Aerosol generating device heating part

Abstract

An aerosol-generating device heating portion (102; 602; 702) is provided. The heating portion is configured to generate an aerosol from an aerosol-generating substrate (120; 620) and includes a heating chamber (116; 616; 716) configured to accommodate the aerosol-generating substrate. A supercapacitor module (106; 606; 706) is configured to power a heater (118; 618; 718) associated with the heating chamber. The supercapacitor module is adjacent to the heating chamber. A phase-change material (122; 622; 722) is disposed between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module.

Description

[Technical Field]

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

[0002] Aerosol generating devices, such as e-cigarettes and other aerosol inhalers or vaporization devices, are becoming increasingly popular consumer products.

[0003] Heating devices for vaporization or aerosolization are known in the art. Such devices typically include a heating chamber and a heater. In operation, an operator inserts the product to be aerosolized or vaporized into the heating chamber. The product is then heated by an electronic heater to vaporize the product's ingredients for inhalation by the operator. In some embodiments, the product is a tobacco product similar to a traditional cigarette. Such devices are sometimes referred to as "heat-not-burn" devices, in that the product is heated to the point of aerosolization without being burned.

[0004] Challenges faced by known aerosol generating devices include providing efficient power management and heating. Summary of the Invention [Means for solving the problem]

[0005] In a first aspect, there is provided an aerosol-generating device heating portion configured to generate an aerosol from an aerosol-generating substrate, the heating portion comprising: a heating chamber configured to contain an aerosol-generating substrate; and a supercapacitor module adjacent to the heating chamber configured to power a heater associated with the heating chamber; An aerosol generating device heating portion is provided that includes a phase change material disposed between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module.

[0006] Aerosol-generating devices configured to heat the aerosol-generating material without burning it must deliver a relatively high amount of thermal energy to the aerosol-generating material, given its size. Furthermore, to meet operator or consumer expectations, the device must have a small form factor, which presents challenges for thermal management within the device. One approach is to insulate the heat source as much as possible from the rest of the device using insulating materials with very low thermal conductivity and direct heat transfer toward the consumables. However, over longer aerosolization sessions (e.g., about 5 minutes), heat conducts to other parts of the device. Therefore, a sufficient amount of insulating and thermal mass must be incorporated into the device to protect other components, such as the supercapacitor module or battery module. This inherently increases the size.

[0007] By positioning the supercapacitor module adjacent to the heating chamber instead of separate from it, the size of the heating portion can be reduced, thereby providing a compact aerosol generating device heating portion, which may be easier for an operator to hold and use, as well as store and transport, thus improving the user experience.

[0008] By providing a phase change material between the heating chamber and the supercapacitor module, the supercapacitor module is protected from the heat of the heating chamber, allowing the supercapacitor module to be placed closer to the heating chamber, contributing to a reduction in device size. The phase change material also inhibits heat transfer from the heating chamber to the outer shell of the device, thereby improving device operability.

[0009] The use of a phase-change material can reduce the size of the device compared to using only an insulating material. Components such as a supercapacitor module can then be protected from excessive temperatures while the device has a small form factor. In addition, the outer shell temperature of the aerosol generating device can be reduced, or the same outer shell temperature can be achieved using a smaller heating section.

[0010] In this way, a compact aerosol generating device heating portion with an integrated supercapacitor module is provided.

[0011] Preferably, the phase change material at least partially surrounds the heating chamber.

[0012] In this way, thermal energy from the heating chamber is efficiently absorbed by the phase change material, protecting the supercapacitor module and inhibiting heat flow across the device to the outer shell.

[0013] Preferably, the supercapacitor module at least partially surrounds the heating chamber.

[0014] In this way, a compact configuration of the heating chamber and the supercapacitor module is achieved, allowing for a reduction in device size.

[0015] Preferably, the supercapacitor module is adapted to the shape of the heating chamber.

[0016] In this way, a compact configuration of the heating chamber and the supercapacitor module is achieved, allowing for a reduction in device size.

[0017] Preferably, the supercapacitor module comprises two supercapacitors, the two supercapacitors being arranged on either side of the heating chamber so as to at least partially surround the heating chamber.

[0018] In this way, a compact configuration of the heating chamber and the supercapacitor module is achieved, allowing for a reduction in device size.

[0019] Preferably, the heating chamber is planar in shape and adapted to accommodate a planar aerosol-generating substrate.

[0020] In this way, compact aerosol-generating substrates can be used, reducing the overall device size.

[0021] Preferably, the heating chamber is cylindrical in shape and adapted to accommodate a rod-shaped aerosol-generating substrate.

[0022] In this way, a rod-shaped aerosol-generating substrate can be used for an aerosolization session that provides the operator with an experience similar to that of conventional smoking.

[0023] Preferably, the rod-shaped aerosol-forming substrate is a tobacco rod.

[0024] In this way, a tobacco rod can be used for an aerosolization session that provides the operator with an experience similar to traditional smoking.

[0025] Preferably, the heater is integrated into or on the sidewall of the heating chamber.

[0026] In this way, a compact and easy to use heating chamber is provided.

[0027] Preferably, the aerosol generating device heating portion further comprises control electronics integrated into the flexible circuit board.

[0028] In this way, the flexible circuit board can accommodate any changes in the shape of the phase change material as it undergoes a phase transition, allowing for a more compact device. Moreover, the circuit board can be adapted to better utilize the reduced space in the heating section, thereby contributing to a reduction in device size.

[0029] Preferably, the phase change material is substantially indium-based.

[0030] In this way, the beneficial properties of indium-based phase change materials can be exploited. Preferably, the phase change material is substantially or entirely indium.

[0031] Alternatively or additionally, the phase change material may be based on one or more of liquid ammonia, liquid hydrogen, acetic acid, paraffin wax.

[0032] Preferably the phase change material comprises a hydrated salt phase change material. Preferably the phase change material is or is substantially a hydrated salt phase change material.

[0033] Hydrated salt phase change materials have been found to have particularly beneficial heat storage capabilities in the heating portion of aerosol generating devices.

[0034] Preferably the phase change material comprises an organic solution phase change material. Preferably the phase change material is or is substantially an organic solution phase change material.

[0035] Organic solution phase change materials have been found to have heat storage capabilities that are particularly beneficial in the heating portion of aerosol generating devices.

[0036] Preferably the phase change material comprises a solid to solid phase change material. Preferably the phase change material is a solid to solid phase change material or is substantially a solid to solid phase change material.

[0037] Solid-solid phase change materials have been found to have particularly beneficial heat storage capabilities in the heating portion of aerosol generating devices.

[0038] Preferably, the aerosol generating device heating portion further comprises a thermal insulating layer disposed between the heating chamber and the phase change material.

[0039] In this way, the thermal insulation layer can improve the efficiency of the heating portion of the aerosol-generating device by reducing heat loss from the heating chamber by directing heat towards the aerosol-generating substrate.

[0040] Preferably, the thermal insulation layer has a total thickness in the radial direction of the heating portion of the aerosol generating device that is approximately twice the total thickness of the phase change material.

[0041] Preferably, the phase change material is about 1 mm thick and the thermal insulation layer is at least 1 mm thick, or preferably, the thermal insulation layer is 1.5 mm thick, or more preferably, the thermal insulation layer is 2 mm thick, or the thermal insulation layer is at most 3 mm thick.

[0042] These configurations of thermal insulation layer thickness and phase change material thickness have been found to be particularly beneficial in inhibiting heat flow into the supercapacitor module.

[0043] Preferably, the insulating layer comprises a plurality of thermal insulating layers.

[0044] Preferably, the thermal insulation layer comprises an aerogel.

[0045] Preferably, the phase change material comprises multiple layers of phase change material.

[0046] Preferably, the aerosol generation device heating portion further comprises a first temperature sensor configured to monitor the temperature of the heater of the heating chamber and a second temperature sensor configured to monitor the temperature of the phase change material; The controller of the aerosol generating device heating portion is configured to recalibrate the monitored temperature of the heater based on determining that the phase change material has reached a melting temperature and that at the melting temperature the monitored temperature of the phase change material has substantially plateaued based on a predetermined relationship between the temperature of the heater and the melting temperature of the phase change material.

[0047] In this way, the phase change material can be used to provide a reference for continuously recalibrating the control of the heating temperature during an aerosolization session, ensuring that the aerosol-generating substrate is heated to the correct temperature, thereby improving the quality of the aerosolization session and thereby improving the user experience.

[0048] In a second aspect, there is provided an aerosol generation device comprising the aerosol generation device heating portion of the first aspect, further comprising an auxiliary power supply portion, the auxiliary power supply portion comprising a battery module; An aerosol generating device is provided in which the auxiliary power supply portion is removably connectable to the heating portion, and when connected, the battery module is configured to charge the supercapacitor module via an electrical connection between the heating portion and the auxiliary power supply portion.

[0049] In this way, a modular system is provided in which the battery module can be replaced by removing the auxiliary power section. This provides increased flexibility by decoupling power between the supercapacitor module and the battery module. Moreover, the supercapacitor module can be charged from the battery module to have a sufficient charge level to power the preheating phase of a subsequent aerosolization session. The preheating phase is energy intensive, and powering it solely with the battery can stress the battery. Moreover, the supercapacitor can power the heater for more rapid preheating. Therefore, the higher charge storage capacity of the battery module can be used to ensure that the supercapacitor module is ready to power the heater for a subsequent aerosolization session.

[0050] Preferably, the battery module is configured to power a heater associated with the heating chamber when the auxiliary power section is connected to the heating section by an electrical connection between the heating section and the auxiliary power section.

[0051] In this way, the battery module can supplement the power supply to the heater, which allows for a reduced size of the supercapacitor, resulting in a more compact heating section.

[0052] Embodiments of the present invention will now be described, by way of example, with reference to the drawings, in which: [Brief explanation of the drawings]

[0053] [Figure 1] FIG. 1 is a conceptual cross-sectional view of a first aerosol generating device. [Figure 2] FIG. 1 is a conceptual circuit diagram of a power and heating system for an aerosol generating device including a supercapacitor module, a battery module, and a heater. [Figure 3A] FIG. 1 is a diagram of a planar aerosol-generating substrate. [Figure 3B] FIG. 3B is a diagram of the aerosol-generating substrate of FIG. 3A inserted into a heating chamber. [Figure 3C] A diagram of the heating part of the aerosol generating device with a mouthpiece fitted. [Figure 4] FIG. 2 is a schematic cross-sectional view of a heating section for the aerosol generating device of FIG. 1. [Figure 5] 1 is a plot of phase change material temperature versus heater temperature. [Figure 6A] FIG. 1 is a schematic cross-sectional view of a second aerosol generating device. [Figure 6B] FIG. 6B is a schematic cross-sectional view of a heating portion for the aerosol generating device of FIG. 6A. [Figure 6C] FIG. 6B is a schematic cross-sectional view of an alternative heating portion for the aerosol generating device of FIG. 6A. [Figure 7] FIG. 1 is a diagram of an exemplary aerosol generating device heating portion. [Figure 8A] FIG. 1 is a perspective view of an exemplary layout of a heater track. [Figure 8B] FIG. 8B is a perspective view of the heater track of FIG. 8A encased in an electrically insulating layer. [Figure 8C] FIG. 8C is a cross-sectional view of a portion of a heater track encased within the electrically insulating layer of FIG. 8B. [Figure 8D] FIG. 1 is a perspective view of a heating chamber and heater track in combination with a mouthpiece. [Figure 8E] FIG. 10 is a diagram of possible locations for temperature probes on the heating portion. [Figure 9] FIG. 1 is a diagram of a conformal heating section having six thermal insulation layers. [Figure 10] 1 is a plot of temperatures recorded at temperature probes T1, T2, T3, and T4 as a function of time during an aerosolization session for a heating section having six thermal insulation layers. [Figures 11A-11E] FIG. 10 shows a view of a heating portion of an aerosol-generating device consistent with that of FIG. 9, but with one or more of the thermal insulating layers replaced with a phase-change material layer. [Figures 12A-12E] 11A to 11E show plots of temperature versus time during an aerosolization session at the first temperature probe T1, the second temperature probe T2, the third temperature probe T3, and the fourth temperature probe T4 for the heating portion of the aerosol generation device. [Figures 13A-13F] 11E shows plots of temperature versus time during an aerosolization session at a first temperature probe T1, a second temperature probe T2, a third temperature probe T3, and a fourth temperature probe T4 in a heating section having an insulating layer and a phase change material layer structured according to FIG. 11E and various phase change materials. [Figure 14] 11B shows plots of temperature as a function of time recorded at the fourth temperature probe T4 during an aerosolization session for a heating section structured as described with reference to FIG. 11E using various phase change materials. [Figure 15] 11B is a simulated heat map of a heating section having an insulating layer and a phase change material layer structured as described with reference to FIG. 11E. [Figure 16] 11E and 11F. FIG. 11C is a cross-sectional view of a heating portion having an insulating layer and a phase change material layer structured as described with reference to FIG. 11E, and a supercapacitor module adjacent to and at least partially surrounding the heating chamber. DETAILED DESCRIPTION OF THE INVENTION

[0054] 1 is a schematic cross-sectional view of an aerosol generation device 100, also known as a vapor generation device or e-cigarette. The cross-section is taken perpendicular to the axial direction of the aerosol generation device 100, i.e., a cut-away view along the length of the aerosol generation device 100.

[0055] For purposes of this application, it will be understood that the terms "vapor" and "aerosol" are interchangeable. The aerosol-generating device 100 is configured to generate an aerosol by heating an aerosol-generating material without burning the aerosol-generating material. The aerosol-generating material may include tobacco or a combination of tobacco and other ingredients, such as one or more humectants. Alternatively or additionally, the aerosol-generating material may include other non-tobacco materials suitable for generating aerosols, such as aerosol-generating liquids.

[0056] The aerosol-generating device 100 comprises a heating portion 102 (also referred to as a heating module) and an auxiliary power portion 104 (also referred to as an auxiliary power module). The heating portion 102 comprises a heating cavity or chamber (not shown in FIG. 1 but discussed in more detail below) into which an aerosol-generating substrate 120 (also known as an aerosol-generating consumable) is inserted. The aerosol-generating substrate 120 may include an aerosol-generating material or may itself be an aerosol-generating material. A heater 118 within the heating chamber 116 is configured to heat the aerosol-generating substrate 120 to generate an aerosol that can be inhaled by a consumer through a mouthpiece 110 of the heating portion 102.

[0057] A supercapacitor module 106 is disposed within the heating section 102 to power the heater 118. A battery module 108 is disposed within the auxiliary power section 104. The battery module 108 is operable to charge the supercapacitor module 106 and / or to power the heater 118 when the heating section 102 and the auxiliary power section 104 are connected. This will be discussed in more detail with reference to FIG. 2.

[0058] The supercapacitor module 106 may include one or more supercapacitors. The battery module 108 may include one or more batteries. In one example, the supercapacitor module 106 may be implemented as two supercapacitors connected in series, such as in a 2s1p pack. In one such example, the supercapacitors may be conventional supercapacitors, each having a voltage of 2.5V, thereby providing a total voltage of 5V to the supercapacitor module 106. In another such example, the supercapacitors may each have a voltage of 3V, thereby providing a total voltage of 6V to the supercapacitor module 106. In another such example, the supercapacitors may each have a voltage of 3.3V, thereby providing a total voltage of 6.6V to the supercapacitor module 106. More generally, the supercapacitors may each have a voltage between 2.5V and 3.3V, thereby providing a total voltage of 5V and 6.6V to the supercapacitor module 106.

[0059] In other embodiments, multiple supercapacitors may be connected in series to meet the voltage requirements needed to power the heater 118. Connecting multiple smaller supercapacitors in series, rather than using a single larger supercapacitor, is advantageous in allowing for greater design flexibility.

[0060] The life expectancy of a supercapacitor depends on the maximum operating voltage as well as the temperature, and in some embodiments, a compromise on life expectancy may be made when using a supercapacitor with a higher operating voltage to achieve a smaller device size with better energy density.

[0061] In one example, the battery module 108 may be implemented as a single battery. This may be a high-energy battery, such as a battery using lithium-ion, aluminum-ion, or zinc-ion technology, or any other suitable type of battery. Alternatively, the battery module 108 may include multiple batteries. In a particular example, the battery is a lithium-ion battery with a voltage of 3.7 V. Thus, the voltage of the battery module 108 may be 3.7 V.

[0062] The heating section 102 and the auxiliary power section 104 may each have a corresponding electrical connector 112 so that power can flow from the battery module 108 to the components of the heating section 102 when the heating section 102 and the auxiliary power section 104 are connected to each other.

[0063] The heating portion 102 may include a controller configured to control the operation of the aerosol generation device 100, including controlling the flow of power from the supercapacitor module 106 to the heater 118 and from the battery module 108 to the supercapacitor module 106 and / or the heater 118. The controller may be implemented as a microcontroller unit (or any other suitable control unit) comprising a memory having instructions stored therein for operating the aerosol generation device 100 and one or more processors configured to execute the instructions. The controller may be part of a circuit board 114, such as a printed circuit board, that comprises the control electronics of the aerosol generation device 100.

[0064] In operation, the controller controls the aerosol generating device 100 to perform an aerosolization session in which the aerosol-generating substrate 120 is heated to generate an aerosol for inhalation by the operator. The aerosolization session can include a pre-heating mode and a heating mode. In the pre-heating mode, the controller controls the flow of power to the heater 118 so that the heater 118 can be heated to a predetermined temperature for generating an aerosol from the aerosol-generating substrate 120. The pre-heating phase can be considered the time during which the pre-heating mode is performed, for example, the time until the heater 118 reaches the predetermined temperature. The pre-heating mode occurs during a first period of the aerosolization session. In one example, the first period can be a fixed, predetermined period. In another example, the first period can vary, corresponding to the length of time required to heat the heater 118 to the predetermined temperature. Once the heater 118 reaches the predetermined temperature, the controller terminates the pre-heating mode and controls the aerosol generating device 100 to perform the heating mode. In the heating mode, the controller controls the power flow to maintain the heater 118 at substantially a predetermined temperature so that an aerosol is generated for inhalation by the consumer. The heating phase can be considered the time during which the heating mode is performed, e.g., the time during which the heater 118 aerosolizes one (or at least a portion of one) of the aerosol-generating substrates 120 after a pre-heating phase. The controller can control the power system to operate the heating mode for a second period of the aerosolization session. The second period can be predetermined and stored in the controller.

[0065] FIG. 2 shows a conceptual circuit diagram of the supercapacitor module 106, the battery module 108, and the heater 118.

[0066] The supercapacitor module 106 may be connected to the battery module 108. Optionally, a DC / DC voltage converter 134 may be disposed between the two. The DC / DC voltage converter may be used to boost the battery module voltage when charging the supercapacitor module 106 from the battery module 108.

[0067] A first switching means 128 is disposed between the battery module 108 and the supercapacitor module 106. The supercapacitor module 106 can be connected to a heater 118, represented as a load, with a second switching means 130 disposed therebetween. In one embodiment, the first switching means 128 and the second switching means 130 can be transistors connected to a controller (not shown in FIG. 2).

[0068] The supercapacitor module 106 and battery module 108 can be configured to operate in many different ways to power the heater 118 and recharge the supercapacitor module 106 .

[0069] In a first example, during a pre-heating mode, only the supercapacitor module 106 is controlled to power the heater 118. Then, during a heating mode, only the battery module 108 is configured to power the heater 118. This arrangement is beneficial because a higher discharge rate from the supercapacitor allows for faster pre-heating than with a battery. This also prevents the battery from being stressed during the pre-heating phase, when higher currents may be required. A lower, more constant discharge rate from the battery module 108 can then be used for a longer heating mode, which requires less power than the pre-heating mode.

[0070] In the second example, similar to the first example, during a pre-heating mode, both the supercapacitor module 106 and the battery module 108 can be controlled to power the heater 118. Then, during the heating mode, only the battery module 108 is configured to power the heater 118. This arrangement is beneficial because the supercapacitor module 106 can support the battery module 108 during pre-heating. However, because the supercapacitor module 106 is only supporting the battery module 108 during the pre-heating mode rather than exclusively powering the heater 118, a smaller supercapacitor module 106 can be used, thereby reducing device size.

[0071] In a third example, during a pre-heating mode, only the supercapacitor module 106 is controlled to power the heater 118. Then, during a heating mode, both the battery module 108 and the supercapacitor module 106 are configured to power the heater 118. In this way, the supercapacitor module 106 can assist the battery module 108 during the heating phase.

[0072] In a fourth example, during a pre-heating mode, both the supercapacitor module 106 and the battery module 108 may be controlled to power the heater 118. Then, during a heating mode, both the battery module 108 and the supercapacitor module 106 are configured to power the heater 118. In this way, the supercapacitor module 106 can assist the battery module 108 during the pre-heating and heating phases.

[0073] The pre-heating phase, in particular, may require a high discharge rate to power the heater 118 for rapid pre-heating. Such a high discharge rate can stress the battery, shortening its useful life. Using the supercapacitor module 106 during pre-heating reduces / eliminates stress on the battery module 108 compared to heating with the battery alone, thereby improving the useful life of the battery. Moreover, the higher discharge rate available to the supercapacitor module 106 allows for faster pre-heating, thereby improving the user experience.

[0074] In these previous embodiments, the battery module 108 may be controlled by the controller to direct power flow to the supercapacitor module 106 during an aerosolization session and to recharge the supercapacitor module 106 for a subsequent aerosolization session. In this manner, the supercapacitor module 106 may be appropriately charged for the pre-heating phase of the subsequent aerosolization session.

[0075] Power flows between the battery module 108 and the supercapacitor and / or heater 118, and the supercapacitor and / or heater 118 may be controlled using a first switching means 128 and a second switching means 130. For example, opening the first switching means 128 and closing the second switching means 130 may be used to direct power flow from the supercapacitor module 106 to the heater 118. Opening the second switching means 130 and closing the first switching means 128 may be used to direct power flow from the battery module 108 to the supercapacitor module 106 to charge the supercapacitor module 106. Closing both the first switching means 128 and the second switching means 130 may be used to direct power flow from both the battery module 108 and the supercapacitor module 106 to the heater 118.

[0076] The first switching means 128 and the second switching means 130 may be controlled by a controller to apply a pulse width modulated (PWM) power flow by rapidly switching the switching means between an open and closed state. Varying the open / close switching speed to adjust the duty cycle may be used to adjust the power flow.

[0077] In further embodiments, the battery module may be configured to charge the supercapacitor module 106 during an aerosolization session in addition to, or instead of, charging the supercapacitor module 106 between aerosolization sessions.

[0078] In a first example embodiment in which the battery module 108 charges the supercapacitor module 106 during an aerosolization session, the battery module 108 charges the supercapacitor module 106 during both the pre-heating mode and the heating mode. In such an example embodiment, the controller controls the PWM power flow such that the supercapacitor module 106 is controlled to power the heater 118 and the battery module 108 is controlled to recharge the supercapacitor module 106. In the pre-heating mode and the heating mode, only the supercapacitor module 106 powers the heater 118, and the battery module 108 recharges the supercapacitor module 106. During the PWM cycle on period of the pulse-width modulated power flow from the supercapacitor module 106 to the heater 118, the supercapacitor module 106 powers the heater 118, and during the PWM cycle off period of the pulse-width modulated power flow from the supercapacitor module 106 to the heater 118, the battery module 108 recharges the supercapacitor module 106. That is, during the preheat mode and the heating mode, the supercapacitor module 106 switches between powering the heater 118 during the on portion of the duty cycle and being recharged by the battery module 108 during the off portion of the duty cycle. The battery module 108 does not charge the supercapacitor module 106 during the on portion of the duty cycle.

[0079] In the heating mode, the pulse-width modulated power flow from the supercapacitor module 106 to the heater 118 may operate in a first duty cycle range including one or more PWM cycles having a first duty cycle ratio D1. In the pre-heating mode, the supercapacitor module 106 may power the heater 118 with a pulse-width modulated power flow in a second duty cycle range including one or more PWM cycles having a second duty cycle ratio D2. The relationship between D1 and D2 may be considered as D2 = D1 * K, where K is a factor that is >>1 and may be selected as an implementation choice. In one example, the first duty cycle ratio may be much less than 1, and the second duty cycle ratio may be close to but less than 1. In other examples, the first duty cycle ratio may be << 0.5 and the second duty cycle ratio may be ≥ 0.5. In a further embodiment, the first duty cycle is configured to apply <3 W in the heating mode, and the second duty cycle is configured to apply approximately 16 W in the pre-heating mode. More generally, 2 W to 6 W can be applied during the heating mode, and 10 W to 30 W can be applied during the pre-heating mode. The controller, the first switching means 128, and the second switching means 130 provide the above-described control over heating and charging. During a PWM cycle ON period of the pulse-width modulated power flow, the controller controls the second switching means 130 to close and the first switching means 128 to open. In this manner, power flows from the supercapacitor module 106 to the heater 118 during the PWM ON period, while the battery module 108 is isolated from the supercapacitor module 106 and the heater 118. During a PWM cycle OFF period of the pulse-width modulated power flow, the controller controls the second switching means 130 to open and the first switching means 128 to close. In this way, power flows from the battery module 108 to the supercapacitor module 106 to recharge the supercapacitor module 106 while isolating the supercapacitor module 106 from the heater 118 .Thus, during pulse width modulated power flow, rapid switching occurs between powering the heater 118 during the PWM cycle ON period and recharging the supercapacitor module 106 during the PWM cycle OFF period. In some embodiments, there may be a small delay between opening the first switching means 128 and closing the second switching means 130. This prevents power flow from the battery module 108 from unintentionally reaching the heater 118 during the ON period of the pulse width modulated power flow duty cycle.

[0080] In a second example where the battery module 108 charges the supercapacitor module 106 during an aerosolization session, the battery module 108 charges the supercapacitor module 106 during the heating mode, as described in the previous example. However, the battery module 108 does not charge the supercapacitor module 106 during the pre-heating mode. In such an example, the controller controls the PWM power flow from the supercapacitor module 106 to the heater 118 during the pre-heating mode using the second switching means 130, and the first switching means 128 remains open throughout the pre-heating mode. Because a higher duty cycle is used in the pre-heating mode, not charging the supercapacitor module 106 during the pre-heating mode reduces system complexity because the battery module 108 does not need to apply PWM switching at this higher duty cycle.

[0081] 1, the heating section 102 and the auxiliary power section 104 may each have a corresponding electrical connector 112 so that when the heating section 102 and the auxiliary power section 104 are connected to one another, power can flow from the battery module 108 to the components of the heating section 102. These electrical connectors 112 are represented in FIG. 2 by connection nodes 132.

[0082] 3A-3C show diagrams of configurations in which a planar aerosol-generating substrate 120 can be mounted on the heating portion 102 of the aerosol-generating device described with reference to FIG. 1. FIG. 3A is a diagram of the planar aerosol-generating substrate 120, and FIG. 3B is a diagram of the aerosol-generating substrate 120 inserted into the heating chamber 116, suitable for mounting on the aerosol-generating device described with reference to FIG. 1. FIG. 3C is a diagram of the heating portion 102 of the aerosol-generating device 100 according to FIG. 1, fitted with a mouthpiece 110. In this embodiment, the heating chamber 116 is disposed within the housing 126 of the heating portion 102. As can be seen, the mouthpiece 110 is fitted onto the mouthpiece portion 138 of the aerosol-generating substrate 120, which extends from the heating chamber 116, such that an opening in the mouthpiece 110 coincides with the end of the aerosol-generating substrate 120 through which the generated aerosol is drawn when the operator inhales through the mouthpiece 110.

[0083] 3A, the aerosol-generating substrate 120 may be planar or flat in shape, for example, in the form of a flat rectangular parallelepiped. In a specific example, the length of the substrate 120 along the substrate axis X is substantially 33 mm, and the width and depth are substantially 12 mm and 1.2 mm, respectively. That is, the substrate 120 can be considered planar in shape in that it has a depth that is much shorter than its length and width. However, in other embodiments, the aerosol-generating substrate 120 and the corresponding heating chamber 116 may have other suitable shapes or dimensions. For example, the aerosol-generating substrate 120 may be a circular tubular shape similar to a conventional cigarette.

[0084] The aerosol-generating substrate 120 may comprise a heating portion 140 and a mouthpiece portion 138. The heating portion 140 is housed within the heating chamber 116, and the mouthpiece portion 138 is housed within the mouthpiece 110 of the aerosol-generating device 100. That is, the heating portion 140 defines an abutting end of the substrate 120 that may abut or be proximate to a bottom 150 of the heating chamber 116, and the mouthpiece portion 138 defines a mouth end of the substrate 120.

[0085] The heating portion 140 is configured to be heated by the heater 118 within the heating chamber 116 and contains an aerosol-forming material. The aerosol-forming material may be, for example, a material that may include nicotine or tobacco and an aerosol-forming agent. The tobacco may take the form of various materials, such as cut tobacco, granulated tobacco, tobacco leaf, and / or reconstituted tobacco. Suitable aerosol-forming agents include polyols (sorbitol, glycerol, and glycols (e.g., propylene glycol or triethylene glycol)), non-polyols (e.g., monohydric alcohols), acids (e.g., lactic acid), glycerol derivatives, esters (e.g., triethylene glycol diacetate, triethyl citrate, glycerin, or vegetable glycerin). In some embodiments, the aerosol-forming agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate 120 may also include at least one of a gelling agent, a binder, a stabilizer, and a humectant. When the aerosol-forming material is heated, an aerosol or vapor is formed.

[0086] The mouthpiece portion 138 is intended to be housed inside the mouthpiece 110 of the heating portion 102 of the aerosol generating device 100. The mouthpiece portion 138 comprises a core 144 that may provide filtering functionality. In some embodiments, the core 144 may be foam or a bundle of fiber strands. The mouthpiece portion 138 may have a plurality of ventilation holes 142 arranged in the wall of the substrate 120, allowing fresh air to enter inside the substrate 120 to achieve certain vaping / tasting effects.

[0087] 3C, the mouthpiece 110 has a through-hole designed to accommodate the mouthpiece portion 138 of the aerosol-generating substrate 120. The through-hole may have the same cross-sectional shape as the aerosol-generating substrate 120, with internal dimensions slightly larger than the external dimensions of the mouthpiece portion 138 of the aerosol-generating substrate 120.

[0088] In some cases, the substrate 120 may not include vent holes 142, in which case air can flow into the substrate 120 by being drawn through the abutment end. For example, air can be drawn into the device through an inlet 146 in the mouthpiece 110 or through a sidewall of the device to counteract the pressure drop caused by an operator inhaling through the mouthpiece 110.

[0089] 3B, the heating chamber 116 may be cup-shaped and have an open end 148 into which the aerosol-generating substrate 120 is inserted, and an opposite sealed end 150. The heating chamber 116 houses the heating portion 140 of the aerosol-generating substrate 120. The heating chamber 116 has substantially the same cross-sectional shape as the aerosol-generating substrate 120. The walls of the heating chamber 116 may have one or more heating elements of the heater 118 therein or thereon. Each of the walls of the heating chamber 116, or one or more of the walls, has a heating element therein or thereon.

[0090] The walls of the heating chamber 116 can be ceramic with heater wires or tracks embedded therein or on their surfaces. In one example, a heating element can be positioned in contact with one of the heating chamber walls on the exterior of the heating chamber 116. As shown in the example of FIG. 3B, the heating element can be positioned on the exterior surface of the chamber wall. Similarly, a second heating element can be positioned on the exterior surface of the opposite chamber wall (not shown). Thus, the chamber wall transfers heat from the heating element to the aerosol-generating substrate 120. In other examples, the heating element can be embedded within the chamber wall. In further examples, the heating element can be on a chamber wall inside the heating chamber 116. As described, the chamber wall can be a ceramic material with heater tracks or wires embedded therein or on its surface. Alternatively, each heating element can comprise a polyimide film heater extending along substantially the entire area of ​​the exterior surface of the corresponding heating wall, or along only a portion of this surface.

[0091] In a preferred embodiment, the heating chamber 116 has two major inner surfaces corresponding to the opposing wider surfaces of the planar aerosol-generating substrate 120 and two minor inner surfaces corresponding to the opposing narrower surfaces of the planar aerosol-generating substrate 120. The minor inner surfaces are perpendicular to and connect the major inner surfaces. The walls of the heating chamber 116 corresponding to the major inner surfaces can be arranged so that heater wires or tracks are embedded therein or thereon to form two ceramic heaters. In some embodiments, the walls of the heating chamber 116 corresponding to the minor inner surfaces can also be ceramic. Such ceramic heaters can provide a compact heating chamber 116 with good heat distribution directed to the planar aerosol-generating substrate 120. However, such ceramic heaters can require significantly more heating power (e.g., >10 W and / or >1600 J) than heaters in aerosol-generating devices configured to accommodate more traditional cigarettes or cigarette-like consumables. Therefore, such heaters greatly benefit from heating power management utilizing one or more supercapacitors as described herein.

[0092] Alternatively, each of the walls may be made of a thermally conductive material, such as metal, in particular stainless steel. Additionally, at least some of the walls, or all of the walls, may form one single piece.

[0093] The interior dimensions of the heating chamber 116 may be defined such that, when the aerosol-generating substrate 120 is inserted into the heating chamber 116, an air flow path is formed between the walls of the heating chamber 116 and the aerosol-generating substrate 120. That is, when the heating portion 140 of the aerosol-generating substrate 120 is inserted into the heating chamber 116, an air flow path is formed along the axial length of the substrate 120.

[0094] The heating portion 102 may include additional components not shown in Figures 3A-3C, which will be discussed in more detail with respect to Figure 4.

[0095] Figure 4 shows a schematic cross-sectional view of the heating portion 102 of the aerosol-generating device 100 described with reference to Figure 1 and the heating chamber 116 described with reference to Figures 3A to 3C. The cross-section is taken along the axial direction of the heating portion 102, i.e., in the direction of insertion / removal of the aerosol-generating substrate 120 into / from the heating chamber 116.

[0096] The heating portion 102 comprises a heating chamber 116 configured to accommodate an aerosol-generating substrate 120. In one example, the heating chamber 116 and the aerosol-generating substrate 120 may be of the planar type described with reference to Figures 3A-3C. Alternatively, alternative heating chambers and aerosol-generating substrates may be implemented within the heating portion 102. For example, the heating chamber 116 may be configured to accommodate a non-planar aerosol-generating substrate, a rod-type aerosol-generating substrate (similar to a conventional cigarette), or loose aerosol-generating material (such as loose tobacco).

[0097] The heating portion 102 also includes a supercapacitor module 106 configured to power the heater 118. The supercapacitor module 106 is adjacent to (i.e., near or proximal to) the heating chamber 116 and may be configured to at least partially or completely surround the heating chamber 116. The supercapacitor module 106 may be configured to conform to the shape of the heating chamber 116. In this manner, the heating portion 102 may have a compact shape and size.

[0098] In some embodiments, the supercapacitors of the supercapacitor modules 106 may be curved rather than flat so as to substantially (or at least partially) surround the heating chamber 116. These may provide a more compact heating portion 102. In other embodiments, the supercapacitors of the supercapacitor modules 106 may be flat supercapacitor cells. These may be easier to fabricate and place within the heating portion 102, although this may be balanced by the need for a larger heating portion 102 to accommodate such flat cells.

[0099] In the particular embodiment of FIG. 4 , the supercapacitor module 106 includes two supercapacitors. These two supercapacitors are disposed on opposite sides of the heating chamber 116. In this manner, the two supercapacitors partially (and almost completely) surround the heating chamber 116. In the embodiment of FIG. 4 , the supercapacitors are disposed on larger surfaces of the planar heating chamber 116 (i.e., the major surfaces of the heating chamber 116) and are bent around these larger surfaces so that the supercapacitors substantially surround the heating chamber 116. The supercapacitors may be arranged in a 2s1p configuration. In other embodiments, only one supercapacitor may be used, or two or more supercapacitors may be used. In some embodiments, the supercapacitors may completely surround the heating chamber 116.

[0100] A phase change material 122 is disposed between the heating chamber 116 and the supercapacitor module 106 to separate the heating chamber 116 from the supercapacitor module 106 .

[0101] The phase change material 122 absorbs heat from the heating chamber 116 during the aerosolization session and changes phase from a solid to a liquid phase while melting. The temperature of the phase change material 122 plateaus during melting as the phase change material 122 continues to absorb thermal energy. The temperature may rise again when the phase change material 122 reaches its maximum absorbable energy content through absorption of thermal energy from the heating chamber 116.

[0102] The phase change material 122 is configured to protect the supercapacitor module 106 by absorbing heat from the heating chamber 116. The phase change material 122 functions as a heat storage component, whereby at its phase transition temperature, its latent heat capacity absorbs thermal energy from the heat source, preventing excessive temperature peaks in the supercapacitor module 106. This absorption of heat from the heating chamber 116 also prevents heating of the housing 126 of the heating portion 102, thereby protecting the consumer holding the heating portion 102. The absorbed heat is then released from the phase change material 122 after an aerosolization session when the device is no longer in use. Upon cooling, the phase transition of the phase change material 122 releases thermal energy back into the system. The phase change material 122 thereby mitigates excessive temperatures that may result from high heat flux through the system, for example, during initial heating of the heater.

[0103] The main thermal properties desired for a phase change material in such an aerosol generating device 100 configured to heat the aerosol generating material without burning it are high latent heat capacity, high specific heat capacity of both phases, low thermal conductivity, high density, and a phase transition temperature lower than the maximum temperature defined for the components that need to be protected (e.g., a supercapacitor module).

[0104] The phase change material 122 may also at least partially or completely surround the heating chamber 116. This may be achieved, for example, by fitting a single piece of phase change material 122 around the heating chamber 116. Alternatively, it may be achieved by positioning multiple pieces of phase change material 122 around the chamber. In some embodiments, the phase change material 122 may be one or more sheets of material. In other embodiments, the phase change material 122 may be a filler material that is injected or inserted, for example, between the heating chamber 118 and the supercapacitor module 106. In some embodiments, the phase change material 122 may be indium or an indium-based phase change material 122. Alternatively or additionally, the phase change material 122 may be based on one or more of liquid ammonia, liquid hydrogen, acetic acid, or paraffin wax. In further embodiments, the phase change material 122 may be a hydrated salt phase change material, an organic solution phase change material, or a solid-solid phase change material, as described below.

[0105] An optional thermal insulation layer 124 substantially or completely surrounds the heating chamber 116 along its axial length (i.e., in the direction of insertion / removal of the aerosol-generating substrate 120). In some embodiments, the thermal insulation layer is a superwool material or an aerogel-based material, e.g., in sheet form. The phase change material 122 substantially or completely surrounds the heating chamber 116 along its axial length, and also surrounds the thermal insulation layer 124, if included. The supercapacitor module 106 then substantially or completely surrounds the phase change material 122 at least partially along the axial length of the heating chamber 116. This allows for one or more supercapacitors to be positioned adjacent to the heating chamber 116, which can be bent or conformed to conform to the shape of the heating chamber 116 along the axial length of the heating chamber 116. Alternatively, this can be achieved by positioning multiple flat supercapacitors adjacent to the heating chamber 116, at least partially along the axial length of the heating chamber 116. Thus, a layered device is formed within the heating portion 102, with the heating chamber 116 in the center, followed in an outward direction by a thermal insulation layer 124 (optional), then a phase change material 122, then a supercapacitor module 106, all within the housing 126 of the heating portion 102.

[0106] The heating chamber 116 or heater unit may be contained within a heater unit housing. The phase change material 122 may be thermally connected to the outside of the heater unit for heat dissipation. The heater unit housing may be metal, such as aluminum. The phase change material 122 may be connected using metal tape, such as copper tape, and / or thermal paste.

[0107] Supercapacitors can operate at higher temperatures than battery technologies commonly used in portable electronic applications, such as lithium-ion batteries, nickel-metal hydride batteries, primary batteries, and nickel-cadmium products. For example, the maximum operating temperature for discharging a lithium-ion battery is approximately 60°C. Therefore, supercapacitors are well suited for use in the heating portion 102 of the aerosol generating device 100. However, for optimal operation, the supercapacitor module 106 should be protected from excessive heat conducted from the heating chamber 116. The phase change material 122 can be selected to absorb enough thermal energy to prevent the supercapacitor from reaching temperatures above an appropriate operating threshold. The combination of the supercapacitor module 106 and the phase change material 122 further accentuates these advantages, as the supercapacitor module 106 can be placed very close to the heating chamber 116 but can be protected from excessive thermal energy by the phase change material 122.

[0108] Supercapacitors are also well suited for this application in the heating portion 102 of the aerosol generating device 100, which has a phase change material 122, because supercapacitor technology is safe by design in the event of device failure (e.g., if the phase change material 122 breaks down, if the heating chamber 116 overheats, or if the supercapacitor breaks down). Supercapacitors have no expansion constraints and cannot suffer a thermal event or breakdown. Therefore, the supercapacitor module 106 is safer to use in the heating portion 102 than, for example, a battery. Supercapacitors can also be discharged to 0 V without risk and without the need for under-discharge protection, or, in the case of asymmetric supercapacitors, to the minimum voltage to which they can be discharged, and still without safety risks.

[0109] Furthermore, the supercapacitor cells are well suited for applications that use phase change material 122 because they can be bent as the phase change material 122 changes phase without adversely affecting the operation of the supercapacitor module 106 .

[0110] The thickness and exact dimensions of the supercapacitor may depend on the power requirements of the heater 118. However, in one embodiment, the supercapacitor may range from 1 to 5 mm in thickness. The thickness of the phase change material 122 may depend on the latent heat requirements and type of phase change material 122 used. However, in one embodiment, the phase change material 122 may range from 0.2 to 2 mm in thickness.

[0111] The temperature of the phase change material 122 can be monitored and used to recalibrate the temperature of the heater 118. The temperature of the heater 118 can be monitored using a first temperature sensor 136, and the temperature of the phase change material 122 can be monitored using a second temperature sensor 136-2. In some embodiments, these temperature sensors can be temperature sensor subcircuits. In some embodiments, the second temperature sensor 136-2, which monitors the temperature of the phase change material 122, does not need to have a high level of accuracy, which means that a low-cost or basic sensor can be used. This is because the saturation (phase change) temperature of the phase change material 122 is a known, fixed parameter, so only the plateau of the temperature reading needs to be detected, not the explicit, precise temperature value.

[0112] 5 shows a plot of phase change material temperature 502 versus heater temperature 504. When phase change material 122 is in the solid phase, the temperature of phase change material 122 increases as the temperature of heater 118 increases. However, once phase change material 122 reaches its melting point 506, the temperature of phase change material 122 plateaus and remains substantially constant while the heater temperature continues to increase.

[0113] The melting temperature of the phase change material 122 is a known characteristic. This temperature can be stored in the firmware of the aerosol generation device 100, for example, in a storage device accessible to the controller. Because the melting temperature of the phase change material 122 is known and predetermined, a relationship can be established between the temperature of the heater (or heating chamber) and the melting temperature of the phase change material 122. For example, it can be known that the phase change material 122 reaches its melting point (i.e., melting temperature) at X°C. It can be predetermined that the phase change material 122 reaches X°C when the heater 118 is at Y°C. That is, Y°C is the expected heater temperature at which the phase change material 122 will melt within the device. Thus, if it is determined that the phase change material 122 has reached its melting temperature because its temperature has plateaued, it can be determined that the heater 118 should be at the expected temperature, Y°C. This can be used to correct for any temperature measurement offset or error in the measured heater temperature. If the measured heater temperature is offset by ΔY°C from the expected temperature Y°C when the temperature of the phase change material 122 plateaus, this ΔY°C offset in the measured heater temperature can be corrected by recalibrating the measured heater temperature. This can be done continuously during an aerosolization session. In this way, the melting point of the phase change material 122 can be used to accurately calibrate and control the heater temperature. This leads to more precise control of the heater temperature, allowing the heater 118 to be precisely heated to the desired temperature for the aerosolization session, leading to improved aerosol production for the consumer.

[0114] Returning to FIG. 4 , the components of the heating portion 102 may be contained within a heating portion housing 126. The components of the heating portion 102 may further include a circuit board 114 on which the control electronics of the aerosol generating device 100 are located. In some embodiments, this may be a flexible printed circuit board. A flexible circuit board is advantageous because it can be adapted to fit compactly around the heating chamber 116 and other components within the heating portion housing 126, leading to a compact heating portion 102. In the embodiment of FIG. 4 , the circuit board 114 is positioned along the axial direction of the heating portion 102, in the direction of insertion / removal of the aerosol-generating material, and adjacent to a minor surface of the heating chamber 116. In other embodiments, the circuit board 114 may be positioned along the axial direction of the heating portion 102, in the direction of insertion / removal of the aerosol-generating material, and adjacent to a major surface of the heating chamber 116. In a further embodiment, the circuit board 114 may be positioned below the heating chamber 116 (i.e., away from the mouthpiece 110 end of the heating portion 102) in the insertion / removal direction of the aerosol-generating material, as shown in FIG. 1.

[0115] As mentioned above, the thermal insulation layer 124 may optionally be disposed between the phase change material 122 and the heating chamber 116. For example, the thermal insulation layer 124 may be a thermal insulation material disposed around or partially around the heating chamber 116. This may improve the efficiency of the aerosol generation device by reducing heat loss from the heating chamber 116.

[0116] As described with reference to FIG. 1 , the heating section 102 and the auxiliary power section 104 may each have a corresponding electrical connector 112 so that power can flow from the battery module 108 to the components of the heating section 102 when the heating section 102 and the auxiliary power section 104 are connected to one another. In the embodiment of FIG. 4 , two sets of electrical connectors 112 are included. In such an embodiment, a first set of electrical connectors 112-1 may be between a controller on the circuit board and the battery module 108 in the auxiliary power section 104. This first set of electrical connectors 112-1 may be used to control the battery module 108. A second set of electrical connectors 112-2 may be between the supercapacitor module 106 and / or heater 118 and the battery module 108 of the auxiliary power section. However, it will be understood that any suitable number of electrical connectors may be included. For example, a single set of electrical connectors may be used to both control the auxiliary power supply section 104 using a controller in the heating section 102 and to control the flow of power from the battery module 108 to the supercapacitor module 106 and / or heater 118.

[0117] These electrical connectors 112 allow for electrical separation between the supercapacitor module 106 and the battery module 108 by disconnecting the heating section 102 from the auxiliary power section 104. This provides for an improved flexibility and modular energy system design, as the battery module 108 and the supercapacitor module 106 are decoupled. In this way, for example, the battery can be replaced by replacing the auxiliary power section 104, without having to replace the entire aerosol generation device 100 or the entire power system (supercapacitor module 106 and battery module 108).

[0118] The decoupling between the supercapacitor module 106 and the battery module 108 in the manner described above contributes to simplifying the replacement of the battery module 108 in terms of flexibility. Using different battery sizes in an aerosol generation system can increase technical complexity. For example, if 20 W is required from the battery (5 A at 4 V), a 2500 mAh battery requires a 2 C discharge rate. However, a 1250 mAh battery requires a 4 C discharge rate, which is more difficult to meet in terms of the battery's life cycle. However, the decoupling power system provided by the present invention enables the use of the supercapacitor module 106 to power the heater 118, which reduces battery stress, thereby improving the battery life cycle and allowing the use of lower-capacity batteries, while also providing a safer aerosol generation device 100. In this way, the battery module 108 can be easily replaced at the end of its life cycle, providing flexibility in battery selection.

[0119] In some embodiments, the connections between the supercapacitor cells may be configured in a 2s1p configuration. This connection may also be applied to a controller to sense the voltage of each supercapacitor cell in the 2s1p configuration so that the controller can control the power flow. In some embodiments, another connection may be made separately to the controller. An additional connection may be made between the heater and a circuit board through the controller, for example, at the bottom of the heater unit.

[0120] 4, there are two supercapacitors on substantially each side of the planar heating chamber 116. However, in other examples, a continuous supercapacitor may surround the heating chamber 116, or multiple supercapacitors may be positioned around the heating chamber 116. Such examples are described in more detail with respect to FIGS. 6A-6C.

[0121] A second aerosol generation device 600 is shown in Figures 6A-6C. This aerosol generation device 600 can perform an aerosolization session in the same manner as described with reference to the embodiment of Figures 1-5, e.g., with regard to how the pre-heating and heating phases are powered by the supercapacitor module 106 and / or the battery module 108, and therefore these will not be repeated here for the sake of brevity.

[0122] Figure 6A shows a schematic cross-sectional view of an aerosol generation device 600 configured to accommodate a substantially rod-shaped aerosol-generating substrate 620, such as a tobacco rod. The aerosol generation device 600 of Figure 6A has a heating portion 602 and an auxiliary power supply portion 604. The heating portion 602 and the auxiliary power supply portion 604 are removably connectable in the same manner as the aerosol generation device 100 described with reference to Figures 1 to 5.

[0123] The auxiliary power supply section 604 includes a battery module 608 that is connectable to the components of the heating section 602, but via a connector 612. The auxiliary power supply section 604, battery module 608, and connector 612 can be implemented in the same manner as the auxiliary power supply section 104, battery module 108, and connector 112 of the aerosol generation device 100 described with reference to Figures 1 to 5, and therefore this description will not be repeated here for the sake of brevity.

[0124] The heating portion 602 includes a heating chamber 616 configured to accommodate and heat a rod-shaped aerosol-generating substrate 620. The heating portion 602 includes a supercapacitor module 606 and a phase change material 622 that may be implemented in the same manner as the supercapacitor module 106 and phase change material 122 described with reference to Figures 1-5, and therefore this description will not be repeated here for the sake of brevity.

[0125] The heating portion 602 may also include a housing 126, a thermal insulation layer 124, and a circuit board 114, which may be implemented in the same manner as the housing 626, the thermal insulation layer 624, and the circuit board 614 described with reference to Figures 1-5, and therefore, this description will not be repeated here for the sake of brevity. The heating portion 602 may also include a first temperature sensor (not shown) configured to monitor the heater temperature and a second temperature sensor (not shown) configured to monitor the temperature of the phase change material 622, which may be implemented in the same manner as those of the aerosol generation device 100 described with reference to Figures 1-5.

[0126] The main difference between the aerosol generating device 100 described with reference to Figures 1 to 5 and the aerosol generating device 600 described with reference to Figures 6A to 6C is that the aerosol generating device 600 of Figures 6A to 6C has a heating chamber 616 configured to accommodate a substantially rod-shaped aerosol generating substrate 620, such as a tobacco rod.

[0127] The heating chamber 616 is disposed within the heating unit 602. The heating chamber 616 is accessed by an opening in the heating unit 602 into which the aerosol-generating substrate 620 is inserted.

[0128] The aerosol-generating substrate 620 can contain an aerosol-generating material, such as a tobacco rod containing tobacco. The tobacco rod can be similar to a traditional cigarette. The heating chamber 616 can have a cross-section approximately equal to the cross-section of the aerosol-generating substrate 620. The heating chamber 616 can have a circular or substantially circular cross-sectional shape that matches the cross-sectional shape of the tobacco rod aerosol-generating substrate 620.

[0129] The heating chamber 616 may have a depth such that when an associated aerosol-generating substrate 620 is inserted into the heating chamber 616, a first end of the aerosol-generating substrate 620 reaches the bottom of the heating chamber 616 (i.e., the end of the chamber 616 distal from the opening) and a second end of the aerosol-generating substrate 620 distal from the first end extends outward from the heating chamber 616. In this way, a consumer can inhale from the aerosol-generating substrate 620 when it is inserted into the aerosol-generating device 600.

[0130] The heater 618 is positioned within the heating chamber 616 such that the aerosol-generating substrate 620 engages the heater 618 when inserted into the heating chamber 616. In the example of FIG. 6A , the heater 618 is positioned as a tube defining the heating chamber 616 such that when a first end of the aerosol-generating substrate 620 is inserted into the heating chamber 616, the heater 618 substantially or completely surrounds the portion of the aerosol-generating substrate 620 within the heating chamber 616. The heater 618 may be a wire, such as a coiled wire heater, or a ceramic heater, or any other suitable type of heater. The heater 618 may be embedded in the wall of the heating chamber 616 or attached to the interior or exterior surface of the heating chamber wall. The heater 618 may comprise multiple heating elements arranged consecutively along the axial length of the heating chamber 616, which can be activated (i.e., powered) in sequence and independently.

[0131] In an alternative embodiment (not shown), the heater may be disposed within the heating chamber 616 as an elongated piercing member (e.g., in the form of a needle, rod, or blade), and in such an embodiment, the heater may be configured to penetrate the aerosol-generating substrate 620 and engage the aerosol-generating material when the aerosol-generating substrate 620 is inserted into the cavity.

[0132] In another alternative embodiment (not shown), the heater may be in the form of an induction heater. In such an embodiment, a heating element (i.e., a susceptor) may be provided in the aerosol-generating substrate 620, and when the aerosol-generating substrate 620 is inserted into the heating chamber 616, the heating element is inductively coupled to an induction element (i.e., an induction coil) within the heating chamber 616. The induction heater then heats the heating element by induction.

[0133] The heater 618 is configured to heat the tobacco (or other aerosol-forming material) to generate an aerosol without burning the tobacco. That is, the heater 618 heats the tobacco to a predetermined temperature below the combustion point of the tobacco so that a tobacco-based aerosol is generated. Those skilled in the art will readily appreciate that the aerosol-generating substrate 620 need not necessarily include tobacco, and that any other suitable substance, particularly for aerosolization (or vaporization) by heating without burning the substance, can be used in place of or in combination with tobacco.

[0134] Alternatively, the aerosol-generating substrate 620 may be a vaporizable liquid, which may be contained in a cartridge that can be housed within the aerosol-generating device, or may be placed directly into the aerosol-generating device.

[0135] Figure 6B shows a cross-sectional view of the heating portion 602 of the aerosol-generating device 600 described with reference to Figure 6A. The cross-section is taken along the axial direction of the heating portion 602, i.e., in the direction of insertion / removal of the aerosol-generating substrate 620 into the heating chamber 616.

[0136] Supercapacitor module 606 is adjacent to and substantially surrounds heating chamber 616. Heating chamber 616 is defined by heater 618. Phase change material 622 is disposed between heating chamber 616 and supercapacitor module 606 to separate heating chamber 616 from supercapacitor module 606. Optionally, thermal insulation layer 624 is disposed between heating chamber 616 and phase change material 622. These components have the same functionality and advantageous technical effects as the corresponding components described with reference to FIGS.

[0137] The thermal insulation layer 624 surrounds (partially or completely) the heating chamber 616 along its axial length (i.e., in the direction of insertion / removal of the aerosol-generating substrate 620). The phase change material 622 surrounds (partially or completely) the heating chamber 616 along its axial length, and also surrounds the thermal insulation layer 624, if included. The supercapacitor module 606 then substantially surrounds the phase change material 622 at least partially along the axial length of the heating chamber 616. This is achieved by multiple supercapacitors that can be bent or conformed to follow the shape of the heating chamber 616 along its axial length. In the example of FIG. 6B, five supercapacitors are included, although any suitable number of supercapacitors can be used.

[0138] Thus, a layered device is formed within the heating portion 602, with the heating chamber 616 in the center, followed in an outward direction by a thermal insulation layer 624 (optional), then a phase change material 622, then a supercapacitor module 606, all within the housing 626 of the heating portion 602.

[0139] Figure 6C shows a cross-sectional view of an alternative heating portion 602 of the aerosol-generating device 600 described with reference to Figure 6A. The cross-section is taken along the axial direction of the heating portion 602, i.e., in the direction of insertion / removal of the aerosol-generating substrate 620 into / from the heating chamber 616. The heating portion 602 of Figure 6C corresponds to the heating portion 602 of Figure 6B, except that the supercapacitor module 606, instead of being formed from multiple supercapacitors, is a single supercapacitor that completely surrounds (or substantially completely surrounds) the heating chamber 616. This single supercapacitor, adjacent to and extending at least partially along the length of the heating chamber 616, may conform to the shape of the heating chamber 616 (e.g., a tubular shape).

[0140] An analysis of considerations for the phase-change material and thermal insulation layer for the heating portion of the aerosol-generating device 100 described with reference to Figures 1-4, which is configured to heat the aerosol-generating material to generate an aerosol without burning it, will now be described with reference to Figures 7-16. For brevity, features consistent with those of the aerosol-generating device heating portion 102 of Figures 1-4 will not generally be repeated here. However, it should be noted that the teachings may also be applied to the heating portion of the aerosol-generating device 600 described with reference to Figures 6A-6C.

[0141] 7 shows a diagram of an exemplary aerosol-generating device heating portion 702. This configuration of the aerosol-generating heating portion 702 is used to evaluate the effects of different configurations of the phase-change material 722 and thermal insulation layer 724.

[0142] The heating portion 702 includes a heating chamber 716 in which an aerosol-generating substrate (e.g., consistent with that described with reference to FIGS. 3A-3C ) is housed and aerosolized. In some embodiments, the heating chamber 716 is made of or includes stainless steel. The heating chamber 716 has a heater track 718, as described in more detail with reference to FIGS. 8A-8E . The heater track 718 may be encased in a thermally conductive, electrically insulating layer 719, such as Kapton, to provide electrical insulation while dispersing the heater from the heater track. Such a Kapton layer can electrically insulate the heater track from other metal or conductive parts. While Kapton itself as a material can have poor heat transfer properties (thermal conductivity), the layer can be made very thin (e.g., less than 50 μm thick), meaning that heat is conducted to other parts with relatively little loss.

[0143] Optionally, a heat spreading layer 721 may be included. The heat spreading layer 721 may be configured to help spread heat from the heating chamber 716 to the phase change material 722. In some embodiments, the heat spreading layer 721 may be a conductive layer, such as graphite foil. In particular embodiments, the heat spreading layer 721 may have a thickness of about 40 micrometers.

[0144] Similar to that described with reference to Figures 1-4 and 6A-6C, a supercapacitor module 706 comprising one or more supercapacitors is positioned adjacent to and at least partially surrounds the heating chamber 716.

[0145] Layers may be disposed between the supercapacitor module 706 and the heat spreading layer 721 (if included), or the electrical insulation layer 719 (if a heat spreading layer is not included), or the heater track 718 (if neither the heat spreading layer 721 nor the electrical insulation layer 719 is included). The layers surround or at least partially surround the heating chamber. The layers may include one or more thermal insulation layers 724 and one or more phase change material layers 722. In the example of FIG. 7 , there are four thermal insulation layers and one phase change material layer, with two of the thermal insulation layers (labeled 724-1, 724-2) disposed between the phase change material layer 722 and the heating chamber 716 and two thermal insulation layers (labeled 724-3, 724-4) disposed between the phase change material layer 722 and the supercapacitor module 706. 11A-11E, for example, the phase change material 722 may comprise one or more phase change material layers between the heating chamber 716 and the supercapacitor module 706, and the thermal insulation layer 724 may comprise one or more thermal insulation layers arranged in any suitable order between the heating chamber 716 and the supercapacitor module 706.

[0146] In one embodiment, thermal insulation layer 724 can be an aerogel, such as a SiO2-based aerogel. In particular embodiments, thermal insulation layer 724 can be Finesulight. In some embodiments, phase change material 722 can be indium or an indium-based phase change material, a hydrated salt phase change material, an organic solution phase change material, or a solid-solid phase change material.

[0147] Mouthpiece 710 may be attachable to the heating portion. Mouthpiece 710 may be configured for a user to inhale from it. Mouthpiece 710 may be attached to other components of heating portion 702 at a first end of heating portion 702. In one embodiment, mouthpiece 710 may be PEEK. Mouthpiece 702 may be attached to the heating portion by a top cap 711. In one embodiment, top cap 711 may be PEEK. A seal 713 may be disposed between mouthpiece 710 and top cap 711. In one embodiment, seal 713 may be silicone.

[0148] A plug cap 715 may be disposed at a second end of the heating component 702 opposite the first end. In one example, the plug cap may be PEEK.

[0149] An adhesive material 717 such as silicone or glue may be used to hold the heating chamber 716 in place within the heating portion 702 .

[0150] FIG. 8A shows a perspective view of an exemplary layout of a heater track 718 configured to substantially surround a heating chamber and that may be used with the heating portion of FIG. 7 . In this particular example, the heater track 718 is configured to wrap around two opposing major surfaces of the heating chamber and one minor surface connecting the two major surfaces. FIG. 8B shows a perspective view of the heater track 718 encased in an electrically insulating layer 719 (e.g., Kapton). FIG. 8C shows a cross-sectional view of a portion of the heater track 718 encased or encapsulated in the electrically insulating layer 719. In this example, the heater track 718 has a cross-sectional thickness A, and the electrically insulating layer 719 has a cross-sectional thickness B. In a particular example, A may be 5 micrometers and B may be 15 micrometers. FIG. 8D shows a perspective view of the heating chamber 716 and heater track 718 in combination with the mouthpiece 710, with the other layers of the heating portion removed. Figure 8E shows where a temperature probe 723 may be placed on the heating portion. Temperature probes are discussed in more detail with reference to Figures 9-14.

[0151] Figure 9 shows a diagram of a heating section consistent with that described with reference to Figure 7. The heating section of Figure 9 has six layers 930-1, 930-2, 930-3, 930-4, 930-5, 930-6, which may be phase change materials or insulators. Different combinations of phase change materials and thermal insulation layers are discussed with reference to Figures 11A-11E and 12A-12E. To demonstrate the effectiveness of different combinations of phase change materials and thermal insulation layers, temperature probes T1, T2, T3, T4 may be placed between each two of these layers.

[0152] The first layer 930-1 is the phase change material layer or thermal insulation layer closest to the heating chamber 716. After the first layer 930-1, in a direction outward from the heating chamber (i.e., in a radial direction in the heating portion), the phase change material layer or thermal insulation layer closest to the heating chamber is the second layer 930-2. After the second layer 930-2, the phase change material layer or thermal insulation layer closest to the heating chamber 716 in the outward direction is the third layer 930-3. After the third layer 930-3, the phase change material layer or thermal insulation layer closest to the heating chamber 716 in the outward direction is the fourth layer 930-4. After the fourth layer 930-4, the phase change material layer or thermal insulation layer closest to the heating chamber 716 in the outward direction is the fifth layer 930-5. In the outward direction, after the fifth layer 930-5, the layer of phase change material or thermal insulation closest to the heat chamber 716 is the sixth layer 930-6. In other words, if there are six layers of phase change material or insulation, the sixth layer is farther away from the heat chamber 716 in the outward direction from the heat chamber.

[0153] A first temperature probe T1 is placed within the heating chamber 716. A second temperature probe T2 is placed between the second layer 930-2 and the third layer 930-3. A third temperature probe T3 is placed between the fourth layer 930-4 and the fifth layer 930-5. A fourth temperature probe T4 is placed on the outside of the sixth layer 930-6 (outward from the heating chamber 716). The temperature probes may be thermocouples. The first temperature probe may be displaced a distance X into the heating chamber in the axial direction of the heating portion; in one example, X may be 11 mm. The second, third, and fourth temperature probes may then be aligned with the temperature probes such that all temperature measurements are taken at the same axial location on the heating portion.

[0154] FIG. 10 is a plot 1000 of the temperatures 1004 recorded at each of the temperature probes (T1, T2, T3, T4) as a function of time 1002 during an aerosolization session. In this example, all six layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 are thermal insulation layers made from Finesulight, each shrink-wrapped in plastic. As can be seen, throughout the aerosolization session, lower temperatures are observed as the number of thermal insulation layers between the heating chamber 716 and the temperature probes increases (zero layers at T1, two layers at T2, four layers at T3, and six layers at T4). The lowest temperature is observed on the outer surface of the sixth layer 930-6, thereby demonstrating the suitability of placing a supercapacitor module on this surface by leveraging the thermal relief provided by the thermal insulation layers.

[0155] 11A-11E show diagrams of the heating portion of the aerosol-generating device consistent with that of FIG. 9, but with one or more of the thermal insulation layers replaced with phase change material layers. Parametric studies are performed through these different combinations of thermal insulation layers and phase change material layers to determine which combination of thermal insulation layers and phase change material layers provides the most beneficial thermal shielding for the supercapacitor module adjacent to and at least partially surrounding the heating chamber (and the insulation layers and phase change material layers).

[0156] The temperature as a function of time during the aerosolization session at each temperature probe (T1, T2, T3, T4) for each exemplary heating section in Figures 11A-11E is presented in Figures 12A-12E, respectively.

[0157] In the exemplary heating section for the parametric study, the thermal insulation layer is a SiO2-based aerogel (Finesulight), whose parameters are presented in Table 1.

[0158] [Table 1]

[0159] In an exemplary heating section for a parametric study, the phase change material layer is indium, and its parameters are presented in Table 2. Indium phase change material has a melting point of 156° C. and a latent heat of 3.26 kJ / mol=28.35 kJ / kg.

[0160] [Table 2]

[0161] For the parametric study, the heater temperature for the aerosolization session is set to 280°C.

[0162] 11A-11E have different combinations of insulating and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6. In each of these examples, the layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 abut one another in a stacked configuration in the following order, starting with the first layer 930-1 closest to the heating chamber 718 and moving outward: first layer 930-1, second layer 930-2, third layer 930-3, fourth layer 930-4, fifth layer 930-5, and sixth layer 930-6. In these examples, each layer is 0.5 mm thick.

[0163] For each of the heating sections described with reference to FIGS. 11A-11E, FIGS. 12A-12E show plots of temperature 1204 versus time 1202 during an aerosolization session at first temperature probe T1, second temperature probe T2, third temperature probe T3, and fourth temperature probe T4. First temperature probe T1 is located within heating chamber 716. Second temperature probe T2 is located between second layer 930-2 and third layer 930-3. Third temperature probe T3 is located between fourth layer 930-4 and fifth layer 930-5. Fourth temperature probe T4 is located on the outside of sixth layer 930-6 (facing outward from heating chamber 716). For comparison purposes, each plot also shows the temperature of fourth temperature probe T4 as a function of time when no phase change material layer is included (i.e., when six insulating layers are present), as in FIG. 10. Thus, comparisons can be made between different heating sections as described with reference to Figures 11A-11E using the same power in the heater track.

[0164] 11A shows the combination of insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a first exemplary heating portion 1100A. The first layer 930-1 and second layer 930-2 are each thermal insulation layers. The third layer 930-3 is a phase change material layer. The fourth layer 930-4, fifth layer 930-5, and sixth layer 930-6 are each thermal insulation layers. That is, from the heating chamber 718 outward, there are two thermal insulation layers, followed by one phase change material layer, and three additional thermal insulation layers. In this example, each thermal insulation layer is 0.5 mm and the phase change material layers are 0.5 mm, so the phase change material layers have an effective thickness of 0.5 mm and are separated from the heating chamber by 1 mm of thermal insulation. FIG. 12A shows a plot 1200A of temperature 1204 versus time 1202 for each of the first temperature probe T1, the second temperature probe T2, the third temperature probe T3, and the fourth temperature probe T4 in the heating portion 1100A of FIG. 11A.

[0165] 11B shows the combination of insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a second exemplary heating portion 1100B. The first layer 930-1 and the second layer 930-2 are each thermal insulation layers. The third layer 930-3 and the fourth layer 930-4 are each phase change material layers. The fifth layer 930-5 and the sixth layer 930-6 are each thermal insulation layers. That is, from the heating chamber 718 outward, there are two thermal insulation layers, followed by two phase change material layers, and then two more thermal insulation layers. In this example, each thermal insulation layer is 0.5 mm and each phase change material layer is 0.5 mm, so the phase change material layers have an effective thickness of 1 mm and are separated from the heating chamber by 1 mm of thermal insulation. FIG. 12B shows a plot 1200B of temperature 1204 versus time 1202 for each of the first temperature probe T1, the second temperature probe T2, the third temperature probe T3, and the fourth temperature probe T4 in the heating portion 1100B of FIG. 11B.

[0166] 11C shows the combination of insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a third exemplary heating portion 1100C. The first layer 930-1 and the second layer 930-2 are each thermal insulation layers. The third layer 930-3, the fourth layer 930-4, the fifth layer 930-5, and the sixth layer 930-6 are each phase change material layers. That is, from the heating chamber 718 outward, there are two thermal insulation layers followed by four phase change material layers. In this example, each thermal insulation layer is 0.5 mm and each phase change material layer is 0.5 mm, so the phase change material layers have an effective thickness of 2 mm and are separated from the heating chamber by 1 mm of thermal insulation. FIG. 12C shows a plot 1200C of temperature 1204 versus time 1202 for each of the first temperature probe T1, the second temperature probe T2, the third temperature probe T3, and the fourth temperature probe T4 in the heating portion 1100C of FIG. 11C.

[0167] 11D shows the combination of insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a fourth exemplary heating portion 1100D. The first layer 930-1, the second layer 930-2, the third layer 930-3, and the fourth layer 930-4 are each thermal insulation layers. The fifth layer 930-5 is a phase change material layer. The sixth layer 930-6 is a thermal insulation layer. That is, from the heating chamber 718 outward, there are four thermal insulation layers, followed by one phase change material layer, and then one more thermal insulation layer. In this example, each thermal insulation layer is 0.5 mm and the phase change material layers are 0.5 mm, so the phase change material layers have an effective thickness of 0.5 mm and are separated from the heating chamber by 2 mm of thermal insulation. FIG. 12D shows a plot 1200D of temperature 1204 versus time 1202 for each of the first temperature probe T1, the second temperature probe T2, the third temperature probe T3, and the fourth temperature probe T4 in the heating portion 1100D of FIG. 11D.

[0168] 11E shows the combination of insulation layers and phase change material layers 930-1, 930-2, 930-3, 930-4, 930-5, and 930-6 in a fifth exemplary heating portion 1100E. The first layer 930-1, the second layer 930-2, the third layer 930-3, and the fourth layer 930-4 are each thermal insulation layers. The fifth layer 930-5 and the sixth layer 930-6 are phase change material layers. That is, from the heating chamber 718 outward, there are four thermal insulation layers followed by two phase change material layers. In this example, each thermal insulation layer is 0.5 mm and each phase change material layer is 0.5 mm, so the phase change material layers have an effective thickness of 1 mm and are separated from the heating chamber by 2 mm of thermal insulation. FIG. 12E shows a plot 1200E of temperature 1204 versus time 1202 for each of the first temperature probe T1, the second temperature probe T2, the third temperature probe T3, and the fourth temperature probe T4 in the heating portion 1100E of FIG. 11E.

[0169] 12A-12E, as expected, in each case the fourth temperature probe T4, placed on the outside of the sixth layer 930 (facing outward from the heating chamber 716), recorded the lowest temperature.

[0170] In Figure 12A, for the first exemplary heating portion 1100A, the temperature at the fourth temperature probe T4 reaches 98.88°C, which is higher than the maximum temperature at the fourth temperature probe T4 in the control example (i.e., Figure 10) with six insulating layers and no phase change material layer.

[0171] In Figure 12B, for the first exemplary heating portion 1100B, the temperature at the fourth temperature probe T4 reaches 102.28°C, which is higher than the maximum temperature at the fourth temperature probe T4 in the control example (i.e., Figure 10) with six insulating layers and no phase change material layer.

[0172] In Figure 12C, for the first exemplary heating portion 1100C, the temperature at the fourth temperature probe T4 reaches 107.10°C, which is higher than the maximum temperature at the fourth temperature probe T4 in the control example (i.e., Figure 10) with six insulating layers and no phase change material layer.

[0173] In Figure 12D, for the first exemplary heating portion 1100D, the temperature at the fourth temperature probe T4 reaches 98.06°C, which is higher than the maximum temperature at the fourth temperature probe T4 in the control example (i.e., Figure 10) with six insulating layers and no phase change material layer.

[0174] In FIG. 12E, for the fifth exemplary heating portion 1100E, the temperature at the fourth temperature probe T4 reached 89.72°C, which is approximately equal to the maximum temperature at the fourth temperature probe T4 of the control example (i.e., FIG. 10) with six insulating layers and no phase change material layer. However, it is noteworthy that the temperature recorded at the temperature probe T4 during the aerosolization session was consistently lower than that of the aforementioned control example. This demonstrates the benefit of placing an insulator between the phase change material and the heating chamber, and placing the phase change material between the insulator and the supercapacitor module, to protect the supercapacitor module, which at least partially surrounds the heating chamber, from heat flowing from the heating chamber. Therefore, from the parametric study, it can be concluded that the arrangement of the insulating material and phase change material in the fifth exemplary heating portion 1100E provides the most beneficial heat shielding.

[0175] That is, it was determined that the best configuration of the phase change material and insulator is when a phase change material layer with a total thickness of 1 mm is placed next to the supercapacitor module and a thermal insulation layer with a total thickness of 2 mm is placed between the phase change material and the heating chamber. In other words, the total thickness of the thermal insulation layer is approximately twice the total thickness of the phase change material layer in the radial direction of the heating section.

[0176] 11A-11E, where multiple stacked adjacent layers of insulating or phase change material are described, these stacked layers can instead be configured as a single layer of greater thickness, with the important portion being the total thermal mass of the phase change material and the total thickness of the insulating layers. For example, the fifth exemplary heating portion 1100E of FIG. 11E can have one 2 mm thermal insulating layer and one 1 mm phase change material layer, rather than four 0.5 mm thermal insulating layers and two 0.5 mm phase change material layers.

[0177] The parametric studies presented with respect to Figures 11 and 12 use indium as the phase change material. Indium has a high transition temperature as a phase change material and a low latent heat capacity. There are alternative phase change materials to indium, some of which include hydrated salt phase change materials, organic solution phase change materials, and solid-solid phase change materials.

[0178] As discussed, the combination of insulating and phase change material layers of the fifth exemplary heating portion 1105 of Figure 11E provides the best heat shielding for the supercapacitor module at least partially surrounding the heating chamber. As a next step in this work, various phase change materials will replace the indium in the heating portion having insulating and phase change material layers structured according to the fifth exemplary heating portion 1105 of Figure 11E.

[0179] Various phase change materials that have been investigated as alternatives to indium are detailed in Table 3.

[0180] [Table 3]

[0181] Further details about each phase change material (PCM) type can be found below: https: / / www.pcmproducts.net / Phase_Change_Material_Products.htm

[0182] For each of the phase change materials detailed in Table 3, FIGS. 13A-13F show plots of temperature 1304 versus time 1302 during an aerosolization session for first temperature probe T1, second temperature probe T2, third temperature probe T3, and fourth temperature probe T4 in a heating section having an insulating layer and a phase change material layer structured according to the fifth exemplary heating section 1105 of FIG. 11E. The first temperature probe T1 is located within the heating chamber 716. The second temperature probe T2 is located between the second layer 930-2 and the third layer 930-3. The third temperature probe T3 is located between the fourth layer 930-4 and the fifth layer 930-5. The fourth temperature probe T4 is located on the outside of the sixth layer 930-6 (directed outward from the heating chamber 716).

[0183] 13A-13F, as expected, in each case the fourth temperature probe T4, placed on the outside of the sixth layer 930-6 (facing outward from the heating chamber 716), recorded the lowest temperature.

[0184] In FIG. 13A, for the hydrated salt Type 1 phase change material, the temperature at the fourth temperature probe T4 reaches 32° C., which is lower than the maximum temperature at the fourth temperature probe T4 for the indium phase change material in FIG. 12E.

[0185] In FIG. 13B, for the hydrated salt-type two phase change material, the temperature at the fourth temperature probe T4 reaches 48° C., which is lower than the highest temperature at the fourth temperature probe T4 of the indium phase change material in FIG. 12E.

[0186] In FIG. 13C, for the organic solution Type 1 phase change material, the temperature at the fourth temperature probe T4 reaches 43° C., which is lower than the highest temperature at the fourth temperature probe T4 of the indium phase change material in FIG. 12E.

[0187] In FIG. 13D, for the organic solution type two phase change material, the temperature at the fourth temperature probe T4 reaches 48° C., which is lower than the highest temperature at the fourth temperature probe T4 of the indium phase change material in FIG. 12E.

[0188] In FIG. 13E, for the solid-solid Type 1 phase change material, the temperature at the fourth temperature probe T4 reaches 54° C., which is lower than the highest temperature at the fourth temperature probe T4 of the indium phase change material in FIG. 12E.

[0189] In FIG. 13F, for the solid-solid type two phase change material, the temperature at the fourth temperature probe T4 reaches 57° C., which is lower than the highest temperature at the fourth temperature probe T4 of the indium phase change material in FIG. 12E.

[0190] The temperatures recorded at fourth temperature probe T4, located on the exterior of sixth layer 930-6 (direction outward from heating chamber 716), for each of the hydrated salt type 1, hydrated salt type 2, organic solution type 1, organic solution type 2, solid-solid type 1, and solid-solid type 2 phase change materials are lower than the temperatures at the indium phase change material in Figure 12E. This can be seen clearly from Figure 14, which presents temperature 1404 as a function of time 1402 recorded at fourth temperature probe T4 for aerosolization sessions of a heating portion structured as described with reference to Figure 11E using each of the hydrated salt type 1, hydrated salt type 2, organic solution type 1, organic solution type 2, solid-solid type 1, and solid-solid type 2 phase change materials, and the indium phase change material.

[0191] Moreover, the temperature recorded at the fourth temperature probe T4 is also lower than the control example (ie, FIG. 10) using six insulating layers and no phase change material.

[0192] Importantly, for all of these phase change materials, the maximum temperatures recorded at the fourth temperature probe T4 are all generally below the maximum operating temperature of the supercapacitor module.

[0193] These results highlight the advantages of a heating section having an insulating layer and a phase change material layer structured as described with reference to Figure 11E using a hydrated salt phase change material, an organic solution phase change material, or a solid-solid phase change material as the phase change material layer, which is particularly true for hydrated salt Type 1 phase change materials.

[0194] In some examples, the phase change material can include a hydrated salt phase change material, an organic solution phase change material, or a solid-solid phase change material, or a combination of one or more of a hydrated salt phase change material, an organic solution phase change material, or a solid-solid phase change material.

[0195] Figure 15 shows a simulated heat map 1500 of a heating section having an insulating layer and a phase change material layer structured as described with reference to Figure 11E. As can be seen, the temperature adjacent to the heating chamber 716, where the supercapacitor module may be placed, is significantly reduced by providing the insulating layer and the phase change material layer.

[0196] FIG. 16 shows a cross-sectional view of a heating portion having insulating and phase-change material layers structured as described with reference to FIG. 11E, and a supercapacitor module 706 adjacent to and at least partially surrounding the heating chamber. The first layer 930-1, second layer 930-2, third layer 930-3, and fourth layer 930-4 are thermal insulating layers, and the fifth layer 930-5 and sixth layer 930-6 are thermal insulating layers. Beneficially, heating in the region where the supercapacitor module is connected to the heating portion is significantly reduced by the structure of the insulating and phase-change material layers, as discussed. This heat reduction prevents the temperature of the supercapacitor module from reaching temperatures above 55°C to 65°C. This allows the supercapacitor module to be placed adjacent to and at least partially surrounding the heating chamber without being damaged. Positioning the supercapacitor module adjacent to the heating chamber allows for a reduced size of the heating portion, thereby providing a compact aerosol generating device heating portion. This may make it easier for an operator to hold and use, as well as store and transport, thus improving the user experience. Furthermore, providing a phase change material between the heating chamber and the supercapacitor module protects the supercapacitor module from the heat of the heating chamber, thereby allowing the supercapacitor module to be closer to the heating chamber, contributing to a reduction in device size. The phase change material also inhibits heat transfer from the heating chamber to the outer shell of the device, thereby improving the operability of the device.

[0197] The aerosol generating devices described herein have been described as two-part devices having a heating portion and an auxiliary power portion. However, in an alternative embodiment, these aerosol generating devices may be configured as one-part devices in which the heating portion and the auxiliary power portion are formed as a single device. In such devices, the supercapacitor module is adjacent to and / or at least partially surrounds the heating chamber, and a phase change material is disposed between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module. This allows for a compact device because the supercapacitor module can be located adjacent to the heating chamber rather than separate from it. The battery module can be located separately from the heating chamber within the device to avoid damage to the battery and maintain the safety of the device.

[0198] The embodiments described above are not limiting, and it will be readily apparent to those skilled in the art that the features of each embodiment may be incorporated into other embodiments as appropriate.

[0199] In the foregoing examples, the processing steps described herein performed by the controllers or control electronics may be stored on non-transitory computer-readable media or storage devices associated with the respective controllers or control electronics. Computer-readable media may include non-volatile media and volatile media. Volatile media may include semiconductor memory and dynamic memory, among others. Non-volatile media may include optical and magnetic disks, among others.

Claims

1. 1. An aerosol-generating device heating portion configured to generate an aerosol from an aerosol-generating substrate, comprising: a heating chamber configured to contain the aerosol-generating substrate; and a supercapacitor module adjacent to the heating chamber configured to power a heater associated with the heating chamber; a phase change material disposed between the heating chamber and the supercapacitor module to separate the heating chamber from the supercapacitor module.

2. The aerosol generating device heating portion of claim 1 , wherein the phase change material at least partially surrounds the heating chamber.

3. The heating portion of the aerosol generating device according to claim 1 or 2, wherein the supercapacitor module at least partially surrounds the heating chamber.

4. The aerosol generating device heating portion of claim 3 , wherein the supercapacitor module is adapted to the shape of the heating chamber.

5. The heating portion of an aerosol generating device described in any one of claims 1 to 4, wherein the supercapacitor module comprises two supercapacitors, the two supercapacitors being arranged on either side of the heating chamber so as to at least partially surround the heating chamber.

6. The heating portion of the aerosol generating device according to any one of claims 1 to 5, wherein the heating chamber is planar in shape and configured to accommodate a planar aerosol generating substrate.

7. The heating portion of the aerosol generating device according to any one of claims 1 to 5, wherein the heating chamber is cylindrical in shape and configured to accommodate a rod-shaped aerosol-generating substrate.

8. The heating portion of the aerosol-generating device according to claim 7 , wherein the rod-shaped aerosol-generating substrate is a tobacco rod.

9. The aerosol generating device heating portion according to any one of claims 1 to 8, wherein the heater is integrated in or on a side wall of the heating chamber.

10. The aerosol generation device heating portion according to any one of claims 1 to 9, further comprising control electronics integrated into a flexible circuit board.

11. The heating portion of the aerosol generating device according to any one of claims 1 to 10, wherein the phase change material is substantially indium-based.

12. The aerosol generating device according to any one of claims 1 to 10, wherein the phase change material comprises a hydrated salt phase change material.

13. The aerosol generating device according to any one of claims 1 to 10, wherein the phase change material comprises an organic solution phase change material.

14. The aerosol generating device according to any one of claims 1 to 10, wherein the phase change material comprises a solid-solid phase change material.

15. The aerosol generating device heating portion according to any one of claims 1 to 14, further comprising a thermal insulating layer disposed between the heating chamber and the phase change material.

16. 16. The aerosol generating device of claim 15, wherein the thermal insulation layer has a total thickness in a radial direction of the aerosol generating device heating portion that is approximately twice the total thickness of the phase change material.

17. 17. An aerosol generating device as described in claim 15 or 16, wherein the phase change material is approximately 1 mm thick and the thermal insulation layer is at least 1 mm thick, or preferably the thermal insulation layer is 1.5 mm thick, or more preferably the thermal insulation layer is 2 mm thick, or the thermal insulation layer is at most 3 mm thick.

18. The aerosol generating device according to any one of claims 15 to 17, wherein the thermal insulation layer comprises a plurality of insulating layers.

19. The aerosol generating device according to any one of claims 15 to 18, wherein the thermal insulation layer comprises an aerogel.

20. 20. The aerosol generating device according to claim 1, wherein the phase change material comprises multiple layers of phase change material.

21. the aerosol generation device heating portion further comprises a first temperature sensor configured to monitor a temperature of a heater of the heating chamber and a second temperature sensor configured to monitor a temperature of the phase change material; The aerosol generating device heating portion of any one of claims 1 to 20, wherein the controller of the aerosol generating device heating portion is configured to recalibrate the monitored temperature of the heater based on determining that the phase change material has reached a melting temperature and that at the melting temperature the monitored temperature of the phase change material has substantially plateaued based on a predetermined relationship between the temperature of the heater and the melting temperature of the phase change material.

22. 22. An aerosol generating device comprising the aerosol generating device heating portion according to claim 1, further comprising an auxiliary power supply portion, the auxiliary power supply portion comprising a battery module; An aerosol generation device, wherein the auxiliary power supply portion is removably connectable to the heating portion, and when connected, the battery module is configured to charge the supercapacitor module via an electrical connection between the heating portion and the auxiliary power supply portion.

23. 23. The aerosol generation device of claim 22, wherein the battery module is configured to power the heater associated with the heating chamber when the auxiliary power supply portion is connected to the heating portion by the electrical connection between the heating portion and the auxiliary power supply portion.

Images