in a second preheating manner when the holding unit is connected to the charging unit; The method includes the steps of:

[0046] The non-transitory computer readable medium of the fourth aspect may optionally include preferred features of the aerosol generating device of the first aspect. [Brief description of the drawings]

[0047] Embodiments of the invention will now be described, by way of example only, with reference to the drawings in which:

[0048] [Figure 1A] FIG. 1 is a diagram of a first exemplary aerosol generating device including a hand piece and a charging unit, showing the hand piece detached from the charging unit. [Figure 1B] FIG. 1 is a diagram of a first exemplary aerosol generating device including a hand piece and a charging unit, showing the hand piece housed in the charging unit. [Figure 1C] FIG. 1 illustrates a first exemplary aerosol generating device including a hand piece and a charging unit, the hand piece being pivotally connected to the charging unit. [Diagram 2] FIG. 1B is a more detailed view of the handpiece of FIGS. [Diagram 3] FIG. 3 is a diagram of an aerosol-generating substrate configured for use with the handpiece of FIG. 2. [Figure 4A] 4 is a diagram of the heating chamber of the handpiece 10 of FIG. 2 and the aerosol-generating substrate of FIG. 3. [Figure 4B] FIG. 4B is a more detailed view of the heating chamber of FIG. 4A. [Diagram 5] FIG. 3 is a more detailed view of the mouthpiece portion of the handpiece of FIG. 2. [Figure 6] 1 is an exemplary plot of average power supplied to a heater versus time during an aerosolization session. [Figure 7] 13 is an operational flowchart of a control process for power management during an aerosolization session. [Figure 8A] FIG. 13 is a diagram of a second exemplary aerosol generating device including a hand piece and a charging unit, showing the hand piece housed in the charging unit. [Figure 8B]FIG. 13 is a diagram of a second exemplary aerosol generating device including a hand piece and a charging unit, showing the hand piece detached from the charging unit. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0049] 1A, 1B, and 1C show various configurations of a first exemplary aerosol generating device 100 (also referred to as a vapor generating device, vaping device, or e-cigarette), which includes a handpiece 10 (also referred to as a holding unit) and a charging unit 50. The handpiece 10 is removably connectable to the charging unit 50.

[0050] Handpiece 10 includes a first charge and storage module 11 and a heater 47 (also referred to as a heater component). First charge and storage module 11 is configured to provide power to heater 47 for aerosolizing an aerosol-generating substrate (not shown), as will be described in more detail with reference to Figures 2-5. Handpiece 10 also includes a mouthpiece 32 into which an operator inhales generated aerosol during an aerosolization session.

[0051] The charging unit 50 includes a second charge storage module 51 configured to charge the first charge storage module 11 and to provide power to the heater 47 .

[0052] The first charge storage module 11 may be one or more batteries or supercapacitors, or a combination of these. The first charge storage module 11 may be a fast charging battery, such as a battery having a chemistry such as Lithium Titanate Oxide (LTO). This type of battery is capable of providing the high current required at the beginning of an aerosolization session and has good safety characteristics.

[0053] The second charge storage module 51 may be one or more batteries or supercapacitors, or a combination thereof. In one example, the second charge storage module 51 may be a single high energy density lithium ion battery with a medium power source capability. In another example, the second charge storage module 51 may be a combination of a high energy density lithium ion battery with a low power source capability and a high power battery (e.g., LTO, or lithium iron phosphate (LFP)) or a supercapacitor module.

[0054] In the following description, the first charging and storage module will be referred to as the handpiece battery 11 and the second charging and storage module will be referred to as the charging unit battery 51, although each of these may be one or more batteries, supercapacitors, or a combination thereof, as will be readily understood by those skilled in the art.

[0055] The charging unit battery 51 has a greater charge storage capacity than the handpiece battery 11. That is, the charging unit battery 51 can hold more charge than the handpiece battery 11. The handpiece battery 11 may be capable of providing power to the heater 47 to aerosolize a first number of aerosol-generating substrates, and the charging unit battery 51 may be capable of providing power to the heater 47 to aerosolize a second number of aerosol-generating substrates, the second number being greater than the first number. For example, the handpiece battery 11 may be capable of providing power to the heater 47 to aerosolize two aerosol-generating substrates, and the charging unit battery 51 may be capable of providing power to the heater 47 to aerosolize twenty aerosol-generating substrates.

[0056] In this manner, the handpiece 10 may be smaller in size than the charging unit 50 so that it is easier for an operator to hold during an aerosolization session, and the larger charging unit 50 may be used to charge the handpiece 10 between aerosolization sessions. Thus, a technical advantage of providing an aerosol generating device with a smaller, more user-friendly handpiece 10 for an aerosolization session is that it can be powered for multiple sessions without requiring connection to an external power source.

[0057] The charging unit 50 is dimensioned to receive and accommodate the handpiece 10 at the opening of the charging unit 50. The charging unit battery 51 is connected to a corresponding connector of the handpiece 10 by a connector in the charging unit opening when the handpiece 10 is accommodated in the charging unit 50. A controller of the handpiece 10 or the charging unit 50 can detect signals between the handpiece connector and the charging unit connector to control the flow of power from the charging unit battery 51 to the handpiece battery 11. The power flow described herein may be considered to be a flow of charge (i.e., current) from one element to another. In this manner, when an operator inserts the handpiece 10 into the charging unit 50, the handpiece battery 11 and the charging unit battery 51 are connected, and through the connection between the connectors, the handpiece battery 11 can be charged by the charging unit battery 51. The charging unit 50 may thus be considered to be a charging case for the handpiece 10. Similarly, the charging unit battery 51 can be used to power the heater 47, with power flowing from the charging unit battery 51 to the heater 47 through a connector.

[0058] The charging unit battery 51 is capable of storing enough charge to fully charge multiple times the handpiece battery 11. The charging unit battery 51 itself can be charged from an external power source such as a power bank or mains power, by a connection such as a USB cable, or through a connection to a docking station.

[0059] 1A illustrates the handpiece 10 removed from the charging unit 50 and not interconnected. FIG. 1B illustrates the handpiece 10 housed in and connected to the charging unit 50. In the example of FIG. 1B, the mouthpiece 32 of the handpiece 10 extends out from the charging unit 50. In this manner, an operator can conduct an aerosolization session while the handpiece 10 is housed in the charging unit 50.

[0060] Alternatively or additionally, in some examples, the charging unit 50 and handpiece 10 may be configured such that the handpiece 10 can be pivoted outwardly from the charging unit 50 while still connected to the charging unit 50 by a hinge connection at the end of the handpiece 10 remote from the mouthpiece 32, as shown in FIG. 1C. This may make it easier to use the handpiece 10 while connected to the charging unit 50.

[0061] Figures 2-5 show the handpiece 10 of the first exemplary aerosol generating device 100 in more detail. Figure 2 shows the handpiece 10 with a mouthpiece portion 32 connected thereto. Figure 3 shows an aerosol-generating substrate 12 configured for use with the handpiece 10 of Figure 2. Figure 4A shows the heating chamber 45 of the handpiece 10 of Figure 2 together with the aerosol-generating substrate 12 of Figure 3, and Figure 4B shows the heating chamber 45 in more detail. Figure 5 shows the mouthpiece portion 32 of the handpiece 10 of Figure 2 in more detail.

[0062] The aerosol-generating substrate 12 is planar or flat in shape, for example in the form of a rectangular parallelepiped of flat shape extending along a substrate axis X and having outer dimensions L x W x D. In one specific example, the length L of the substrate along the substrate axis X is approximately 33 mm, the width W is approximately 12 mm, and the depth D is approximately 1.2 mm. That is, the substrate may be considered to be planar in shape in that the depth is much less than the length and width.

[0063] The depth D of the substrate 12 is defined by a pair of parallel walls 13A, 13B, referred to as substrate side walls 13A, 13B. The width W of the substrate is defined by a pair of parallel walls 14A, 14B, referred to as substrate contact walls 14A, 14B. In other examples, the aerosol-forming substrate 12 may be of any other suitable shape or size. For example, the aerosol-forming substrate may be tubular in shape, similar to a conventional cigarette.

[0064] The aerosol-generating substrate 12 may include a heating portion 15 and a mouthpiece portion 16 aligned along a substrate axis X. However, in some examples, the aerosol-generating substrate 12 may include only the heating portion 15. The mouthpiece portion has a length L1 and the heating portion has a length L2. In some examples, the heating portion 15 may be slightly longer than the mouthpiece portion 16; that is, L2 may be greater than L1. The heating portion 15 defines an abutment end 18 of the substrate 12, and the mouthpiece portion 16 defines a mouth end 20 of the substrate 12. The heating portion 15 and the mouthpiece portion 16 may be connected by a wrapper extending around the substrate axis X. Alternatively, the heating portion 15 and the mouthpiece portion 16 may be wrapped in separate wrappers and secured together by any other suitable means. The wrapper may include paper and / or nonwoven fabric and / or aluminum. The wrapper may be porous or air impermeable. The wrapper may define a number of air passages extending within the substrate 12 between the abutment end 18 and the mouth end 20 .

[0065] The heating section 14 is configured to be heated by a heater and includes an aerosol-generating material. The aerosol-generating material may be, for example, a material that may include nicotine or tobacco and an aerosol-forming agent. The tobacco may be in the form of various materials, for example, cut tobacco, granulated tobacco, tobacco leaves, and / or reconstituted tobacco. Suitable aerosol-forming agents include polyols (such as sorbitol, glycerol, and glycols (such as propylene glycol or triethylene glycol)), non-polyols (such as monohydric alcohols), acids (such as lactic acid), glycerol derivatives, esters (such as triacetin), triethylene glycol diacetate, triethyl citrate, glycerin, or vegetable glycerin. In some embodiments, the aerosol-generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate may also include at least one of a gelling agent, a binder, a stabilizer, and a humectant. When the aerosol-generating material is heated, an aerosol or vapor is formed. It will be appreciated that the terms aerosol and vapor may be used interchangeably herein. In one example, the aerosol-generating material forms an aerosol when heated, but not combusted, by heater 47.

[0066] The mouthpiece portion 16 is intended to be housed within the mouthpiece 32. The mouthpiece portion 16 includes a core 17 that may have filtering functionality. In some examples, the core 17 may be a foam or packed fiber strands. The core 17 may be formed into a stable shape by an extrusion and / or rolling process. The substrate 12 may be shaped to provide one or more air flow passages. As shown in the example of FIG. 3, the mouthpiece portion 16 defines a plurality of ventilation holes 22 aligned with the walls of the substrate, which may include one or more of the substrate side walls 13A, 13B and the substrate contact walls 14A, 14B. The ventilation holes 22 allow fresh air to flow into the interior of the substrate 12 to achieve a particular vaping / tasting effect.

[0067] The handpiece 10 includes a handpiece body 30 that extends along a handpiece axis Y and forms at least one sidewall 40 of the handpiece 10. The handpiece body 30 includes a mouthpiece 32 and a housing 34 that are aligned consecutively along the handpiece axis Y. In the example of FIG. 1, the mouthpiece 32 and the housing 34 form two separate pieces. The mouthpiece 32 is designed to be removably secured to or received in an insertion opening 36 formed in one end of the housing 34. This opening 36 extends perpendicular to the handpiece axis Y, as shown in FIG. 4 (where the mouthpiece 32 has been removed from the housing 34).

[0068] The housing 34 may form a generally rectangular shape with rounded edges in each cross section, for example, having at least four side walls 40. In another example, the housing may have at least one different cross-sectional shape (e.g., a circular shape). The housing 34 may be sealed at an end opposite the insertion opening 36 that receives the mouthpiece 32. The housing 34 may be formed of a single piece or several assembled pieces made of any suitable material, such as aluminum or plastic. One or more side walls 40 of the housing may have one or more openings for control and / or viewing elements. For example, such elements may include one or more of a control button, a touch panel, a screen, an LED, etc. In one example, the housing 34 has a slot 42 for an LED that indicates at least an on state of the handpiece 10. In some examples, the LED may also indicate status information of the handpiece (e.g., battery status, error status, etc.).

[0069] The housing 34 contains a handpiece battery (not shown) that powers the handpiece 10, a controller 43 that controls the operation of the handpiece 10, a heating chamber (also called a heating cavity) 45 that heats the aerosol-generating substrate 12, and at least two heating elements 47A, 47B that heat the heating chamber 45.

[0070] The mouthpiece 32 is configured to be connected to the insertion opening 36 while attached to the housing 34 .

[0071] The mouthpiece 32 has a throughbore along the handpiece axis Y designed to receive the mouthpiece portion 16 of the aerosol-generating substrate 12 such that the substrate axis X and the handpiece axis Y are coincident. The throughbore may have the same cross-sectional shape as the aerosol-generating substrate 12 and may have internal dimensions slightly larger than the external dimensions of the mouthpiece portion 16 of the aerosol-generating substrate 12. In one example, the throughbore defines a rectangular cross-section that receives the mouthpiece portion 16 of the aerosol-generating substrate 12.

[0072] The mouthpiece 32 may have a recess that forms an opening 66 when the mouthpiece 32 is inserted into the insertion opening 36, which forms the flow inlet 66. If the aerosol-generating substrate 12 includes vent holes 22, at least some of the vent holes 22 are positioned opposite the flow inlet 66.

[0073] 4A and 4B in more detail, the heating chamber 45 may be cup-shaped and extend along the handpiece axis Y between an open end 70, into which the aerosol-generating substrate 12 is inserted, and an opposing sealed end 71. The heating chamber 45 houses the heating portion 15 of the aerosol-generating substrate 12. The heating chamber 45 has a cross-sectional shape that is approximately the same as the aerosol-generating substrate 12. In one example, the heating chamber 45 defines a rectangular cross-sectional shape having two parallel chamber side walls 73A, 73B and two parallel chamber contact walls 74A, 74B. The walls 74A, 74B form two major inner surfaces within the chamber 45 that face each other, and the aerosol-generating substrate is configured to be housed between these opposing major inner surfaces. These major inner surfaces include the heating elements 47A, 47B, respectively, of the heater component 47. Walls 73A, 73B form the two smaller inner surfaces of the chamber and connect to the two larger inner surfaces. The two smaller inner surfaces are smaller than the two larger inner surfaces, and the cavity is configured to accommodate a generally planar aerosol-generating substrate. Each chamber wall 74A, 74B is, for example, at least three times, advantageously five times, and more advantageously eight times, wider than each chamber wall 73A, 73B.

[0074] The heating chamber 45 has a distal wall disposed perpendicular to the handpiece axis Y and sealing the sealing end 71. The distal wall is adjacent to each of the walls 73A, 73B, 74A, 74B, sealing the chamber at the sealing end 71 and forming the cup shape of the chamber. Each of the walls 73A, 73B, 74A, 74B, 75 may be made of a thermally conductive material (e.g., metal, especially stainless steel). Additionally, at least some of the walls 73A, 73B, 74A, 74B, 75, or all of these walls may form one single piece. Alternatively, the walls 74A, 74B may be ceramic and heater wires or heater tracks may be embedded in or on the ceramic. The walls 73A, 73B, and 75 may also be ceramic. Such a ceramic heater may provide a compact heating cavity with well-distributed heat directed to the substrate. However, this may require significantly more heating power (e.g., >>10 W and / or >>1600 J) than heaters in aerosol generating devices configured to accommodate more conventional tobacco or tobacco-like consumables, and such heaters therefore benefit greatly from the heating power management operations described below with reference to FIG.

[0075] The interior dimensions of the heating chamber 45 are defined by a length L3 measured along the handpiece axis Y, a width W3 measured as the distance between the chamber side walls 73A, 73B, and a depth D3 measured as the distance between the chamber contact walls 74A, 74B. These interior dimensions L3, W3, and D3 are selected based on the exterior dimensions L2, W, and D of the heating portion 15 of the aerosol-generating substrate 12.

[0076] The depth D3 of the heating chamber 45 may be slightly larger than or approximately equal to the depth D of the aerosol-generating substrate 12. In this case, the substrate-contacting walls 14A, 14B may contact the chamber-contacting walls 74A, 74B, in particular the contact surfaces of these walls 74A, 74B, when the heated portion 15 of the aerosol-generating substrate 12 is accommodated in the heating chamber 45. In this case, the chamber-contacting walls 74A, 74B, in particular their contact surfaces, advantageously come into intimate contact with the substrate-contacting walls 14A, 14B. In another example, the depth D3 of the heating chamber 45 may be slightly smaller than the standard depth D of the aerosol-generating substrate 12. In this case, the heating chamber 45 and / or the mouthpiece 32 are configured to apply a force to the substrate-contacting walls 14A, 14B to compress the heated portion 15 of the aerosol-generating substrate 12. This allows for enhanced intimate contact between the corresponding contact walls of the heating chamber 45 and the substrate 12, and therefore enhanced heat transfer between these walls.

[0077] The width W3 of the heating chamber 45 may be defined such that at least one of the pairs of opposing side walls 73A, 13A or 73B, 13B of the heating chamber 45 and the aerosol-generating substrate 12 forms an air flow passage therebetween. When the heating portion 15 of the aerosol-generating substrate 12 is inserted into the heating chamber 45, an air flow passage is formed on either side of the aerosol-generating substrate 12 along the handpiece axis Y. Alternatively, no air flow passage is formed between the pairs of opposing side walls 73A, 13A or 73B, 13B of the heating chamber 45 and the aerosol-generating substrate 12. Instead, the pairs of side walls 73A, 13A or 73B, 13B may be in contact. This may be appropriate when the distal wall 75 or any other wall of the heating chamber 45 forms an opening suitable for air inflow.

[0078] The walls 74A and 74B of the chamber 45 each have a heating element 47A, 47B. The heating elements 47A, 47B form the heater 47 (also called the heater component) of the device. In one example, the heating elements 47A, 47B may be arranged outside the heating chamber 45 in contact with one of the chamber contacting walls 74A, 74B. In the example of FIG. 4B, the heating element 47A is arranged adjacent to the outer surface of the chamber contacting wall 74A, and the heating element 47B is arranged adjacent to the outer surface of the chamber contacting wall 47A. The chamber contacting wall thus transfers heat from the heating elements 47A, 47B to the aerosol-generating substrate 12. Each heating element 47A, 47B may include a polyimide film heater that extends along substantially the entire outer surface of the corresponding heating wall 74A, 74B, or along only a portion of this surface. In another example, the heating element may be embedded in the chamber wall. For example, heating element 47A may be embedded in chamber contacting wall 74A and heating element 47B may be embedded in chamber contacting wall 74B. In yet another example, the heating elements may be on the chamber walls inside heating chamber 45.

[0079] Optionally, handpiece 10 may also include insulation disposed between each heating element 47A, 47B and the inner surface of housing 34. The same insulation may also be disposed between the outer surface of each of chamber sidewalls 73A, 73B and the inner surface of housing 34.

[0080] The handpiece 10 includes a controller 43. The controller 43 is configured to control the operation of the handpiece 10. This may include inhibiting or enabling operation of the device based on the operating mode of the aerosol generating device 100, as well as controlling power flow to the handpiece battery 11 and the charging unit battery 51 (if connected).

[0081] The controller 43 may be at least one microcontroller unit including a memory containing instructions for operating the handpiece 10 and one or more processors configured to execute those instructions, including instructions to disable or enable operation of the device, execute each operating mode of the device, control the flow of power from the battery, etc.

[0082] The controller 43 may be configured to separately activate the operation of each heating element 47A, 47B according to a heating profile selected from a set of predefined heating profiles. The selection of the corresponding heating profile may be made according to an operation mode of the handpiece 10 and / or according to at least some external / internal parameters related to the operation of the handpiece 10.

[0083] The controller 43 controls the flow of power to the heater 47 during an aerosolization session, which may include a pre-heating phase and a heating phase.

[0084] In the pre-heat phase, the heater 47 is heated to a predetermined temperature at which aerosol is generated from the aerosol-generating substrate 12. The pre-heat phase may be considered the time during which the pre-heat mode is performed, e.g., the time it takes the heater 47 to reach the predetermined temperature. The pre-heat mode occurs during a first time of the aerosolization session. In one example, the first time may be a fixed, predetermined time. In another example, the first time may vary depending on the amount of time required to heat the heater 47 to the predetermined temperature. The predetermined temperature may be stored in a memory accessible to the controller.

[0085] Once the pre-heat phase is complete, the controller 43 controls the power flow to the heater 47 to terminate the pre-heat mode and to power the heating phase. In the heating phase, the controller 43 controls the power flow to the heater 47 to keep the heater 47 at approximately a predetermined temperature so that the generated aerosol is inhaled by the consumer. The heating phase may be considered the time during which the heating mode is performed, e.g., the time during which the heater 47 is aerosolizing one (or at least a portion of one) of the aerosol-generating substrates 12 after the pre-heat phase. The controller 43 may control the power flow to the heater 47 in the heating mode for a second time period of the aerosolization session. The second time period may be predetermined and stored in the controller 43.

[0086] 6 shows an exemplary plot of average power 132 delivered to the heater 47 versus time 134 during an aerosolization session. In the preheat phase, the controller 43 controls the power flow to the heater 47 to apply power to the heater 47 for a first time 136 until the temperature of the heater 47 reaches a predetermined temperature. In one example, the predetermined temperature may be 230° C. In one example, the first time is 20 seconds. In some examples, the controller 43 is configured to heat the heater 47 to the predetermined temperature within a fixed, predetermined first time. In another example, the first time varies depending on the time it takes the heater 47 to reach the predetermined temperature.

[0087] Once the heater 47 reaches the predetermined temperature, the controller 43 switches the operation mode to a heating phase for a second time 138, during which the temperature of the heater 47 is maintained at approximately the predetermined temperature. In one example, the second time may be 250 seconds. Typically, the power level applied to the heater 47 during the heating phase to maintain the heater 47 at the predetermined temperature is less than the power level applied to the heater 47 during the preheat phase to heat the heater 47 to the predetermined temperature. This can be seen in FIG. 6. That is, the power supplied to the heater 47 during the second time 138 is less than the power supplied to the heater 47 during the first time 136. The power level supplied to the heater 47 may be controlled by various means, for example, by adjusting the power output from one or more batteries or by adjusting the on / off period of the pulse width modulated power flow.

[0088] After the aerosolization session, a user of the handpiece 10 may be notified (e.g., by a visual, tactile, or audible indicator) that the aerosolization session has ended so that the user knows that the substrate is no longer being aerosolized.

[0089] FIG. 7 illustrates an operational flow chart of the control process for power management during an aerosolization session, which controls power between the handpiece battery 11, the charging unit battery 51, and the heater 47 during an aerosolization session.

[0090] In step 701, the controller determines whether the handpiece 10 and the charging unit 50 are connected to each other. In one example, the controller of the handpiece 10 may determine that the handpiece 10 is connected to the charging unit 50 by detecting that there is a signal between the connector of the handpiece 10 and the connector of the charging unit 50 when the handpiece 10 and the charging unit 50 are connected to each other. Similarly, the controller of the handpiece 10 may determine that the handpiece 10 is not connected to the charging unit 50 by detecting that there is no signal between the connector of the handpiece 10 and the connector of the charging unit 50 when the handpiece 10 and the charging unit 50 are not connected to each other.

[0091] Prior to step 701, the controller may determine whether an aerosolization session has been triggered. In some examples, the controller may determine that an aerosolization session has been triggered if there is a user input, such as pressing or operating a button (e.g., an "on" button) on the aerosol generating device, which the user can press or operate to initiate the aerosolization session. The controller may be configured to perform step 701 if it determines that an aerosolization session has been triggered.

[0092] If the controller determines in step 701 that the handpiece 10 and the charging unit 50 are not connected to each other, the process proceeds to step 702. If the controller determines that the handpiece 10 and the charging unit 50 are connected to each other, the process proceeds to step 703.

[0093] The controller is configured to preheat the heater 47 in a preheat phase to a predetermined temperature for an aerosolization session by directing a first power flow from the handpiece battery 11 to the heater 47 in a first preheat manner in step 702. This may occur if the controller determines that an aerosolization session has been triggered. The controller may also determine when the preheat phase is complete in step 702. In some examples, the preheat phase may be determined to be complete when the controller determines that a predetermined preheat time (stored in memory accessible to the controller) has expired. In another example, the preheat phase may be determined to be complete when the controller monitors a temperature associated with the heater 47 using a temperature sensor and determines that a predetermined heater temperature (stored in memory accessible to the controller) has been reached. Once preheating is complete in step 702, the process proceeds to step 705.

[0094] As previously discussed, if the controller determines in step 701 that the handpiece 10 and the charging unit 50 are connected to each other, the process proceeds to step 703. The controller is configured to preheat the heater 47 in a preheat phase to a predetermined temperature for an aerosolization session in step 703 by directing a second power flow from the charging unit battery 51 to the heater 47 in a second preheating manner. This may occur if the controller determines that an aerosolization session has been triggered.

[0095] In a first example of the second power flow, the controller controls the charging unit battery 51 such that the heater 47 is powered only from the charging unit battery 51. In a second example of the second power flow, the controller controls the charging unit battery 51 and the handpiece battery 11 such that both supply power to the heater 47. In the first example, the charge of the handpiece battery 11 may be conserved for the heating phase. In a second example, the charging unit battery 51 may be used to boost the power flow from the handpiece battery 11 to make the heating phase shorter.

[0096] The controller may also determine when the preheat phase is complete at step 703. In some examples, the preheat phase may be determined to be complete when the controller determines that a predetermined preheat time (stored in memory accessible to the controller) has expired. In another example, the preheat phase may be determined to be complete when the controller monitors a temperature associated with the heater 47 using a temperature sensor and determines that a predetermined heater temperature (stored in memory accessible to the controller) has been reached. Once preheat is complete at step 703, the process proceeds to step 704.

[0097] More specifically, the controller may be configured to direct a first power flow from the handpiece battery 11 to the heater 47 for a first predetermined time period in a first pre-heating regime. The controller may be configured to direct a second power flow from the charging unit battery 51 to the heater 47 for a second predetermined time period in a second pre-heating regime.

[0098] As previously mentioned, the handpiece battery 11 may be smaller than the charging unit battery 51. In addition, the handpiece battery 11 may be a type of battery that is more suited to fast charging rather than having a high power output. Thus, the handpiece battery 11 may have a smaller power output than the charging unit battery 51.

[0099] Thus, the first predetermined time may be longer than the second predetermined time, and the first power flow may be less power than the second power flow. In this manner, the preheat phase of a first preheat scheme using a lower power level may take longer than the preheat phase of a second preheat scheme using a higher power level.

[0100] In one example, the first predetermined time period may be 50 seconds and the second predetermined time period may be 20 seconds.

[0101] This ability to choose between the first and second pre-heating methods makes the aerosolization session more flexible for the operator. (a) long-term preheating in the first preheating method (but with the advantage that it is not necessary to keep the handpiece 10 connected to the charging unit 50, so that only a smaller handpiece 10 is needed, which is more comfortable to use); (b) a second preheating scheme for short periods of time (but requires connecting a smaller handpiece 10 to a larger charging unit 50); A choice can be made between:

[0102] After the pre-heating phase in step 702, where a first power flow is directed from the handpiece battery 11 to the heater 47 for the pre-heating phase, the process proceeds to step 705. The controller is configured in step 705 to direct a power flow from the handpiece battery 11 to the heater 47 to maintain a predetermined temperature during the heating phase of the aerosolization session.

[0103] In this way, both the pre-heating and heating phases can be performed without connecting the handpiece 10 to the charging unit 50. Thus, the operator only needs the handpiece 10, which is smaller and more user-friendly to operate. The operator can perform an aerosolization session entirely without needing the charging unit 50 (although it will require a longer pre-heating time). This can be advantageous, for example, if the operator does not want to carry both units of the set with him / her, but would like to move to another location to perform an aerosolization session, leaving the charging unit 50 on his / her desk.

[0104] This assumes that the handpiece 10 is not reconnected to the charging unit 50 after the preheat phase. Alternatively, the controller may determine whether the handpiece 10 and charging unit 50 are connected to each other before initiating the heating mode, and may direct power flow from the handpiece battery 11 to the heater 47 if they are not connected, or from the charging unit battery 51 to the heater 47 if they are connected.

[0105] After the pre-heat phase in step 703 , where a second power flow is directed from the charging unit battery 51 to the heater 47 for the pre-heat phase, the process proceeds to step 704 .

[0106] The controller may be configured to determine whether the handpiece 10 and the charging unit 50 are still connected to each other before starting the heating phase in step 704. If the controller determines in step 704 that the handpiece 10 and the charging unit 50 are not connected to each other, the process proceeds to step 705. If the controller determines that the handpiece 10 and the charging unit 50 are connected to each other, the process proceeds to step 706.

[0107] In one example, in step 704, the controller 43 determines whether the handpiece 10 and the charging unit 50 have been disconnected or are not yet disconnected by determining whether there is no longer a signal between the connectors of the two units (whether they are disconnected) or whether there is still a signal between the connectors of the two units (whether they are still connected).

[0108] The controller is configured in step 705 to direct power flow from the handpiece battery 11 to the heater 47 to maintain a predetermined temperature during the heating phase of the aerosolization session.

[0109] Thus, in step 703, a short-term pre-heating may be performed using the more powerful charging unit battery 51. This allows the size of the battery to be minimized by using a smaller, less powerful battery in the handpiece 10, which also allows the overall size of the handpiece 10 to be reduced. And, in a user-friendly manner, only the smaller handpiece 10 needs to be held in the hand during the heating phase, since the handpiece battery 11 powers the heating phase. In the pre-heating phase, the handpiece 10 and the charging unit 50 do not need to be held up to the user's mouth. Thus, the advantage of short-term pre-heating is simultaneous with the advantage that only the smaller, more user-friendly handpiece 10 needs to be held up in the heating phase. Thus, this configuration is advantageous for both the pre-heating phase and the heating phase, since the advantage of short-term pre-heating is simultaneous with the advantage that only the smaller, more user-friendly component (handpiece 10) needs to be held up to the mouth in order to inhale the generated aerosol in the heating phase.

[0110] As previously discussed, if the controller determines in step 704 that the handpiece 10 and charging unit 50 are connected to each other during the heating phase of an aerosolization session, the process proceeds to step 706 .

[0111] The controller is configured to direct power flow from the charging unit battery 51 to the heater 47 to maintain a predetermined temperature during the heating phase of the aerosolization session, step 706.

[0112] In this way, it is possible to conserve the charge level of the handpiece battery 11 for a later aerosolization session in which the handpiece 10 and the charging unit 50 are not connected to each other.

[0113] In a first example of directing power flow from the charging unit battery 51 to the heater 47 in step 706, the controller controls the charging unit battery 51 such that the heater 47 is powered only from the charging unit battery 51. In a second example of directing power flow from the charging unit battery 51 to the heater 47 in step 706, the controller controls the charging unit battery 51 and the handpiece battery 11 such that both power the heater 47. In the first example, charge in the handpiece battery 11 may be conserved for a later aerosolization session. In a second example, the charging unit battery 51 may be used to boost the power flow from the handpiece battery 11, thereby drawing less charge from the handpiece battery 11 and conserving charge for a later aerosolization session.

[0114] Optionally, the controller may monitor the charge level of the handpiece battery 11 and control an indicator (e.g., a visual, audio, or tactile indicator) of the aerosol generating device 100 to output a first indication if the handpiece battery 11 does not have enough charge to power the heating phase alone, and / or to output a different, second indication if the handpiece battery 11 has enough charge to power the heating phase alone. In this way, the user can be informed whether the two units can be disconnected during the heating phase. This internal state information thus allows the user to know whether it is appropriate to disconnect the handpiece 10 and the charging unit 50 before the heating phase.

[0115] In addition to the power management process described with reference to Figure 7, the controller may be further configured to direct power flow from the charging unit battery 51 to the handpiece battery 11 to charge the handpiece battery 11 when the handpiece 10 is connected to the charging unit 50. In a first example, this charging may occur between aerosolization sessions. In a second example, the controller may be configured to direct power flow from the charging unit battery 51 to the handpiece battery 11 to charge the handpiece battery 11 both between and during aerosolization sessions. In this way, the handpiece battery 11 can be ready for the heating phase when disconnected from the charging unit 50, for example by being charged during a pre-heating phase.

[0116] The power management control process described with reference to FIG. 7 has the advantage that the operation of the aerosol generating device is more flexible by providing user selectable pre-heat and heating power control options.

[0117] The operator can choose to keep the handpiece 10 and charging unit 50 disconnected during both the pre-heating and heating phases (i.e., the entire aerosolization session). The smaller the handpiece battery 11, the smaller the handpiece 10 itself can be, making it easier for the operator to hold. This smaller battery size (and output power) is compensated for by a longer pre-heating time. Thus, the operator can perform an aerosolization session completely without having to operate the charging unit 50, but with the compromise of a longer pre-heating time. This option is illustrated in the flow of steps 701 to 702 to 705.

[0118] On the other hand, if the operator requires pre-heating for a shorter period of time, the operator may choose to leave the handpiece 10 connected to the charging unit 50 during the pre-heating phase and utilize the more powerful charging unit battery 51 to provide power to the heater 47 for pre-heating.

[0119] The operator may then disconnect the handpiece 10 from the charging unit 50 during the heating phase, allowing both a short pre-heating period with the larger charging unit battery 51 (while not holding the device to the operator's mouth) and improved usability during the heating phase, by only having to hold the smaller handpiece 10 to the mouth to inhale the generated aerosol. This option is illustrated in the flow of steps 701 through 703 and 704 to 705.

[0120] Alternatively, the operator may choose to keep the handpiece 10 connected to the charging unit 50 throughout both the pre-heating and heating phases (i.e., throughout the entire aerosolization session). This may be advantageous, for example, if the operator wishes to conserve charge in the handpiece battery 11 for a later aerosolization session, or if the operator wishes to perform an additional aerosolization session before having sufficient time to recharge the handpiece battery 11. This option is illustrated in the flow of steps 701 through 703 and 704 to 706.

[0121] 7 can also be implemented in several ways for an operator to perform two aerosolization sessions in succession. In some examples, this can be when an operator wants to aerosolize two substrates, or when a first operator aerosolizes a first substrate, followed by a second operator aerosolizing a second substrate using the same aerosol generating device.

[0122] In a first example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 may be disconnected (as in the process from steps 701 to 702 to 705) during both the pre-heating and heating phases of the first aerosolization session. Then, in a second aerosolization session, the handpiece 10 and the charging unit 50 may remain disconnected (as in step 702) during the pre-heating phase. However, the handpiece battery 11 may not have enough charge remaining to power the heating phase of the second aerosolization session. Thus, during the heating phase of the second aerosolization session, the handpiece 10 and the charging unit 50 may be connected so that the charging unit battery 51 can provide power to the heater 47. In this case, an additional determination of whether the handpiece 10 and the charging unit 50 are connected may be made after step 702, which is not shown in FIG. 7. In this example, the controller may control an indicator (e.g., a visual, audio, or tactile indicator) on the aerosol generating device to monitor the charge level of the handpiece battery 11 and output an indication if the handpiece battery 11 does not have enough charge to power the heating phase of the second aerosolization session. The indication may be configured to alert the operator that the handpiece 10 and charging unit 50 must be connected in order for the heating phase of the second aerosolization session to be performed.

[0123] In a second example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 may remain disconnected (as in the process from steps 701 to 702 to 705) during both the pre-heating and heating phases of the first aerosolization session. Then, in the second aerosolization session, the handpiece 10 and the charging unit 50 may be connected during the pre-heating phase (as in step 703). By using the charging unit battery 51 to power the pre-heating phase of the second aerosolization session, the charge level of the handpiece battery 11 can be conserved for the heating phase of the second aerosolization session. Additionally, the handpiece battery 11 can be charged by the charging unit battery 51 while the handpiece 10 and the charging unit 50 are connected during the pre-heating phase of the second aerosolization session. Furthermore, the operator has the advantage of short pre-heating time for the second aerosolization session by using a more powerful charging unit battery 51. Thus, the handpiece 10 may then be disconnected from the charging unit 50 during the heating phase of the second aerosolization session (as in step 705) because the handpiece 10 has a charge level sufficient to power the heating phase of the second aerosolization session.

[0124] In a third example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 may be disconnected (as in the process from steps 701 to 702 to 705) for both the pre-heating and heating phases of a first aerosolization session. Then, in a second aerosolization session, the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 706) for both the pre-heating and heating phases of the second aerosolization session. This is advantageous in allowing consecutive aerosolization sessions to be performed when the handpiece battery 11 is too small (and cannot store enough charge) to power more than one aerosolization session, or when the handpiece battery 11 is not sufficiently recharged during the second (short) pre-heating phase while connected to the charging unit 50 to power the second heating phase alone when disconnected from the charging unit 50. That is, a smaller handpiece battery 11 can be used that only needs to have the capacity to power one pre-heat phase and one heating phase, allowing the size of the handpiece 10 to be reduced by the smaller battery while still allowing continuous aerosolization sessions to be performed.

[0125] In a fourth example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 705) during the pre-heating phase of the first aerosolization session, and then disconnected during the heating phase of the first aerosolization session. The handpiece 10 and the charging unit 50 may then be connected (as in the process from steps 701 to 703 and 704 to 705) during the pre-heating phase of the second aerosolization session, and then disconnected during the heating phase of the second aerosolization session. In this way, the advantage of short pre-heating using the charging unit battery 51 is achieved during both aerosolization sessions, while allowing the comfort of the operator to only hold the handpiece 10 during the heating phase. In this manner, the handpiece battery 11 may be configured to store enough charge to power two heating phases, or may be configured to be recharged during the second pre-heating phase to power the second heating phase.

[0126] In a fifth example of consecutive aerosolization sessions, all power for both aerosolization sessions is provided by the handpiece battery 11. That is, the handpiece 10 and the charging unit 50 may be disconnected (as in the process of steps 701 to 702 to 705) during both the pre-heating and heating phases of the first aerosolization session. Then, the handpiece 10 and the charging unit 50 may be disconnected (as in the process of steps 701 to 702 to 705) during both the pre-heating and heating phases of the second aerosolization session. In this manner, the handpiece battery 11 may be configured to store enough charge to power at least two pre-heating phases and at least two heating phases. This allows the operator flexibility to perform two aerosolization sessions without relying on the charging unit 50, although the handpiece battery 11 may provide power for a longer period of time for the pre-heating phase. However, the operator still has the option to connect the handpiece 10 to the charging unit 50 to perform a shorter pre-heating phase, if desired.

[0127] In a sixth example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 are connected for both aerosolization sessions. That is, the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 706) for both the pre-heating and heating phases of the first aerosolization session. And the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 706) for both the pre-heating and heating phases of the second aerosolization session. In this way, the heater 47 is powered from the charging unit battery 51 for both the pre-heating and heating phases of both aerosolization sessions. The advantage of this is that the pre-heating is short in both sessions, and furthermore, the charge level of the handpiece battery 11 is preserved for further aerosolization sessions after the second aerosolization session (e.g., a third aerosolization session powered (at least in part) only by the handpiece battery 11).

[0128] In a seventh example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 705) during the pre-heating phase of a first aerosolization session, and then disconnected during the heating phase of the first aerosolization session. Then, the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 705) during the pre-heating phase of a second aerosolization session, and then disconnected during the heating phase of the second aerosolization session. During the pre-heating phase, the controller controls the charging unit battery 51 and the handpiece battery 11 such that both the charging unit battery 51 and the handpiece battery 11 provide power to the heater 47. In this way, the charging unit battery 51 may be used to boost the power flow to the heater 47 by combining with the power flow from the handpiece battery 11 to make the heating phase shorter.

[0129] In an eighth example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 705) during the pre-heating phase of a first aerosolization session, and then disconnected during the heating phase of the first aerosolization session. The handpiece 10 and the charging unit 50 may then be connected (as in the process from steps 701 to 703 and 704 to 706) during both the pre-heating and heating phases of a second aerosolization session. In this manner, a minimized battery size of the handpiece 10 may be utilized because the handpiece battery 11 only needs to store charge for the heating phase of one aerosolization session (e.g., the first aerosolization session) and still be capable of powering the aerosol generating device for consecutive aerosolization sessions.

[0130] In a ninth example of consecutive aerosolization sessions, the handpiece 10 and the charging unit 50 may be connected (as in the process from steps 701 to 703 and 704 to 705) during the pre-heating phase of the first aerosolization session, and then disconnected during the heating phase of the first aerosolization session. The handpiece 10 and the charging unit 50 may then be connected (as in the process from steps 701 to 703 and 704 to 706) throughout both the pre-heating and heating phases of the second aerosolization session. This example is similar to the eighth example, except that the controller may be configured to use both the handpiece battery 11 and the charging unit battery 51 to power the first aerosolization session and the pre-heating phase of the second aerosolization session. The same advantages as in the eighth example are achieved, but in addition, the charging unit battery 51 may be used to boost the power flow to the heater 47 by combining with the power flow from the handpiece battery 11 to make the heating phase shorter.

[0131] In the seventh and ninth examples, the handpiece battery 11 may be considered to assist the charging unit battery 51 in the preheating phase. This assistance may be achieved by the handpiece battery powering the heater at its maximum discharge rate (e.g., the maximum discharge rate specified by the battery manufacturer), which may be less than the heater requires, combined with a much greater discharge rate from the charging unit battery to deliver the power required for preheating to the heater (e.g., within the desired preheating time (e.g., 20 seconds)). For example, the handpiece battery 11 may assist the charging unit battery 51 by delivering its maximum current (e.g., 1 A). At the same time, the current delivered from the charging unit battery 51 may be significantly greater (e.g., 5 times greater) than the current delivered from the handpiece battery 11.

[0132] In some cases, a predetermined waiting time (e.g., 30 seconds) may be required with the handpiece 10 connected to the charging unit 50 between the completion of the first aerosolization session and the start of the second aerosolization session, especially if the handpiece 10 was disconnected from the charging unit 50 during the heating phase of the first aerosolization session and the battery charge level may be depleted. This is to allow sufficient time for the handpiece battery 11 to recharge from the charging unit battery 51 in preparation for the second aerosolization session, especially if the handpiece 10 is to be disconnected from the charging unit 50 during the pre-heating phase of the second aerosolization session. The controller 43 may control an indicator (e.g., a visual, audio, or tactile indicator) of the aerosol generating device 100 to inform the operator when the predetermined waiting time has expired.

[0133] Although only two consecutive aerosolization sessions have been described, it should be understood that three or more sessions may be performed, and in fact consecutive aerosolization sessions may be performed as long as the charging unit battery 51 has sufficient capacity.

[0134] Some of these exemplary power management schemes for successive aerosolization sessions are summarized in Table 1. Of course, the above examples of successive aerosolization sessions are not the only ways in which they can be implemented. Any combination of the pre-heating and heating phases described with reference to FIG. 7 may be performed in each of the successive aerosolization sessions.

[0135] [Table 1]

[0136] In the above control process, when the handpiece 10 and the charging unit 50 are not connected to each other, the functionality performed by the components of the handpiece 10 may be controlled by the controller of the handpiece 10, and the functionality performed by the components of the charging unit 50 may be controlled by the controller of the charging unit 50. When the handpiece 10 and the charging unit 50 are connected to each other, all of the functionality performed by the components of the handpiece 10 and the charging unit 50 may be controlled by the controller of the charging unit 50. Alternatively, when the handpiece 10 and the charging unit 50 are connected to each other, all of the functionality performed by the components of the handpiece 10 and the charging unit 50 may be controlled by the controller of the handpiece 10. As another alternative, when the handpiece 10 and the charging unit 50 are connected to each other, some of the functionality performed by the components of the handpiece 10 and the charging unit 50 may be controlled by the controller of the charging unit 50, and some of the functionality performed by the components of the handpiece 10 and the charging unit 50 may be controlled by the controller of the handpiece 10.

[0137] 8A and 8B show a second exemplary aerosol generating device 800. The second exemplary aerosol generating device 800 is configured to operate in the same manner as the first exemplary aerosol generating device 100, and therefore, for the sake of brevity, specific details of the operation process will not be repeated. It will be appreciated that the operation process described with reference to the first exemplary aerosol generating device 100 (FIGS. 1-7) is readily applicable to the second exemplary aerosol generating device 800. It will further be appreciated that the components described with respect to the first exemplary aerosol generating device 100 are readily applicable to the second exemplary aerosol generating device 800 described with reference to FIGS. 8A and 8B, even if not mentioned with reference to FIGS. 8A and 8B for the sake of brevity.

[0138] The second exemplary aerosol generating device 800, like the first exemplary aerosol generating device 100, includes a handpiece (holding unit) 810 and a charging unit (charging case) 850. The handpiece 810 is removably connectable to the charging unit 850. Fig. 8A shows the handpiece 810 connected to the charging unit 850, and Fig. 8B shows the handpiece 810 disconnected from the charging unit 850.

[0139] The handpiece 810 includes a first charge storage module 811, which is configured to power the heater 847 and provide the same functionality as the first charge storage module 11 of the first exemplary aerosol generating device 100. The first charge storage module 811 may be one or more batteries or supercapacitors, or a combination thereof. The first charge storage module 11 may be a fast charging battery, such as a battery having a chemistry such as Lithium Titanate Oxide (LTO). This type of battery is capable of providing the high current required at the beginning of an aerosolization session and has good safety characteristics.

[0140] The charging unit 850 includes a second charging and storage module 851 configured to charge the first charging and storage module 811, provide power to the heater 847, and provide the same functionality as the second charging and storage module 51 of the first exemplary aerosol generating device 100. The second charging and storage module 851 may be one or more batteries or supercapacitors, or a combination thereof.

[0141] In the following description of the second exemplary aerosol generating device 800, the first charging and storage module will be referred to as the handpiece battery 811 and the second charging and storage module will be referred to as the charging unit battery 851, although each of these may be one or more batteries, supercapacitors, or a combination thereof, as will be readily understood by those skilled in the art.

[0142] The handpiece 810 includes a controller 843 that is configured to provide the same functionality as the controller 43 of the handpiece 11 of the first exemplary aerosol generating device 100.

[0143] The handpiece 811 has a body portion (housing) 812 that houses a controller 843 and a handpiece battery 811. A heater or heater component 843 is housed in the body portion 812. In such an example, the heater 843 is disposed within a cavity 845 or chamber in the body portion 812. The cavity 845 is accessed through an opening 845A in the body portion 812. The cavity 845 is configured to house an associated aerosol-generating substrate or consumable 812.

[0144] The aerosol-generating substrate 812 may include an aerosol-generating material, such as a tobacco rod containing tobacco. The tobacco rod can resemble a conventional cigarette. The cavity 845 may have a cross-section that is approximately the same as the cross-section of the aerosol-generating substrate 812. The depth of the cavity 845 may be such that when the associated aerosol-generating substrate 812 is inserted into the cavity 845, the first end 812A of the aerosol-generating substrate 812 reaches the bottom 845B of the cavity 845 (i.e., the end 845B of the cavity 845 that is distal to the cavity opening 845A) and the second end 812B of the aerosol-generating substrate 812 that is distal to the first end 812A extends outside the cavity 845. In this manner, the aerosol-generating substrate 812 is inserted into the aerosol-generating device 100, allowing inhalation by the consumer.

[0145] In the example of Figures 8A and 8B, the heater 847 is disposed within the cavity 845 such that when the aerosol-generating substrate 812 is inserted into the cavity 845, it engages the heater 847. In the example of Figures 8A and 8B, the heater 847 is disposed as a tube within the cavity 845 such that when the first end 812A of the aerosol-generating substrate 812 is inserted into the cavity 845, the heater 847 substantially or completely surrounds the portion of the aerosol-generating substrate 812 that is within the cavity 845. The heater 847 may be a wire (e.g., a coiled wire heater) or a ceramic heater, or any other suitable type of heater. The heater 847 may include multiple heating elements that are sequentially disposed along the axial length of the cavity and can be activated (i.e., powered) individually and sequentially.

[0146] In an alternative embodiment (not shown), the heater may be disposed within the cavity as an elongated piercing member (e.g. in the form of a needle, rod or blade) and in such an embodiment, the heater may be configured to penetrate into the aerosol-generating substrate and engage the aerosol-generating material when the aerosol-generating substrate is inserted into the cavity.

[0147] In another alternative embodiment (not shown), the heater may be in the form of an inductive heater. In such an embodiment, a heating element (i.e., a susceptor) may be provided in the substrate, which is inductively coupled with an inductive element (i.e., an induction coil) in the cavity when the substrate is inserted into the cavity. The inductive heater then heats the heating element by induction.

[0148] The heater 847 is configured to heat the tobacco without burning it to generate an aerosol. That is, the heater 847 heats the tobacco to a predetermined temperature below the combustion point of the tobacco so that a tobacco-based aerosol is generated. As will be readily understood by those skilled in the art, the aerosol-generating substrate 812 need not necessarily include tobacco, and any other material suitable for aerosolization (vaporization) (especially by heating without burning) may be used in place of tobacco.

[0149] Alternatively, the aerosol-generating substrate may be a vaporizable liquid, which may be stored in a cartridge that can be accommodated in the aerosol-generating device, or which may be deposited directly within the aerosol-generating device.

[0150] The charging unit 850 is sized to receive and accommodate the handpiece 810 at an opening 890 in the charging unit 50. The charging unit battery 851 is connected by a connector 880B in the charging unit opening 890 to a corresponding connector 880A of the handpiece 10 when the handpiece 810 is accommodated in the charging unit 850. A controller in the handpiece 810 or charging unit 850 can detect signals between the handpiece connector 880A and the charging unit connector 880B to control the flow of power from the charging unit battery 851 to the handpiece battery 811.

[0151] The hand piece 810 may be positioned such that, when housed in the charging unit 850, the cavity 845 is accessible through an opening 890 in the charging unit 850. In this manner, the aerosol-generating substrate 812 may be inserted into the cavity 845 when the hand piece 810 is connected (housed) in the charging unit. Furthermore, the consumer may subsequently conduct an aerosolization session by inhaling on the accessible end 812B of the substrate 812 extending from the hand piece 810 and the charging unit 850 when the hand piece 810 is connected (housed) in the charging unit.

[0152] As already mentioned, the second exemplary aerosol generating device 800 is capable of performing the same operations with respect to an aerosolization session (particularly with respect to the pre-heating and heating phases of the aerosolization session, the charging unit battery for charging the handpiece battery, and the operations described with reference to Figure 7) as those described with respect to the first exemplary aerosol generating device, which will not be repeated here for the sake of brevity.

[0153] In each of the above examples, the process steps described herein performed by the handpiece controller or the charging unit controller may be stored in a non-transitory computer readable medium (storage) associated with the respective controller. Computer readable media may include non-volatile media and volatile media. Volatile media may include semiconductor memory and dynamic memory, among others. Non-volatile media may include optical and magnetic disks, among others.

[0154] As will be readily understood by those skilled in the art, the embodiments described above are not limiting, and the features of each embodiment may be incorporated into other embodiments as necessary.

Claims

1. An aerosol generating device including a holding unit configured to accommodate an aerosol generating substrate and aerosolize it, and a charging unit connectable to the holding unit, The holding unit includes a heater component configured to aerosolize the aerosol generating substrate, and a first charging and storage module configured to supply power to the heater component, The charging unit includes a second charging and storage module configured to supply power to the heater component when the charging unit is connected to the holding unit, The aerosol generating device further includes a controller, and the controller When the holding unit is not connected to the charging unit, by directing a first power flow from the first charging and storage module to the heater component in a first preheating method, preheat the heater component to a predetermined temperature for an aerosolization session, When the holding unit is connected to the charging unit, by directing a second power flow from the second charging and storage module to the heater component in a second preheating method, preheat the heater component to the predetermined temperature for the aerosolization session An aerosol generating device configured as described above.

2. The first preheating method includes directing the first power flow from the first charging and storage module to the heater component over a first predetermined time, The second preheating method includes directing the second power flow from the second charging and storage module to the heater component over a second predetermined time, The aerosol generating device according to claim 1.

3. The aerosol generating device according to claim 2, wherein the first predetermined time is longer than the second predetermined time, and the first power flow is lower in power than the second power flow.

4. When the holding unit is connected to the charging unit, the controller causes the power flow to be directed from the second charge storage module to the heater component so as to maintain the predetermined temperature during the heating phase of the aerosolization session after the heater component has been preheated. When the holding unit is not connected to the charging unit, the controller causes the power flow to be directed from the first charge storage module to the heater component so as to maintain the predetermined temperature during the heating phase of the aerosolization session after the heater component has been preheated. The aerosol generating device according to claim 1, wherein the controller is configured as described above.

5. The controller further causes the power flow to be directed from the second charge storage module to the first charge storage module so as to charge the first charge storage module when the holding unit is connected to the charging unit. The aerosol generating device according to claim 1, wherein the controller is configured as described above.

6. The holding unit is configured to be received within the charging unit when the holding unit is connected to the charging unit. The aerosol generating device according to claim 1.

7. The holding unit includes a cavity, the aerosol generating substrate is insertable into the cavity for generating aerosol by being heated by the heater component, and when the holding unit is received within the charging unit, the cavity is accessible for receiving the aerosol generating substrate. The aerosol generating device according to claim 6.

8. The second charge storage module has a larger charge storage capacity than the first charge storage module. The aerosol generating device according to claim 1.

9. ​The aerosol generator is configured to perform a first aerosolization session and continuously perform a second aerosolization session. Each aerosolization session includes a preheating phase in which the heater component is preheated to the predetermined temperature, and a heating phase in which the heater component is maintained at the predetermined temperature after being preheated. The aerosol generator according to claim 1.

10. Both the preheating phase of the first aerosolization session and the preheating phase of the second aerosolization session are performed when the holding unit is connected to the charging unit. The controller is configured to direct the second power flow from the second charge storage module to the heater component in the second preheating mode during the preheating phase of the first aerosolization session and the preheating phase of the second aerosolization session. Both the heating phase of the first aerosolization session and the heating phase of the second aerosolization session are performed when the holding unit is not connected to the charging unit. The controller is configured to direct the power flow from the first charge storage module to the heater component during the heating phase of the first aerosolization session and the heating phase of the second aerosolization session. The aerosol generator according to claim 9.

11. Both the preheating phase of the first aerosolization session and the preheating phase of the second aerosolization session are performed when the holding unit is connected to the charging unit. The controller is configured to direct the second power flow from the second charge storage module to the heater component in the second preheating mode during the preheating phase of the first aerosolization session and the preheating phase of the second aerosolization session. The heating phase of the first aerosolization session is performed when the holding unit is not connected to the charging unit, and the controller is configured to direct an electric power flow from the first charge storage module to the heater component during the heating phase of the first aerosolization session. The heating phase of the second aerosolization session is performed when the holding unit is connected to the charging unit, and the controller is configured to direct an electric power flow from the second charge storage module to the heater component during the heating phase of the second aerosolization session. The aerosol generating device according to claim 9.

12. The controller is configured to direct the second power flow and the power flow from the first charge storage module to the heater component during the preheating phase of the first aerosolization session and the preheating phase of the second aerosolization session. The aerosol generating device according to claim 10.

13. An aerosol generation system including the aerosol generating device according to any one of claims 1 to 12, wherein the aerosol generating device has an aerosol generating substrate housed in the holding unit of the aerosol generating device.

14. A method of operating an aerosol generating device, the aerosol generating device comprising: a holding unit configured to contain and aerosolize an aerosol generating substrate; and a charging unit connectable to the holding unit, the holding unit including a heater component configured to aerosolize the aerosol generating substrate and a first charge storage module configured to supply power to the heater component, the charging unit including a second charge storage module configured to supply power to the heater component when the charging unit is connected to the holding unit. The method comprises: When the holding unit is not connected to the charging unit, preheating the heater component to a predetermined temperature for an aerosolization session by directing a first power flow from the first charge storage module to the heater component in a first preheating manner; When the holding unit is connected to the charging unit, preheating the heater component to the predetermined temperature for an aerosolization session by directing a second power flow from the second charge storage module to the heater component in a second preheating manner; A method comprising the above steps. **Claim 15** A non-transitory computer-readable medium storing instructions executable by one or more processors of an aerosol generating device, the aerosol generating device comprising: A holding unit configured to contain an aerosol generating substrate and aerosolize it, and a charging unit connectable to the holding unit, the holding unit comprising a heater component configured to aerosolize the aerosol generating substrate and a first charge storage module configured to supply power to the heater component, the charging unit comprising a second charge storage module configured to supply power to the heater component when the charging unit is connected to the holding unit; The instructions cause the one or more processors to: When the holding unit is not connected to the charging unit, preheating the heater component to a predetermined temperature for an aerosolization session by directing a first power flow from the first charge storage module to the heater component in a first preheating manner; When the holding unit is connected to the charging unit, preheating the heater component to the predetermined temperature for an aerosolization session by directing a second power flow from the second charge storage module to the heater component in a second preheating manner; A non-transitory computer-readable medium that causes steps including

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