Method for Monitoring an Aerosol Generating Article Comprising an Electrolytic Capacitor

Abstract

A method of monitoring an aerosol-generating article (1) is described. The article (1) includes a capacitor (6). The capacitor (6) contains an electrolyte solution that generates an aerosol for inhalation by a user upon heating. The method includes estimating or determining the amount of the electrolyte solution.

Description

Technical Field

[0001] The present disclosure generally relates to a method of monitoring an aerosol-generating article and, in particular, to an aerosol-generating article adapted to be received in an aerosol-generating device for generating an aerosol for inhalation by a user.

[0002] As part of an aerosol-generating system of the present disclosure, the aerosol-generating article may be received in an aerosol-generating device including a controller adapted to implement the method. The present disclosure is particularly applicable to portable aerosol-generating devices.

Background Art

[0003] Devices that heat an aerosol-generating material without combustion to generate an aerosol for inhalation have gained popularity among consumers in recent years. A commonly available risk reduction or risk modification device is a heated material aerosol-generating device or so-called non-combustion heating device. This type of device generates an aerosol or vapor by heating the aerosol-generating material typically to a temperature in the range of 150°C to 300°C. This temperature range is considerably lower compared to normal tobacco. By heating the aerosol-generating material to a temperature within this range without combustion, vapor is generated, which typically cools and condenses to form an aerosol for inhalation by the user of the device.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Such a device can supply heat to the aerosol - generating material using one of many different methods. Since all methods of heating the aerosol - generating material require some kind of power source, such as a battery, the size and weight of the device increase. Embodiments of the present disclosure aim to provide a power source within the aerosol - generating article that can be used to supplement or partially replace the power source within the device. As a result, while maintaining precise control of the heating of the aerosol - generating material and optimizing the characteristics of the generated aerosol, it is possible to miniaturize and lightweight the device, which is beneficial to the user.

Means for Solving the Problems

[0005] According to a first aspect of the present disclosure, a method of monitoring an aerosol - generating article including a capacitor is provided. The capacitor contains an electrolytic solution that generates an aerosol for inhalation by a user upon heating. The electrolytic solution can thus be aerosolized, i.e., converted into an aerosol by heating, and the aerosol is then inhaled by the user. Then, upon heating of the capacitor, the electrolytic solution contained in the capacitor is converted into an aerosol, and the aerosolized electrolytic solution is inhaled by the user. Since the aerosolized electrolytic solution is inhaled by the user, the amount of electrolytic solution in the capacitor decreases during the vaping session. The method includes estimating or determining the amount of the electrolytic solution.

[0006] The capacitor can have any suitable structure, but in a preferred embodiment, it is a supercapacitor such as an electric double - layer supercapacitor. The capacitor can further include a pair of electrodes and a porous separator between the electrodes. The first electrode is the positive electrode, and the second electrode can be the negative electrode or vice versa. The electrodes and the separator are immersed in the electrolytic solution.

[0007] Similar to conventional capacitors, in an electric double layer supercapacitor, charges are stored in the electric field between the electrodes, and the capacitance is a function of the surface area of the electrodes, the distance between the electrodes, and the dielectric constant of the separator material. Capacitors have a higher power density than conventional power sources such as batteries. When a capacitor is charged by an external circuit connected to a pair of electrodes, while electrons move from the negative electrode to the positive electrode through the external circuit, cations in the electrolyte move to the negative electrode and anions move to the positive electrode. Therefore, two layers of charges of opposite polarities (electric double layers) are formed at the interfaces with the electrodes. When charging is complete, the positive charges on the positive electrode and the anions in the electrolyte attract each other, while the negative charges on the negative electrode and the cations in the electrolyte attract each other to stabilize the double layer of the electrodes. A stable voltage is generated. When the capacitor discharges, the reverse process occurs.

[0008] Each electrode may include at least one carbon-based electrode layer, such as a layer of porous carbon material or activated carbon having a high specific surface area per volume and high compatibility with the proposed electrolyte.

[0009] Each electrode may further include a current collector including a metal foil layer, such as an aluminum foil layer. The carbon-based electrode layer may be disposed adjacent to one or both sides of the current collector. Each carbon-based electrode layer may be formed as a coating. Such electrodes can be manufactured relatively easily and inexpensively using materials that are already known to be used in aerosol generating articles.

[0010] As will be understood by those skilled in the art, the electrolytic solution serves two functions. First, it allows the movement of cations and anions that occur when the capacitor is charged or discharged. Second, when heated, it forms an aerosol that is safe for the user to inhale and has good properties. The electrolytic solution should therefore be appropriately selected. The electrolytic solution is preferably a food-grade electrolytic solution and may include, for example, one or more of sodium chloride, sodium citrate, sodium bicarbonate, potassium chloride, calcium lactate, calcium carbonate, tricalcium phosphate, magnesium citrate, magnesium carbonate, citric acid, tartaric acid, benzoic acid, glycerol, and any suitable equivalents. The electrolytic solution may optionally include a gelling agent such as, for example, polyvinyl alcohol, gellan gum, xanthan gum, etc. In one example, the electrolytic solution may include sodium chloride and glycerol, and optionally polyvinyl alcohol as a gelling agent. Such an electrolytic solution has been found to allow the movement of cations and anions and is safe for the user to inhale.

[0011] When all of the electrolytic solution has evaporated, the capacitor can no longer be discharged or charged, and it may be necessary to appropriately discard the article or refill it with electrolytic solution.

[0012] The separator must dielectrically separate between pairs of oppositely charged electrodes. The separator also stores the electrolytic solution within its pores and allows the passage of cations and anions during the charge and discharge process. The separator may include any suitable material. The separator may include a plant-derived material, particularly a tobacco material such as a porous tobacco sheet, or it may include any suitable cellulose-based or polypropylene-based material. The separator material can release one or more volatile compounds when heated. The volatile compounds may include flavor compounds such as nicotine or tobacco or other fragrances.

[0013] The aerosol-generating article may further comprise any kind of solid or semi-solid material downstream of the capacitor in the aerosol flow path. Examples of the kind of solid or semi-solid material include crumbs, powders, granules, pellets, flakes, strands, particles, gels, strips, loose leaf, cut filler, porous materials, foamed materials or sheets. The material may include plant-derived materials and particularly tobacco materials. The aerosol generated by heating the electrolyte of the capacitor may flow through, for example, a solid or semi-solid material disposed between the capacitor and a filter section, i.e., a mouthpiece, through which the user inhales the aerosol. The solid or semi-solid material may release one or more volatile compounds that add, for example, flavor and nicotine to the aerosol. Heating by the capacitor may also heat or warm the solid or semi-solid material that promotes the release of the volatile compounds.

[0014] The aerosol inhaled by the user may comprise essentially vaporized, i.e., aerosolized, electrolyte and optionally one or more volatile compounds that may be released by the separator material and / or the downstream solid or semi-solid material.

[0015] The capacitor may have any suitable structure, such as a flat spiral wound (i.e., "jelly roll") structure, a prismatic structure, a folded or curved structure or a laminated structure, which is more cube-like and more suitable for a substantially cylindrical or flat article.

[0016] In one embodiment, the layered capacitor substrate may include a first electrode, a separator adjacent to the first electrode, and a second electrode adjacent to the separator, such that the separator is sandwiched between the first and second electrodes, more specifically, between a pair of carbon-based electrode layers. The first electrode may be the positive electrode and the second electrode may be the negative electrode, or vice versa. Such a substrate may be wound or folded into an appropriate shape while maintaining a void or other dielectric separation between opposing electrodes or between different portions of the same electrode. Dielectric separation may be achieved not only by the separator but also, for example, by one or more layers of a dielectric material. The dielectric material may include any suitable material. The dielectric material may include a plant-derived material, particularly a tobacco material such as a porous tobacco sheet, or it may include any suitable cellulose-based or polypropylene-based material. The dielectric material releases one or more volatile compounds when heated. The volatile compounds may include flavor compounds such as nicotine or tobacco or other fragrances. The dielectric material and the separator material may be the same or different.

[0017] In another embodiment, the layered capacitor substrate may include a first electrode, a first separator adjacent to the first electrode, and a second electrode adjacent to the first separator, such that the first separator is sandwiched between the first and second electrodes, more specifically, between a pair of carbon-based electrode layers, and may include a second separator adjacent to the second electrode. The second electrode is sandwiched between the first and second separators. The first electrode may be the positive electrode and the second electrode may be the negative electrode, or vice versa. Such a substrate is particularly suitable for a flat spiral-wound (i.e., "jelly roll") structure that forms a substantially cylindrical or more cube-like shape. Dielectric separation between the turns of the spiral-wound capacitor is achieved by the second separator, and the wound substrate may be sandwiched between the first and second electrodes, more specifically, between a pair of carbon-based electrode layers.

[0018] In yet another configuration, the layered capacitor substrate may include a plurality of first electrodes, a plurality of second electrodes, and a plurality of separators. The first electrode is the positive electrode, and the second electrode may be the negative electrode or vice versa. The first and second electrodes are alternately laminated such that the substrate includes the first electrode, the second electrode, the first electrode, the second electrode, etc. in the lamination direction. The separator is sandwiched between each pair of electrodes, more specifically between pairs of carbon-based electrode layers, to achieve dielectric separation. Such a substrate is useful for flat articles. The first electrodes may be electrically connected to each other, and the second electrodes may be electrically connected to each other. The first electrode may be electrically connected to the first capacitor terminal, and the second electrode may be electrically connected to the second capacitor terminal.

[0019] The capacitor may be housed within a casing. More specifically, the casing may include a capacitor substrate including electrodes, separators, etc., and an electrolytic solution. The electrolytic solution may be injected into the casing during manufacture or when the capacitor needs to be replenished. The casing may electrically insulate the capacitor and may be formed of any suitable material.

[0020] The casing may comprise, for example, wrapping paper with a metal or polymer coating. The casing may include a pair of end caps made of any suitable material. The casing may include a suitable puncture or opening or incorporate a suitable aerosol permeable membrane material to allow the user to freely inhale the aerosol generated when the electrolyte is heated while preventing leakage when the electrolyte is in a liquid or gel state. The aerosol generating article may include, for example, a filter section containing cellulose acetate fibers at the proximal end of the aerosol generating article. The filter section may include a mouthpiece filter. One or more vapor collection regions, cooling regions and other structures may also be included in some designs. The vapor cooling region advantageously allows the vapor to cool and condense to form an aerosol having properties suitable for the user to inhale, for example, through the filter section. Generally, a vapor is a substance that is in the gas phase at a temperature below its critical temperature and can be condensed into a liquid by increasing the pressure without lowering the temperature, whereas an aerosol is a suspension of fine solid particles or droplets in air or other gas. However, it should be noted that the terms "aerosol" and "vapor" may be used interchangeably herein.

[0021] The capacitor is preferably pre-charged within the packaged article, i.e., already charged at the time the user purchases it and before it is removably inserted into the aerosol generating device. Pre-charging the capacitor reduces the amount of energy that needs to be supplied from the device's power source for heating. This can lead to a reduction in the size and weight of the device.

[0022] As described above, the aerosol generating device may be adapted to receive an aerosol generating article during use. The device may include an external circuit (e.g., a switching circuit) that is electrically connected between a pair of electrodes or capacitor terminals when the article is received within the device. The switching circuit may be configured to control the discharge of the capacitor. The switching circuit may optionally also be configured to control the charging of the capacitor from a power source of the device, such as a battery. The switching circuit may include a switching device that is controlled by a controller to selectively provide a continuous or switched (i.e., discontinuous or intermittent) short - circuit path between a pair of electrodes or capacitor terminals that enables the charge stored in the capacitor to be discharged through the switching circuit. The switching device may include one or more switches. The one or more switches may be semiconductor switching devices that are connected, for example, as a bridge circuit or a converter circuit. The one or more switches can be opened and closed or switched on / off by the controller to provide a short - circuit path.

[0023] The switching circuit may include a first terminal that is electrically connected to the first electrode or terminal of the capacitor and a second terminal that is electrically connected to the second electrode or terminal of the capacitor when the aerosol-generating article is received within the device. Prior to the article being inserted into the device, at least one of the electrodes or terminals of the capacitor is preferably inaccessible to the user in order to prevent unintentional or intentional discharge of the pre-charged capacitor. For example, one or both of the electrodes or terminals of the capacitor may be concealed within the casing of the article and be made accessible only for electrically connecting to the terminals of the switching circuit after or during the process of inserting the aerosol-generating article into the device. To make the electrical connection, it may be necessary to rupture the casing at one or more locations, and the device may include suitable means for rupturing, piercing or severing the casing. The first terminal of the switching circuit may be electrically connected directly to the first electrode at one or more locations or may be electrically connected to a first capacitor terminal that is sequentially electrically connected to the first electrode. Similarly, the second terminal of the switching circuit may be electrically connected directly to the second electrode at one or more locations or may be electrically connected to a second capacitor terminal that is sequentially electrically connected to the second electrode. The capacitor terminals may be located anywhere on the article, such as near the end cap or side of the article. The insertion direction of the aerosol-generating article into the device may be restricted such that the terminals are properly aligned to achieve a reliable electrical connection between the capacitor and the external switching circuit.

[0024] The terminals of the switching circuit can be formed as rupture devices designed to rupture, puncture, or sever the casing to establish electrical connection with the electrodes or terminals of the capacitor. The rupture device can be fixed to or stationary with respect to the device and can be designed to rupture, puncture, or sever the casing when an article is inserted into the device, for example, into the aerosol generation space or the heating chamber. The rupture device can be movable. For example, in one configuration, the rupture device can be attached to a panel or door of the device that is opened or removed to allow insertion of the article, and the rupture device is designed to rupture, puncture, or sever the casing when the user closes the panel or door. The panel or door can be, for example, hinged. In another configuration, the rupture device can be movable by a suitable actuator, such as an electric motor or a piston, that can force the rupture device to move within the casing to establish the electrical connection. The rupture device can move through an opening or slot within a portion of the device that defines the aerosol generation space or the heating chamber. The rupture device can have any suitable shape and can be formed, for example, as a needle-type or crown-type having one or more pointed ends, a blade-type having an edge, or a punch-type having non-pointed ends. The rupture device can be designed to cooperate with any of the capacitor structures described above. If only one of the electrodes or terminals of the capacitor is accessible, only one rupture device may be required.

[0025] Heat is generated in the electrodes by discharging a pre-charged capacitor through an external circuit such as the switching circuit of the device, and as a result, the electrolyte in which the electrodes are immersed is heated. By sufficiently heating the electrolyte, an aerosol that is inhaled by the user during a vaping session is generated. To improve heating, the internal resistance of the capacitor can be increased by increasing the thickness of the separator between the oppositely charged electrodes. As a result, the winding or folding of the capacitor can be reduced while maintaining the same overall dimensions. Heat is also generated in the electrodes by charging the capacitor using an external circuit, and as a result, the electrolyte is heated to generate the inhaled aerosol.

[0026] The discharge of the capacitor and optional charging, and thus the heating of the electrolytic solution, can be controlled using a switching circuit which may be part of the aerosol generating device. The device may include an external heater that heats the capacitor to generate an aerosol for inhalation by the user. In other words, the heating of the electrolytic solution is not limited to the heat generated when the capacitor is discharged or charged, and the capacitor can be heated by an external heater in a similar manner to conventional aerosol generating materials or substrates. Even with such heating, the electrolytic solution is heated to generate an aerosol for inhalation. By using an external heater, heating becomes more controllable in a specific phase of the vaping session, thus optimizing the user experience. Any suitable heater, such as a low-output thin-film heater, a printed heater, etc. can be used. The heat generated by discharging the capacitor can be used in the initial preheating phase, and the external heater can be used, for example, to heat the electrolytic solution to generate an aerosol in a subsequent heating or vaping phase. The power for preheating can thus be provided at least in part by the capacitor rather than the power source of the device. As a result, the power source can be miniaturized, and thus the device can be made smaller and lighter. Alternatively, the electrolytic solution may be heated in a subsequent heating or vaping phase by periodically charging and discharging the capacitor. In the heating or vaping phase, heating may not be required, and thus discharging or charging of the capacitor may not be required. When heating is required, the capacitor can be continuously discharged or charged, or intermittently discharged or charged using, for example, a suitable duty cycle. In this alternative embodiment, an external heater can be used to heat the electrolytic solution in the initial preheating phase. The preheating phase may generally be intended to preheat the electrolytic solution to a target temperature, and the heating or vaping phase may generally be intended to heat the electrolytic solution over a longer period during which the aerosol is generated. If all heating can be provided by the capacitor, the cost of the device can be reduced and the overall design can be simplified when an external heater is not required.

[0027] When all heating can be performed by the capacitor, the aerosol-generating article can be formed as a single-use, i.e., disposable device that does not need to be inserted into another device. In other words, the aerosol-generating article can include an external circuit that controls the discharge of the capacitor, such as a switching circuit, and other elements necessary for a properly functioning single-use, i.e., disposable device.

[0028] The method according to the first aspect of the present disclosure may further include notifying the user of the amount of the electrolytic solution. The amount of the electrolytic solution can be notified visually or by any other means such as using an auditory or tactile notification. The amount of the electrolytic solution can be notified to the user by the aerosol-generating device or an external device such as a smartphone connected to the device by a suitable wireless communication protocol. When the amount of the electrolytic solution falls below a certain amount, a warning can be notified to the user. The warning can be notified visually or by any other means.

[0029] By monitoring and notifying the user of the amount of the electrolytic solution, it becomes easier for the user to grasp the amount of the electrolytic solution remaining in the capacitor during the vaping session, and thus it is possible to estimate how much more aerosol a specific aerosol-generating article can continue to generate.

[0030] The amount of the electrolytic solution is - one or more electrical parameters of the capacitor, and - the time required for discharging or charging the capacitor between a predetermined upper limit and a lower limit and optionally the time required for substantially completely discharging or substantially completely charging the capacitor can be estimated or determined from one or both of them.

[0031] One or more electrical parameters of the capacitor are electrical parameters known to change according to the amount of the electrolytic solution, such as internal resistance and capacitance. These parameters are directly proportional to the surface contact area between the electrolytic solution and the electrodes of the capacitor.

[0032] For example, the internal resistance of the capacitor is R DCcan be estimated or determined therefrom.

Number

[0033] The capacitance C of the capacitor can be estimated or determined from the following formula.

Number

[0034] In a conventional capacitor, since the electrolyte is contained within a sealed casing, the amount of the electrolyte remains constant. However, in the article according to the present disclosure, since the user inhales the electrolyte as an aerosol during a vaping session, the amount of the electrolyte gradually decreases. Accordingly, one or more electrical parameters also change during the vaping session as the amount of the electrolyte decreases. Other factors such as the temperature of the capacitor can also affect the way in which one or more electrical parameters of the capacitor change, and thus can be considered when one or more electrical parameters are used for the estimation or determination of the amount of the electrolyte.

[0035] One or more electrical parameters of the capacitor can be estimated or determined using at least one of the voltage and current measurement values obtained when the capacitor is discharged or charged through an external circuit, as described above. For example, the voltage and current measurement values can be obtained from voltage and current sensors when the capacitor is being discharged or charged between a predetermined upper and lower limit and optionally when the capacitor is substantially fully discharged or substantially fully charged. The estimation or determination of one or more electrical parameters of the capacitor can also use the time measurement value, such as the time required for the capacitor to discharge or charge while obtaining the current and voltage measurement values.

[0036] The time required for the capacitor to discharge or charge between a predetermined upper and lower limit is known to vary depending on the amount of the electrolyte. In particular, the time required for the capacitor to discharge or charge typically decreases as the remaining amount of the electrolyte decreases during a vaping session.

[0037] As will be understood by those skilled in the art, "fully discharging" a capacitor means discharging the capacitor from an initially substantially fully charged state (e.g., a state of charge (SOC) greater than about 90%, more preferably greater than about 95% or about 98%) to a state where it is substantially fully discharged (e.g., an SOC less than about 10%, more preferably less than about 5% or about 2%). "Fully charging" a capacitor means charging the capacitor from an initially substantially fully discharged state (e.g., an SOC less than about 10%, more preferably less than about 5% or about 2%) from a power source such as a battery until it reaches a substantially fully charged state (e.g., an SOC greater than about 90%, more preferably greater than about 95% or about 98%). Here, the SOC is determined as the available capacity of the capacitor (in Ah) and is expressed as a percentage of the rated capacity. The predetermined upper and lower limits, when expressed in terms of SOC, can be, for example, about 90 - 100% and about 0 - 10%. It will be understood that other predetermined upper and lower limits can be selected and can be expressed in terms of different items such as voltage. Since the output voltage of the capacitor linearly corresponds to the SOC of the capacitor, the computational load can be reduced when using the output voltage of the capacitor instead of the SOC.

[0038] The monitoring method may include one or more electrolyte volume determination steps capable of obtaining one or more measured values of voltage, current, and time while the capacitor is discharging or charging. More specifically, the method may include an initial step of estimating or determining an initial value of one or more electrical parameters of the capacitor or an initial time for discharging or charging the capacitor. The initial step may be performed, for example, when the aerosol generating article is inserted into the device or before the preheating phase. Using the initial value or time, a "baseline" indicating the initial amount of electrolyte in the capacitor before the start of the vaping session can be determined. The initial amount of electrolyte may be the maximum amount, i.e., it can be assumed that the capacitor is filled with electrolyte. Alternatively, using the initial value or time, the initial amount of electrolyte in the capacitor can be estimated or determined using an appropriate linear or non-linear function or reference table etc. that associates the initial value or time with the initial amount of electrolyte. The initial amount of electrolyte may be notified to the user.

[0039] The method may further include one or more subsequent steps of estimating or determining subsequent values of one or more electrical parameters of the capacitor or subsequent times for discharging or charging the capacitor. In each subsequent step, using the initial value and each subsequent value or the initial time and each subsequent time, the amount of electrolyte remaining in the capacitor can be estimated or determined. For example, the remaining amount of electrolyte can be estimated by comparing each subsequent value or time with the initial (or "baseline") value or time. Alternatively, in each subsequent step, using only the subsequent value or time, the amount of electrolyte in the capacitor can be estimated or determined using an appropriate linear or non-linear function or reference table etc. that associates the subsequent value with the remaining amount of electrolyte. The amount of electrolyte remaining in the capacitor may be notified to the user.

[0040] Using the value of one or more electrical parameters and / or the amount of the electrolytic solution estimated or determined in the initial step or any subsequent step, it is possible to control the operation of the device, such as changing the heating, or prevent further use of the device if the amount of the electrolytic solution is less than the minimum amount. This ensures that the user can operate the device safely. Such an operation can, for example, heat the capacitor until the electrolytic solution is substantially completely consumed, rather than limiting the puff count or the duration of the vaping session. It is also possible to identify a defect in the article using the value of one or more electrical parameters and / or the amount of the electrolytic solution estimated or determined, for example, if the initial value or the initial amount of the electrolytic solution is too low or below a specific amount.

[0041] Each subsequent step can be performed during the heating or vaping phase of the aerosol-generating article. Each subsequent step can be performed at regular or irregular intervals during the heating or vaping phase. Each subsequent step can be performed in response to puff detection, i.e., the user inhaling the generated aerosol. This makes it easier for the user to know how much electrolytic solution remains in the capacitor after a puff. Each subsequent step can be performed when the temperature of the capacitor is maintained substantially constant.

[0042] During the initial step and each subsequent step, the one or more electrical parameters or the time required for discharging or charging the capacitor can be estimated or determined multiple times to obtain an average value or an average time. In practice, this usually involves periodically discharging and charging the capacitor. The capacitor can be discharged or charged at least twice. For example, if one or more electrical parameters of the capacitor are estimated or determined while the capacitor is discharging through an external circuit, the capacitor is discharged, charged, and then discharged a second time. The values obtained during the first and second discharges of the capacitor can then be averaged to obtain a single value for each step.

[0043] According to a second aspect of the present disclosure, A capacitor, for example an electric double layer capacitor, comprising an aerosol generating article comprising a capacitor containing an electrolytic solution that generates an aerosol for inhalation by a user during heating, an aerosol generating device into which the aerosol generating article is received An aerosol generating system is provided that includes, and the aerosol generating device further includes a controller adapted to implement the method described above.

[0044] The device may further include a notification device adapted to notify the user of the amount of electrolytic solution estimated or determined by the controller.

Brief Description of the Drawings

[0045]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Modes for Carrying Out the Invention

[0046] Embodiments of the present disclosure will be described exclusively by way of example with reference to the accompanying drawings.

[0047] Referring first to FIG. 1, an example of an aerosol generating article 1 is schematically shown. The article 1 has a proximal end 2 and a distal end 4.

[0048] Article 1 includes a capacitor 6 containing an electrolytic solution. The capacitor 6 is wrapped with a wrapping paper 8 coated with a metal or polymer. End caps 10a and 10b are provided at both ends of the capacitor 6. The wrapping paper 8 and the end caps 10a and 10b define an outer casing of the capacitor 6 that contains the electrolytic solution and realizes electrical insulation.

[0049] Article 1 is substantially cylindrical.

[0050] At the proximal end 2, Article 1 includes a mouthpiece 12 having an outlet 14 through which the user can inhale an aerosol generated by heating the electrolytic solution. Although not shown, the proximal end cap 10a may include an appropriate puncture or opening or incorporate an appropriate aerosol permeable membrane material so that the generated aerosol can reach the outlet 14 through the end cap.

[0051] Referring to FIG. 2, the capacitor 6 is an electric double layer supercapacitor and has a substantially cylindrical spiral wound (i.e., "jelly roll") structure. The capacitor 6 includes a positive electrode 16 and a negative electrode 18. The electrodes 16 and 18 are separated by a pair of porous separators 20a and 20b. As clearly shown in FIG. 3, the positive electrode 16 includes a positive current collector 22. Each side surface of the positive current collector 22 is provided with a porous carbon-based electrode layer 24 such as a layer of porous carbon material or activated carbon. The negative electrode 18 includes a negative current collector 26. Each side surface of the negative current collector 24 is provided with a porous carbon-based electrode layer 28 such as a layer of porous carbon material or activated carbon. The positive and negative current collectors 22 and 26 are, for example, aluminum foil layers.

[0052] The separators 20a, 20b are formed of a tobacco material such as a porous tobacco sheet that releases volatile compounds when heated. In an alternative configuration (not shown), the separator is formed of a suitable cellulose or polypropylene-based material, and the electrolyte can flow through a tobacco material such as crumb tobacco downstream of the capacitor in the aerosol flow path. The tobacco material can be disposed between the capacitor and the mouthpiece. The tobacco material adds flavor and nicotine to the aerosol. Heating by the capacitor also heats or warms the tobacco material, promoting the release of volatile compounds. A nicotine-free flavor source can be used instead of the tobacco material.

[0053] The electrodes 16, 18 and the separators 20a, 20b are immersed in an electrolyte that permits the movement of cations and anions when the capacitor 6 is charged or discharged, generating an aerosol for inhalation by the user upon heating. The electrolyte can include sodium chloride and glycerol and optionally polyvinyl alcohol as a gelling agent. However, other food-grade electrolytes can also be used. The capacitor 6 is pre-charged in the manufacturing process and packaged in a charged state for sale to the user.

[0054] The article 1 includes a positive capacitor terminal 30 electrically connected at one or more locations to the positive electrode 16, i.e., the positive current collector 22, and a negative capacitor terminal 32 electrically connected at one or more locations to the negative electrode 18, i.e., the negative current collector 26. The capacitor terminals 30, 32 can be disposed inside the outer casing of the article 1 so as to be inaccessible to the user. This helps prevent unintentional or intentional discharge of the capacitor 6 before the article is removably inserted into the aerosol generating device as a preparation for starting a vaping session.

[0055] Figure 4 shows an aerosol generating device 34 adapted to receive the aerosol generating article 1. The device 34 includes a cavity 36 into which the article 1 can be inserted.

[0056] The device 34 includes a pair of rupture devices 38, 40 adapted to rupture the distal end cap 10b of the article 1 when the article 1 is inserted into the cavity 36. The angular orientation of the article 1 relative to the device 34 when inserted into the cavity 36 can be limited such that the rupture device 38 makes electrical contact with the positive electrode 30 and the rupture device 40 makes electrical contact with the negative electrode 32. Other methods can be used to ensure a reliable electrical connection. For example, the positive and negative terminals of the article can have an annular structure and appropriately positioned rupture devices can be coaxially arranged with respect to each other to make electrical contact with the terminals regardless of the angular orientation of the article relative to the device.

[0057] The device 34 includes a switching circuit 42 and a power source 44 such as a battery.

[0058] An example of the switching circuit 42 is shown in FIG. 5. The switching circuit 42 includes rupture devices 38, 40 that function as positive and negative terminals and are electrically connected to the positive and negative terminals 30, 32 of the article 1 when the article 1 is properly received within the cavity 36. The switching circuit 42 includes a switching device 46 that can be operated by a controller 48 to control the discharge of the capacitor 6 through the switching circuit 42. The controller 48 can include, for example, at least one microcontroller unit (MCU) or microprocessor unit (MPU).

[0059] After article 1 is inserted into device 34, capacitor 6 can be discharged by controlling switching device 46 so as to provide a continuous or switched short - circuit path between the positive and negative terminals 30, 32 of article 1 and thus between the positive and negative electrodes 16, 18 of capacitor 6. The short - circuit path between the positive and negative terminals 30, 32 is formed via switching device 46. Further, switching device 46 may include a resistor to prevent over - discharge current or an electrical load to enable constant - current discharge. If the discharge current is maintained at a predetermined value, the current sensor described later may be omitted. By discharging capacitor 6 through switching circuit 42, electrodes 16, 18 dissipate heat. Thereby, the electrolyte is heated and an aerosol that can be inhaled by the user from the discharge port 14 of the suction port 12 is generated. By pre - charging capacitor 6, the amount of energy required for heating from the power source 44 of the device is reduced. This can lead to a reduction in the overall size and weight of device 34. In particular, the size and weight of power source 44 can be reduced. This is significant because the power source is often the largest and heaviest element of device 34. In some cases, all the energy for heating is supplied by capacitor 6 and power source 44 can be removed or reduced to provide power to other elements of the device such as a controller. However, in other cases, the energy provided by capacitor 6 is used to complement or partially replace the energy provided by power source 44.

[0060] Capacitor 6 can also be charged from power source 44 by controlling switching device 46 (or a separate switching device not shown in the switching circuit). The charging of capacitor 6 also dissipates the heat of electrodes 16, 18 that heats the electrolyte to generate an aerosol that the user can inhale through the discharge port 14 of the suction port 12. Heat can thus be repeatedly generated by charging capacitor 6 from power source 44 and then discharging the capacitor through switching circuit 42.

[0061] The switching device 46 that can be used to enable discharging and charging of the capacitor 6 described above may include, for example, one or more switches. The discharge switch that controls the discharge current of the capacitor 6 may be connected in series between the rupture devices 38, 40 that define the positive and negative terminals of the switching circuit 42. The charging switch that controls the charging current of the capacitor 6 may be connected in series between the rupture device 38 that becomes the positive terminal of the switching circuit 42 and the positive terminal of the power source 44, and / or between the rupture device 40 that becomes the negative terminal of the switching circuit 42 and the negative terminal of the power source. These switches may be semiconductor switching devices, such as transistors.

[0062] Although not shown, the device 34 may include a current sensor that measures the discharge current or charging current of the capacitor 6 and a voltage sensor that measures the voltage output by the capacitor. Using the measurement values provided by the current sensor and the voltage sensor, electrical parameters of the capacitor, such as internal resistance or capacitance, are determined.

[0063] The device 34 may optionally include one or more heaters 50. The heaters 50 can be used to heat the electrolyte in the capacitor 6 to generate an aerosol that can be inhaled by the user through the discharge port 14 in the suction port 12. Such heating can be used to improve, for example, the heating control of the electrolyte during the heating or vaping phase.

[0064] The device 34 includes a notification device 52 that notifies the user of the amount of electrolyte. The amount of electrolyte can be notified to the user using an external device, such as a smartphone, connected to the device by an appropriate wireless communication protocol.

[0065] The remaining amount of the electrolyte can be estimated or determined by the controller 48 from the electrical parameters of the capacitor 6, such as the internal resistance or capacitance, which are known to change according to the amount of the electrolyte. The electrical parameters of the capacitor 6 can be estimated or determined using at least one of the measured values of voltage, current, and time obtained when the capacitor 6 is discharged or charged through the switching circuit 42, as described above. For example, in a specific case where the electrical parameter is the internal resistance R of the capacitor 6 DC it can be estimated or determined from the following formula. [Number] Here, ΔV is the initial voltage step when the capacitor 6 is discharged or charged, and I is the discharge or charge current maintained constant.

[0066] FIG. 6 represents a vaping session including a preheating phase PHP and a heating phase or vaporizing phase VP.

[0067] The controller 48 executes a plurality of electrolyte amount determination steps.

[0068] In an initial step executed at a time point T0 before the preheating phase is started, an initial value V0 of the electrical parameter of the capacitor 6 is estimated or determined. This initial value V0, therefore, indicates the initial amount of the electrolyte in the capacitor 6 before the start of the vaping session. The initial value V0 is assumed to determine a "baseline" that can be compared with subsequent values. It is also assumed that the initial amount of the electrolyte is the maximum amount. The notification device 52 can notify the user that the capacitor 6 is filled with the electrolyte.

[0069] In subsequent steps executed at time points T1, T2, and T3, subsequent values V1, V2, and V3 of the electrical parameters of the capacitor 6 are estimated or determined. The subsequent steps are carried out during a heating or vaping phase and may respond to puff detection. The subsequent steps are executed when the temperature of the capacitor 6 is maintained substantially constant. In other words, the subsequent steps are not executed during the period between time points T1 and T2 and are not executed between T2 and T3 when the temperature is rising.

[0070] Then, using the initial value V0 and each subsequent value V1, V2, and V3, the remaining amount of the electrolytic solution is estimated or determined. For example, using the initial value V0 and the first subsequent value V1, the amount of the electrolytic solution at time point T1 is estimated or determined, using the initial value V0 and the second subsequent value V2, the amount of the electrolytic solution at time point T2 is estimated or determined, and so on. When the electrical parameter is directly proportional to the amount of the electrolytic solution, that is, when the electrical parameter decreases as the amount of the electrolytic solution in the capacitor 6 decreases, the amount of the electrolytic solution at a subsequent time point T i can be estimated or determined by the following formula.

Equation

[0071] For example, when the subsequent value V1 is three - quarters of the initial value V0, the remaining amount of the electrolytic solution can be calculated as 75% of the initial amount at the start of the vaping session and can be notified to the user by the notification device 52. Similarly, when the subsequent values V2, V3 are one - half and one - third of the initial value V0 respectively, the remaining amount of the electrolytic solution can be calculated as 50% and 33% of the initial amount at the start of the vaping session and can be notified to the user by the notification device 52.

[0072] Referring to FIG. 7, during the initial step and each subsequent step, the capacitor 6 is discharged and charged three times. Each time the capacitor 6 is discharged, the value of the electrical parameter is estimated or determined from one or more of the measured values of voltage, current, and time. The three values are then averaged to obtain the values V0, V1,..., V3 described above. The capacitor 6 is discharged and charged between a predetermined upper limit and a lower limit represented as the state of charge (SOC) in FIG. 6. In particular, the capacitor 6 is substantially fully discharged and then substantially fully charged, the upper limit is about 90-100% SOC, and the lower limit is about 0-10% SOC.

[0073] The discharge current of the capacitor 6 close to the fully charged state tends to be larger than that in the intermediate state. The same is true for the charging current of the capacitor 6 close to the fully discharged state. Such a large current is not suitable for the above-described temperature control. Therefore, when the capacitor is discharged or charged to heat the electrolytic solution to generate an aerosol for inhalation by the user, that is, when the initial step and each subsequent step are executed for the purpose of estimating or determining the amount of the electrolytic solution, this discharge and / or charging is preferably performed in a narrow range between an intermediate state away from the fully discharged state and the fully charged state. The narrow range for discharging and / or charging the capacitor to heat the electrolytic solution can be determined by a predetermined upper limit and a lower limit. For example, when represented by SOC, the upper limit can be about 50-80%, and the lower limit can be about 20-40%.

[0074] Although the exemplary embodiments have been described in the previous paragraphs, it should be understood that various modifications can be made to these embodiments without departing from the scope of the appended claims. Therefore, the breadth and scope of the claims are not limited to the exemplary embodiments described above.

[0075] The combination of the above-described features in all possible variations is included in the present disclosure unless otherwise indicated herein or clearly inconsistent from the context.

[0076] Unless clearly negated by context, throughout this specification and the claims, terms such as "comprising," "including," etc. shall be construed in an inclusive sense rather than an exclusive or exhaustive sense.

Claims

1. A method for monitoring an aerosol product (1) including a capacitor (6) containing an electrolyte that generates an aerosol for inhalation by a user when heated, the method comprising estimating or determining the amount of the electrolyte.

2. The method according to claim 1, further comprising notifying the user of the amount of the electrolyte.

3. The amount of the electrolyte is One or more electrical parameters of the capacitor (6), and The time required to discharge or charge the capacitor (6) between a predetermined upper and lower limit. The method according to claim 1 or 2, which is estimated or determined from one or both of the above.

4. The method according to claim 3, wherein one or more electrical parameters of the capacitor (6) are estimated or determined using at least one of voltage and current measurements obtained when the capacitor (6) is being discharged or charged.

5. The method according to claim 4, wherein at least one of the voltage and current measurements is obtained when the capacitor (6) is discharged or charged between a predetermined upper and lower limit.

6. The method according to claim 3, wherein the predetermined upper limit is where the capacitor (6) is substantially fully charged, and the predetermined lower limit is where the capacitor (6) is substantially completely discharged.

7. The method according to claim 3, further comprising heating the electrolyte to generate an aerosol for inhalation by a user by discharging and charging the capacitor (6) in a range narrower than the range determined by the predetermined upper and lower limits for estimating or determining the amount of the electrolyte.

8. In the initial step, the initial values ​​of one or more electrical parameters of the capacitor (6) are estimated or determined. In one or more subsequent steps, the subsequent values ​​of one or more electrical parameters of the capacitor (6) are estimated or determined. The method according to claim 1, wherein for each subsequent step, at least the respective subsequent value is used to estimate or determine the amount of electrolyte in the capacitor (6), and optionally, both the initial value and the respective subsequent value are used to estimate or determine the amount of electrolyte in the capacitor (6).

9. In the initial step, the initial time required to discharge or charge the capacitor (6) between predetermined values ​​is estimated or determined. In one or more subsequent steps, the subsequent time required to discharge or charge the capacitor (6) between predetermined values ​​is estimated or determined. The method according to claim 1, wherein for each subsequent step, at least the respective subsequent time is used to estimate or determine the amount of electrolyte in the capacitor (6), and optionally, both the initial time and the respective subsequent time are used to estimate or determine the amount of electrolyte in the capacitor (6).

10. The method according to claim 8 or 9, wherein the initial step is performed before the preheating phase.

11. The method according to claim 8 or 9, wherein each subsequent step is performed during the heating or vaping phase.

12. The method according to claim 8 or 9, wherein each subsequent step is performed in response to puff detection.

13. The method according to claim 8 or 9, wherein each subsequent step is performed during a heating or vaping phase in which the temperature of the capacitor (6) changes according to a temperature profile, and each subsequent step is performed when the temperature of the capacitor (6) is maintained substantially constant according to the temperature profile.

14. The method according to claim 8 or 9, wherein during the initial step and each subsequent step, the capacitor (6) is discharged or charged at least twice.

15. Aerosol generation system, An aerosol product (1) includes a capacitor (6) containing an electrolyte that generates an aerosol for inhalation by the user when heated, an aerosol generating apparatus (34) that accepts the aerosol product and an aerosol generating system comprising, wherein the aerosol generating apparatus (34) further comprises a controller (48) adapted to carry out the method according to claim 1 or 2.

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