Aerosol generation system with improved electronics arrangement

Abstract

An aerosol generating system comprising a case including a moldable material and a processing circuit having at least one controller and at least one conductive trace, wherein at least one of the controller and the trace is at least partially embedded within the moldable material of the case.

Description

[Technical Field]

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

[0002] Aerosol-generating devices are typically designed as handheld devices that a user can use to consume or experience the aerosol generated by heating an aerosol-generating substrate or aerosol-generating article, for example, in one or more use sessions. The aerosol-generating devices to which this disclosure relates are commonly referred to as heated tobacco products (HTPs), heat-not-burn devices, electronic cigarettes, and / or vaporizers.

[0003] Exemplary aerosol-generating substrates may include solid substrate materials, such as tobacco or tobacco cast leaf (TCL) materials. The substrate material, for example, can often be assembled with other elements or components to form a substantially rod-shaped aerosol-generating article. Such rods or aerosol-generating articles may be configured in a shape and size to be at least partially inserted into an aerosol-generating device. The aerosol-generating system may include a heating element or heater device for heating the aerosol-generating article and / or the aerosol-generating substrate. The heating element or heater device may be part of the aerosol-generating article and / or the aerosol-generating device. Alternatively or additionally, the aerosol-generating substrate may include one or more liquids and / or solids that can be supplied to the aerosol-generating device, for example, in the form of a cartridge or container. Corresponding exemplary aerosol-generating articles may include, for example, a cartridge containing or fillable with a liquid and / or solid substrate, which can vaporize during aerosol consumption by a user upon heating of the substrate and / or liquid. Typically, such a cartridge or container can be coupled, attached, or at least partially inserted into the aerosol-generating device. Alternatively, the cartridge may be fixedly attached to the aerosol-generating device and refilled by inserting liquids and / or solids into the cartridge. The aerosol generated from the aerosol-generating substrate or article may comprise or include one or more of nicotine, aroma, sugar, humectant, preservative, flavoring agent, such as cocoa, licorice, menthol, and lactic acid, or other additives.

[0004] To generate an aerosol during use or consumption, heat can be supplied by a heating element, heater device, or heat source to heat at least a portion or parts of the aerosol-generating substrate. The heating element, heater device, or heat source can be disposed in the handheld device or the handheld portion of the aerosol-generating device. Alternatively or additionally, at least a portion or the entire heating element, heater device, or heat source can be fixedly associated with or disposed within the aerosol-generating article, for example in the form of a wand or cartridge that can be attached to and / or powered by the handheld device or the handheld portion of the aerosol-generating device.

[0005] Exemplary heating elements or heater devices may be based on one or more of resistive heating, inductive heating, and microwave heating using electrical energy supplied via, drawn from, or stored in the aerosol-generating device's battery. As used herein, the aerosol-generating device's battery may generally refer to an energy storage unit of the aerosol-generating device configured to store electrical energy. Thus, the term battery may include one or more capacitors, one or more accumulators, or other types of energy storage units. Also, any reference herein to a battery may include multiple batteries.

[0006] Typically, the aerosol-generating device comprises an energy storage unit, e.g., a battery, which provides the electrical energy required to operate the aerosol-generating device, in particular to heat the aerosol-generating substrate and / or article, e.g., to generate aerosol using one or more aerosol-generating articles for one or more use sessions. The battery may, for example, be a lithium-ion battery.

[0007] As used herein, a use session may refer to a period of time during which a user may use an aerosol-generating device to generate, consume, experience, or inhale aerosol. A use session may be finite. In other words, a use session may have a beginning, an end, and a duration. The duration of a use session, as measured by time, may be affected by use during the use session. The duration of a use session may have a maximum duration determined by the longest time from the start of the use session. If one or more monitored parameters reach a predetermined threshold before the longest time from the start of the use session, the duration of the use session may be shorter than the maximum time. As an example, the one or more monitored parameters may include one or more of i) the cumulative number of puffs in a series of puffs taken by the user since the start of the use session, and ii) the cumulative volume of aerosol emitted from the aerosol-forming substrate since the start of the use session.

[0008] The battery capacity may typically be selected so that the aerosol generating device can provide the user with at least a minimum number of consecutive use sessions or experiences, e.g., at least two or more, without the need to recharge the battery or the aerosol generating device in between. To improve the user experience, the aerosol generating device is typically configured to allow the user to initiate a use session only if the battery contains sufficient electrical energy to fully complete the use session. Battery capacity may degrade over time due to accumulated charge / discharge cycles. It is generally desirable to provide the user with as many use sessions as possible without the need to recharge the device, even when the battery has already degraded. Therefore, it is desirable to implement an energy storage unit, e.g., a battery, with as high a capacity as possible in the aerosol generating device. The capacity is typically limited by the size of the energy storage unit and / or the aerosol generating device. If the energy storage unit is increased, for example, by providing a larger battery, the aerosol generating device may become bulky and / or cumbersome, which may detract from the user experience.

[0009] It may therefore be desirable to provide an aerosol generating device with an improved user experience, for example, by optimizing the relationship of energy storage capacity to the overall size of the aerosol generating device.

[0010] This is achieved by the subject matter of the independent claims. Optional features are provided by the dependent claims and the description. Summary of the Invention

[0011] According to one aspect of the present invention, an aerosol generation system is provided, comprising a case or housing comprising a moldable material, and a processing circuit comprising at least one controller and at least one conductive trace, wherein at least one of the controller and the trace is at least partially embedded in the moldable material of the case.

[0012] The aerosol generating system may include an energy storage unit for storing electrical energy, e.g., a battery or battery pack, wherein the case at least partially encloses the energy storage unit, and preferably the energy storage unit is removable and / or replaceable by the user. To this end, the case may include an opening, preferably having a removable lid, through which the energy storage unit may be removed or inserted. The case may further include electrical contacts configured to electrically connect the energy storage unit to the rest of the system when a battery is inserted into the case through the opening.

[0013] The aerosol generating system may have a longitudinal axis in the direction of the maximum extension of the aerosol generating system. The longitudinal axis may be parallel to the direction in which the aerosol-generating article is inserted into and / or extracted from the aerosol generating system. The case may have at least one wall surface. The wall surface may, for example, at least partially or completely surround the energy storage unit in at least one of the axial and radial directions of the longitudinal axis. The wall surface of the case may comprise, include, or be at least partially made of a moldable material. The moldable material need not be moldable during operation of the aerosol generating system, but may be moldable only during manufacture of the aerosol generating system. In other words, the case may be at least partially formed from a moldable material during manufacture of the aerosol generating system. The moldable material may then be hardened to provide a case that can withstand the physical strains of operation of the aerosol generating system and does not easily break or deform. The moldable material may, for example, comprise, include, or be at least one of a thermosetting plastic, for example, a thermoplastic material, and a ceramic material.

[0014] The controller may comprise, include, or be, for example, a microcontroller. It may comprise or include at least one of data storage, e.g., memory, and programmable input / output peripherals. The conductive traces may be configured to electrically connect the controller to other electrical components of the aerosol generation system, for example, via the input / output peripherals.

[0015] In conventional aerosol generating systems, at least one of the controller and the conductive traces is typically disposed on a printed circuit board (PCB). The PCB comprises electrical components, i.e., at least the controller and the conductive traces, as well as a substrate on which the electrical components are disposed. Therefore, such a PCB is a separate component that needs to be inserted into the case of the aerosol generating system. Typically, the PCB and its components, such as the controller, are so large that disposing the PCB and the energy storage unit of the aerosol generating system at the same spot along the longitudinal axis is mutually exclusive. In other words, in the sector along the longitudinal axis where the PCB is disposed, conventionally, there is not enough space for the energy storage unit components, and vice versa. Therefore, for a given total size of the aerosol generating system, the size of the energy storage unit is limited by the space available for the PCB.

[0016] According to the present disclosure, a PCB may no longer be required. At least one or both of the controller and the conductive traces are at least partially disposed and / or embedded in the moldable material of the case itself. Thus, the case of the aerosol generation system may directly function as a substrate on which and / or within which the electrical components, i.e., the controller and / or the conductive traces, are disposed. By embedding the electrical components in the moldable material of the case, a separate substrate, e.g., in the form of a PCB, may not be required to dispose these components within the aerosol generation system. Thus, the aerosol generation system according to the present disclosure may be implemented without using a separate substrate to dispose the electrical components on the PCB, i.e., without a PCB. The space saved herein may be used, for example, to accommodate a larger energy storage unit.

[0017] Also, according to the present disclosure, by at least partially embedding at least one of the controller and the traces in the moldable material of the case, the extent to which these electrical components protrude from the case or the surface of the case may be reduced. In other words, the dimensions of the parts of the electrical components that protrude from the case or the surface of the case may be smaller because the electrical components are at least partially disposed inside the material or thickness of the case. Thus, the electrical components may be embedded in the material and / or thickness of the case. Thus, at least one of the controller and the conductive traces may be embedded within the moldable material of the case. This may be achieved by a process that includes molding these components into the moldable material of the case. Specifically, at least one of the controller and the conductive traces may be molded within the material of the case. As used herein, the terms "embedding" or "embedded" may mean that the respective components are disposed at least partially surrounded by the material of the case. This arrangement may be achieved by at least partially forming and / or molding the case around the respective electrical components while the material of the case is still moldable. Through this process, contact surfaces of the material of the case and the electrical components may be in intimate contact with each other. However, this intimate contact is not achieved by inserting parts of the electrical component into the case when the case material is not moldable. For example, components that are glued, clamped, soldered, welded, fused, screwed, bolted, or nailed into and / or onto the case are not "embedded" in the moldable material of the case within the meaning of this disclosure. The electrical component may be partially or completely embedded in the moldable material of the case. Partially embedded may mean that the electrical component is embedded or submerged within the material, for example, surrounded by material on at least two sides. At least one side of the component may be free of moldable material and therefore accessible from outside the material. Completely embedded may mean that the electrical component is surrounded by material on all sides.Thus, the component may be arranged such that it is completely covered by the moldable material and is therefore not accessible from outside the moldable material.

[0018] Thus, the electrical components, i.e., the controller and / or conductive traces, may be arranged in a space-efficient manner within the case of the aerosol generation system. This is further improved in that the electrical components may be arranged on and / or within the case in a manner that conforms to the shape of the case's wall surfaces. For example, the case may include curved and / or angled wall surfaces. Thus, the electrical components may be arranged on and / or within the case in accordance with the curved and / or angled surfaces of the case.

[0019] In particular, the controller may have significant spatial extension, for example, in one or more of thickness, width, and length. Therefore, at least partially embedding the controller in the material of the case may free up space inside the case that would traditionally be consumed by a bulky controller and / or PCB. The arrangement according to the present disclosure may save space to the extent that at least one controller and energy storage unit may overlap each other in a radial direction of the longitudinal axis of the aerosol generation system. Overlapping each other in a radial direction of the longitudinal axis of the aerosol generation system may mean that the controller and energy storage unit follow each other in a radial direction of the longitudinal axis, with the controller preferably being disposed further away from the longitudinal axis than the energy storage unit. In other words, at least one controller and energy storage unit may be disposed at the same height or level in a longitudinal direction of the aerosol generation system. Thus, the energy storage unit may extend along the longitudinal axis of the aerosol generation system, even in a section along the longitudinal axis where the controller may be disposed. For a given total size of the aerosol generating system, this can lead to a significantly larger energy reservoir, increasing its capacity.

[0020] Of all the electrical components of the aerosol generation system, the controller may be the one with the largest spatial dimension. Typically, the controller may have a rectangular base shape with a variable thickness, but any other shape is possible. The controller may have a direction of maximum extension, for example, along the longer side of the rectangular base shape. As already mentioned, the case may have curved or angled wall surfaces. The most space can be saved by the present disclosure when the electrical components, especially the controller, follow the shape of the case as closely as possible. For this purpose, it may be provided that at least one controller of the processing circuit is disposed on the case, preferably on the inner wall of the case, so that the direction of maximum extension of the controller is oriented parallel to the longitudinal axis of the aerosol generation system. In the present disclosure, the maximum extension may be oriented along one of the sides of the base shape of the component in question. This means, for example, that even if the diagonal of a rectangular base shape is longer than the longer side of the rectangle, the diagonal may be exempt from being the direction of maximum extension within the meaning of the present disclosure. With a rectangular base shape, the longer side of the rectangle may still be the maximum extension within the meaning of the present disclosure. This feature may also be applied to any one or more of the additional electrical components of the aerosol generation system mentioned herein, such as the sensor, the controller subunit, and the heater device, which may also be disposed on the case, preferably on the inner wall of the case, such that the direction of the maximum extension of each component is oriented parallel to the longitudinal axis of the aerosol generation system.

[0021] To maximize the saved space inside the case, other electrical components of the aerosol generation system, preferably all electrical components except the energy storage unit and the heater blades, may also be at least partially embedded in the moldable material of the case. For each of these components, all of the features described herein for the controller and / or conductive traces may also be applicable. For example, the processing circuit may include at least one sensor, preferably one or more of a temperature sensor, a strain sensor, and an accelerometer, and the at least one sensor may be at least partially embedded in the moldable material of the case.

[0022] As already mentioned, the controller may be the electrical component with the largest dimensions (excluding the energy storage unit). Therefore, it may be provided that the controller is broken down into smaller subunits with smaller spatial dimensions. These subunits may be arranged separately and independently from each other on the case, but may also be connected, for example, via traces, so that they together form and / or function as one single controller. Therefore, it may be provided that the controller includes at least two controller subunits, each of which is individually at least partially embedded within the moldable material of the case. By dividing the controller into subunits with smaller dimensions, more space can be saved inside the case. Furthermore, by dividing the controller into subunits, the subunits can be arranged on the surface walls of the case, more closely following the shape of the case than would be possible with one single, larger controller.

[0023] The capacity of the energy storage unit may depend significantly on its temperature. Because the aerosol generation system includes a heater device for heating the aerosol-generating article during aerosol generation, the energy storage unit of the aerosol generation system may be adapted to high temperatures. Therefore, particularly low temperatures may impair the performance of the energy storage unit. To prevent the temperature of the energy storage unit from becoming too low, the aerosol generation system may include an energy storage unit heater, such as a resistive energy storage unit heater, configured to heat the energy storage unit, and the energy storage unit heater may be at least partially embedded within the moldable material of the case. The aerosol generation system may also include at least one temperature sensor capable of sensing the temperature of the energy storage unit. If the sensed temperature of the energy storage unit is too low or falls below a predetermined lower threshold temperature, the energy storage unit heater is activated to heat the energy storage unit, preferably until the temperature of the energy storage unit reaches a predetermined higher threshold temperature. The predetermined lower and upper threshold temperatures may be selected to keep the energy storage unit within an optimal temperature range for optimal performance.

[0024] To increase the efficiency of the energy storage heater, the moldable material of the case may include a heat spreader. The heat spreader may include a thermally conductive material. The heat spreader may include, for example, at least one of a moldable ceramic material, a metal, preferably copper, and a coating, preferably a non-conductive coating and / or a non-thermally conductive coating. The heat spreader may be disposed to at least partially surround the energy storage unit so that heat generated by the energy storage heater can be distributed as uniformly as possible within the energy storage unit. The heat spreader may be part of the moldable material of the case so that the electrical components described herein can be at least partially embedded within the heat spreader. Thus, the heat spreader may be part of the case or part of the moldable material of the case. Thus, the heat spreader may be manufactured and molded together with the case in the same manufacturing process. This ensures a uniform shape and uniform heat distribution, for example, from the energy storage heater.

[0025] On the other hand, some of the electrical components of the aerosol generation system, particularly the controller, may perform better when not heated or heated as little as possible by the energy storage heater. Therefore, the case may include an unheated area that is free of and / or spaced apart from the energy storage heater and / or heat spreader, and the controller and at least one of the additional electrical components may be disposed within the unheated area. The additional electrical component may be any of the electrical components of the aerosol generation system mentioned in this disclosure. In other words, in the unheated area, the moldable material of the case may not include a heat spreader. Furthermore, in the unheated area, there may not be an energy storage heater embedded in the moldable material of the case. By disposing temperature-sensitive electrical components, such as the controller, in the unheated area, the performance of these components may be improved.

[0026] The case of the aerosol generating system may at least partially enclose an interior space for the energy storage unit of the aerosol generating system. The case and / or the wall surface of the case may be shaped so that the interior space may be a cylinder, an elliptical cylinder, a cube, a rectangular parallelepiped, a polyhedron, or any other suitable shape or mixture of shapes. At least one of the controller and the trace may be at least partially embedded in a surface of the case facing the interior space and / or the energy storage unit. In other words, at least one of the controller and the trace may be at least partially embedded in an inner wall surface of the case. Thus, electrical components protruding from the case may protrude toward the interior space, for example, toward the energy storage unit.

[0027] The case may be formed, for example, so that the interior space has the shape of a cylinder or elliptical cylinder with an additional flat surface extending in the direction of the cylindrical axis. The cylindrical axis may be parallel to the longitudinal axis of the aerosol generation system. In such an arrangement, the electrical components may be disposed on and at least partially embedded in the flat surface of the case. In other words, the case may have rounded and flat surfaces in a plane perpendicular to the longitudinal axis of the aerosol generation system, the rounded and flat surfaces connected to each other and together enclosing the interior space, with at least one of the controller and traces being at least partially embedded in the flat surface. It may be particularly advantageous to dispose the electrical component, preferably the controller, on the flat surface next to the connection to the rounded surface. Thus, the electrical component may be disposed eccentrically on the flat surface, for example, offset in the direction of intersection of the flat and rounded surfaces. Because the aerosol generation system may use a cylindrical energy storage unit, the area where the flat and rounded surfaces meet may provide space that may be beneficially used by electrical components that at least partially protrude from the case.

[0028] In particular, for controllers with large dimensions, it may be beneficial to arrange the controller axially offset from the energy storage unit along the longitudinal axis of the aerosol generation system, with the controller oriented so that its plane or surface of maximum extension is perpendicular to said longitudinal axis. In other words, the controller and the energy storage unit may not overlap in the radial direction of the longitudinal axis. In contrast, the controller and the energy storage unit may follow each other in the direction of the longitudinal axis. The controller may be oriented so that its maximum extension is perpendicular to the longitudinal axis. For example, the controller may be embedded in a moldable material of a portion of the case that is also oriented perpendicular to the longitudinal axis. In this arrangement, the controller may be embedded or embedded in the moldable material of the case in the direction of the longitudinal axis, thereby increasing the available space for the energy storage unit.

[0029] The aerosol-generating system may include a heating element for heating an aerosol-generating substrate or article, e.g., for generating an aerosol for consumption by a user. The heating element may include a heating blade configured to be inserted into the aerosol-generating substrate or article, and a resistance heater or induction coil. Thus, the heating blade may be disposed to extend into the interior space of the case so as to penetrate into the aerosol-generating substrate or article inserted into the interior space. The heating blade may be configured to heat the aerosol-generating substrate or article from the inside of the substrate or article. The heating blade may comprise a moldable material, and the resistance heater or induction coil may be at least partially embedded in the moldable material of the heating blade. In this way, the heating blade may be thinner than usual, allowing for larger aerosol-generating substrates or articles.

[0030] Additionally or alternatively, the aerosol-generating system may include a heating element for heating the aerosol-generating substrate or article, which may include a resistance heater or an induction coil, which may be at least partially embedded within the moldable material of the case. The heating element may be disposed to at least partially surround the interior space, and may thus be configured to heat the aerosol-generating substrate or article from outside the substrate or article. Thus, an aerosol-generating substrate or article inserted into the interior space of the case is also at least partially inserted within and / or surrounded by the heating element.

[0031] The heat generated by the one or more heating elements to heat the aerosol-generating substrate or article needs to be directed toward the substrate or article while avoiding heat transfer to the outside of the case, so as not to lead to an uncomfortable temperature in the case for the user holding the aerosol-generating system, or even to burns to their hands. Therefore, the case may include a thermal insulator, which may be disposed at least partially surrounding the one or more heating elements. Thus, the thermal insulator may be disposed between the one or more heating elements and the outer surface of the case.

[0032] One or more heating elements and the case may be configured as a single, integrated unit. For example, the heating blade and / or the heating element embedded in the heating blade may be configured as a single, integrated unit with the case. This means that one or more heating elements, e.g., the heating blade, may be manufactured together with the case and in the same molding process as the case. The moldable material of the case and one or more heating elements, e.g., the heating blade, may therefore be a single, continuous unit. This may, on the one hand, reduce manufacturing costs. On the other hand, because the one or more heating elements are not produced as separate units, they do not need to be separately mounted within the case of the aerosol generating system, eliminating the need for separate, additional mounting means. This also saves space within the case, which can then be used for other components, e.g., energy storage.

[0033] Another electrical component that may be advantageously embedded in the moldable material of the case may be, for example, an input device for receiving a control signal from a user. Thus, the aerosol generation system may include an input device for receiving a control signal, the input device may be configured as a capacitive button, and the input device may be at least partially embedded in the moldable material of the case. The input device may be disposed on an outer surface of the case facing away from the interior space.

[0034] Another electrical component that may be advantageously embedded in the moldable material of the case may be an electrical connector for establishing an electrical connection to an external device. Thus, the aerosol generation system may include an electrical connector for establishing an electrical connection to an external device, and the electrical connector may be at least partially embedded in the moldable material of the case. The electrical connector may be configured to establish an electrical connection to, for example, a companion device, a smartphone, a personal computer, or other suitable device.

[0035] Another electrical component that may be advantageously embedded in the moldable material of the case may be an electric field-generating component. Thus, the aerosol generation system may include at least one electric field-generating component, preferably a wireless charging coil or antenna, which may be at least partially embedded within the moldable material of the case. The at least one electric field-generating component may be configured to establish a wireless data connection to an external device, such as a companion device, smartphone, personal computer, or other suitable device. Thus, the at least one electric field-generating component may be part of the communication device of the aerosol generation system.

[0036] To further simplify the manufacture of the aerosol generating system, the processing circuit may comprise printed components. For example, traces may be printed using conductive and flexible ink. However, more complex electrical components, such as the capacitive buttons described above, may also be provided as printed components. The printed components may be printed directly onto the moldable material of the case. A separate PCB may not be required. This may also save space inside the case, as printed components typically have a reduced thickness compared to conventional components.

[0037] As mentioned above, the use of a PCB can lead to unnecessary waste of space within the interior space of the case. While it is already advantageous to reduce the size of the PCB by directly embedding some of the electrical components of the aerosol generation system in the moldable material of the case, it may be desirable to omit the PCB entirely. Thus, it may be provided that the processing circuitry is disposed exclusively on the case of the aerosol generation system. Thus, the aerosol generation system may not include a separate printed circuit board. All of the electrical components of the aerosol generation system may be disposed on the case, and a separate, additional substrate for the electrical components may not be required. This may lead to the greatest possible space savings compared to conventional systems.

[0038] In the direction of the longitudinal axis of the aerosol generation system, the energy storage unit cannot extend over the entire aerosol generation system because other components may require space. However, an arrangement according to the present disclosure may provide that the energy storage unit extends over at least one of 50%, 55%, 60%, 65%, 70%, 75%, or 80% of the total extension of the aerosol generation system along the longitudinal axis of the aerosol generation system. The energy storage unit may be configured, for example, as a cylindrical battery, preferably arranged with its cylindrical axis parallel to the longitudinal axis of the aerosol generation system.

[0039] According to one aspect of the present disclosure, an aerosol generation system includes one or more of an aerosol generation device configured to generate an aerosol and a companion device configured to provide electrical energy to the aerosol generation device. The companion device may include an energy storage unit with a larger capacity than the aerosol generation device, for example, so that the companion device can be used to recharge the aerosol generation device several times. The companion device may include an opening through which the aerosol generation device can be at least partially received during charging.

[0040] One or more of the energy storage unit, the controller and traces as well as the processing circuitry, the case, and any or all of the additional components and electrical components mentioned in this disclosure for the aerosol generation system may be part of the aerosol generation device and / or companion device, and the particular arrangements of electrical components in the aerosol generation system described in this disclosure may also be applied to the aerosol generation device and / or companion device.

[0041] In certain cases, for example, an aerosol generation system may comprise an aerosol generation device. All arrangements, features, functions, and advantages described for the aerosol generation system herein may apply to the aerosol generation device in this case, and vice versa. In another specific case, for example, an aerosol generation system may comprise a companion device. All arrangements, features, functions, and advantages described for the aerosol generation system herein may apply to the companion device in this case, and vice versa. In another specific case, for example, an aerosol generation system may comprise an aerosol generation device and a companion device. All arrangements, features, functions, and advantages described for the aerosol generation system herein may apply to the aerosol generation device and / or the companion device in this case, and vice versa.

[0042] The aerosol-generating system may further comprise an aerosol-generating article, which may be configured to generate an aerosol from the article. The aerosol-generating article may be configured as described herein, for example, to comprise an aerosol-generating substrate or a cartridge containing an aerosol-generating liquid. [Example]

[0043] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0044] Example 1 1. An aerosol generating system comprising: a case including a moldable material; a processing circuit comprising at least one controller and at least one conductive trace; An aerosol generation system, wherein at least one of the controller and the trace is at least partially embedded within the moldable material of the case. Example 1A. An aerosol generation system as described in Example 1, wherein the system includes an energy storage unit for storing electrical energy, the case at least partially enclosing the energy storage unit, and preferably the energy storage unit being removable and / or replaceable by the user. Example 2. The aerosol generation system of any of Examples 1 to 1A, wherein at least one of the controller and energy storage unit of the aerosol generation system overlap each other in a radial direction of the longitudinal axis of the aerosol generation system. Example 3. An aerosol generation system described in any of Examples 1 to 2, wherein at least one controller of the processing circuit is arranged on the case, preferably on the inner wall of the case, so that the direction of the controller's maximum extension is oriented parallel to the longitudinal axis of the aerosol generation system. Example 4. An aerosol generation system described in any of Examples 1 to 3, wherein the processing circuit includes at least one sensor, preferably one or more of a temperature sensor, a strain sensor, and an accelerometer, and the at least one sensor is at least partially embedded within the moldable material of the case. Example 5. An aerosol generation system as described in any of Examples 1 to 4, wherein the controller comprises at least two controller subunits, each of the at least two controller subunits being individually at least partially embedded within the moldable material of the case. Example 6 6. An aerosol generation system according to any one of Examples 1 to 5, comprising an energy storage heater configured to heat an energy storage unit of the aerosol generation system, the energy storage heater being at least partially embedded within the moldable material of the case. Example 7 An aerosol generating system according to any one of Examples 1 to 6, wherein the moldable material of the case comprises a heat spreader, preferably the heat spreader comprises at least one of a moldable ceramic material, a metal, preferably copper, and a coating. Example 8 An aerosol generation system described in any of Examples 6 to 7, wherein the case has a non-heated area that is free of and / or separated from the energy storage heater and / or heat spreader, and the controller and at least one of the additional electrical components are arranged within the non-heated area. Example 9. An aerosol generation system described in any of Examples 1 to 8, wherein the case at least partially encloses an internal space for the energy storage unit of the aerosol generation system, and at least one of the controller and the trace is at least partially embedded in a surface of the case facing the internal space. Example 10. An aerosol generation system as described in Example 9, wherein the case has rounded and flat surfaces in a plane perpendicular to the longitudinal axis of the aerosol generation system, the rounded and flat surfaces connected to each other and together enclosing an internal space, and at least one of the controller and traces being at least partially embedded in the flat surface. Example 11 An aerosol generation system as described in any of Examples 1 to 10, wherein the controller is disposed axially offset from the energy storage unit of the aerosol generation system along the longitudinal axis of the aerosol generation system, and the controller is oriented so that the plane of its greatest extension is perpendicular to the longitudinal axis. Example 12 An aerosol generating system as described in any of Examples 1 to 11, comprising a heating element for heating an aerosol-generating substrate or article, the heating element comprising a heating blade configured to be inserted into the aerosol-generating substrate or article, and a resistive heater, the heating blade comprising a moldable material, and the resistive heater being at least partially embedded within the moldable material of the heating blade. Example 13 13. The aerosol-generating system of any one of Examples 1 to 12, further comprising a heating element for heating the aerosol-generating substrate or article, wherein the heating element comprises a resistive heater, and wherein the resistive heater is at least partially embedded within the moldable material of the case. Example 14. 14. The aerosol generating system according to any one of Examples 12 to 13, wherein the case includes a thermal insulator, and the thermal insulator is disposed so as to at least partially surround the heating element. Example 15. 15. The aerosol generating system according to any one of Examples 12 to 14, wherein the heating element and the case are configured as a single integrated unit. Example 16. An aerosol generation system described in any of Examples 1 to 15, comprising an input device for receiving a control signal, the input device being configured as a capacitive button, and the input device being at least partially embedded within the moldable material of the case. Example 17. An aerosol generation system described in any of Examples 1 to 16, comprising an electrical connector for establishing an electrical connection to an external device, the electrical connector being at least partially embedded within the moldable material of the case. Example 18. 18. An aerosol generation system according to any one of Examples 1 to 17, comprising at least one electric field-generating component, preferably a wireless charging coil or antenna, wherein the electric field-generating component is at least partially embedded within the moldable material of the case. Example 19. 19. The aerosol generating system of any one of Examples 1 to 18, wherein the processing circuitry comprises printed components. Example 20. 20. The aerosol generation system of any of Examples 1 to 19, wherein the processing circuitry is disposed exclusively on the casing of the aerosol generation system, and preferably does not include a separate printed circuit board. Example 21. An aerosol generation system as described in any of Examples 1 to 20, wherein the energy storage unit is configured as a cylindrical battery and extends along the longitudinal axis of the aerosol generation system over at least one of 50%, 55%, 60%, 65%, 70%, 75%, or 80% of the total extension of the aerosol generation system. Example 22. an aerosol generation device configured to generate an aerosol; and a companion device configured to provide electrical energy to the aerosol generation device. Example 23. An aerosol generation system according to any one of Examples 1 to 22, wherein one or more of the energy storage unit, processing circuitry, and case of the aerosol generation system are part of the aerosol generation device or a companion device. Example 24. 24. An aerosol-generating system according to any one of Examples 1 to 23, further comprising an aerosol-generating article, wherein the aerosol-generating system is configured to generate an aerosol from the article. [Brief explanation of the drawings]

[0045] The embodiments will now be further described with reference to the figures.

[0046] [Figure 1] FIG. 1 shows an aerosol generation system comprising an aerosol generating apparatus and a companion device. [Figure 2] FIG. 2 shows the arrangement of energy storage and processing circuitry in a prior art aerosol generating system. [Figure 3] FIG. 3 shows the arrangement of the processing circuitry of the aerosol generation system. [Figure 4] FIG. 4 shows the arrangement of the energy store in the aerosol generating system according to FIG. [Figure 5] FIG. 5 shows a cross-sectional view of the aerosol generation system. [Figure 6]FIG. 6 shows a cross-sectional view of a prior art aerosol generation system. [Figure 7] FIG. 7 shows a cross-sectional view of an alternative aerosol generation system. [Figure 8] FIG. 8 shows the arrangement of the processing circuitry of an aerosol generating system having a heater device. [Figure 9] FIG. 9 shows the arrangement of the energy storage unit of the aerosol generation system according to FIG. [Figure 10] FIG. 10 shows the arrangement of the processing circuitry of an aerosol generating system having a different heater device. [Figure 11] FIG. 11 shows the arrangement of the energy storage unit of the aerosol generating system according to FIG. [Figure 12] FIG. 12 shows the arrangement of the processing circuitry of an aerosol generating system with an energy reservoir heater. [Figure 13] FIG. 13 shows the arrangement of the energy storage unit in the aerosol generating system according to FIG.

[0047] The drawings are schematic only and are not to true scale. DETAILED DESCRIPTION OF THE INVENTION

[0048] FIG. 1 illustrates an aerosol generation system 1 for generating an aerosol, e.g., for consumption by a user in one or more use sessions. The system 1 may include an aerosol generation device 2 for generating the aerosol and a companion device 3 for at least partially receiving the aerosol generation device 2. The companion device 3 may be a charging device for charging the aerosol generation device 2 and / or its energy storage or battery. Both the aerosol generation device 2 and the companion device 3 may include a case 22 or housing. The case 22 may encase or house additional components of the devices 2, 3 described herein. The case 22 may include or be made of a moldable material, e.g., a thermosetting plastic material such as a thermoplastic material or a moldable ceramic material.

[0049] The aerosol-generating device 2 may include an insertion opening 4 for at least partially inserting an aerosol-generating article 17. The aerosol-generating article 17 may include an aerosol-forming substrate, such as a tobacco-containing substrate, and / or a cartridge containing a liquid.

[0050] The aerosol generating device 2 may further include a processing circuit 30 or control circuit 30 having at least one controller 5 and one or more processors 6. To generate aerosol during use or consumption of the aerosol-generating article 17, the aerosol generating device 2 may include at least one heating element 7 or heater device for heating at least a portion of the aerosol-generating article 17. The processing circuit 30 and / or controller 5 may be configured to control the activation, activation, and / or deactivation of the at least one heating element 7.

[0051] In order to power the at least one heating element 7, the aerosol generation device 2 may further comprise at least one energy storage unit 15, for example in the form of a battery, for storing electrical energy or power. The aerosol generation device 2 may further comprise at least one electrical connector 12 for coupling to at least one corresponding electrical connector 13 of the companion device 3. For example, when the aerosol generation device 2 is at least partially inserted into the opening 14 of the companion device 3, the one or more electrical connectors 12 of the aerosol generation device 2 may couple with the one or more electrical connectors 13 of the companion device 3 to charge the at least one energy storage unit 15 of the aerosol generation device 2.

[0052] The aerosol generating device 2 may further comprise a user interface component, e.g., comprising an input element or input device 8, e.g., in the form of a push button. The input device 8 may be used as a power button to activate or deactivate the heating element 7 for aerosol generation, thereby activating or deactivating the aerosol generating device 2. Upon activation of the aerosol generating device 2, the heating element 7 may be activated, and heat may be applied to at least a portion of the aerosol-generating article 17, thereby generating aerosol for consumption by a user in a use session, for example. The aerosol generating device 2 and companion device 3 may each comprise a user interface comprising one or more output elements, such as LED(s), for outputting a signal to a user.

[0053] The aerosol generating device 2 may further include a communication device 9 or communication circuitry 9 having one or more communication interfaces 10 for communicatively linking the aerosol generating device 2 to the companion device 3, for example, via an Internet connection, a wireless LAN connection, a WiFi connection, a Bluetooth connection, a cellular network, a 3G / 4G / 5G connection, an edge connection, an LTE connection, a BUS connection, a wireless connection, a wired connection, a radio connection, a short-range connection, and / or an IoT connection.

[0054] The aerosol generation device 2 may further include a data storage 11 for storing information, program code, or data. One or more sensors 16 may be disposed on, at, or within the aerosol generation device 2 to collect data. One or more of the sensors 16 may be, for example, a temperature sensor, a strain sensor, an accelerometer, or any other suitable sensor.

[0055] Both the aerosol generation device 2 and the companion device 3 may have a longitudinal axis 28. The longitudinal axis 28 may extend in the direction of the greatest extension of the respective device 2, 3. In the case of the aerosol generation device 2, the longitudinal axis 28 may extend parallel to or may be parallel to the direction in which the aerosol-generating article 17 is inserted into or withdrawn from the insertion opening 4 of the aerosol generation device 2. In the case of the companion device 3, the longitudinal axis 28 may extend in the same direction as or parallel to the longitudinal axis 28 of the aerosol generation device 2 when the aerosol generation device 2 is inserted into the opening 14 of the companion device 3.

[0056] The further figures focus on describing the content of the present disclosure implemented in the aerosol generating device 2, however all descriptions in Figures 2-13 are applicable to the companion device 3 as well.

[0057] FIG. 2 illustrates a prior art aerosol generating device 2. The processing circuit 30, including the controller 5 and additional electrical components 18, is typically disposed on a PCB 19, particularly on a separate board of the PCB 19. The electrical components 18 and the controller 5 are connected to each other via traces 20, which are also disposed on the PCB 19. The PCB 19 is manufactured as a separate component from the case 22 and must be mounted within the case 22 during manufacture of the aerosol generating device 2. Furthermore, because the PCB 19 comprises a separate board on which the controller 5, electrical components 18, and traces 20 are disposed, the PCB 19 is large and bulky. As can be seen in FIG. 2 , the PCB 19 fills the case 22 of the aerosol generating device 2 in a manner that precludes the placement of an energy storage unit 15 axially along the longitudinal axis 28 in the same region as the PCB 19. In other words, there is no space for the energy storage unit 15 in the region of the aerosol generating device 2 where the PCB 19 is located. This is a dramatic limitation on the total space available for the energy storage unit 15, significantly limiting the capacity of the energy storage unit 15.

[0058] This problem can be alleviated by the arrangement according to the present disclosure shown in FIGS. 3 and 4. The aerosol generating system 1, exemplarily represented by the aerosol generating device 2 shown in FIGS. 3 and 4, may not include a separate PCB. Instead, the processing circuit 30, specifically one or more of the controller 5, the sensor 16, the additional electrical components 18, and the conductive traces 20, may be disposed directly on the case 22, specifically at least partially embedded within the moldable material of the case 22. Thus, the processing circuit 30 may be included in the manufacturing process of the case 22 or may be manufactured during a molding process in which the case 22 is formed from the moldable material. The mentioned components may be disposed, for example, on the interior surface of the case 22. By at least partially embedding one or more of the electrical components within the moldable material of the case 22, a separate substrate is not required for mounting these components. Thus, a separate PCB may be omitted entirely. Essentially, the entire surface of the case 22 may be available for embedding components, allowing the components to be arranged in a more widely distributed manner than on a conventional PCB, where the components are concentrated in one smaller area. The lack of a separate substrate, separate from case 22, for mounting components and the ability to distribute components more widely over the surface of case 22 can both contribute to space savings within the interior volume of case 22. Additionally, by embedding components within the moldable material of case 22, the extent to which components protrude from the wall surfaces of case 22 can be reduced. This may leave more space within case 22, even within regions of the interior volume of case 22 directly adjacent to electrical components, such as controller 5.

[0059] Thus, in contrast to the prior art shown in FIG. 2 , it may be possible to arrange the energy storage unit 15 even in the region along the longitudinal axis 28 of the aerosol generation device 2, where the processing circuit 30 including the controller 5 is located. For clarity, the energy storage unit 15 of the aerosol generation device 2 is not shown in FIG. 3 . However, FIG. 4 shows the arrangement and extension of the energy storage unit 15 of the aerosol generation device 2 according to FIG. 3 . Also for clarity reasons, the processing circuit 30 is not shown in FIG. 4 . As can be seen in FIG. 4 , the energy storage unit 15 may extend along most of the aerosol generation device 2 in the direction of the longitudinal axis 28. The energy storage unit 15 may be arranged in the same region as the processing circuit 30 including the controller 5. In other words, the processing circuit 30 including the controller 5 may overlap the energy storage unit 15 in the radial direction of the longitudinal axis 28 of the aerosol generation device 2. Thus, the energy storage unit 15 may extend through most of the extension of the aerosol generation device 2 along the longitudinal axis 28. Through this increase in the size of the energy storage unit 15, its capacity may be increased significantly.

[0060] FIG. 5 shows a cross section perpendicular to the longitudinal axis 28 through an aerosol generation system 1, exemplarily represented by an aerosol generation device 2. As shown, the aerosol generation device 2 may have a circular or elliptical cross section, although other shapes are possible. FIG. 5 illustrates how embedding electrical components, particularly the controller 5, traces 20, and additional electrical components 18, within the moldable material of the case 22 can increase the space available for the energy storage unit 15 within the case 22. First, the electrical components may be arranged on the case 22 in a manner that closely follows the shape of the case 22 itself. Because the interior surface of the case 22 shown in FIG. 5 may be rounded, the components of the processing circuit 30 are arranged according to this rounded shape. This is not possible with a conventional PCB, which is typically planar and therefore requires more space to be installed within the case 22, as shown in FIG. 5. Furthermore, FIG. 5 shows that the electrical components may be embedded within the moldable material of the case 22 itself. In other words, the electrical components are embedded or sunk within the material of the walls of the case 22. Thus, part of the thickness of the electrical components is absorbed by the thickness of the case 22 so that the electrical components may protrude less into the interior space of the case 22. This leaves more space inside the case 22 so that an energy storage unit 15 with an increased radius or circumference may be used, despite the fact that the energy storage unit 15 may be disposed directly adjacent to the electrical components, particularly the controller 5.

[0061] 6 and 7 show cross sections similar to FIG. 5 through an exemplary aerosol generating device 2 having a circular or cylindrical base shape of the case 22 and an additional flat sidewall 23. FIG. 6 shows a prior art device, and FIG. 7 shows an improved device according to the present disclosure. In the prior art device according to FIG. 6, the components of the processing circuit 30 are again disposed on the PCB 19. Because the PCB 19 is typically planar, it may typically be disposed on the flat sidewall 23 of the case 22. In this arrangement, the components of the processing circuit 30, such as the controller 5 and additional electrical components 18, are spaced from the flat sidewall 23 by the thickness of the PCB 19 substrate. Furthermore, when the components of the processing circuit 30 are disposed on the outer surface of the PCB 19 substrate, they extend into the interior space of the case 22 through its entire thickness. Thus, from the flat sidewall 23, the components extend into the interior space of the case 22 through both the entire thickness and the thickness of the PCB 19 substrate. As can be seen in FIG. 6, this significantly limits the radius or circumference and size of the energy storage unit 15 that can be used in the interior space of the case 22.

[0062] FIG. 7 shows a cross section through an aerosol generation system 1, illustratively represented by aerosol generating device 2, according to the present disclosure. The processing circuit 30 and its components may be disposed directly on the flat sidewall 23 of the case 22 without the use of an additional PCB board. Through this arrangement, the components of the processing circuit 30 do not need to be separated from the flat sidewall 23 by an additional layer of PCB board. Furthermore, the components of the processing circuit 30 may be at least partially embedded within the moldable material of the flat sidewall 23 of the case 22. Overall, the extension of the components above the surface of the sidewall 23 in the arrangement of FIG. 7 may be even less than the thickness of the components themselves. As seen in FIG. 7, this may facilitate the use of an energy storage unit 15 with an increased radius or circumference, and therefore increased size and capacity. Additionally, the components of the processing circuit 30, such as the controller 5 and additional electrical components 18, may be disposed on the edge of the flat sidewall 23, which may also be connected to a rounded portion of the case 22. When an energy store 15 having a cylindrical or elliptical cylindrical shape is used, this can lead to another possible increase in the size of the energy store 15, as the shape of the case 22 can automatically result in unused interior space in the area where the flat side wall 23 connects with the rounded portion of the case 22. It can therefore be advantageous to arrange the components of the processing circuitry 30 in this area.

[0063] Figures 8 and 9 show another example of an aerosol generation system 1, illustratively represented by an aerosol generating device 2. The example is generally similar to that shown in Figures 3 and 4, and as a result, only aspects that differ from these figures will be described to avoid repetition.

[0064] As shown in FIG. 8 , the controller 5 may be divided into at least two or more separate controller subunits 21. The controller subunits 21 may be connected to each other, for example, by traces 20, and together form the controller 5. Each controller subunit 21 may have smaller spatial dimensions than a single-unit controller 5. The controller subunits 21 may be disposed on the case 22 such that the direction of their greatest extension is parallel to the longitudinal axis 28 of the aerosol generation device 2. While this is illustratively shown for the controller subunit 21 in FIG. 8 , it may also apply to all other electrical components mentioned in this disclosure, such as the single-unit controller 5. In this way, the controller subunits 21 or other electrical components may conform as closely as possible to the shape of the walls of the case 22, as also shown in FIG. 5 .

[0065] FIG. 9 illustrates an alternative arrangement of the controller 5. As shown, the controller 5 may be disposed axially offset from the energy storage unit 15 along the longitudinal axis 28. In this case, the controller 5 may be at least partially embedded in a portion of the case 22 extending perpendicular to the longitudinal axis 28. The controller 5 may also be disposed such that its direction of minimum extension is parallel to the longitudinal axis 28. In other words, a planar controller 5 may be disposed perpendicular to the longitudinal axis 28. A planar controller 5 may also be a controller 5 having at least one direction of extension that extends less in one direction than in the other directions. Such an arrangement may be advantageous when the controller 5 is too large to be disposed within the case 22 radially from the longitudinal axis 28 next to the energy storage unit 15. By at least partially embedding the controller 5 within the moldable material of the case 22 at this location, the interior space available for the energy storage unit 15 may be increased.

[0066] 8 and 9 also illustrate an exemplary heating element 7 of the aerosol-generating device 2. The heating element 7 may be configured so that an aerosol-generating article 17 can be inserted into the heating element 7 through the insertion opening 4. The heating element 7 may include a resistance heater 24 or an induction coil configured to heat the aerosol-generating article 17. The resistance heater 24 or induction coil may be at least partially embedded within the moldable material of the case 22. With this arrangement, the resistance heater 24 or induction coil may enclose an interior space into which the aerosol-generating article 17 can be inserted through the insertion opening 4. The moldable material of the case 22 may also include insulation 25, which may be disposed at least partially surrounding the resistance heater 24 or induction coil in a radial direction of the longitudinal axis 28. The insulation 25 ensures that heat from the heating element 7 is primarily conducted to the aerosol-generating article 17 and not conducted outward through the case 22, where heat may be uncomfortable for the user. The heating element 7 may be manufactured in the same manufacturing process as the molding of the case 22, and may be manufactured with the case 22 as a single integral unit.

[0067] Figures 10 and 11 show another example of an aerosol generation system 1, illustratively represented by an aerosol generation device 2. The example is generally similar to those shown in Figures 3, 4, 8, and 9, and as a result, only aspects that differ from these figures will be described to avoid repetition.

[0068] Specifically, Figures 10 and 11 show another type of heating element 7. The heating element 7 may be configured as a heating blade. The heating blade may be configured to fit within the aerosol-generating article 17 inserted into the aerosol-generating device 2 through the insertion opening 4. Thus, the heating blade may be configured to heat the aerosol-generating article 17 from within the article 17 itself. The heating blade may include a resistance heater 24 or an induction coil configured to heat the aerosol-generating article 17. Furthermore, the heating blade may comprise a moldable material, for example, a moldable material similar to the material of the case 22. The resistance heater 24 or induction coil may be at least partially embedded within the moldable material of the heating blade. The heating element 7 configured as a heating blade may be manufactured in the same manufacturing process as the case 22, or may be manufactured as a single, integral unit with the case 22.

[0069] Figures 12 and 13 show another example of an aerosol generation system 1, illustratively represented by an aerosol generation device 2. The example is generally similar to those shown in Figures 3, 4, 8, 9, 10, and 11, and as a result, only aspects that differ from these figures will be described to avoid repetition.

[0070] As shown in FIG. 12 , the aerosol generating device 2 may include a battery heater 27 configured to heat the energy storage unit 15. The battery heater 27 may include a resistance heater 24 or an induction coil. The battery heater 27 may be at least partially embedded within the moldable material of the case 22. The battery heater 27 may be disposed to cover the entire extension of the energy storage unit 15 along the longitudinal axis 28. Specifically, the battery heater 27 may be disposed to surround the energy storage unit 15 in a radial direction of the longitudinal axis 28. To facilitate heating of the energy storage unit 15, the case 22 may include a heat spreader 29. The heat spreader 29 may include, for example, a thermally conductive moldable material, such as a moldable, thermally conductive ceramic material. The heat spreader 29 may be included within the case 22 during a molding process in the manufacture of the case 22 so that the heat spreader 29 and the case 22 can be molded together. Also, in this same process, the battery heater 27 may be at least partially embedded within the material of the case 22 and the heat spreader 29 .

[0071] The battery heater 27 and heat spreader 29 may be configured to completely cover the energy storage unit 15 in a radial direction of the longitudinal axis 28. However, as shown in FIG. 13 , an unheated area 26 may be provided in which the case 22 does not include or is devoid of the battery heater 27 and / or heat spreader 29. The unheated area 26 is disposed in a location in the case 22 where electronic components that may be heat-sensitive or whose performance may be impaired by high temperatures are disposed. For example, the unheated area 26 may be disposed around the controller 5. The unheated area 26 may also be disposed around additional electrical components 18. Providing the battery heater 27 with the heat spreader 29 and then providing an unheated area in which temperature-sensitive components are disposed may ensure that the energy storage unit 15 is maintained at an optimal temperature while preventing other temperature-sensitive components from becoming overheated. Furthermore, by at least partially embedding the battery heater 27 in the moldable material of the case 22, and by providing the heat spreader 29 as additional moldable material of the case 22, the overall arrangement may be very space efficient and may allow for an energy storage unit 15 of increased size and capacity.

[0072] For purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​expressing amounts, quantities, percentages, and the like are to be understood as being modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is to be understood as A±10%. Within this context, the number A may be considered to include numerical values ​​that are within the common standard error for measurement of the property that the number A modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. An aerosol generating system comprising: a case including a moldable material; a processing circuit comprising at least one controller and at least one conductive trace; The aerosol generating system, wherein at least one of the controller and the trace is at least partially embedded within the moldable material of the case.

2. 2. The aerosol generation system of claim 1, wherein the at least one of the controller and the trace is at least partially embedded within the moldable material of the case such that the at least one of the controller and the trace is embedded within the material of the case.

3. the system comprises an energy storage unit for storing electrical energy, the case at least partially enclosing the energy storage unit, preferably the energy storage unit being removable and / or replaceable by a user; And / or an aerosol generation system according to any one of claims 1 to 2, wherein the at least one controller and energy storage unit of the aerosol generation system overlap each other in the radial direction of the longitudinal axis of the aerosol generation system.

4. An aerosol generation system as described in any one of claims 1 to 3, wherein at least one controller of the processing circuit is arranged on the case, preferably on the inner wall of the case, so that the direction of the maximum extension of the controller is oriented parallel to the longitudinal axis of the aerosol generation system.

5. An aerosol generation system as described in any one of claims 1 to 4, wherein the processing circuit comprises at least one sensor, preferably one or more of a temperature sensor, a strain sensor, and an accelerometer, and the at least one sensor is at least partially embedded within the moldable material of the case.

6. An aerosol generation system as described in any one of claims 1 to 5, wherein the controller comprises at least two controller subunits, each of which is individually at least partially embedded within the moldable material of the case.

7. 7. An aerosol generation system as described in any one of claims 1 to 6, comprising an energy storage heater configured to heat an energy storage unit of the aerosol generation system, the energy storage heater being at least partially embedded within the moldable material of the case.

8. 8. The aerosol generating system of claim 7, wherein the moldable material of the case comprises a heat spreader, preferably the heat spreader comprising at least one of a moldable ceramic material, a metal, preferably copper, and a coating.

9. An aerosol generation system as described in any one of claims 7 to 8, wherein the case has an unheated area that is free of and / or separated from the energy storage heater and / or the heat spreader, and at least one of the controller and further electrical components is arranged within the unheated area.

10. the case at least partially encloses an interior space for an energy storage unit of the aerosol generation system, and the controller and at least one of the traces are at least partially embedded within a surface of the case facing the interior space; An aerosol generation system as described in any one of claims 1 to 9, wherein the case preferably has a rounded surface and a flat surface in a plane perpendicular to the longitudinal axis of the aerosol generation system, the rounded surface and the flat surface being connected to each other and together enclosing the internal space, and at least one of the controller and the traces being at least partially embedded within the flat surface.

11. 11. An aerosol generation system according to any preceding claim, comprising a heating element for heating an aerosol-generating substrate or article, the heating element comprising a heating blade configured to be inserted into the aerosol-generating substrate or article, and a resistive heater, the heating blade comprising a moldable material, the resistive heater being at least partially embedded within the moldable material of the heating blade.

12. 12. An aerosol generating system as described in any one of claims 1 to 11, comprising a heating element for heating an aerosol-generating substrate or article, said heating element comprising a resistive heater, said resistive heater being at least partially embedded within the moldable material of the case.

13. An aerosol generation system according to any preceding claim, wherein the processing circuitry is disposed exclusively on the case of the aerosol generation system and preferably does not include a separate printed circuit board.

14. an aerosol generating device configured to generate an aerosol; a companion device configured to provide electrical energy to the aerosol generating device; An aerosol generation system as described in any one of claims 1 to 13, wherein preferably one or more of the energy storage unit, the processing circuitry, and the case of the aerosol generation system are part of the aerosol generation device or the companion device.

15. 15. The aerosol generating system of any preceding claim, further comprising an aerosol-generating article, the aerosol generating system being configured to generate an aerosol from the article.

Images