Aerosol Generator and Aerosol Delivery System

Abstract

An aerosol generating device for use in generating an inhalable aerosol from an aerosol-forming substrate is provided. The aerosol generating device comprises a lithium ion battery. The battery comprises an electrolyte and at least one pair of electrodes. The pair of electrodes are spaced apart within the electrolyte. One of the pair of electrodes defines an anode and includes an anode active material. The other of the pair of electrodes defines a cathode and includes a cathode active material. The electrolyte includes a halogenated carbonate. An aerosol delivery system is also provided, comprising such an aerosol generating device and an aerosol-generating article comprising the aerosol-forming substrate, wherein the aerosol generating device is configured to receive the aerosol-generating article.

Description

[Technical Field]

[0001] The present disclosure relates to aerosol generating devices and aerosol delivery systems. [Background technology]

[0002] Aerosol generating devices configured to generate aerosols from aerosol-forming substrates, such as tobacco-containing substrates, are known in the art. To provide portability, it is known for such aerosol generating devices to incorporate their own on-board power source, such as a battery. It is known for such aerosol generating devices to use heat as a mechanism for releasing volatile compounds from the aerosol-forming substrate, with a battery providing the electrical energy necessary to drive the heating process. The temperatures required to release volatile compounds from the aerosol-forming substrate can exceed 300 degrees Celsius. When the aerosol-forming substrate is in liquid form, it is also known to generate aerosols by contacting the substrate with a vibrating membrane, with a battery providing the energy necessary to generate a drive signal to induce the vibration. The usage session for consumable aerosol-generating articles containing aerosol-forming substrates is finite, typically on the order of a few minutes. Whether heat or vibration is used as a mechanism for generating aerosols from the aerosol-forming substrate, the battery used to provide the electrical energy necessary to drive the aerosol generation process is required to deliver a large amount of energy within a short period of time. It is also desirable that the battery have sufficient capacity to meet the energy requirements of the aerosol generating device over at least one session of use. Portable aerosol generating devices may also be used in a variety of different environments and temperatures. It is known that low temperature environments can adversely affect the performance of known batteries.

[0003] It would therefore be desirable to provide an aerosol generating device with an improved battery. Summary of the Invention

[0004] According to a first aspect of the present disclosure, there is provided an aerosol generating device for use in generating an inhalable aerosol from an aerosol-forming substrate. The aerosol generating device includes a lithium ion battery. The battery includes an electrolyte and at least one pair of electrodes. The pair of electrodes are spaced apart within the electrolyte. One of the pair of electrodes defines an anode and includes an anode active material. The other of the pair of electrodes defines a cathode and includes a cathode active material. The electrolyte includes a halogenated carbonate.

[0005] Lithium-ion batteries are particularly suitable for aerosol generating devices due to their high energy density and low self-discharge characteristics. The use of a halogenated carbonate may facilitate the battery having increased performance at low temperatures. Preferably, the battery may be a rechargeable battery. If the battery is rechargeable, the use of a halogenated carbonate may facilitate the battery having improved cycle life. By "improved cycle life" is meant that the battery retains a higher maximum capacity (as a percentage of the battery's initial capacity in its "new" state) after a given number of charge cycles than a battery lacking the halogenated carbonate. By "charge cycle" is meant the period of use of a battery that is fully charged, then fully discharged, and then fully recharged; the term "charge / discharge cycle" may be used instead of the term charge cycle. When referring to the capacity of a battery, the term "capacity" is a measure of the charge stored by the battery, and capacity is commonly expressed in ampere-hours (Ah).

[0006] The electrode pair and electrolyte may form components of an individual cell of a battery. The battery may comprise a single cell or multiple cells.

[0007] The halogenated carbonate may comprise one or more of fluoroethylene carbonate (FEC), difluoroethylene carbonate (DFEC), trifluoropropylene carbonate (TFPC), 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolan-2-one (HFEEC), 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolan-2-one (NFPEC), bis(2,2,2-trifluoroethyl)carbonate (TFEC), and 2,2,3,4,4,4-hexafluorobutylmethyl carbonate (HFBMC). Advantageously, the halogenated carbonate may comprise or consist of fluoroethylene carbonate (FEC). As discussed in more detail in the specific description, the use of FEC as a component of the electrolyte has been found to provide an improved life cycle for the battery relative to an identical battery in all respects except for the absence of FEC in the electrolyte.

[0008] The halogenated carbonate may be present in the electrolyte at a concentration of 0.05% to 15% by weight of the electrolyte, or 0.05% to 10% by weight of the electrolyte, or 0.05% to 5% by weight of the electrolyte, or 0.1% to 2% by weight of the electrolyte.

[0009] Advantageously, the electrolyte may include a lithium salt. The lithium salt may function as a source of lithium ions for the battery. The lithium salt may include one or more of LiPF, LiBF, LiSbF, LiAsF, LiClO, LiCFSO, LiN(SOCF), LiN(SOCF), LiC(SOCF), LiN(SOCF), LiC4FSO, LiAlO, LiAlCl, LiCl, and LiI. Preferably, the lithium salt may include or consist of LiPF. In addition to the lithium salt, the electrolyte may include a solvent. The solvent functions as a medium for the passage of ions associated with the electrochemical reactions occurring within the battery during use. The solvent may be aqueous or non-aqueous. LiPF has properties of solubility in the solvent and high ionic conductivity. The solvent may include a non-aqueous organic solvent including one or more of propylene carbonate (PC), ethylene carbonate (EC), and ethyl methyl carbonate (EMC).

[0010] The positive electrode active material may include one or more of carbon, a carbon allotrope, lithium titanate oxide, and silicon. Preferably, the carbon allotrope includes or consists of graphite. The graphite may be natural or synthetically produced. Graphite is preferred as the positive electrode active material due to its high electrical conductivity and ability to reversibly position lithium ions between constituent layers, which can be maintained over thousands of charging cycles.

[0011] The anode may further comprise an anode collector. A coating comprising the anode active material may be applied to the anode collector. The coating may be applied to the anode collector by a baking operation. The anode collector may comprise copper. Alternatively, the anode collector may comprise nickel. The anode collector may be in the form of a foil. The anode collector may have a mesh structure.

[0012] The negative electrode active material may include one or more of lithium iron phosphate, lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide, and lithium sulfur. Preferably, the negative electrode active material includes or consists of lithium iron phosphate. Lithium iron phosphate has the properties of thermal stability and long cycle life.

[0013] The cathode may further comprise a cathode collector. A coating including the cathode active material may be applied to the cathode collector. The coating may be applied to the cathode collector by a baking operation. The cathode collector may comprise aluminum. In a manner similar to the anode collector, the cathode collector may be in the form of a foil and / or have a mesh construction.

[0014] The coating applied to the anode collector and the coating applied to the cathode collector may each further include a binder, a conductive agent, and a stabilizer. The binder, conductive agent, and stabilizer may be mixed with either an aqueous or non-aqueous solvent. The solvent may include one or more of N-methyl-2-pyrrolidone (NMP), dimethylformamide (DMF), dimethylacetamide, N,N-dimethylaminopropylamine, ethylene oxide, and tetrahydrofuran (THF).

[0015] The binder may facilitate mixing of the coating components into a paste or slurry. The binder may also facilitate adhesion of the coating material to the anode or cathode collector. The binder may include one or more of polyvinylidene fluoride (PVDF), polyhexafluoropropylene-polyvinylidene fluoride copolymer, poly(vinyl acetate), polyvinyl alcohol, polyethylene oxide (PEO), polyvinylpyrrolidone (PVP), alkylated polyethylene oxide, polyvinyl ether (PVE), poly(methyl methacrylate) (PMMA), poly(ethyl acrylate), polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyacrylonitrile (PAN), polyvinylpyridine, styrene-butadiene rubber (SBR), and acrylonitrile-butadiene rubber. The binder may be present in each coating at a concentration of 0.1% to 30% by weight of the coating, or preferably 1% to 10% by weight of the coating.

[0016] The conductive agent may include one or more of a graphite agent, a carbon black agent, a metal, and a metal compound agent. When the conductive agent includes a graphite agent, the graphite agent may include one or more of artificial graphite and natural graphite. When the conductive agent includes a carbon black agent, the carbon black agent may include one or more of acetylene black, ketjen black, denka black, thermal black, and channel black. When the conductive agent includes a metal or metal compound agent, the metal or metal compound agent may include one or more of Sn, SnO2, SnPO4, TiO2, KTiO3, LaSrCoO3, and LaSrMnO3. The conductive agent may be present in the coating at a concentration of 0.1% to 10% by weight of the coating. Limiting the concentration of the conductive agent to 10% by weight or less of the coating may be beneficial from the perspective of energy density per unit weight. Maintaining the concentration of the conductive agent to 0.1% by weight or more of the coating may be beneficial in enhancing the electrochemical properties of the coating.

[0017] The stabilizer may include one or more of carboxymethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose. The stabilizer may be selected to adjust the viscosity of a slurry of the anode / cathode active material for use in forming the coating.

[0018] Preferably, the battery may further include a permeable barrier configured to allow the passage of lithium ions, the permeable barrier being positioned between the anode and the cathode within the electrolyte. The permeable barrier facilitates preventing short circuits between the anode and the cathode while also allowing the passage of ionic charge carriers between the anode and the cathode during use of the battery. Advantageously, the permeable barrier is formed of a polymer material. The permeable barrier may include one layer or multiple layers. The permeable barrier may have a porous structure. The permeable barrier may be formed of any one or more of a multilayer film, a microporous film, a woven fabric, and a nonwoven fabric. The material selected for the permeable barrier is preferably chemically unreactive with ions released from the electrolyte and / or the anode and cathode during use of the battery.

[0019] In an advantageous embodiment, the halogenated carbonate may include fluoroethylene carbonate (FEC). Preferably, the negative electrode active material may include lithium iron phosphate. Preferably, the electrolyte may include LiPF6.

[0020] Advantageously, the negative electrode active material may comprise one or more of lithium iron phosphate, lithium nickel manganese cobalt oxide, and lithium cobalt oxide. The positive electrode active material may comprise graphite.

[0021] The battery may provide power to support the functioning of the aerosol generating device in generating an inhalable aerosol from the aerosol-forming substrate.

[0022] If heating of the aerosol-forming substrate is used in generating the aerosol from the substrate, the aerosol-generating device may further comprise an electric heating arrangement and control electronics configured to control the supply of energy from the battery to the heating arrangement. The heating arrangement may take a variety of forms. In one example, the electric heating arrangement may comprise a resistive heating element. In another example, the electric heating arrangement may comprise an inductor configured to induce eddy currents in the susceptor. The susceptor may form part of the heating arrangement. Alternatively, the susceptor may form part of an aerosol-generating article used with the aerosol-generating device, the article housing the aerosol-forming substrate. The susceptor may be embedded within the aerosol-forming substrate.

[0023] When a vibrational membrane is used to generate the aerosol from the substrate, the aerosol-generating device may further comprise a membrane for releasing the aerosol from the aerosol-forming substrate through the vibrational membrane. An actuator may be coupled to the membrane. The aerosol-generating device may further comprise control electronics configured to control the supply of energy from the battery to the actuator to drive the vibrational membrane.

[0024] Preferably, the aerosol-generating device may be configured to receive an aerosol-generating article comprising an aerosol-forming substrate.

[0025] Preferably, the aerosol generating device is configured to be of a size and mass that allows it to be handheld. Conveniently, the aerosol generating device is generally elongated, and by way of example, the aerosol generating device may be generally cylindrical.

[0026] According to another aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol-generating device according to any of the variants discussed above. The aerosol delivery system may further comprise an aerosol-generating article comprising an aerosol-forming substrate. The aerosol-generating device may be configured to receive the aerosol-generating article.

[0027] As used herein, the term "aerosol-generating device" is used to describe a device that interacts with the aerosol-forming substrate of an aerosol-generating article to generate an aerosol. The aerosol-generating device is preferably a smoking device that interacts with the aerosol-forming substrate of the aerosol-generating article to generate an aerosol that is inhalable directly through the user's mouth into the user's lungs. The aerosol-generating device may also be a holder for a smoking article.

[0028] Preferably, the aerosol-generating article is a smoking article that generates an aerosol that is inhalable directly through the user's mouth into the user's lungs. More preferably, the aerosol-generating article is a smoking article that generates a nicotine-containing aerosol that is inhalable directly through the user's mouth into the user's lungs.

[0029] As used herein, the term "aerosol-forming substrate" means a substrate made of or including an aerosol-forming material capable of releasing volatile compounds upon heating to generate an aerosol.

[0030] As used herein, the term "aerosol-forming material" means a material that has the ability to release volatile compounds upon heating to generate an aerosol. The aerosol-forming substrate may comprise or consist of an aerosol-forming material.

[0031] As used herein, the terms "upstream" and "downstream" are used to describe the relative position of an element or portion of an element of a heated aerosol-generating article with respect to the direction in which a user draws on the aerosol-generating article during use of the heated aerosol-generating article.

[0032] The aerosol-forming substrate is preferably a solid aerosol-forming substrate. However, the aerosol-forming substrate may comprise both solid and liquid components. Alternatively, the aerosol-forming substrate may be a liquid aerosol-forming substrate.

[0033] Preferably, the aerosol-forming substrate comprises nicotine. More preferably, the aerosol-forming substrate comprises tobacco. Alternatively, or additionally, the aerosol-forming substrate may comprise a non-tobacco-containing aerosol-forming material.

[0034] Where the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate may comprise, for example, one or more of powder, granules, pellets, shreds, threads, strips, or sheets containing one or more of herb leaves, tobacco leaves, tobacco stems, expanded tobacco, and homogenized tobacco.

[0035] Optionally, the solid aerosol-forming substrate may contain tobacco or non-tobacco volatile flavor compounds, which are released upon heating of the solid aerosol-forming substrate. The solid aerosol-forming substrate may also contain one or more capsules, for example containing additional tobacco or non-tobacco volatile flavor compounds, which may melt during heating of the solid aerosol-forming substrate.

[0036] Optionally, the solid aerosol-forming substrate may be provided on or embedded in a thermally stable carrier. The carrier may take the form of a powder, granules, pellets, pieces, threads, strips, or a sheet. The solid aerosol-forming substrate may be deposited on the surface of the carrier in the form of, for example, a sheet, foam, gel, or slurry. The solid aerosol-forming substrate may be deposited over the entire surface of the carrier, or alternatively, may be deposited in a pattern to provide non-uniform flavor delivery during use.

[0037] In a preferred embodiment, the aerosol-forming substrate comprises a homogenized tobacco material. As used herein, the term "homogenized tobacco material" refers to a material formed by agglomerating particulate tobacco.

[0038] Preferably, the aerosol-forming substrate comprises an assembly of sheets of homogenized tobacco material. As used herein, the term "sheet" refers to a layered element having a width and length that is substantially greater than its thickness. As used herein, the term "assembled" is used to describe a sheet that is rolled, folded, or otherwise compressed or clamped in a direction substantially transverse to the longitudinal axis of the aerosol-generating article.

[0039] Preferably, the aerosol-forming substrate comprises an aerosol former. As used herein, the term "aerosol former" is used to describe any suitable known compound or mixture of compounds that facilitates the formation of an aerosol during use and that is substantially resistant to thermal decomposition at the operating temperatures of the aerosol-generating article.

[0040] Suitable aerosol formers are known in the art and include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). Preferred aerosol formers are polyhydric alcohols or mixtures thereof (such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin).

[0041] The aerosol-forming substrate may comprise a single aerosol former, or alternatively, the aerosol-forming substrate may comprise a combination of two or more aerosol formers.

[0042] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0043] Example Ex1: An aerosol-generating device for use in generating an inhalable aerosol from an aerosol-forming substrate, comprising: Equipped with a lithium-ion battery, the battery comprising an electrolyte and at least one pair of electrodes, the pair of electrodes spaced apart within the electrolyte, one of the pair of electrodes defining an anode and comprising an anode active material, and the other of the pair of electrodes defining a cathode and comprising a cathode active material; An aerosol generating device, wherein the electrolyte comprises a halogenated carbonate.

[0044] Example Ex2: The aerosol generating device according to Ex1, wherein the halogenated carbonate comprises one or more of fluoroethylene carbonate, difluoroethylene carbonate, trifluoropropylene carbonate, 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolan-2-one, 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolan-2-one, bis(2,2,2-trifluoroethyl)carbonate, and 2,2,3,4,4,4-hexafluorobutylmethyl carbonate.

[0045] Example Ex3: An aerosol generator according to either one of Ex1 or Ex2, wherein the halogenated carbonate is present in the electrolyte at a concentration of 0.05% to 15% by weight of the electrolyte, or 0.05% to 10% by weight of the electrolyte, or 0.05% to 5% by weight of the electrolyte, or 0.1% to 2% by weight of the electrolyte.

[0046] Example Ex4: An aerosol-generating device according to any one of Ex1 to Ex3, wherein the electrolyte comprises a lithium salt.

[0047] Example Ex5: An aerosol generator according to Ex4, wherein the lithium salt comprises one or more of LiPF6, LiBF4, LiSbF6, LiAsF6, LiClO4, LiCF3SO3, LiN(SO2CF3)2, LiN(SO2C2F5)2, LiC(SO2CF3)3, LiN(SO3CF3)2, LiC4F9SO3, LiAlO4, LiAlCl4, LiCl, and LiI.

[0048] Example Ex6: The aerosol-generating device according to any one of Ex1 to Ex5, wherein the anode active material comprises one or more of carbon, an allotrope of carbon, lithium titanate oxide, and silicon.

[0049] Example Ex7: An aerosol generator according to Ex6, wherein the allotrope of carbon comprises graphite.

[0050] Example Ex8: The aerosol-generating apparatus according to any one of Ex1 to Ex7, wherein the anode further comprises an anode collector, and wherein a coating comprising the anode active material is applied to the anode collector.

[0051] Example Ex9: An aerosol generator according to Ex8, wherein the anode collector comprises copper.

[0052] Example Ex10: The aerosol-generating device according to any one of Ex1 to Ex9, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide, and lithium sulfur.

[0053] Example Ex11: The aerosol-generating device according to any one of Ex1 to Ex10, wherein the cathode further comprises a cathode collector, and wherein a coating comprising the cathode active material is applied to the cathode collector.

[0054] Example Ex12: An aerosol generator according to Ex11, wherein the cathode collector comprises aluminum.

[0055] Example Ex13: An aerosol-generating device according to either example Ex8 or Ex11, wherein the coating applied to the anode collector and the coating applied to the cathode collector further comprise a binder, a conductive agent, and a stabilizer.

[0056] Example Ex14: An aerosol-generating device according to Ex13, wherein the binder comprises one or more of polyvinylidene fluoride, polyhexafluoropropylene-polyvinylidene fluoride copolymer, poly(vinyl acetate), polyvinyl alcohol, polyethylene oxide, polyvinylpyrrolidone, alkylated polyethylene oxide, polyvinyl ether, poly(methyl methacrylate), poly(ethyl acrylate), polytetrafluoroethylene, polyvinyl chloride, polyacrylonitrile, polyvinylpyridine, styrene butadiene rubber (SBR), and acrylonitrile butadiene rubber.

[0057] Example Ex15: An aerosol-generating device according to Ex14, wherein the binder is present in the respective coating at a concentration of 0.1% to 30% by weight of the coating, or 1% to 10% by weight of the coating.

[0058] Example Ex16: The aerosol-generating apparatus according to any one of Ex13 to Ex15, wherein the conductive agent comprises one or more of a graphite agent, a carbon black agent, a metal, and a metal compound agent.

[0059] Example Ex17: An aerosol-generating device according to Ex16, wherein the graphite agent comprises one or more of artificial graphite and natural graphite.

[0060] Example Ex18: An aerosol generating device according to either Ex16 or Ex17, wherein the carbon black agent comprises one or more of acetylene black, ketjen black, denka black, thermal black, and channel black.

[0061] Example Ex19: An aerosol-generating apparatus according to any one of Ex16 to Ex18, wherein the metal or metal compound agent comprises one or more of Sn, SnO2, SnPO4, TiO2, KTiO3, LaSrCoO3, and LaSrMnO3.

[0062] Example Ex20: An aerosol-generating device according to any one of Ex16 to Ex19, wherein the conductive agent is present in the coating in a concentration of 0.1% to 10% by weight of the coating.

[0063] Example Ex21: An aerosol-generating device according to any one of Ex1 to Ex20, wherein the battery further comprises a permeable barrier configured to allow the passage of lithium ions therethrough, the permeable barrier being positioned within the electrolyte between the anode and the cathode.

[0064] Example Ex22: An aerosol generator according to Ex1, wherein the halogenated carbonate comprises fluoroethylene carbonate and preferably the cathode active material comprises lithium iron phosphate.

[0065] Example Ex23: An aerosol generator according to Ex22, wherein the electrolyte comprises LiPF6.

[0066] Example Ex24: An aerosol-generating device according to either Ex22 or Ex23, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel manganese cobalt oxide, and lithium cobalt oxide.

[0067] Example Ex25: The aerosol-generating apparatus according to any one of Ex22 to Ex24, wherein the anode active material comprises graphite.

[0068] Example Ex26: An aerosol-generating device according to any one of Ex1 to Ex25, wherein the lithium-ion battery is a rechargeable battery.

[0069] Example Ex27: an electric heating arrangement; An aerosol generating apparatus according to any one of Ex1 to Ex26, further comprising control electronics configured to control the supply of energy from the battery to the heating arrangement.

[0070] Example Ex28: An aerosol generating device according to Ex27, wherein the electric heating arrangement comprises a resistance heating element.

[0071] Example Ex29: An aerosol generating apparatus according to Ex27, wherein the electric heating arrangement comprises an inductor configured to induce eddy currents into the susceptor.

[0072] Example Ex30: An aerosol generating apparatus according to Ex29, wherein the electric heating arrangement further comprises a susceptor.

[0073] Example Ex31 a membrane for releasing the aerosol from the aerosol-forming substrate through vibration of the membrane; an actuator coupled to the membrane; An aerosol generator according to any one of Ex1 to Ex30, further comprising control electronics configured to control the supply of energy from the battery to the actuator to drive the vibration of the membrane.

[0074] Example Ex32: An aerosol-generating device according to any one of Ex1 to Ex31, wherein the aerosol-generating device is configured to receive an aerosol-generating article comprising an aerosol-forming substrate.

[0075] Example Ex33: An aerosol delivery system comprising an aerosol-generating device according to any one of Ex1 to Ex32 and an aerosol-generating article comprising an aerosol-forming substrate, wherein the aerosol-generating device is configured to receive the aerosol-generating article.

[0076] The embodiments will now be further described with reference to the figures. [Brief explanation of the drawings]

[0077] [Figure 1] FIG. 1 illustrates a schematic diagram of a first embodiment of an aerosol generating device and aerosol delivery system according to the present disclosure. [Figure 2] FIG. 2 illustrates a schematic diagram of a second embodiment of an aerosol generating device and aerosol delivery system according to the present disclosure. [Figure 3] FIG. 3 illustrates a schematic diagram of a third embodiment of an aerosol generating device and aerosol delivery system according to the present disclosure. [Figure 4] FIG. 4 illustrates a schematic diagram of a lithium-ion battery according to the present disclosure suitable for use in the aerosol generating devices of FIGS. [Figure 5] FIG. 5 is a schematic representation of the chemical structures of seven different halogenated carbonates for use as additives to the electrolyte of a battery such as the battery shown in FIG. [Figure 6] FIG. 6 provides a graph showing the variation of maximum capacity versus number of charge cycles for lithium-ion cells containing fluoroethylene carbonate (FEC) and corresponding cells lacking FEC. DETAILED DESCRIPTION OF THE INVENTION

[0078] FIG. 1 illustrates an exemplary aerosol generating device 10. The aerosol generating device 10 is a handheld aerosol generating device and has an elongated shape defined by a substantially circular, cylindrically shaped housing 11. The housing 11 contains a lithium ion battery 12, control electronics 13, and an electric heating element 14. A closed cavity 15 is located at a proximal end 16 of the housing 11 for receiving an aerosol-generating article 20. The heating element 14 extends longitudinally along the cavity from a closed end 17 of the cavity 15. The heating element 14 is a resistive heater element. The combination of the aerosol generating device 10 and the aerosol-generating article 20 forms an aerosol delivery system 100.

[0079] The aerosol-generating article 20 has the form of a cylindrical rod, which is formed by the combination of an aerosol-forming substrate 21 and a filter element 22. The aerosol-forming substrate 21 and the filter element 22 are coaxially aligned and enclosed within a cigarette paper wrapper 23. The aerosol-forming substrate 21 is a solid aerosol-forming substrate containing tobacco. However, in alternative embodiments, the aerosol-forming substrate 21 may instead be a liquid aerosol-forming substrate or may be formed from a combination of a liquid and a solid aerosol-forming substrate. The filter element 22 functions as the mouthpiece of the aerosol-generating article 20. The aerosol-generating article 20 has a diameter substantially equal to the diameter of the cavity 15 of the device 10 and a length greater than the depth of the cavity 15. When the aerosol-generating article 20 is received in the cavity 15 of the device 10, the portion of the article containing the filter element 22 extends outside the cavity and may be smoked by a user in a manner similar to a conventional cigarette.

[0080] The lithium-ion battery 12 serves as a power source to support operation of the aerosol generating device 10. The control electronics 13 are configured to control the supply of energy from the battery 12 to the resistive heating element 14 during use of the device 10 over a use session. The control electronics 13 includes or is coupled to a memory module 13a. During use, the control electronics 13 controls the supply of energy from the lithium-ion battery 12 to the resistive heating element 14 according to instructions and data stored in the memory module 13a. The memory module 13a contains instructions and data governing when and for how long power is supplied from the battery 12 to the heating element 14. The instructions and data may include a target thermal profile for the heating element 14 over a use session. The target thermal profile defines a target operating temperature for the heating element 141. The target operating temperature may be defined as a function of time elapsed in a given use session, as a function of the number of puffs applied to the device 10 in a given use session, or a combination thereof. The duration of a use session may be defined by the first occurrence of a use session lasting for a predetermined maximum duration and the number of puffs applied to the aerosol-generating article 20 reaching a predetermined maximum number of applied puffs. By way of example, the predetermined maximum duration may be 6 minutes and the predetermined maximum number of applied puffs may be 14.

[0081] FIG. 2 shows an alternative embodiment to the aerosol-generating device 10 of FIG. 1. Instead of the resistive heating element 14 of the device 10 of FIG. 1, the aerosol-generating device 10 of FIG. 2 has an induction coil 141 provided within a housing 11 and surrounding a tubular wall, which defines a cavity 15. For the illustrated embodiment, a susceptor 241 is embedded within the aerosol-forming substrate 21 of the aerosol-generating article 20. However, in alternative embodiments, the susceptor may instead form part of the aerosol-generating device 10; for example, the susceptor may define the tubular wall of the cavity 15. In use, the control electronics 13 controls the supply of energy from the lithium-ion battery 12 to the induction coil 141 in accordance with instructions and data stored in the memory module 13a, in a manner similar to that described with reference to the embodiment of FIG. 1. When the aerosol-generating article 20 is fully inserted into the cavity 15, the susceptor 241 is located within the induction coil 141. Current flowing through induction coil 141 induces eddy currents through susceptor 241 and results in heating of susceptor 241 .

[0082] FIG. 3 illustrates an alternative embodiment to the thermal-based aerosol-generating devices of FIGS. 1 and 2. The aerosol-generating device 10 of FIG. 3 generates an aerosol from an aerosol-forming substrate through vibration of a membrane in contact with the substrate, rather than through heating of the substrate. Like the aerosol-generating device 10 of FIGS. 1 and 2, the aerosol-generating device 10 of FIG. 3 has a housing 11 containing a lithium-ion battery 12 and control electronics 13. The housing 11 has a first housing portion 11a and a second housing portion 11b. The first housing portion 11a is in the form of a cylindrical tube and is connected to the second housing portion 11b. The second housing portion 11b defines the mouthpiece of the aerosol-generating device 10, with an opening provided at one end of the mouthpiece. A replaceable / disposable cartridge 200 is located within the housing 11. The cartridge 200 contains a reservoir 201 of liquid aerosol-forming substrate. The feed assembly 212 is fluidly coupled to the cartridge 200 and is located downstream of the cartridge 200. The feed assembly 212 may be a passive structure, such as a suction element. Alternatively, the feed assembly 212 may be an active feed assembly (such as a pump or the like) powered by the battery 12. A vibrating aerosolization module 142 is provided downstream of the feed assembly 212. The aerosolization module 142 includes an actuator assembly 142a coupled to a perforated membrane 142b. The actuator assembly 142a is coupled to the battery 12 via the control electronics 13. In use, the control electronics 13 controls the supply of energy from the lithium-ion battery 12 to the actuator assembly 142a according to instructions and data stored in the memory module 13a. The control electronics 13 provides a drive signal to the actuator assembly 142a, which induces a vibrational response from the membrane 142b. A feed assembly 212 feeds the liquid aerosol-forming substrate from the cartridge 200 onto one side of the membrane 142b. Vibration of the membrane 142b results in the substrate 201 being expelled through the perforated membrane and dispersed as a spray of aerosol droplets through openings in the mouthpiece 11b, as shown schematically in FIG.

[0083] In all three embodiments of the aerosol-generating device 10 of FIGS. 1-3, the lithium-ion battery 12 functions as a source of electrical energy to facilitate the generation of an inhalable aerosol from the aerosol-forming substrate 21, 201, either through heating (as in FIGS. 1 and 2) or through vibration (as in FIG. 3). The aerosol-generating device 10 has a size and mass that allows it to be handheld by a user. The battery 12 provides a high level of energy for a short, finite period of time, specifically, over a use session. The battery 12 only has sufficient capacity to complete a predetermined number of use sessions. Upon completion of the predetermined number of use sessions, the battery 12 is recharged. The predetermined number of use sessions may be a single use session, or may be two or more use sessions.

[0084] The following paragraphs describe exemplary configurations for battery 12 and how the use of particular forms of additives within the battery's electrolyte can help enhance the battery's maximum capacity in a fully charged state over thousands of charge cycles.

[0085] Figure 4 illustrates a schematic diagram of a lithium-ion battery 12 as employed in the aerosol generating device 10 of Figures 1-3. Figure 4 also includes a representation of the external circuit formed by the connection of the battery to control electronics 13 and other electrical loads of the aerosol generating device 10. The other electrical loads would include the resistive heater element 14 of Figure 1, the induction coil 141 of Figure 2, and the actuator assembly 142a of the vibratory aerosolization module 142 of Figure 3. The control electronics 13 and these other electrical loads are represented by the reference character "L" in Figure 4.

[0086] 4 shows a single cell of lithium-ion battery 12. A cell of lithium-ion battery 12 has a pair of electrodes in the form of an anode 121 and a cathode 122. The anode and cathode are separated from each other within an electrolyte 123. A separator 124 is positioned within the cell between the anode 121 and the cathode 122. Of course, in other embodiments, battery 12 may include multiple cells.

[0087] The anode 121 has an anode collector 1211 formed of copper foil. The anode collector 1211 is coated with an anode active material 1212. The anode active material 1212 is formed of graphite. The cathode 122 has a cathode collector 1221 formed of aluminum foil. The cathode collector 1221 is coated with a cathode active material 1222. The cathode active material 1222 is formed of lithium iron phosphate.

[0088] In other embodiments, the anode active material is formed of a material other than graphite, such as silicon, lithium titanate oxide, or an allotrope of carbon other than graphite. Additionally, in other embodiments, the cathode active material is formed of a material other than lithium iron phosphate, such as one or more of lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide, and lithium sulfur.

[0089] The electrolyte 123 is formed of a non-aqueous organic solvent, a lithium salt, and a halogenated carbonate additive. For the described embodiment, the halogenated carbonate is fluoroethylene carbonate (FEC), the lithium salt is LiPF6, and the FEC present in the electrolyte is at a concentration of 0.1% to 2% by weight of the electrolyte. The FEC dissolves in the non-aqueous organic solvent of the electrolyte. In other embodiments, the halogenated carbonate is other than an FEC, such as one or more of difluoroethylene carbonate (DFEC), trifluoropropylene carbonate (TFPC), 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolan-2-one (HFEEC), 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolan-2-one (NFPEC), bis(2,2,2-trifluoroethyl)carbonate (TFEC), and 2,2,3,4,4,4-hexafluorobutylmethyl carbonate (HFBMC). Figure 5 provides a schematic representation of an FEC and six alternative forms of halogenated carbonates that may be used in place of an FEC. Similarly, in other embodiments, the lithium salt is other than LiPF, such as one or more of LiBF, LiSbF, LiAsF, LiClO, LiCFSO, LiN(SOCF), LiN(SOCF), LiC(SOCF), LiN(SOCF), LiC4FSO, LiAlO, LiAlCl, LiCl, and LiI. In other embodiments, the concentration of FEC or other halogenated carbonate in the electrolyte is between 0.05% and 15% by weight of the electrolyte, or between 0.05% and 10% by weight of the electrolyte, or between 0.05% and 5% by weight of the electrolyte.

[0090] When the battery 12 is being discharged (e.g., when providing electricity to the control electronics 13 and other electrical loads of the aerosol generating device 10 described above), lithium ions flow from the cathode 122 to the anode 121 through the electrolyte 123 and separator 124 (as indicated by the dashed arrows in Figure 4). Additionally, electrons flow from the anode 121 to the cathode 122 via the external circuit and its components L. When the battery 12 is being charged, the direction of ion passage is reversed, i.e., from the anode 121 to the cathode 122.

[0091] Figure 6 shows the percentage of a battery's maximum capacity (relative to its initial capacity) versus the number of charge cycles for two different batteries, which differ only in the presence or absence of FEC as an additive in the electrolyte. The two batteries were fabricated as follows:

[0092] First, a mixture of lithium iron phosphate as the cathode active material, polyvinylidene fluoride (PVDF) as the binder, and carbon as the conductive agent is provided in a relative weight ratio of 94:3:3 to 96:2:2. These components are mixed together in a non-aqueous solvent of N-methyl-2-pyrrolidine (NMP) to form a cathode active slurry. The slurry is then coated onto an aluminum foil collector having a thickness of 10 to 40 micrometers, and then dried and rolled to produce a cathode.

[0093] Second, a mixture of synthetic graphite as the anode active material, styrene butadiene rubber (SBR) as the binder, and carboxymethyl cellulose as the stabilizer is provided in a relative weight ratio of 92:4:4 to 94:3:3. These components are mixed together in water to produce an anode active slurry. The slurry is then coated onto a copper foil collector 10 to 30 micrometers thick, and then dried and rolled to produce an anode.

[0094] Each battery uses an anode and a cathode prepared according to the above paragraph. The anode and cathode are placed in an electrolyte, where the electrolyte is prepared by dissolving LiPF6 in a non-aqueous organic solvent. A separator formed of polyethylene 7 to 12 micrometers thick is positioned between the anode and cathode. For the first battery, 0.1 to 0.2 weight percent fluoroethylene carbonate (FEC) is added to the electrolyte solution, the weight percentage of FEC being relative to the weight of the non-aqueous organic solvent alone. For the second battery, no FEC is added to the electrolyte solution.

[0095] Both batteries were then charged at a constant current and voltage of 6 C / 3.65 volts at 25°C for 0.1 hours, then discharged at a pulsed current of 10-20 C with a minimum voltage of 2.55 V. "C" is the multiplier for the battery's charge or discharge rate; a 1 C rate is equivalent to charging the battery from 0 to 100% in 1 hour, and a 2 C rate achieves the same level of charge in half the time, i.e., 30 minutes. The charge / discharge cycle outlined above was repeated for approximately 10,000 cycles, and the battery's maximum capacity was calculated as a percentage of the battery's initial capacity. Figure 6 provides an illustration of how incorporating FEC into the electrolyte results in a significant increase in the battery's maximum capacity after approximately 6,000 charge / discharge cycles. More specifically, when considering the percentage of maximum capacity remaining at the 10,560th cycle, it was found that the maximum capacity for the battery lacking FEC dropped below 75%, while the maximum capacity for the battery containing FEC remained above 85% of the battery's initial capacity.

[0096] Tests were also conducted on the same two batteries discussed above (one with FEC added to the electrolyte and one without FEC added) to determine whether each battery could provide 170 mAh when discharged from a fully charged state at a temperature of 5 degrees Celsius. It was found that the battery containing FEC was able to achieve 100% passage, while the battery lacking FEC was only able to achieve 40% passage.

[0097] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number "A" is understood as "A" ± 10% of "A." Within this context, the number "A" may be considered to include numerical values ​​that are within the common standard error of measurement for the property that the number "A" modifies. The number "A," in some cases as used in the appended claims, may deviate by the percentages recited above, provided that the amount by which "A" deviates does not materially affect the basic and novel properties of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. An aerosol generating device for use in generating an inhalable aerosol from an aerosol-forming substrate, comprising: Equipped with a lithium-ion battery, the battery comprising an electrolyte and at least one pair of electrodes, the pair of electrodes spaced apart within the electrolyte, one of the pair of electrodes defining an anode and comprising an anode active material, and the other of the pair of electrodes defining a cathode and comprising a cathode active material; the electrolyte comprises a halogenated carbonate; 1. An aerosol generating device, wherein the halogenated carbonate comprises one or more of difluoroethylene carbonate, trifluoropropylene carbonate, 4-[(2,2,3,3-tetrafluoropropoxy)methyl]-1,3-dioxolan-2-one, 4-(2,2,3,3,4,4,5,5,5-nonafluoropentyl)-1,3-dioxolan-2-one, bis(2,2,2-trifluoroethyl)carbonate, and 2,2,3,4,4,4-hexafluorobutylmethyl carbonate.

2. 2. The aerosol generating device of claim 1, wherein the halogenated carbonate is present in the electrolyte at a concentration of 0.05% to 15% by weight of the electrolyte, or 0.05% to 10% by weight of the electrolyte, or 0.05% to 5% by weight of the electrolyte, or 0.1% to 2% by weight of the electrolyte.

3. 3. The aerosol generating device according to claim 1, wherein the electrolyte comprises a lithium salt.

4. The lithium salt is LiPF 6 , LiBF 4 , LiSbF 6 , LiAsF 6 , LiClO 4 , LiCF 3 SO 3 , LiN(SO 2 CF 3 ) 2 , LiN(SO 2 C 2 F 5 ) 2 , LiC(SO 2 CF 3 ) 3 , LiN(SO 3 CF 3 ) 2 , LiC 4 F 9 SO 3 , LiAlO 4 , LiAlCl 4 4. The aerosol generating device of claim 3, comprising one or more of LiCl, LiCl, and LiI.

5. 10. The aerosol generating device of claim 1, wherein the anode active material comprises one or more of carbon, an allotrope of carbon, lithium titanate oxide, and silicon.

6. 6. The aerosol generating device of claim 5, wherein the allotrope of carbon comprises graphite.

7. 10. The aerosol generating device of claim 1, wherein the anode further comprises an anode collector, and a coating comprising the anode active material is applied to the anode collector.

8. 8. The aerosol generating device of claim 7, wherein the anode collector comprises copper.

9. 2. The aerosol generating device of claim 1, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese oxide, lithium manganese cobalt oxide, lithium nickel manganese cobalt oxide, and lithium sulfur.

10. 2. The aerosol generating device of claim 1, wherein the halogenated carbonate comprises fluoroethylene carbonate and preferably the cathode active material comprises lithium iron phosphate.

11. 11. The aerosol generating device of claim 10, wherein the cathode active material comprises one or more of lithium iron phosphate, lithium nickel manganese cobalt oxide, and lithium cobalt oxide.

12. 2. The aerosol generating device of claim 1, wherein the lithium ion battery is a rechargeable battery.

13. 10. The aerosol generating device of claim 1, wherein the aerosol generating device is configured to receive an aerosol-generating article comprising an aerosol-forming substrate.

14. 10. The aerosol generating device of claim 1, further comprising an electric heating arrangement and control electronics configured to control the supply of energy from a battery to said heating arrangement.

15. 10. An aerosol delivery system comprising the aerosol generating device of claim 1 and an aerosol-generating article comprising an aerosol-forming substrate, the aerosol generating device configured to receive the aerosol-generating article.

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