Aerosol Generator

Abstract

An aerosol generating device is provided that includes a holding unit (10) configured to receive and aerosolize an aerosol-generating substrate (12) and a charging unit (50) connectable to the holding unit. The holding unit includes a heater component (47) for aerosolizing the aerosol-generating substrate, a first charged storage module (11) for providing power to the heater component, and a cavity into which the aerosol-generating substrate can be inserted for heating. The cavity is configured to receive an aerosol-generating substrate having a substantially planar shape. The charging unit includes a second charged storage module (51) configured to charge the first charged storage module and provide power to the heater component. The aerosol generating device further includes a controller configured to preheat the heater component for an aerosolization session by directing power flow from the second charged storage module to 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 aim 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; a first charge storage module configured to provide power to the heater component; and a cavity into which the aerosol-generating substrate can be inserted for heating by the heater component to generate an aerosol, the cavity configured to accommodate the aerosol-generating substrate having a substantially planar shape; the charging unit includes a second charge storage module configured to charge the first charge storage module and to provide power to the heater component; The aerosol generating device further includes a controller, the controller comprising: Pre-heating the heater component for an aerosolization session by directing power flow from the second charge storage module to the heater component when the holding unit is connected to the charging unit. It is structured as follows.

[0007] A significant amount of power may be required to preheat the heater component, which may significantly deplete the charge level of the first charge storage module. By directing power flow from the second charge storage module to the heater component to preheat the heater component when the holding unit is connected to the charging unit, the charge level of the first charge storage module can be preserved for later preheating of the aerosolization session. In this way, a smaller charge storage module may be built into the holding unit, thereby improving ease of use and safety.

[0008] An advantage of configuring the cavity to accommodate an aerosol-generating substrate having a substantially planar or flat shape is that the heater components and heating chamber are provided in a very compact physical size in combination with the substantially planar aerosol-generating substrate, thereby providing a smaller and easier to use holding unit for an operator to hold, improving ease of use of the device.

[0009] However, cavities having heater components and configured to accommodate aerosol-generating substrates of generally planar shape can use significantly more heating power than conventional aerosol-generating devices configured to accommodate cigarette-like tubular substrates, which can be particularly true during pre-heating.

[0010] The power level of the preheating may be too high for the first charge storage module to provide power on its own. By using the second charge storage module to provide power to the heater components during preheating, the charge level of the first charge storage module can be preserved for the post-preheating phase of the aerosolization session. Then, during the heating phase, during which the substrate is kept at the aerosolization temperature and the operator inhales the generated aerosol, the holding unit can be disconnected from the charging unit and the charge level preserved in the first charge storage module can be used to power the heater. This advantageously allows for a short preheating of the heater components with power provided by the second charge storage module while at the same time maintaining a sufficient charge level in the first charge storage module for the heating phase. Furthermore, this allows for a smaller battery to be available, allowing for a smaller size of the holding unit to be used in the heating phase, thereby improving the ease of use when the operator brings the device to the mouth for aerosol inhalation. Thus, the synergistic effect is improved power utilization and improved ease of use.

[0011] Preferably the aerosol-forming substrate is a tobacco-containing aerosol-forming substrate. Preferably the aerosol-forming substrate is of substantially planar shape. Preferably the aerosol-forming substrate is within a cavity.

[0012] Preferably, the cavity includes two major inner surfaces facing each other, the aerosol-generating substrate is configured to be received between the facing major inner surfaces, and each of the major inner surfaces is associated with a heating element of the heater component.

[0013] In this manner, an aerosol-generating substrate that is substantially planar or flat may be "sandwiched" between the heating elements for uniform overall heating and aerosolization.

[0014] Preferably, the larger inner surface is formed by two opposing walls of a cavity which comprise a ceramic material with the heater wire embedded in or on the ceramic material.

[0015] In this way, a compact heating cavity is provided that provides good distribution of heat directed towards the substrate.

[0016] Preferably, the cavity has two smaller inner surfaces connected to two larger inner surfaces, the two smaller inner surfaces being smaller than the two larger inner surfaces.

[0017] In this way, by minimizing the dimensions of the cavity, it is possible to reduce the overall size of the holding unit of the aerosol generating device.

[0018] Preferably, the controller directing electrical power flow from the second charge storage module to the heater component to heat the aerosol-generating substrate contained in the holding unit during an aerosolization session when the holding unit is connected to the charging unit; directing electrical power flow from the first charge storage module to the heater component to heat the aerosol-generating substrate contained in the holding unit during an aerosolization session when the holding unit is not connected to the charging unit. It is structured as follows.

[0019] In this way, the charge level of the first charge storage module can be maintained in case the holding unit is disconnected from the charging 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.

[0020] Preferably, the first charged storage module is configured to supply power to the heater component to aerosolize a first number of aerosol-generating substrates and the second charged storage module is configured to supply power to the heater component to aerosolize a second number of aerosol-generating substrates, the second number of aerosol-generating substrates being greater than the first number of aerosol-generating substrates.

[0021] In this way, a physically smaller charge storage module may be housed in the holding unit for improved comfort and safety.

[0022] Preferably, the controller further comprises: directing a power flow from the second charging storage module to the first charging storage module to charge the first charging storage module when the holding unit is connected to the charging unit; It is structured as follows.

[0023] 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.

[0024] Preferably, the holding unit is configured to be received within the charging unit when connected to the charging unit.

[0025] In this way, when the holding unit is connected with the charging unit, the whole device becomes compact, thereby improving the overall usability.

[0026] Preferably, the holding unit includes a mouthpiece portion configured to be accessible for inhalation by an operator when the holding unit is housed within and connected to the charging unit.

[0027] In this manner, an operator can conduct an aerosolization session with the holding unit and charging unit connected, thereby enhancing overall usability and power management.

[0028] Preferably, the mouthpiece portion includes a mouthpiece extending outward from the charging unit when the holding unit is housed in the charging unit.

[0029] In this way, an operator can comfortably access the mouthpiece for an aerosolization session while the holding unit and charging unit are connected.

[0030] Preferably, the mouthpiece is removable for inserting the aerosol-generating substrate into the holding unit.

[0031] In this manner, the aerosol-generating substrate can be easily inserted into the holding unit while still maintaining the compact physical dimensions of the holding unit for ease of use.

[0032] Preferably, the first charge storage module includes at least one battery, supercapacitor, or hybrid capacitor, and the second charge storage module includes at least one battery, supercapacitor, or hybrid capacitor.

[0033] In a second aspect, there is provided an aerosol generation system comprising an aerosol generating device according to any one of the preceding claims, the aerosol generating device having an aerosol-generating substrate contained in a holding unit of the aerosol generating device.

[0034] In a third aspect, there is provided a method of operating an aerosol generating device comprising: a holding unit configured to receive and aerosolize an aerosol-generating substrate, the holding unit including a heater component configured to aerosolize the aerosol-generating substrate, a first charged storage module configured to provide power to the heater component, and a cavity into which the aerosol-generating substrate can be inserted for heating by the heater component to generate an aerosol, the cavity configured to receive an aerosol-generating substrate having a substantially planar shape; and a charging unit connectable to the holding unit, the charging unit including a second charged storage module configured to charge the first charged storage module and to provide power to the heater component; Including, The method is: confirming that the holding unit is connected to the charging unit; pre-heating the heater component for an aerosolization session by directing power flow from the second charge storage module to the heater component when the holding unit is connected to the charging unit; Includes.

[0035] The method of the third aspect may, where appropriate, include preferred features of the aerosol generating device of the first aspect.

[0036] 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, the holding unit including a heater component configured to aerosolize the aerosol-generating substrate, a first charged storage module configured to provide power to the heater component, and a cavity into which the aerosol-generating substrate can be inserted for heating by the heater component to generate an aerosol, the cavity configured to receive an aerosol-generating substrate having a substantially planar shape; and a charging unit connectable to the holding unit, the charging unit including a second charged storage module configured to charge the first charged storage module and to provide power to the heater component; Including, The instructions are sent to one or more processors: confirming that the holding unit is connected to the charging unit; pre-heating the heater component for an aerosolization session by directing power flow from the second charge storage module to the heater component when the holding unit is connected to the charging unit; The method includes the steps of:

[0037] The non-transitory computer readable medium of the fourth aspect may optionally include preferred features of the aerosol generating device of the first aspect.

[0038] Embodiments of the invention will now be described, by way of example only, with reference to the drawings in which: [Brief description of the drawings]

[0039] [Figure 1A] FIG. 1 is a diagram of an aerosol generating device including a handpiece and a charging unit, the handpiece being shown detached from the charging unit. [Figure 1B] FIG. 1 is a diagram of an aerosol generating device including a handpiece and a charging unit, showing the handpiece housed in the charging unit. [Figure 1C]FIG. 1 is a diagram of an aerosol generating device including a handpiece and a charging unit, the handpiece 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] 1 is an operational flow chart of an aerosolization session. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] 1A, 1B, and 1C show various configurations of an aerosol generating device (also called a vapor generating device, vaping device, or e-cigarette) that includes a handpiece 10 (also called a holding unit) and a charging unit 50. The handpiece 10 is removably connectable to the charging unit 50.

[0041] 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.

[0042] 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 .

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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 having 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.

[0048] 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 power flow 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 therefore 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] Figures 2-5 show the handpiece 10 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.

[0053] 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.

[0054] 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.

[0055] 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, i.e., 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 .

[0056] 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.

[0057] 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.

[0058] 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).

[0059] 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.).

[0060] 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.

[0061] The mouthpiece 32 is configured to be connected to the insertion opening 36 while attached to the housing 34 .

[0062] 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.

[0063] 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.

[0064] 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.

[0065] The heating chamber 45 has a distal wall disposed perpendicular to the handpiece axis Y and sealing the sealing end 71. The distal wall adjoins each of the walls 73A, 73B, 74A, 74B to seal the chamber at the sealing end 71 and form the cup shape of the chamber. Each of the walls 73A, 73B, 74A, 74B, 75 may be made of a thermally conductive material, such as a metal, particularly 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.

[0066] 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.

[0067] The depth D3 of the heating chamber 45 may be slightly larger than the depth D of the aerosol-generating substrate 12 or may be approximately equal to this depth D. 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. Advantageously, in this case, the chamber-contacting walls 74A, 74B, in particular their contact surfaces, are in 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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 device operation based on the operating mode of the handpiece 10, as well as controlling power flow of the handpiece battery 11.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] After the aerosolization session, a user of the handpiece 10 may be notified (e.g., by a visual, tactile, or audio indicator) that the aerosolization session has ended so that the user knows that the substrate is no longer being aerosolized.

[0080] An advantage of the arrangement of the heating chamber 45 and heater 47 in combination with the aerosol-generating substrate 12, as described in detail with reference to Figures 2-5, is that the heater 47 is very compact, allowing the aerosol-generating substrate 12 to have a planar shape with compact dimensions. This therefore reduces the overall size of the aerosol-generating device and consumables compared to aerosol-generating devices configured to accommodate more conventional tobacco or tobacco-like consumables (sometimes referred to as tobacco rods). However, the heater 47 of the example described in detail with reference to Figures 2-5, especially if it includes a ceramic heater, may require significantly more heating power (e.g., >>10 W and / or >>1600 J) than heaters of aerosol-generating devices configured to accommodate more conventional tobacco or tobacco-like consumables. This is particularly true during the pre-heating phase, where a higher power flow to the heater is required. As mentioned above, during the pre-heating phase of an aerosolization session, a higher power level is applied to the heater 47. This power level may be too high for the battery of the handpiece 10 to power alone. Thus, during the pre-heating phase, the handpiece 10 and the charging unit 50 may be connected.

[0081] For example, for the handpiece battery, a preheat battery current of (say) 8A is a big challenge in terms of capacity. This means that a 200mAh battery must be able to achieve a discharge rate of 40C (8A / 0.2Ah), which is very high in the Li-Ion battery space. In contrast, for a larger battery in the charging unit, e.g. a 2000mAh battery, this rate is only 4C. This allows for a smaller size of the handpiece to be achieved, where the handpiece battery does not need to be oversized to meet the power requirements.

[0082] In this way, a larger / more powerful battery in the charging unit 50 can be used alone or in combination with a smaller battery in the handpiece 10 to power the heater 47 during the pre-heating phase, and the handpiece 10 can be removed from the charging unit 50 during the heating phase. This advantageously and synergistically allows the heater 47 to be pre-heated in a short time while at the same time maintaining a sufficient battery level in the handpiece 10 to perform the heating phase while disconnected from the charging unit. Furthermore, using a smaller sized handpiece during the heating phase may improve the ease of use when the consumer brings the device to their mouth for aerosol inhalation.

[0083] In some instances, the heating phase may also be performed with the handpiece 10 and the charging unit 50 connected to one another. For example, this may be done if at the end of the pre-heating phase the handpiece battery has insufficient charge for the heating phase, thereby advantageously allowing a consumer to perform an aerosolization session even if the handpiece battery level is low without waiting for it to be charged.

[0084] FIG. 7 shows an operational flow chart for controlling an aerosolization session of the aerosol generating apparatus of (for example) FIGS.

[0085] In step 701, when the handpiece 10 is connected to the charging unit 50, the controller of the aerosol generating device verifies that the connection has been established. In this step, the controller may be the controller 43 of the handpiece 10 and / or the controller in the charging unit 50.

[0086] In step 702, the controller controls the charging unit battery to direct power flow to the handpiece battery via the connector between the handpiece and the charging unit. In this manner, the charging unit battery is used to charge the handpiece battery. In this step, the controller may be controller 43 of handpiece 10 and / or a controller in charging unit 50.

[0087] In step 703, the controller determines whether an aerosolization session has been triggered. In some examples, the controller may determine that an aerosolization session has been triggered when there is a user input, such as triggering a button on the aerosol generating device that a user can press or otherwise actuate to initiate an aerosolization session. In this step, the controller may be the controller 43 of the handpiece 10 and / or a controller in the charging unit 50.

[0088] The controller is configured to preheat the heater component 47 for the aerosolization session by directing power flow from the charging unit battery 51 to the heater component 47 in step 704. This may occur when the controller determines that an aerosolization session has been triggered. In this step, the controller may be the controller 43 of the handpiece 10 and / or a controller in the charging unit 50. In this manner, the charging unit battery 51 may power the preheat phase such that the smaller handpiece battery 11 has a sufficient charge level for the heating phase.

[0089] Alternatively or additionally, the controller may control both the power flow from the charging unit battery 51 to the heater component 47 and from the handpiece battery 11 to the heater component 47 in preparation for preheating. In this manner, the charging unit battery 51 may assist the smaller handpiece battery 11 (or the handpiece battery 11 may assist the charging unit battery) in the preheating phase so that the handpiece battery 11 still has a sufficient charge level for the heating phase. 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.

[0090] As previously mentioned, the handpiece battery 11 alone cannot provide enough power to preheat the heater component 47, so the handpiece 10 must be connected to the charging unit 50 during the preheat phase. Thus, the controller 43 of the handpiece 10 may determine whether the handpiece 10 is connected to the charging unit by detecting a signal between the handpiece connector and the charging unit connector. If the handpiece 10 and the charging unit 50 are not connected, the controller 43 may prevent power flow to the heater component 47 during the preheat phase to avoid overuse and possible damage to the handpiece battery 11, and to prevent the handpiece battery 11 from running out of charge before the heating phase. If the handpiece 10 and the charging unit 50 are connected, the controller may allow power flow to the heater component 47 during the preheat phase.

[0091] The controller is configured to verify that the pre-heat phase is complete, at step 705. In some examples, the pre-heat phase may be determined to be complete when the controller determines that a predetermined pre-heat time (stored in memory accessible to the controller) has expired. In another example, the pre-heat phase may be determined to be complete when the controller monitors a temperature associated with the heater using a temperature sensor and determines that a predetermined heater temperature (stored in memory accessible to the controller) has been reached. In this step, the controller may be controller 43 of handpiece 10 and / or a controller in charging unit 50.

[0092] After the pre-heating phase, the process proceeds to step 706 if the handpiece 10 is separated from the charging unit 50 during the heating phase, and proceeds to step 708 if the handpiece is not separated from the charging unit 50 during the heating phase.

[0093] In step 706, the controller 43 of the handpiece 10 verifies that the handpiece 10 is disconnected from the charging unit 50. As an example, the controller 43 verifies that the handpiece 10 and the charging unit 50 are disconnected by verifying that there is no signal between the connectors of the two units.

[0094] Once the controller 43 has determined that the handpiece 10 is disconnected from the charging unit 50, in step 707 the controller 43 controls the handpiece 10 to perform a heating phase by directing power flow from the handpiece battery 11 to the heater 47. During the heating phase, the controller 43 of the handpiece 10 directs power flow from the handpiece battery 11 to the heater 47 to heat the aerosol-generating substrate and generate an aerosol that is inhaled by the user.

[0095] In some examples, the handpiece controller 43 may monitor the charge level of the handpiece battery 11 and control an indicator (e.g., a visual, audio, or tactile indicator) on the handpiece 10 or charging unit 50 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.

[0096] In step 708, the controller 43 of the handpiece 10 and / or the controller of the charging unit 50 verifies that the handpiece 10 has not been disconnected from the charging unit 50. That is, the controller 43 of the handpiece 10 and / or the controller of the charging unit 50 verifies that the handpiece 10 and the charging unit 50 are still connected to each other. In one example, the controller 43 of the handpiece 10 or the controller of the charging unit 50 verifies that the handpiece 10 and the charging unit 50 are connected by verifying that there is a signal between the connectors of the two units.

[0097] The controller of the charging unit may be at least one microcontroller unit disposed within the charging unit that includes a memory containing instructions for operating the charging unit in the manner described herein.

[0098] Once the controller 43 of the handpiece 10 and / or the controller of the charging unit 50 determine that the handpiece 10 is connected to the charging unit 50, in step 709, the controller 43 of the handpiece 10 and / or the controller of the charging unit 50 control the handpiece 10 and the charging unit 50 to perform a heating phase by directing power flow from the charging unit battery to the heater.

[0099] That is, during the heating phase, the controller 43 of the handpiece 10 and / or the controller of the charging unit 50 directs power flow from the charging unit battery 51 to the heater 47 to heat the aerosol-generating substrate and generate an aerosol that is inhaled by the user.

[0100] Alternatively or additionally, the controller 43 of the handpiece 10 and / or the controller of the charging unit 50 may direct power flow from both the charging unit battery 51 and the handpiece battery 11 to the heater 47 during the heating phase to heat the aerosol-generating substrate and generate an aerosol that is inhaled by the user. In this manner, the smaller handpiece battery 11 can assist the charging unit battery 51 during the heating phase, which may be useful, for example, when the charge level of the charging unit battery 51 is insufficient to complete an aerosolization session.

[0101] In some examples, the heating phase may begin with the handpiece 10 connected to the charging unit 50 and then be disconnected from the charging unit 50 during the heating phase. In such examples, the controller 43 of the handpiece 10 may constantly monitor the connection status with the charging unit 50, and once the handpiece 10 is disconnected from the charging unit 50, the controller 43 may adjust the power flow to the heater 47 such that the heater 47 is powered solely by the handpiece battery 11 and the heating phase can continue.

[0102] When the handpiece 10 is connected to the charging unit 50, the handpiece controller 43 and / or the charging unit controller may control the flow of power from the charging unit battery 51 to the handpiece battery 11 to charge the handpiece battery 11. This may occur when an aerosolization session is not occurring and / or during an aerosolization session when the two units are connected (e.g., during a pre-heating or heating phase). In this way, the charge level of the handpiece battery is maintained so that charge is readily available when an operator wishes to remove the handpiece 10 from the charging unit 50 during the heating phase of an aerosolization session.

[0103] The operation of an exemplary aerosolization session using the aerosol generating device described with reference to Figures 1-5 will now be described.

[0104] First, it is assumed that the handpiece 10 is housed in and connected to the charging unit (as described with respect to steps 701 and 702 of FIG. 7).

[0105] In the initial state, the aerosol-generating substrate 12 is removed from the handpiece 10. The user removes the mouthpiece 32 from the housing 34 in order to insert the aerosol-generating substrate 12. The user then inserts the heating portion 15 of the aerosol-generating substrate 12 into the heating chamber 45 until the abutment end 18 of the substrate 12 abuts against the stop means of the distal wall 75. The user then attaches the mouthpiece 32 to the housing 34 by sliding the mouthpiece portion 16 of the aerosol-generating substrate 12 into the through-hole of the mouthpiece 32 and inserting the mouthpiece 32 into the insertion opening 36 of the housing 34.

[0106] A user may activate operation of handpiece 10 by actuating (for example) an "on" button (as described with respect to step 703 of FIG. 7). Once handpiece 10 is activated, controller 43 initiates a preheat mode (as described with respect to step 704 of FIG. 7).

[0107] Once it has been determined that the pre-heating phase is complete (as described with reference to step 705 of FIG. 7), the controller 43 proceeds with the heating phase as described with reference to steps 706 and 707 when the handpiece 10 is disconnected from the charging unit 50, and proceeds with the heating phase as described with reference to steps 708 and 709 when the handpiece 10 is connected to the charging unit 50.

[0108] In the heating mode, the user can suck on the mouthpiece. This generates an airflow in the airflow passage formed between the flow inlet 66 and the flow outlet 64 in the device, as shown in FIG. 5. The airflow passes through the flow inlet 66 and into the vent 22. Here, the airflow mixes with the aerosol generated by heating the aerosol-generating material in the heating section 15 of the substrate 12. Alternatively or additionally, another airflow passage may be provided through the opening in the body 34, through the wall of the heating chamber, along the channel between the substrate 12 and the side wall of the heating chamber, to the vent 22 in the substrate. Thus, the airflow is drawn through the mouthpiece section 16 of the substrate 12, out the mouth end 20, and out of the mouthpiece 32 through the flow outlet 64 of the mouthpiece 32. In this manner, the operator can inhale the aerosol generated during the heating mode.

[0109] After the aerosolization session, the operator may reconnect the handpiece 10 and charging unit 50 if they were disconnected during the heating phase, and recharge the handpiece battery 11 from the charging unit battery 51.

[0110] In some instances, if an operator desires to aerosolize a second aerosol-generating substrate shortly or immediately after aerosolizing a first aerosol-generating substrate, the operator will have to connect the handpiece 10 to the charging unit 50 and perform a complete aerosolization session (i.e., both the pre-heating and heating phases) if there is not enough time to recharge the handpiece battery 11 from the charging unit battery 51 before the second aerosolization session.

[0111] The process steps described herein performed by the handpiece controller 43 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.

[0112] 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. 1. An aerosol generating device comprising: a holding unit configured to receive and aerosolize an aerosol-generating substrate comprising tobacco; and a charging unit connectable to the holding unit, the holding unit comprises: a heater component configured to aerosolize the aerosol-generating substrate; a first charge storage module configured to provide power to the heater component; and a cavity into which the aerosol-generating substrate can be inserted for heating by the heater component to generate an aerosol, the cavity configured to receive a planar aerosol-generating substrate; the charging unit includes a second charge storage module configured to charge the first charge storage module and to provide power to the heater component; The aerosol generating device further comprises a controller, preheating the heater component for an aerosolization session by directing power flow from the second charge storage module to the heater component when the holding unit is connected to the charging unit. The aerosol generating device is configured as follows.

2. 2. The aerosol generating device of claim 1, wherein the cavity includes two larger inner surfaces facing each other, the two larger inner surfaces are configured to receive the aerosol-generating substrate between the facing larger inner surfaces, and each of the larger inner surfaces is associated with a heating element of the heater component.

3. 3. The aerosol generating device of claim 2, wherein the larger inner surface is formed by two opposing walls of the cavity, the walls comprising a ceramic material, and a heater wire is embedded in or on the ceramic material.

4. 3. The aerosol generating device of claim 2, wherein the cavity has two smaller inner surfaces connected to the two larger inner surfaces, and the two smaller inner surfaces are smaller than the two larger inner surfaces.

5. The controller: directing electrical power flow from the second charge storage module to the heater component to heat an aerosol-generating substrate received in the holding unit during an aerosolization session when the holding unit is connected to the charging unit; directing power flow from the first charge storage module to the heater component to heat an aerosol-generating substrate received in the holding unit during an aerosolization session when the holding unit is not connected to the charging unit; It is configured as follows: The aerosol generating device according to claim 1 .

6. 2. The aerosol generating device of claim 1, wherein the first charged storage module is configured to supply power to the heater component to aerosolize a first number of aerosol-forming substrates and the second charged storage module is configured to supply power to the heater component to aerosolize a second number of aerosol-forming substrates, the second number of aerosol-forming substrates being greater than the first number of aerosol-forming substrates.

7. The controller further comprises: directing a power flow from the second charge storage module to the first charge storage module 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 , configured as follows:

8. The aerosol generating device of claim 1 , wherein the holding unit is configured to be received within the charging unit when connected to the charging unit.

9. 2. The aerosol generating device of claim 1, wherein the holding unit includes a mouthpiece portion configured to be accessible for inhalation by an operator when the holding unit is housed within the charging unit and connected to the charging unit.

10. 10. The aerosol generating device according to claim 9, wherein the mouthpiece portion comprises a mouthpiece that extends outward from the charging unit when the holding unit is received in the charging unit.

11. 11. The aerosol generating device of claim 10, wherein the mouthpiece is removable for inserting an aerosol-generating substrate into the holding unit.

12. 2. The aerosol generating device of claim 1, wherein the first charging and storage module comprises at least one battery, supercapacitor, or hybrid capacitor, and the second charging and storage module comprises at least one battery, supercapacitor, or hybrid capacitor.

13. An aerosol-generating system comprising an aerosol-generating device according to any one of claims 1 to 12, the aerosol-generating device having an aerosol-generating substrate received in the holding unit of the aerosol-generating device.

14. 1. 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 comprising tobacco, the holding unit comprising: a heater component configured to aerosolize the aerosol-generating substrate; a first charged storage module configured to provide power to the heater component; and a cavity insertable into which the aerosol-generating substrate can be heated by the heater component to generate an aerosol, the cavity configured to receive a planar aerosol-generating substrate; a charging unit connectable to the holding unit, the charging unit including a second charge storage module configured to charge the first charge storage module and to provide power to the heater component; wherein the method comprises: determining that the holding unit is connected to the charging unit; preheating the heater component for an aerosolization session by directing power flow from the second charge storage module to the heater component when the holding unit is connected to the charging unit; A method comprising:

15. 1. 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 comprising tobacco, the holding unit including: a heater component configured to aerosolize the aerosol-generating substrate; a first charge storage module configured to provide power to the heater component; and a cavity into which the aerosol-generating substrate can be inserted for heating by the heater component to generate an aerosol, the cavity configured to receive a planar shaped aerosol-generating substrate; a charging unit connectable to the holding unit, the charging unit including a second charge storage module configured to charge the first charge storage module and to provide power to the heater component; Including, The instructions cause the one or more processors to: determining that the holding unit is connected to the charging unit; preheating the heater component for an aerosolization session by directing power flow from the second charge storage module to the heater component when the holding unit is connected to the charging unit; A non-transitory computer-readable medium for causing execution of steps including:

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