Aerosol-generating device, housing, and battery unit for releasably attaching to the housing

Abstract

The present invention relates to an aerosol-generating device including a housing, and a battery unit for releasably attaching to the housing. The housing comprises a battery compartment opening and is configured to removably engage an aerosol-generating article having a substrate to be heated by a heating element to generate an aerosol. The battery unit comprises a pouch battery, a shell member, including an outer surface, wherein the shell member is configured to be releasably attached to the housing, and an interface layer, arranged between the pouch battery and the shell member, configured to releasably adhere the pouch battery to the shell member. The aerosol-generating device also includes a battery compartment, accessible by the battery compartment opening, and configured to operably receive the battery unit in an attached position within the battery compartment wherein, in the attached position, the housing and the outer surface of the shell member together form an integral enclosure of the aerosol-generating device. A battery unit for the aerosol-generating device is also disclosed.

Description

AEROSOL-GENERATING DEVICE, HOUSING, AND BATTERY UNIT FOR RELEASABLY ATTACHING TO THE HOUSINGTECHNICAL FIELD

[0001] The present invention relates to an aerosol-generating device, a housing, and a battery unit for releasably attaching to the housing.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 pouch battery is required as a power source to provide power to the heating element. Such pouch batteries provide an energy storage means with high energy density and capacity suitable for aerosol-generating devices while maintaining a relatively light weight.

[0004] When the capacity of the pouch battery is depleted, the electronic device no longer works without a replacement pouch 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 to avoid any risk of damage to the electronic componentry of the aerosol-generating device.

[0005] Pouch batteries are thereby required to be installed in the aerosol -generating device so that the user is able to remove and replace the batteries. Pouch batteries are susceptible to physical damage, for example due to punctures or mechanical stress to their thin or flexible outer casings during use. The use of tools or implements to remove or replace pouch batteries further increases the risk of damage.

[0006] 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

[0007] The invention is set out in the appended claims.

[0008] According to an aspect of the invention, there is provided an aerosol-generating device for generating an aerosol from a substrate of 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 unit including: a pouch battery, a shell member, including an outer surface, wherein the shell member is configured to be releasably attached to the housing, and an interface layer, arranged between the pouch battery and the shell member, configured to releasably adhere the pouch battery to the shell member; and a battery compartment, accessible by the battery compartment opening, and configured to operably receive the battery unit in an attached position within the battery compartment; wherein, in the attached position, the housing and the outer surface of the shell member together form an integral enclosure of the aerosol-generating device.

[0009] According to another aspect, there is provided a battery unit for an aerosol-generating device including: a pouch battery; a shell member; and an interface layer arranged between the pouch battery and the shell member, configured to hold the pouch battery onto the shell member.

[0010] According to a further aspect, there is provided an aerosol-generating device for generating an aerosol from a substrate of 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 first connector a battery unit including: a shell member, including an outer surface, wherein the shell member is configured to be releasably attached to the housing, a pouch battery, releasably adhered to the shell member, and a second connector; anda battery compartment, accessible by the battery compartment opening, and configured to operably receive the battery unit in an attached position within the battery compartment; wherein, in the attached position, the housing and the outer surface of the shell member together form an integral enclosure of the aerosol-generating device; and wherein either the first connector or the second connector includes a magnetised portion configured, so that as the battery unit is brought proximal to the battery compartment, the magnetised portion magnetically engages a complementary portion on the other one of the first connector or second connector and draws the battery unit into the attached position.

[0011] Aspects of the present invention provide an aerosol-generating device in which the end-user can replace the pouch battery and easily install a replacement pouch battery ready for use. By incorporating the interface layer the pouch battery is securely held while the battery unit is assembled with the aerosolgenerating device.

[0012] Aspects also enable the user to insert the replacement pouch battery with the correct alignment to electrically connect the pouch battery to the aerosol-generating device for use. The pouch battery is easily inserted into the aerosol-generating device without interference or collision with the housing or battery compartment. Furthermore, the shell member advantageously retains the pouch battery during use so that it is mechanically secure within the battery compartment and protected from external impacts.

[0013] The enclosure also ensures the aerosol-generating device provides a comfortable fit in the user's hands. The risk of abrasion to, or damage caused by, the component parts, or the raised edges, of the aerosolgenerating device housing is reduced.

[0014] The battery compartment opening may be circumscribed by a compartment periphery. In the attached position, the outer surface of the shell member is flush with the compartment periphery.

[0015] The housing has a contoured surface in the vicinity of the battery compartment opening and, in the attached position, the outer surface of the battery unit forms an integral part of the housing, with the outer surface shaped to continue the contoured surface of the housing. That is, a curvature radius of the outer surface of the housing at the compartment periphery is the same or substantially the same as a curvature radius of the outer surface of the shell member.

[0016] In these ways, the shell member of the battery unit forms a continuous surface with the housing, further improving the comfort of the fit in the user's hand, and reducing the risk of abrasion to, or caused by the shell member or housing.

[0017] The aerosol-generating device may include a first connector, and the battery unit may include a second connector. Either the first connector or the second connector includes a magnetised portion configured, so that as the battery unit is brought proximal to the battery compartment, the magnetised portion magnetically engages a complementary portion on the other one of the first connector or second connectorand draws the battery unit into the attached position. The magnetised portion may secure the battery unit in the attached position.

[0018] In these ways, the magnetised portion enables a secure connection between the battery unit and the housing, as well as encouraging correct assembly of the aerosol-generating device.

[0019] The second connector may include a battery terminal. The second connector may include a pair of battery terminals. The second connector may include a elongate bar at the first end portion of the pouch battery. The second connector may project from an outer casing of the pouch battery. The, or each, battery terminal may be adjoined to the pouch battery.

[0020] The first connector may include a device terminal for electrically connecting the aerosol-generating device to the battery terminal of the battery unit

[0021] In these ways, the pouch battery, and the aerosol-generating device itself, may each be manufactured in a compact form, and with a reduced number of parts.

[0022] The battery unit may include an inner surface. The inner surface may be provided on a support mount. The inner surface may be a planar surface. The interface layer may be releasably adhere the pouch battery to the inner surface.

[0023] The inner surface may include an alignment means configured to align the pouch battery with respect to the inner surface prior to the pouch battery engaging with the interface layer. The alignment means may include a projecting rib on the inner surface.

[0024] In these ways, the pouch battery may be releasably attached to the shell member. The pouch battery may be easily and accurately attached so that its second connector aligns with the first connector as the battery unit is engaged with the aerosol-generating device.

[0025] The interface layer may include at least one length of adhesive tape. The at least one length of adhesive tape includes two or more lengths of adhesive tape. The two or more lengths of adhesive tape arranged in parallel on the inner surface of the battery unit.

[0026] The interface layer may be arranged to hold a primary side surface of the pouch battery. That is, a pouch battery may have one, or a pair of primary side surfaces, forming the majority of the outer surface of the pouch battery, as well as other secondary side surfaces. The primary side surfaces may be substantially flat. The secondary side surfaces may be curved, folded, or undulated. The interface layer adheres to a side surface of the pouch battery having a increased contact area, providing more effective grip.

[0027] The at least one length of adhesive tape includes a stretch release tape.

[0028] In these ways, the pouch battery, and the interface layer, may each be readily released from the shell member without leaving any residue that would otherwise interfere with a replacement pouch battery.

[0029] The housing may include a battery interconnection assembly secured within the housing. The battery compartment may be defined by a peripheral wall of the battery interconnection assembly. Thebattery interconnection assembly may also include one or more of: a mounting surface, a first mount portion, or a second mount portion.

[0030] By providing an battery interconnection assembly, along with any associated terminals, the aerosolgenerating device may be more easily assembled during manufacturing.

[0031] The housing may include an engaging element. The engaging element may be configured to engage the second connector of the pouch battery as the battery unit engages the housing. The engaging element may include a slot for receiving the second connector in the attached position. In examples that include a magnetised portion, the engaging element may help the user locate the second connector in a position for the magnetised portion to draw the battery unit into the attached position.

[0032] 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.

[0033] The access opening and an article-receiving 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.

[0034] 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.

[0035] 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.

[0036] The aerosol-generating device may include mutually compatible retainer means provided on the battery unit and in the battery compartment to selectively lock the battery unit to the aerosol-generating device is the attached position.EXAMPLES:

[0037] 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.

[0038] Example Exl : An aerosol-generating device for generating an aerosol from a substrate of 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 unit including: a pouch battery, a shell member, including an outer surface, wherein the shell member is configured to be releasably attached to the housing, and an interface layer, arranged between the pouch battery and the shell member, configured to releasably adhere the pouch battery to the shell member; and a battery compartment, accessible by the battery compartment opening, and configured to operably receive the battery unit in an attached position within the battery compartment; wherein, in the attached position, the housing and the outer surface of the shell member together form an integral enclosure of the aerosol-generating device.

[0039] Ex2. The aerosol-generating device of Exl, wherein, the battery compartment opening is circumscribed by a compartment periphery, and wherein, in the attached position, the outer surface of the shell member is flush with the compartment periphery.

[0040] Ex3. The aerosol-generating device of Exl or Ex 2, wherein the housing has a contoured surface in the vicinity of the battery compartment opening and, in the attached position, the outer surface of the battery unit forms an integral part of the housing, with the outer surface shaped to continue the contoured surface of the housing.

[0041] Ex4. The aerosol-generating device of any one of Exl to Ex3, wherein the aerosol-generating device includes a first connector, and the battery unit includes a second connector, and wherein either the first connector or the second connector includes a magnetised portion configured, so that as the battery unit is brought proximal to the battery compartment, the magnetised portion magnetically engages a complementary portion on the other one of the first connector or second connector and draws the battery unit into the attached position.

[0042] Ex5. The aerosol-generating device of Ex4, wherein the magnetised portion secures the battery unit in the attached position.

[0043] Ex6. The aerosol-generating device of Ex4 or Ex5, wherein the second connector includes a battery terminal.

[0044] Ex7. The aerosol-generating device of Ex6, wherein the battery terminal is adjoined to the pouch battery.

[0045] Ex8. The aerosol-generating device of any one of Ex4 to Ex7, wherein the first connector includes a device terminal for electrically connecting the aerosol-generating device to the battery terminal of the battery unit

[0046] Ex9. The aerosol-generating device of any one of Exl to Ex8, wherein the battery unit further includes an inner surface, and the interface layer releasably adheres the pouch battery to the inner surface.

[0047] ExlO. The aerosol-generating device of Ex9, the inner surface is provided on a support mount.

[0048] Exl 1. The aerosol-generating device of ExlO, the inner surface is a planar surface.

[0049] Exl2. The aerosol-generating device of any one of Ex9 to Exl 1, wherein the inner surface includes an alignment means configured to align the pouch battery with respect to the inner surface prior to the pouch battery engaging with the interface layer.

[0050] Exl3. The aerosol-generating device of Exl2, wherein the alignment means includes a projecting rib on the inner surface.

[0051] Exl4. The aerosol-generating device of any one of Exl to 13, wherein the housing further includes a battery interconnection assembly mounted within the housing.

[0052] Exl5. The aerosol-generating device of Exl4, wherein the battery compartment is defined by a peripheral wall of the battery interconnection assembly.

[0053] Exl6. The aerosol-generating device of Exl4 or Exl5, wherein the battery interconnection assembly includes a first connector.

[0054] Exl7. The aerosol-generating device of any one of Exl to Exl6, wherein the aerosol-generating device further includes mutually compatible retainer means provided on the battery unit and in the battery compartment to selectively lock the battery unit to the aerosol-generating device is the attached position.

[0055] Exl8. A battery unit for an aerosol-generating device including: a pouch battery; a shell member; and an interface layer arranged between the pouch battery and the shell member, configured to hold the pouch battery onto the shell member.

[0056] Exl9. The aerosol-generating device of any one of Exl to Ex 18, wherein the interface layer includes at least one length of adhesive tape.

[0057] Ex20. The aerosol-generating device of Ex 19, wherein the at least one length of adhesive tape includes a stretch release tape.

[0058] Ex21. The aerosol-generating device of Exl9 or Ex20, wherein the at least one length of adhesive tape includes two or more lengths of adhesive tape arranged in parallel on the inner surface of the battery unit.

[0059] Ex22. An aerosol-generating device for generating an aerosol from a substrate of 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 first connector a battery unit including: a shell member, including an outer surface, wherein the shell member is configured to be releasably attached to the housing, a pouch battery, releasably adhered to the shell member, and a second connector; and a battery compartment, accessible by the battery compartment opening, and configured to operably receive the battery unit in an attached position within the battery compartment; wherein, in the attached position, the housing and the outer surface of the shell member together form an integral enclosure of the aerosol-generating device; and wherein either the first connector or the second connector includes a magnetised portion configured, so that as the battery unit is brought proximal to the battery compartment, the magnetised portion magnetically engages a complementary portion on the other one of the first connector or second connector and draws the battery unit into the attached position.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0060] Examples will now be described further with reference to the figures in which:FIG. 1 shows an exploded perspective view of an example aerosol-generating device including a battery unit;FIG. 2 shows a perspective view of the partially assembled aerosol-generating device of FIG. 1 ;FIG. 3 shows a perspective view of the assembled aerosol-generating device of FIG. 1 ;FIG. 4 shows a perspective view of the battery interconnection assembly 130 of the aerosolgenerating device of FIG. 1 ;FIG. 5A shows a perspective view of the battery unit of the aerosol-generating device of FIG. 1 ;FIG. 5B shows a perspective view of the shell member of the battery unit of FIG. 5 A; andFIG. 5C shows a close up perspective view of the battery unit of FIG. 5A.DETAILED DESCRIPTION

[0061] 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 thedrawings 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.

[0062] 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.

[0063] 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.

[0064] Referring now to FIG. 1 to FIG. 4 there is shown there is shown an example aerosol-generating device, including a removable battery unit, 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.

[0065] In FIG. 1, the aerosol-generating device 100 is shown in an exploded view, with a pouch battery 150 dismounted from both the aerosol-generating device 100 and a shell member 142.

[0066] In FIG. 2, the pouch battery 150 mounted to the shell member 142 to form a battery unit 140. The battery unit 140 is dismounted from the rest of the aerosol -generating device 100, ready for insertion into the aerosol-generating device 100.

[0067] In FIG. 3, the battery unit 140 is secured into the housing 110. The pouch battery 150 of the battery unit 140 is electrically connected to aerosol-generating device 100 to act as a power source for the associated heating element.

[0068] The aerosol-generating device 100 includes a housing 110 with a battery compartment opening 114. The battery compartment opening 114 is circumscribed by a compartment periphery. 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 includes an articlereceiving opening 116. The article-receiving opening 116 is configured to receive and secure an aerosolgenerating article (not shown) to the aerosol-generating device 100. The housing 110 and the aerosolgenerating article may each include aspects of mutually compatible means to secure the aerosol-generating article to the housing 110 in an engaged position for use.

[0069] 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 pouch battery 150 in an attached position in which the pouch battery 150 is electrically connected to the aerosol-generating device. In the attached position, the pouch battery 150 provides electrical power to the heating element for heating the aerosol-forming substrate.

[0070] The battery compartment 112 includes a first connector 119. The first connector 119 is associated with a device terminal to provide electrical connectivity to the aerosol-generating device 100.

[0071] The aerosol-generating device 100 further includes a battery unit 140. The battery unit 140 includes a shell member 142 having an outer surface. The shell member 142 is configured to be releasably attached to the housing 110 of the aerosol-generating device 100.

[0072] The battery unit 140 also includes a pouch battery 150. The pouch battery 150 is releasably adhered to the shell member 142, for examples using an interface layer, as described below with reference to FIG. 5 A to FIG. 5C.

[0073] The pouch battery 150 includes a pair of battery terminals 158 and a body portion 152. The body portion 152 of the pouch battery 150 extends between a first end portion 153 and an opposing second end portion 154. The pouch battery 150 also includes a second connector 156 that has the pair of battery terminals 158 provided thereon. The second connector 156, and thereby the battery terminal 158, are adjoined to the first end portion 153 of the pouch battery 150. The pair of battery terminals 158 are electrically connected to an energy-storing cell within the pouch battery 150 to provide opposing battery terminals of the pouch battery 150.

[0074] In the attached position the second connector 156 engages against the second connector within the battery compartment 112 so that the pair of battery terminals 158 are electrically connected to the aerosolgenerating device 100 through the device terminal.

[0075] The second connector 156 includes a magnetised portion configured, so that as the pouch battery 150 is brought proximal to the battery compartment 112, the magnetised portion magnetically engages a complementary portion on the second connector and draws the battery unit 140 into the attached position. In other examples, the second connector may include a magnetised portion and the complementary portion may be provided on the second connector 156 to provide the same draw effect on the battery unit 140.

[0076] In these ways, when a user inserts the battery unit 140, for example when replacing a spent pouch battery 150, as the user brings the battery unit 140 with replacement pouch battery 150 towards the battery compartment opening 114, the magnetised portion pulls the battery unit 140 into the attached position. The battery unit 140 is received into the battery compartment opening 114 with correct alignment and positioning to ensure both that the the pouch battery 150 is electrically connected to the aerosol-generating device 100, and that the shell member 142 is flush with the compartment periphery. Stated differently, the use of amagnetised portion with the first connector and second connector provides a self-locating connection means for inserting the pouch battery 150 into the aerosol-generating device 100.

[0077] The magnetised portion at least partly secures the battery unit 140 within the housing. In certain examples, a retainer means may assist in securing the battery unit 140. The retainer means may include mutually compatible parts on the housing and on the battery unit, for example a clip, a lock, or interference elements formed on one or each of the battery unit and the housing.

[0078] In the attached position, the housing 110 and the outer surface of the shell member 142 together form an integral enclosure of the aerosol-generating device 100. With the pouch battery 150 in the attached position, the battery unit 140 is attached to the housing 110 so that an outer surface of the shell member 142 is flush with the compartment periphery. In particular, in the example shown, the housing 110 has a contoured surface in the vicinity of the battery compartment opening to provide a smooth and aesthetically pleasing shape for the user. When the battery unit 140 is attached to the housing 110, the outer surface of the battery unit 140 forms an integral part of the housing 110. The outer surface is shaped to continue the contoured surface of the housing 110.

[0079] The pouch battery 150 has an outer casing enclosing the electrochemical cell of the pouch battery 150 that stores energy. The pouch 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 outer casing of the battery. In the example, the cross-sectional shape is rectangular, with uniform width and height along the battery length.

[0080] 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 battery compartment are configured such that insertion of the battery into the battery compartment enables the complementary first three-dimensionally patterned surface and second three-dimensionally patterned surface to engage one another.

[0081] 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 112 within the aerosolgenerating device 100. As shown in FIG. 4, the battery interconnection assembly 130 is a sub-unit of the aerosol-generating device 100 that is securable within the housing 110. In this way, the battery interconnection assembly 130 may be formed with the second connector and other components, for example a heating element and other electrical components, for convenient assembly within the aerosol-generating device 100.

[0082] The housing 110 include an engaging element 132. In the example, the engaging element 132 is in the form of a slot in the battery interconnection assembly 130. The engaging element 132 is configured to engage the second connector 156 of the pouch battery 150 as the battery unit 140 engages the housing 110.By receiving the second connector 156 in the slot, the engaging element 132 helps the user locate the second connector 156 in a position for the magnetised portion to draw the battery unit 140 into the attached position.

[0083] The housing 110 includes an access opening 118. In the example shown, the access opening 118 extends through the housing 110 and the battery interconnection assembly 130. The access opening 118 is located to allow a user to engage the pouch battery 150 within the battery compartment 112. The user is able to push against the pouch battery 150 to eject the pouch battery 150 through the battery compartment opening 114.

[0084] In the example shown, the article-receiving opening 116 is arranged at an opposing end of the housing 110 to the access opening 118.

[0085] 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.

[0086] 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.

[0087] Referring additionally to FIG. 5A to FIG. 5C, there are shown close up views of the battery unit 140 for use with the aerosol-generating device 100 described here. In FIG. 5B, the shell member 142 is shown without the pouch battery 150.

[0088] The battery unit 140 includes the pouch battery 150, the shell member 142 and an interface layer 146. The interface layer 146 holds the pouch battery 150 onto the shell member 142 so that the pouch battery 150 is aligned with the shell member 142 ready to for the battery unit 140 to engage with the aerosolgenerating device 100 in the attached position.

[0089] The shell member 142 of the battery unit 140 is typically formed with a wall of uniform thickness. The shell member 142 also includes an inner surface. The inner surface opposes the outer surface but may be disposed away from the wall. In the example shown, the inner surface is provided on a support mount 144 to provide a planar surface on which to provide the interface layer 146.

[0090] The inner surface also includes an alignment means configured to align the pouch battery with respect to the inner surface prior to the pouch battery engaging with the interface layer. In certain examples, the alignment means includes a projecting rib on the inner surface to provide a lengthwise guide by which to align the lengthwise direction of the pouch battery 150. Additionally, or alternatively, the alignment means may include a projecting rib or step on the inner surface to provide a lower limit against which a second end portion of the pouch battery abuts when the pouch battery is releasably adhered to the shell member.

[0091] The interface layer 146 of the battery unit 140 typically includes at least one length of adhesive tape. In the example shown, the interface layer 146 has a two lengths of stretch release tapes. The two lengths are arranged in parallel to one another on the inner surface of the shell member 142.

[0092] Each tape provides a reliable bond to adhere to the pouch battery 150 as it is urged against the inner surface. The pouch battery 150 is held in position relative to the shell member 142 as the battery unit 140 is attached to the housing 110 in the attached position. The magnetised portion ensures the battery terminal 158 are electrically connected to the aerosol-generating device to provide power to the heating element.

[0093] When the pouch battery 150 is spent it is replaced by first removing the battery unit 140 from the aerosol-generating device 100. The pouch battery 150 is released from the shell member 142 by the user pulling an end of each stretch release tape, which causes the bond between the tape and pouch battery 150 to weaken, enabling the pouch battery 150 to be easily detached. A replacement pouch battery may be installed by first applying fresh tape to the inner surface and then urging the pouch battery against the tape, so that the battery unit is ready for installing into the aerosol-generating device 100.

[0094] 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.

[0095] 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.

[0096] 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 generating an aerosol from a substrate of 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 unit comprising: a pouch battery, a shell member, including an outer surface, wherein the shell member is configured to be releasably attached to the housing, and an interface layer, arranged between the pouch battery and the shell member, configured to releasably adhere the pouch battery to the shell member; and a battery compartment, accessible by the battery compartment opening, and configured to operably receive the battery unit in an attached position within the battery compartment; wherein, in the attached position, the housing and the outer surface of the shell member together form an integral enclosure of the aerosol-generating device.

2. The aerosol-generating device of claim 1, wherein, the battery compartment opening is circumscribed by a compartment periphery, and wherein, in the attached position, the outer surface of the shell member is flush with the compartment periphery.

3. The aerosol-generating device of claim 1 or 2, wherein the housing has a contoured surface in the vicinity of the battery compartment opening and, in the attached position, the outer surface of the battery unit forms an integral part of the housing, with the outer surface shaped to continue the contoured surface of the housing.

4. The aerosol-generating device of any one of claims 1 to 3, wherein the aerosol-generating device comprises a first connector, and the battery unit comprises a second connector, and wherein either the first connector or the second connector includes a magnetised portion configured, so that as the battery unit is brought proximal to the battery compartment, the magnetised portion magnetically engages a complementary portion on the other one of the first connector or second connector and draws the battery unit into the attached position.

5. The aerosol-generating device of claim 4, wherein the second connector comprises a battery terminal.

6. The aerosol-generating device of claim 4 or 5, wherein the first connector comprises a device terminal for electrically connecting the aerosol-generating device to the battery terminal of the battery unit7. The aerosol-generating device of any one of claims 1 to 6, wherein the battery unit further comprises an inner surface, and the interface layer releasably adheres the pouch battery to the inner surface.

8. The aerosol-generating device of claim 7, the inner surface is provided on a support mount.

9. The aerosol-generating device of claim 7 or 8, wherein the inner surface comprises an alignment means configured to align the pouch battery with respect to the inner surface prior to the pouch battery engaging with the interface layer.

10. The aerosol -generating device of any one of claims 1 to 9, wherein the housing further comprises a battery interconnection assembly mounted within the housing.

11. The aerosol -generating device of claim 10, wherein the battery compartment is defined by a peripheral wall of the battery interconnection assembly.

12. The aerosol -generating device of any one of claims 1 to 10, wherein the aerosol-generating device further comprises mutually compatible retainer means provided on the battery unit and in the battery compartment to selectively lock the battery unit to the aerosol-generating device is the attached position.

13. The aerosol-generating device of any one of claims 1 to 12, wherein the interface layer comprises at least one length of adhesive tape.

14. The aerosol-generating device of claim 13, wherein the at least one length of adhesive tape comprises a stretch release tape.

15. A battery unit for an aerosol-generating device comprising: a pouch battery; a shell member; and an interface layer arranged between the pouch battery and the shell member, configured to hold the pouch battery onto the shell member.

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