Aerosol-generating device with battery interconnection terminal, and aerosol-generating device battery

Abstract

AEROSOL-GENERATING DEVICE WITH BATTERY INTERCONNECTION TERMINAL, AND AEROSOL-GENERATING DEVICE BATTERY The present invention relates to an aerosol-generating device for an aerosol-generating system including an aerosol-generating article. The aerosol-generating device includes a housing comprising a battery compartment opening, wherein the housing is configured to removably engage an aerosol-generating article having a substrate to be heated by a heating element to generate an aerosol. The aerosol-generating device also includes a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, a battery having a battery terminal and a body portion, and at least one battery interconnection terminal located within the battery compartment. The at least one battery interconnection terminal comprises a coil spring configured, in the use position, to electrically connect with the battery terminal of the battery and to at least partially surround a circumference of the body portion. [FIG. 2]

Description

AEROSOL-GENERATING DEVICE WITH BATTERY INTERCONNECTION TERMINAL,AND AEROSOL-GENERATING DEVICE BATTERYTECHNICAL FIELD

[0001] The present invention relates to an aerosol-generating device for an aerosol-generating system including an aerosol-generating article, the aerosol-generating device includes a battery interconnection terminal for electrically connecting to a battery. An aerosol-generating device battery is also disclosed, particularly for removably engagement with a battery interconnection terminal.BACKGROUND

[0002] Aerosol-generating articles in which an aerosol-forming substrate, such as a tobacco-containing substrate, is heated rather than combusted, are known in the art. Typically in such heated smoking articles, an aerosol is generated by the transfer of heat from a heat source of an aerosol-generating device to a physically separate aerosol-forming substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-forming substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0003] An aerosol-generating system is formed of an electronic device including a heat source or a heater, typically a heating element, arranged to apply heat to the substrate in the aerosol-generating article when the aerosol-generating article is mounted to the electronic device. In known electronic devices a battery is required as a power source to provide power to the heating element.

[0004] Batteries, typically pouch batteries, or prismatic batteries, are installed in the aerosol-generating device so that the user is able to remove and replace the batteries. The battery must be held securely within the aerosol-generating device otherwise there will be an unreliable electrical connection between the battery and the electrical components in the device, causing a loss of function of the heating element.

[0005] Batteries are susceptible to physical damage, for example due to punctures or mechanical stress to batteries. Pouch batteries having thin or flexible outer casings are particularly susceptible to punctures or mechanical stress. Batteries are prone to being damaged as they are inserted or removed from the aerosolgenerating device. In addition, certain known means of hold a battery securely within the aerosol -generating device during use increase the risk of causing physical damage to the battery.

[0006] Swelling of batteries also occurs, primarily due to internal chemical reactions and changes in the physical properties of the battery components during charge and discharge cycles. These changes can lead to expansion and contraction within the cell, causing deformation and potentially compromising the integrity of the battery. Swelling can result in one or more of: reduced performance, increased internal electrical resistance, or an increased risk of cell rupture or thermal runaway.

[0007] When the capacity of the battery is depleted, the electronic device no longer works without a replacement battery. Moreover, due to different types of present and future regulations, and also for repairing the electronic device or to facilitate recycling of different components and specifically the battery, it is desirable to provide for a mechanism that allows to easily replace the battery of the electronic device so that the replacement cell is inserted correctly and ready for use. Replacement of the battery should avoid any risk of damage to the battery or to the electronic componentry of the aerosol-generating device.

[0008] It is an aim of certain examples of the present invention to solve, mitigate or obviate, at least partly, at least one of the problems and / or disadvantages associated with the prior art.BRIEF SUMMARY

[0009] The invention is set out in the appended claims.

[0010] According to an aspect of the invention, there is provided an aerosol -generating device for an aerosol-generating system including an aerosol-generating article, the aerosol-generating device including: a housing including a battery compartment opening, wherein the housing is configured to removably engage an aerosol-generating article having a substrate to be heated by a heating element to generate an aerosol, a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, a battery having a battery terminal and a body portion, at least one battery interconnection terminal located within the battery compartment, the at least one battery interconnection terminal including a coil spring configured, in the use position, to electrically connect with the battery terminal of the battery and to at least partially surround a circumference of the body portion.

[0011] Aspects of the present invention provide an aerosol-generating device in which the end-user can replace the battery and easily install a replacement battery ready for use. By incorporating the coil spring, electrical connectivity to the battery is provided whilst securely holding the battery. It also ensures the user inserts the battery into the battery compartment and electrically connects to the aerosol-generating device with the correct polarity.

[0012] The coil spring is also extendible so that the coil spring stretches when a user removes the battery from the battery compartment. The risk of damage to a battery, or to the aerosol-generating device during battery replacement is reduced.

[0013] The tension within the coil spring advantageously securely holds the battery in a use position within the aerosol-generating device. The conductive springs wrap around the inserted body portion of the battery, providing a stable electrical connection, and additionally mechanical stability to the battery. The tension also ensures that the spring remains in contact with the battery terminal or battery terminals. The electrical connection has increased tolerance of movement, misalignment, or swelling of the battery in the use position.The coil spring is able to accommodate a movement or a change of shape of the battery while maintaining the electrical connection with the battery terminals.

[0014] According to another aspect, there is provided an aerosol-generating device battery including: a body portion, extending between a first end portion and an opposing second end portion; and a pair of battery terminals; wherein the battery includes an outer casing, and a reinforcing sub-layer provided at least in the body portion of the battery, and wherein the first end portion includes an expandable pouch configured to accommodate a volume increase of the battery.

[0015] Aspects of the present invention provide an aerosol-generating device having controlled battery swelling. This provides greater safety for the user and the longevity of the aerosol-generating device by reducing the impact of any swelling of the battery, which would otherwise risk puncture or mechanical damage to the battery. The risk of short circuiting and / or damage to the internal components of the aerosolgenerating device from the battery is also reduced.

[0016] The coil spring may be configured to lengthen as the battery is received into the use position in the battery compartment. That is, the coil spring may be expanded when the battery is in the use position in the battery compartment. In this way, the coil spring may generate a tension to hold the battery in the use position. The tension of the lengthened coil spring may be adjusted by adapting the properties of the coil spring according to the size of the intended battery for the aerosol-generating device. This ensures the coil spring holds the battery effectively.

[0017] The coil spring may include a first mount portion, a second mount portion, and an intermediary length between the first mount portion and the second mount portion.

[0018] The battery compartment may include a mounting surface, wherein each of the first mount portion and the second mount portion may be secured to the mounting surface.

[0019] At least a portion of the intermediary length of the coil spring may contactingly engage the battery terminal.

[0020] In these ways, with the battery in the use position in the battery compartment, the intermediary length may he against the battery terminal. The remainder of the coil spring may urge the battery against the mounting surface.

[0021] The at least one battery interconnection terminal may include a pair of battery interconnection terminals. The battery interconnection terminals may be configured so that, when a battery having a pair of battery terminals is in the use position, the battery interconnection terminals electrically connect to opposing battery terminals. In this way, the battery may be conveniently installed into the device to electrically connect to the aerosol-generating device electrical circuitry. The battery may be installed easily to provide a power source for the heating element of the aerosol-generating device.

[0022] The aerosol-generating device may include a battery interconnection assembly secured within the housing. The at least one battery interconnection terminal may be mounted to the battery interconnection assembly. The battery interconnection assembly may also include one or more of: a mounting surface, a first mount portion, or a second mount portion.

[0023] By providing the battery interconnection assembly, along with any terminals, mounting surface, or mount portions, the aerosol-generating device may be more easily assembled during manufacturing.

[0024] The housing may include an access opening. The access opening may be configured to permit a user to engage the battery within the battery compartment and eject the battery through the battery compartment opening. In this way, the user may easily remove a spent battery.

[0025] The access opening and the battery compartment opening may be arranged at opposing ends of the housing. By providing both openings at opposing ends, the housing may be easily manufactured with each opening formed in the housing.

[0026] The access opening may include a lid to selectively cover the access opening. In this way, ingress of dirt or debris is prevented when the battery is in use.

[0027] The aerosol-generating device may include an air inlet. The air inlet may be configured to provide ingress of air to the aerosol-generating article operably engaged with the aerosol-generating device. In certain examples, the air inlet may be fluidly connected to the access opening. In this way, air may be drawn into the air inlet and directed, for example by suitable channels, to the aerosol-generating article to entrain the aerosol generated from the aerosol-forming substrate of the aerosol-generating article.

[0028] The aerosol-generating device may include a battery. The battery may be operably received in a use position in the battery compartment. The battery may have a pair of battery terminals and a body portion.

[0029] The battery may include a pouch cell. The cell may be an electrochemical cell capable of storing electrical energy for discharging to the aerosol-generating device in order to power the heating element.

[0030] The battery may include a pouch cell. The cell may be an electrochemical cell capable of storing electrical energy for discharging to the aerosol-generating device in order to power the heating element.

[0031] The battery may have a cylindrical, a substantially cylindrical , or an oval shape. In these examples, the battery terminals may be provided with conductive strips or conductive bands. Each conductive band or conductive strip may be arranged to at least partially surround a section of the body portion of the battery, typically to at least partially surround a circumference of the body portion. The conductive band or conductive strip may be a ring-like metallic band exposed on a surface of the body portion of the battery.Each conductive band or conductive strip may be positioned on the body portion to align with a coil spring of the aerosol-generating device.

[0032] The batery may include a batery interconnection adaptor. The battery interconnection adaptor may provide an electrical connection between a battery terminal at an end portion of the battery and a conductive band or a conductive strip at least partially surrounding a section of the body portion of the batery.

[0033] In these ways, bateries may be adapted to operably electrically connect to the coil springs of an aerosol -generating device. The aerosol-generating device may advantageously operate with a range of batery shapes.

[0034] In certain examples, the batery may be chargeable while located in the use position. In this way, the user may recharge a spent batery by connecting the aerosol-generating device to a suitable power supply and connector.

[0035] The body portion of the battery may extend between a first end portion and an opposing second end portion.

[0036] The first end portion may have a profiled shape. The profiled shape may be configured so that, as the batery is inserted into the battery compartment opening with the first end portion leading into the batery compartment opening, the profiled shape deflects the coil spring around the body portion. The profiled shape may include a rounded edge profile, an inclined edge profile or a wedge-shaped edge profile.

[0037] In these ways, the profiled shape may have a leading edge that fits into the opening between the coil spring and the mounting surface and so ensures the first end portion can be inserted into the opening smoothly. The coil spring is lengthened to fit the body portion without inhibiting or catching against the battery.

[0038] The batery may include an outer casing and a reinforcing sub-layer.

[0039] The reinforcing sub-layer may be provided at least in the body portion of the batery. In certain examples, the reinforcing sub-layer is provided in the body portion and second end portion of the batery. The reinforcing sub-layer may enclose the body portion and, optionally, also cap the second end portion.

[0040] The reinforcing sub-layer may include a swell-resistant material. In certain examples, the swellresistant material may include a reinforced fibre material or a pre-impregnated fibre material. For example, the swell-resistant material may include one or both of a reinforced glass fibre or a reinforced carbon fibre. For example, the swell-resistant material may include one or both of a pre-impregnated (prepreg) glass fibre or a pre-impregnated (prepreg) carbon fibre material.

[0041] In these ways, the reinforcing sub-layer resists internal pressure to maintain structural shape of the body portion of the battery. Swelling or distortion within the reinforcing sub-layer, such as in the electrochemical cell, is restrained and the battery does not impinge, or become trapped within, the batery compartment.

[0042] An opening in the reinforcing sub-layer may be provided at the first end portion.

[0043] The first end portion of the battery may include an expandable pouch. The expandable pouch may be configured to accommodate a volume increase of the battery. The expandable pouch moves from a neutral first configuration, to an expanded second configuration. The volume of the expandable pouch in the second configuration is greater than in the first configuration.

[0044] The expandable pouch may be configured to expand away from the body portion of the battery.

[0045] The expandable pouch may be formed from a circumferential band of the outer casing extending from the first end portion of the battery.

[0046] The circumferential band may be configured to expand from a folded first configuration to an unfolded second configuration.

[0047] The expandable pouch may be formed of an elastomeric material. For example, the circumferential band may be formed of an elastomeric material.

[0048] In these ways, if the battery, particularly the electrochemical cell of the battery, swells then the expandable pouch, responds to the volume change and preferentially distorts outwards. This may be in part, or in whole, because the material of the expandable pouch has distorted or stretched. This may be in part, or in whole, because the expandable pouch has moved to an expanded configuration, such as an unfolded configuration. In particular, due to the swell-resistant material around the body portion in combination with an expandable pouch, any volume increase in the battery or cell is resisted in the body portion and is instead directed towards the expandable pouch.

[0049] The battery compartment may include a recessed cavity. The recessed cavity may be configured so that, in the use position, the first end portion of the battery is proximal to the recessed cavity. The recessed cavity may have a capacity to accommodate the volume increase of the expandable pouch of the battery. The expandable pouch may direct the volume increase towards a recessed cavity in the battery compartment in a controlled manner. The recessed cavity may provide space within the battery compartment for the expandable pouch to expand into.

[0050] In these ways, the battery compartment does not restrict or impede expansion of the expandable pouch. The aerosol -generating device is resilient to swelling of the battery, reducing the risk of battery malfunction causing damage or failure of the other components in the aerosol-generating device.

[0051] The invention is defined in the claims. However, below there 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 another example, embodiment, or aspect described herein.Example Exl: An aerosol-generating device for an aerosol-generating system including an aerosolgenerating article, the aerosol-generating device including:a housing including a battery compartment opening, wherein the housing is configured to removably engage an aerosol-generating article having a substrate to be heated by a heating element to generate an aerosol; a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, a battery having a battery terminal and a body portion; at least one battery interconnection terminal located within the battery compartment, the at least one battery interconnection terminal including a coil spring configured, in the use position, to electrically connect with the battery terminal of the battery and to at least partially surround a circumference of the body portion.Ex2. The aerosol-generating device of Exl, wherein the coil spring is configured to lengthen as the battery is received into the use position in the battery compartment.Ex3. The aerosol-generating device of Exl or Ex2 wherein the coil spring applies tension to the body portion of the battery to hold the battery in the use position.Ex4. The aerosol-generating device of any one of Exl to Ex3, wherein the coil spring includes a first mount portion, a second mount portion, and an intermediary length between the first mount portion and the second mount portion.Ex5. The aerosol -generating device of Ex4, wherein the battery compartment includes a mounting surface and wherein each of the first mount portion and the second mount portion are secured to the mounting surface.Ex6. The aerosol -generating device of Ex4 or Ex5, wherein at least a portion of the intermediary length of the coil spring contactingly engages the battery terminal.Ex7. The aerosol -generating device of any one of Exl to Ex6, wherein the at least one battery interconnection terminal includes a pair of battery interconnection terminals configured so that, when the battery having a pair of battery terminals is in the use position, the battery interconnection terminals electrically connect to opposing battery terminals.Ex8. The aerosol -generating device of any one of Exl to Ex7, wherein the housing further includes an access opening configured to permit a user to engage the battery within the battery compartment and eject the battery through the battery compartment opening.Ex9. The aerosol -generating device of Ex8, wherein the access opening and the battery compartment opening are arranged at opposing ends of the housing.ExlO. The aerosol-generating device of Ex8 or Ex9, wherein the access opening includes a lid to selectively cover the access opening.Exl 1. The aerosol-generating device of any one of Exl to ExlO, further including an air inlet configured to provide ingress of air to the aerosol-generating article operably engaged with the aerosolgenerating device.Exl2. The aerosol-generating device of Exl 1 when dependent upon any one of Ex7 to Ex9, wherein the air inlet is fluidly connected to the access opening.Exl3. The aerosol-generating device of any one of Exl to Exl2, further including a battery having a pair of battery terminals and a body portion, wherein the battery is operably received in a use position in the battery compartment.Exl4. The aerosol-generating device of Exl3, wherein the battery includes a pouch cell.Exl 5. The aerosol-generating device of Ex 13 or Ex 14, wherein the body portion of the battery extends between a first end portion and an opposing second end portion.Exl6. The aerosol-generating device of Exl5, wherein the first end portion has a profiled shape configured so that, as the battery is inserted into the battery compartment opening with the first end portion leading into the battery compartment opening, the profiled shape deflects the coil spring around the body portion.Exl 7. The aerosol-generating device of Exl 6, wherein the profiled shape includes a rounded edge profile, an inclined edge profile or a wedge-shaped edge profile.Exl 8. The aerosol-generating device of any one of Exl3 to Exl7, wherein the battery includes an outer casing and a reinforcing sub-layer, wherein the reinforcing sub-layer is provided at least in the body portion of the battery.Exl9. The aerosol-generating device of Exl8, wherein the reinforcing sub-layer includes a swellresistant material.Ex20. The aerosol-generating device of Exl8 or Exl9, wherein the first end portion includes an expandable pouch configured to accommodate a volume increase of the battery.Ex21. The aerosol-generating device of Ex20, wherein the expandable pouch is configured to expand away from the body portion of the battery.Ex22. The aerosol-generating device of Ex20 or Ex21, wherein the expandable pouch is formed from a circumferential band of the outer casing extending from the first end portion of the battery.Ex23. The aerosol-generating device of Ex22, wherein the circumferential band is configured to expand from a first, folded configuration to a second, unfolded configuration.Ex24. The aerosol-generating device of any one of Exl8 to Ex23, wherein the swell-resistant material includes a reinforced fibre material or a pre-impregnated fibre material.Ex25. The aerosol-generating device of any one of Exl 8 to Ex24, wherein the reinforcing sub-layer is provided in the second end portion of the battery.Ex26. The aerosol-generating device of any one of Exl 8 to Ex25, wherein the battery compartment includes a recessed cavity arranged so that, in the use position, the first end portion of the battery is proximal to the recessed cavity .Ex27. The aerosol-generating device of Ex 17, wherein the recessed cavity has a capacity to accommodate the volume increase of the expandable pouch of the battery.Ex28. The aerosol-generating device of any one of Exl to Ex27, further including a battery interconnection assembly, wherein the battery interconnection assembly has a chassis and the at least one battery interconnection terminal mounted to the chassis.Ex29. An aerosol-generating device battery including a body portion, extending between a first end portion and an opposing second end portion, and a pair of battery terminals; wherein the battery includes an outer casing, and a reinforcing sub-layer provided at least in the body portion of the battery; and wherein the first end portion includes an expandable pouch configured to accommodate a volume increase of the battery.Ex30. The aerosol-generating device battery of Ex29, wherein the expandable pouch is configured to expand away from the body portion of the battery.Ex31. The aerosol-generating device battery of Ex29 or Ex30, wherein the reinforcing sub-layer is provided in the second end portion of the battery.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0052] Examples will now be described further with reference to the figures in which:FIG. 1A shows a perspective view of an example aerosol-generating device;FIG. IB shows the example aerosol-generating device of FIG. 1A with a battery for insertion into the aerosol-generating device;FIG. 2 shows a perspective view of a battery interconnection assembly of the aerosol-generating device of FIG. 1A and FIG. IB, with the battery mounted in the battery interconnection assembly;FIG. 3A shows a side view, FIG. 3B shows an end view, and FIG. 3C shows a perspective view of example battery interconnection terminals electrically connected with battery terminals of an example battery;FIG. 4 shows an enlarged perspective view of another example battery, including an expandable pouch mounted within an aerosol-generating device;FIG. 5A shows a perspective view, FIG. 5B shows a cross-sectional perspective view, and FIG. 5C shows an enlarged cross-sectional view, of the battery of FIG. 4;FIG. 6A shows a cross-sectional front view of the battery and aerosol-generating device of FIG. 4 in a first configuration;FIG. 6B shows a cross-sectional front view of the battery and aerosol-generating device of FIG. 4 in a second configuration;FIG. 7A shows a perspective view, and FIG. 7B shows an enlarged cross-sectional view, of a further example battery with an expandable pouch in a first configuration;FIG. 7C shows a perspective view of the battery of FIG. 7A and FIG. 7B with the expandable pouch in a second configuration.DETAILED DESCRIPTION

[0053] Certain terminology is used in the following description for convenience only and is not limiting. The words ‘lower’, ‘upper’, ‘front’, ‘rear’, ‘upward’, ‘down’ and ‘downward’ designate directions in the drawings to which reference is made and are with respect to the described component when assembled and mounted. The words ‘inner’, ‘inwardly1and ‘outer’, ‘outwardly’ refer to directions toward and away from, respectively, a designated centreline or a geometric centre of an element being described (e.g. central axis), the particular meaning being readily apparent from the context of the description.

[0054] Further, as used herein, the terms ‘connected1, ‘coupled’, ‘mounted’ are intended to include direct connections between two members without any other members interposed therebetween, as well as, indirect connections between members in which one or more other members are interposed therebetween. The terminology includes the words specifically mentioned above, derivatives thereof, and words of similar import.

[0055] Further, unless otherwise specified, the use of ordinal adjectives, such as, ‘first’, ‘second’, ‘third’ etc. merely indicate that different instances of like objects are being referred to and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking or in any other manner.

[0056] As used herein, a “reinforcing sub-layer” may be substrate, or layer of a substrate, of a battery wall that is capable of resisting pressure so as to maintain the shape of the wall. In particular, the reinforcing sublayer may form part of a pouch enclosing a body portion and / or an end portion of the battery. The reinforcing sub-layer may include a swell-resistant material that provide resistance to internal pressure, such as caused by distortion of the enclosed cell that stores electrochemical energy, to maintain the shape of the body portion and / or end portion of the battery. The reinforcing sub-layer may include reinforcing elements that resist elongation or twisting along a surface of the reinforcing sub-layer.

[0057] As used herein, “at least partially surround” means that a first element, such as a battery interconnection terminal, engages a second element, such as a battery along more than a single axis or plane. For example, the first element may engage the second element on two surfaces in different planes to each other. For example, the first element may the second element by at least partly wrapping around a curved surface on the second element. The first element thereby not only rests on, or contacts the second element but restrains the second element.

[0058] Referring now to FIG. 1A and FIG. IB, there is shown an example aerosol-generating device 100 according to an aspect of the invention. The aerosol-generating device 100 is part of an aerosol-generating system having an aerosol-generating article that includes an aerosol-forming substrate upon heating. In FIG. IB, the aerosol-generating device 100 is shown with a battery 150 ready for insertion into the aerosolgenerating device 100. The battery 150 includes a body portion 152 and a pair of battery terminals 158, one of each polarity.

[0059] The aerosol-generating device 100 includes a housing 110 with a battery compartment opening 114. The housing 110 is configured to removably engage an aerosol-generating article (not shown) having an aerosol-forming substrate to be heated by a heating element to generate an aerosol. The housing 110 and the aerosol-generating article may each include aspects of mutually compatible means to secure the aerosolgenerating article to the housing 110 in an engaged position for use.

[0060] The aerosol-generating device 100 also includes a battery compartment 112 accessible by battery compartment opening 114. The battery compartment 112 is configured to receive the battery 150 in a use position in which the battery 150 is able to provide electrical power to the heating element for heating the aerosol-forming substrate.

[0061] A pair of battery interconnection assemblies are located within the battery compartment opening 114 of the aerosol-generating device 100, as shown particularly in FIG. 2 to FIG. 3C. Each battery interconnection assembly includes a coil spring 140 configured so that, with the battery 150 in the use position, the coil spring 140 partially surrounds a circumference of the body portion 152 of the battery 150. Furthermore, in the use position, the coil spring 140 contacts and electrically connects to a respective battery terminal 158 of the battery 150.

[0062] The housing 110 encloses a battery interconnection assembly 130. The battery interconnection assembly 130 and an inner surface of the housing 110 form the battery compartment opening 114 within the aerosol -generating device 100.

[0063] As shown in FIG. 2, the battery interconnection assembly 130 is a sub-unit of the aerosolgenerating device 100 that is securable within the housing 110. In this way, the battery interconnection assembly 130 may be formed with the battery interconnection terminals as well as further components, for example a heating element and other electrical components, for convenient assembly within the aerosolgenerating device 100.

[0064] Referring additionally to FIG. 3 A to FIG. 3C, there is shown the battery 150 mounted to the coil springs 140 of the battery interconnection assemblies. The body portion 152 of the battery 150 extends between a first end portion 153 and a second end portion 154.

[0065] A first battery terminal 158 is provided at the first end portion 153 of the battery 150. In the example the first battery terminal 158 may be a positive battery terminal 158. In the use position, a first coil spring 140 surrounds the first end portion 153 of the battery 150 and electrically connects to the first battery terminal 158.

[0066] A second battery terminal 158 is provided at the second end portion 154 of the battery 150. The second battery terminal 158 has an opposing polarity to the first battery terminal 158. In the example the second battery terminal 158 is a negative battery terminal 158. In the use position, a second coil spring 140surrounds the second end portion 154 of the battery 150 and electrically connects to the second battery terminal 158.

[0067] Each coil spring 140 includes a first mount portion 141, a second mount portion 142, and an intermediary length 143 between the first mount portion 141 and the second mount portion 142. Each intermediary length 143 lies against a respective battery terminal 158, to contact and electrically connect with the battery terminal 158. By lying against the battery terminal 158, surface contact between the battery terminal 158 and the coil spring 140 is maximised.

[0068] The battery interconnection assembly 130 includes a mounting surface 132. Each of the first mount portion 141 and the second mount portion 142 are secured to the mounting surface 132.The mounting surface 132 receives the battery 150 in the use position so that the coil spring 140 contacts the outer casing 160 of the battery 150 to hold the battery 150 against the mounting surface 132.

[0069] The battery 150 has an outer casing enclosing the electrochemical cell of the battery 150 that stores energy. The battery 150 has a battery length from the first end portion 153 to the second end portion 154, as well as a cross-sectional shape defined by the circumference of the battery. In the example, the cross- sectional shape is rectangular, with uniform width and height along the battery length. In this way, as the battery 150 is received in the use position, the battery 150 deforms each coil spring 140 away from the mounting surface 132 so that the coil spring 140 surrounds the battery 150 around three sides of the cross- sectional shape. The battery 150 thereby generates a tension within the coil spring 140 that applies a force to hold the battery 150 against the mounting surface 132.

[0070] The battery interconnection assemblies provide a convenient means to both hold the battery 150 within the battery compartment 112, and electrically connect the battery 150 with the aerosol-generating device 100. The tension within the coil spring 140 allows for a degree of amount of movement of the battery 150 within the battery compartment 112 while maintaining electrical connection with the battery terminal 158. The battery 150 is thereby able to continuously provide power to the aerosol-generating device 100 while enduring unexpected impacts and movement.

[0071] In other examples, not shown, the battery may be formed of alternative cross-sectional shapes. The cross-sectional shape may be an irregular shape, for example where the battery includes a pouch cell that has an outer casing formed of a pliable material. The width and height of the cross-sectional shape may be variable along the battery length. Nevertheless, the battery and the coil spring are configured such that insertion of the battery into the battery compartment enables each coil spring to at least partially surround the battery. Each coil spring is deformed by the battery so that the coil spring is lengthened, generating a tension within the coil spring that holds the battery in the use position within the battery compartment.

[0072] In other examples, not shown, the battery 150 first end portion 153 has a profiled shape. For example the first end portion may have a rounded edge profile, an inclined edge profile, or a wedge-shaped edge profile. In this way, as the battery is inserted into the battery compartment with the first end portionleading into the battery compartment opening, the profiled shape deflects the coil spring around the body portion of the battery. That is, the profiled shape has a leading edge that fits into the opening between the coil spring and the mounting surface and so ensures the first end portion can be inserted into the opening smoothly. The coil spring is lengthened to fit the body portion without inhibiting or catching against the battery.

[0073] The battery interconnection assembly 130 also includes an access opening 118. In the example shown, the access opening 118 and the battery compartment opening 114 are arranged at opposing ends of the housing 110. The access opening 118 is located to allow a user to engage the battery 150 within the battery compartment 112. The user is able to push against the battery 150 to eject the battery 150 through the battery compartment opening 114.

[0074] In other examples, the aerosol-generating device may also include a lid to selectively cover the access opening. The lid prevents unwanted ingress of dirt into the access opening.

[0075] Additionally, or alternatively, the aerosol-generating device may also include an air inlet configured to provide ingress of air into the aerosol-generating device. Optionally, the air inlet is fluidly connected to the access opening. Air may be drawn into the air inlet and directed, for example by suitable channels, to the aerosol-generating article to entrain the aerosol generated from the aerosol-forming substrate of the aerosolgenerating article.

[0076] In the aerosol-generating device 100 described here, the battery interconnection assembly 130 is formed as a separate sub-unit of the aerosol-generating device 100. In other examples, some or all of the features of the the battery interconnection assembly may be formed within the housing 110 itself, or on another component. For example the mounting surface and the battery interconnection terminal or terminals may be fixed within the housing, and the battery compartment opening may be formed in a portion of the housing.

[0077] Referring now to FIG. 4 to FIG. 6B, there is shown another example aerosol-generating device 200, including a battery 250, according to an aspect of the invention. The aerosol-generating device 200 is part of an aerosol-generating system having an aerosol-generating article that includes an aerosol-forming substrate upon heating.

[0078] The aerosol -generating device 200 is substantially the same as the aerosol-generating device 100 of FIG. 1A to FIG. 3C, other than the aerosol-generating device 200 includes a recessed cavity 216. The battery 250 is substantially the same as the battery 150 of FIG. 1A to FIG. 3C, other than the first end portion 253 includes an expandable pouch 262. As will be realised, the respective batteries 150, 250, 350 of the examples may used interchangeably with the aerosol-generating devices 100, 200 and the associated battery interconnection assemblies.

[0079] Thus, the aerosol-generating device 200 includes a housing 210 with an access opening 218, where the housing 210 is configured to removably engage an aerosol-generating article (not shown) having an aerosol-forming substrate to be heated by a heating element to generate an aerosol. The aerosol-generating device 200 also includes a battery compartment 212 accessible by the battery compartment opening 214, wherein the battery compartment 212 is configured to receive, in a use position, the battery 250. The battery 250 includes two battery terminals 258, one each at opposing first end portion 253 and second end portion 254 of a body portion 252.

[0080] A pair of battery interconnection terminals are located within the battery compartment 212, each formed of a coil spring 240 configured, in the use position, to electrically connect with a respective battery terminal 258 of the 250, and to at least partially surround a circumference of the body portion 252.

[0081] The battery compartment 212 includes a recessed cavity 216. The recessed cavity 216 is arranged so that, in the use position, the first end portion 253 of the battery 250 is proximal to the recessed cavity 216. The recessed cavity 216 has a capacity to accommodate a volume increase of the battery 250 at the first end portion 253, as is described in more detail here.

[0082] In the example, the recessed cavity 216 is provided in a battery interconnection assembly 230 secured within the housing 210 of the aerosol-generating device 200. The recessed cavity 216 is at an opposing end of the battery compartment 212 to the battery compartment opening 214.

[0083] The recessed cavity 216 opens into the access opening 218. The recessed cavity 216 provides a passageway through the battery interconnection assembly 230 from the access opening 218 to the battery compartment 212.

[0084] Referring particularly to FIG. 5A to FIG. 5C, the battery 250 of the aerosol-generating device 200 includes a body portion 252, extending between a first end portion 253 and a second end portion 254, and a pair of battery terminals 258. A cell 268, such as an electrochemical cell, is held within the battery 250 to store electrical energy. The cell 268 is electrically connected to the battery terminals 258 by suitable internal connectors so that the stored electrical energy may be discharged from the cell 268. Optionally, the cell 268 may also be charged by suitable charging means via the battery terminals 258, in order to store electrical energy .

[0085] The battery 250 includes an outer casing 260 and a reinforcing sub-layer 264, as shown in the cross- sectional view (FIG. 5B) and associated close up view (FIG. 5C). The reinforcing sub-layer 264 includes a swell-resistant material formed of pre-impregnated fibre material, such as pre-impregnated glass fibre.

[0086] The reinforcing sub-layer 264 is provided in the body portion 252 of the battery 250 to surround the cell 268 in the body portion 252 of the battery 250. In the example shown, the reinforcing sub-layer 264 is also provided at the second end portion 254. In this way, the reinforcing sub-layer 264 encloses the bodyportion 252 and caps the second end portion 254. An opening in the reinforcing sub-layer 264 is provided at the first end portion 253.

[0087] The first end portion 253 includes an expandable pouch 262. The expandable pouch 262 extends across an outer face of the first end portion 253 to accommodate a volume increase of the battery. That is, if the battery 250, particularly the cell 268 of the battery 250, swells then the expandable pouch 262 responds to the volume change and distorts outwards with the battery 250. The expandable pouch 262 moves from a neutral first configuration, to an expanded second configuration.

[0088] The volume of the expandable pouch 262 in the second configuration is greater than in the first configuration because the material of the expandable pouch 262 has distorted. In the example, the expandable pouch 262 is formed of the same material as the outer casing, although the expandable pouch 262 may alternatively be formed of another material, such as an elastomer material, that is adjoined to the outer casing 260 at the first end portion 253.

[0089] Due to the swell-resistant material around the body portion 252 and the second end portion 254 of the battery 250, any volume increase in the battery 250 or cell 268 is resisted in the body portion 252 and at second end portion 254. The volume increase is instead directed into the expandable pouch 262. The expandable pouch 262 is able to expand away from the body portion 252 of the battery 250.

[0090] As shown in FIG. 6A and FIG. 6B, with the battery 250 installed in the battery compartment 212 in the use position, the expandable pouch 262 is arranged proximal to the recessed cavity 216 of the aerosolgenerating device 200. The recessed cavity 216 provides space within the battery compartment 212 for the expandable pouch 262 to expand into. The battery compartment 212 does not restrict or impede expansion of the expandable pouch 262. The aerosol-generating device 200 is thereby resilient to swelling of the battery 250 without causing damage or failure of the other components in the aerosol-generating device 200.

[0091] Referring to FIG. 7A to FIG. 7C, a further example of a battery 350 with an expandable pouch 362 is shown. The battery 350 is substantially the same as the battery 250 of FIG. 4 to FIG. 6B other than the expandable pouch 362 is formed of a circumferential band 366 of the outer casing 360.

[0092] The battery 350 a body portion 352, extending between a first end portion 353 and a second end portion 354, and a pair of battery terminals 358. A cell 368, such as an electrochemical cell, is held within the battery 350 to store electrical energy and electrically connected to the battery terminals 358 by suitable internal connectors so that the electrical energy may be discharged from or charged into the cell 368.

[0093] The battery 350 includes the outer casing 360 and a reinforcing sub-layer 364, as shown in the cross-sectional view (FIG. 7B). The reinforcing sub-layer 364 includes a swell-resistant material formed of pre-impregnated fibre material, such as pre-impregnated glass fibre.

[0094] The reinforcing sub-layer 364 is provided in the body portion 352 of the battery 350 to surround the cell 368. In the example shown, the reinforcing sub-layer 364 is also provided at the second end portion 354so that the reinforcing sub-layer 364 encloses the body portion 352 and caps the second end portion 354. An opening in the reinforcing sub-layer 364 is provided at the first end portion 353.

[0095] An elongate seam 361 is formed along the side of the body portion 352 and the second end portion 354, to further reinforce the outer casing in these regions by ensuring the outer casing 360 fits snugly to the cell 368 within.

[0096] The outer casing 360 also includes an expandable pouch 362 formed from a circumferential band 366 of material extending from the first end portion 353. The circumferential band 366 extends beyond the first end portion 353 when the battery 350 is initially formed. A secondary elongate seam (shown in FIG. 7C) is formed along the distal side of the circumferential band 366 to seal the cell 368 within the outer casing 360.

[0097] In a first configuration, as shown in FIG. 7A and FIG. 7B, the circumferential band 366 is folded against the first end portion 353 of the battery 350. The folded circumferential band 366 ensures the battery 350 occupies a minimal volume. The expandable pouch 362 extends across an outer face of the first end portion 353 ready to accommodate a volume increase of the battery 350. Thus, if the battery 350, particularly the cell 368 of the battery 350, swells then the expandable pouch 362 responds to the volume change and unfolds outwards with the battery 350, as shown in FIG. 7C. The expandable pouch 362 moves from a folded first configuration, to an unfolded second configuration.

[0098] The volume of the expandable pouch 362 in the second configuration is greater than in the first configuration because the circumferential band 366 has unfolded away from the first end portion 353. Thus, the circumferential band 366 is not required to be inherently deformable because the volume increase of the battery 350 is accommodated by the change from a folded to an unfolded configuration. In certain examples, by suitable choice of material, the circumferential band 366 may be configured both to distort and to unfold when responding to the volume increase. This may enable the battery to accommodate an even greater volume increase.

[0099] Due to the swell-resistant material around the body portion 352 and the second end portion 354 of the battery 350, a volume increase in the battery 350 or cell 368 is resisted in the body portion 352 and at second end portion 354. The volume increase is instead directed into the expandable pouch 362. The expandable pouch 362 is able to expand away from the body portion 352 of the battery 350.

[0100] The battery 350 may be installed in an aerosol-generating device having a suitable battery compartment, such as the battery compartment 212 of the aerosol-generating device 200 in as shown FIG. 6A and FIG. 6B. With the 350 installed in the use position, the expandable pouch 362 is arranged proximal to the recessed cavity 216 of the aerosol -generating device 200. The recessed cavity 216 provides space within the battery compartment 212 for the expandable pouch 362 to expand into. The battery compartment 212 does not restrict or impede expansion of the expandable pouch 362. The aerosol-generating device 200 is thereby resilient to swelling of the battery 350 without causing damage or failure of the other components in the aerosol-generating device 200.

[0101] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0102] Features, integers, characteristics or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0103] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMS1. An aerosol -generating device for an aerosol -generating system comprising an aerosol-generating article, the aerosol-generating device comprising: a housing comprising a battery compartment opening, wherein the housing is configured to removably engage an aerosol-generating article having a substrate to be heated by a heating element to generate an aerosol; a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, a battery having a battery terminal and a body portion; at least one battery interconnection terminal located within the battery compartment, the at least one battery interconnection terminal comprising a coil spring configured, in the use position, to electrically connect with the battery terminal of the battery and to at least partially surround a circumference of the body portion.

2. The aerosol-generating device of claim 1, wherein the coil spring is configured to lengthen as the battery is received into the use position in the battery compartment.

3. The aerosol-generating device of claim 1 or 2, wherein the coil spring comprises a first mount portion, a second mount portion, and an intermediary length between the first mount portion and the second mount portion.

4. The aerosol-generating device of claim 3, wherein the battery compartment comprises a mounting surface and wherein each of the first mount portion and the second mount portion are secured to the mounting surface.

5. The aerosol-generating device of any one of claims 1 to 4, wherein the at least one battery interconnection terminal comprises a pair of battery interconnection terminals configured so that, when the battery having a pair of battery terminals is in the use position, the battery interconnection terminals electrically connect to opposing battery terminals.

6. The aerosol-generating device of any one of claims 1 to 5, wherein the housing further comprises an access opening configured to permit a user to engage the battery within the battery compartment and eject the battery through the battery compartment opening.

7. The aerosol-generating device of any one of claims 1 to 6, further comprising an air inlet configured to provide ingress of air to the aerosol-generating article operably engaged with the aerosol-generating device.

8. The aerosol-generating device of any one of claims 1 to 7, further comprising a battery having a pair of battery terminals and a body portion from a first end portion to a second end portion, wherein the battery is operably received in a use position in the battery compartment.

9. The aerosol-generating device of claim 8, wherein the first end portion has a profiled shape configured so that, as the battery is inserted into the battery compartment opening with the first end portion leading into the battery compartment opening, the profiled shape deflects the coil spring around the body portion.

10. The aerosol -generating device of claim 8 or 9, wherein the battery comprises an outer casing and a reinforcing sub-layer, wherein the reinforcing sub-layer is provided at least in the body portion of the battery.

11. The aerosol -generating device of claim 10, wherein the reinforcing sub-layer comprises a swell-resistant material.

12. The aerosol -generating device of any one of claims 8 to 11, wherein the first end portion comprises an expandable pouch configured to accommodate a volume increase of the battery.

13. The aerosol-generating device of claim 12, wherein the expandable pouch is formed from a circumferential band of the outer casing extending from the first end portion of the battery, and wherein the circumferential band is configured to expand from a first, folded configuration to a second, unfolded configuration.

14. The aerosol -generating device of any one of claims 8 to 13, wherein the battery compartment comprises a recessed cavity arranged so that, in the use position, the first end portion of the battery is proximal to the recessed cavity .

15. The aerosol-generating device of any one of claims 1 to 14, further comprising a battery interconnection assembly securable to the housing of the aerosol-generating device, wherein the at least one battery interconnection terminal is mounted on the battery interconnection assembly.

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