Aerosol generating device and method of manufacturing an aerosol generating device

Abstract

The present invention relates to an aerosol-generating device for generating an aerosol from a substrate of an aerosol-generating article. The aerosol-generating device comprises 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 comprises a battery comprising a first three-dimensionally patterned surface, and a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, the battery so that the battery is electrically connected to the aerosol-generating device. A second three-dimensionally patterned surface arranged at a side wall of the battery compartment and the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are complementary to one another. An aerosol-generating device battery is also disclosed, particularly for removably engagement within a battery compartment.

Description

AEROSOL GENERATING DEVICE AND METHOD OF MANUFACTURING AN AEROSOL GENERATING DEVICETECHNICAL 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 including a housing, particularly a housing with a battery compartment having a battery compartment opening for access. An aerosolgenerating device battery is also disclosed, particularly for removably engagement within a battery compartment.BACKGROUND

[0002] Aerosol-generating articles in which an aerosol-forming substrate, such as a tobaccocontaining 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 aerosolgenerating device to a physically separate aero sol -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 aero sol -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. Batteries, typically pouch cell batteries, or prismatic cell batteries, are installed in the aerosol-generating device so that the user is able to remove and replace the batteries.

[0004] 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 to avoid any risk of damage to the electronic componentry of the aerosol-generating device.

[0005] Batteries that are not specifically designed to be compatible with the aerosol -generating device have unknown charging or discharging characteristics. Such batteries may not work reliably with the aerosol-generating device. A user may decide to use a battery for an aerosol-generating article inanother device for which it was not intended, again risking damage to the battery and to the other device.

[0006] Counterfeit batteries are marketed for aero sol -generating devices but are of inferior quality and have reduced mechanical strength. Use of counterfeit batter leads to reduced performance of the aerosol-generating device and increases the risk of damage to the device, for example from leakage or puncturing of the battery.

[0007] 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

[0008] The invention is set out in the appended claims.

[0009] 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 including a first three-dimensionally patterned surface; a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, the battery so that the battery is electrically connected to the aerosol-generating device; and a second three-dimensionally patterned surface arranged at a side wall of the battery compartment; wherein the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are complementary to one another.

[0010] Aspects of the present invention provide an aero sol -generating device in which the end-user can replace the battery and easily install a replacement battery ready for use. It also ensures the user inserts the battery cell with the correct alignment and positioning in the battery compartment, ensuring that the battery connects to the aerosol-generating device with the correct polarity.

[0011] Furthermore, the complementary three-dimensionally patterned surfaces become interlinked, enabling a cover of the battery compartment opening to seal the battery compartment. The cover fits flush with the housing of the aerosol-generating device when used with the battery having a three- dimensionally patterned surface complementary to the three-dimensionally patterned surface within the battery compartment.

[0012] By incorporating the complementary three-dimensionally patterned surfaces it is possible to provide a mechanical encryption between the battery and the battery compartment. The mechanical encryption ensures only matching first and second three-dimensionally patterned surfaces conform to one another so that the battery is fully received into the battery compartment. Thus the use of counterfeit batteries is prevented because such batteries will not electrically connect to the aerosolgenerating device in the use position, and the battery will not provide electrical power to the heating element.

[0013] The first three-dimensionally patterned surface and the second three-dimensionally patterned surface may be configured so that, in the use position, the first three-dimensionally patterned surface conforms with the second three-dimensionally patterned surface.

[0014] The first three-dimensionally patterned surface may include a first surface array of embossed regions and debossed regions. The second three-dimensionally patterned surface may include a complementary second surface array of embossed regions and debossed regions. The, or each, of the first three-dimensionally patterned surface or the second three-dimensionally patterned surface may extend in a respective lengthwise direction and a respective crosswise direction, perpendicular to the lengthwise direction. The embossed regions and the debossed regions may each extend in both the lengthwise direction and the crosswise direction.

[0015] The, or each, of the first three-dimensionally patterned surface or the second three- dimensionally patterned surface may include a plurality of irregular surface features.

[0016] The first three-dimensionally patterned surface may be a mutually-inverse version of the second three-dimensionally patterned surface.

[0017] In these ways, the three-dimensionally patterned surfaces may be manufactured in a range of forms, according to the materials and manufacturing process appropriate to a battery. The three- dimensionally patterned surfaces may be modified so that the first three-dimensionally patterned surface can be selective to one second three-dimensionally patterned surface, or a predetermined limited range of second three-dimensionally patterned surfaces.

[0018] The battery may include at least one battery terminal configured to that, in the use position, the battery terminal is contactingly engages a corresponding device terminal to electrically connect the battery to the aerosol-generating device. 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.

[0019] The first connector may include a device terminal for electrically connecting the aerosolgenerating device to the battery terminal of the battery unit

[0020] 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.

[0021] The battery may include a battery terminal and the battery compartment includes a device terminal, and wherein the first three-dimensionally patterned surface and the second three- dimensionally patterned surface are configured such that the device terminal contactingly engages the battery terminal only when the battery is fully engaged within the battery compartment.

[0022] The housing may include 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.

[0023] The access opening and the battery compartment opening may be arranged on opposing sides of the housing. The access opening may include a lid to selectively cover the access opening. In this way, the user may easily remove a spent battery.

[0024] 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.

[0025] 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.

[0026] The aerosol-generating device may include an air inlet. The air inlet may be configured to provide ingress of air to the aero sol -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 aerosolgenerating article to entrain the aerosol generated from the aero sol -forming substrate of the aerosolgenerating article.

[0027] The battery may include a pair of battery terminals and a body portion. The body portion of the battery may extend between a first end portion and an opposing second end portion.

[0028] The aerosol-generating device may include a battery unit having a shell member with an outer surface. The shell member may be configured to be releasably attached to the housing of the aerosolgenerating device. The battery may be mounted to the battery unit .

[0029] 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.

[0030] The housing may have a contoured surface in the vicinity of the battery compartment opening and, in the use 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.

[0031] 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.

[0032] 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 connector and draws the battery unit into the attached position. The magnetised portion may secure the battery unit in the attached position.

[0033] 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.

[0034] According to another aspect, there is provided a method of manufacturing an aerosolgenerating device battery, the method including: providing a battery cell having a body portion; inserting the battery cell into an outer casing preform; inserting a sheet element between the body portion and the outer casing preform, wherein the sheet element includes a three-dimensionally patterned surface; and vacuum-forming the outer casing preform around the body portion so that an external surface portion of the outer casing conforms to the three-dimensionally patterned surface.

[0035] Aspects of the present invention provide a convenient method of applying mechanical encryption to battery. By providing a battery that is compatible with complementary mechanical encryption within an aerosol-generating device, it is convenient to reduce or eliminate the risks from use of counterfeit batteries in aerosol-generating devices.

[0036] In addition, by providing a sheet element adjacent to a face of the battery cell, the outer casing is reinforced. This provides greater safety for the user and the longevity of the aerosol -generating device by reducing the impact of any damage or swelling on the face of the battery that contacts the battery compartment, reducing the risk of puncture or mechanical damage to the battery. The risk of short circuiting and / or damage to the internal components of the aerosol-generating device from the battery is reduced.

[0037] The forming step of the method may include one or both of: vacuum-forming the outer casing preform around the sheet element and cell body portion, or heat-shrinking the outer casing preform around the sheet element and cell body portion.

[0038] In these ways, the manufacturing method for the battery may be adapted according to the component parts.

[0039] The sheet element may be a rigid plate. The sheet element may be include a ceramic material or any porcelain insulators. The sheet element may include an insulating plastic material, such as a polycarbonate material, a polystyrene material, or a polyethylene material.

[0040] In these ways, the sheet element may be formed from a suitable inert material. The sheet element may act as a barrier to protect the aerosol-generating device from unintentional heating or electrical discharge from the battery.

[0041] The method may include a further step of sealing closed an open end of the outer casing preform.

[0042] In this way, the cell is disposed inside a sealed chamber, and the air is gradually removed to create a vacuum. This helps eliminate any moisture or air trapped within the battery, which could potentially lead to oxidation, corrosion, or thermal runaway during operation. Once the desired level of vacuum is achieved, the battery is hermetically sealed to maintain the vacuum environment and prevent any external contaminants from entering the cell.

[0043] The outer casing preform may seal against the second connector. In this way, the second connector projects from the battery while the outer casing preform seals the cell within the outer casing preform. The battery terminals are conveniently arranged to electrically connect to the aerosolgenerating device.

[0044] The method may include a further step of forming an elongate seam at least along at least a portion of a perimeter of the battery cell. This ensures a snug fit of the outer casing preform around the cell, avoiding wear from friction between the cell and outer casing preform.

[0045] As used herein "complementary" parts or features may be sufficiently similar so that a first three-dimensionally patterned surface and second three -dimensionally patterned surface fit together in a unique position relative to one another.

[0046] In certain examples, a pair of three-dimensionally patterned surfaces may be complementary if the first three-dimensionally patterned surface is a mutually-inverse version of the second three- dimensionally patterned surface. That is, the pattern of embossed regions and debossed regions on a first three-dimensionally patterned surface is reversed as corresponding debossed regions and corresponding embossed regions on a second three-dimensionally patterned surface. The respective matches may match across the whole area of the three-dimensionally patterned surfaces.

[0047] In certain examples, the first three-dimensionally patterned surface may not be exactly an inverse of the second three-dimensionally patterned surface, but include a sufficient degree of similarity in discrete regions to fit together in a unique position. The respective matches may match across certain areas of the three-dimensionally patterned surfaces. This may enable a battery with a first three-dimensionally patterned surface to engage, in a use position, with a limited range of differing second three-dimensionally patterned surfaces in different aerosol-generating devices.EXAMPLES:

[0048] 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.

[0049] 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 including a first three-dimensionally patterned surface; a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, the battery so that the battery is electrically connected to the aerosol-generating device; and a second three-dimensionally patterned surface arranged at a side wall of the battery compartment; wherein the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are complementary to one another.

[0050] Ex2. The aerosol-generating device of Exl, wherein the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are configured so that, in the use position, the first three-dimensionally patterned surface conforms with the second three-dimensionally patterned surface.

[0051] Ex3. The aerosol-generating device of Exl or Ex2, wherein the battery includes at least one battery terminal configured to that, in the use position, the battery terminal is contactingly engages a corresponding device terminal to electrically connect the battery to the aerosol-generating device.

[0052] Ex4. The aerosol-generating device of Ex3, wherein the battery includes a battery terminal and the battery compartment includes a device terminal, and wherein the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are configured such that the device terminal contactingly engages the battery terminal only when the battery is fully engaged within the battery compartment.

[0053] Ex5. The aerosol-generating device of any one of Exl to Ex4, wherein the first three- dimensionally patterned surface includes a first surface array of embossed regions and debossed regions.

[0054] Ex6. The aerosol-generating device of any one of Exl to Ex5, wherein the second three- dimensionally patterned surface includes a complementary second surface array of embossed regions and debossed regions.

[0055] Ex7. The aerosol-generating device of any one of Exl to Ex6, wherein each of the first three- dimensionally patterned surface and the second three -dimensionally patterned surface extends in a respective lengthwise direction and a respective crosswise direction, perpendicular to the lengthwise direction, and wherein the embossed regions and the debossed regions each extend in both the lengthwise direction and the crosswise direction.

[0056] Ex8. The aerosol-generating device of any one of Exl to Ex7, wherein each of the first three- dimensionally patterned surface and the second three -dimensionally patterned surface includes a plurality of irregular surface features.

[0057] Ex9. The aerosol-generating device of any one of Exl to Ex8, wherein the first three- dimensionally patterned surface is a mutually -inverse version of the second three-dimensionally patterned surface.

[0058] ExlO. The aerosol-generating device of any one of Exl to Ex9, 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.

[0059] Exl l. The aerosol-generating device of ExlO, wherein the access opening and the battery compartment opening are arranged on opposing sides of the housing.

[0060] Exl2. The aerosol-generating device of ExlO or Exl 1, wherein the access opening includes a lid to selectively cover the access opening.

[0061] Exl3. The aerosol-generating device of any one of Exl to Exl2, further including an air inlet configured to provide ingress of air to the aero sol -generating article operably engaged with the aerosolgenerating device.

[0062] Exl4. The aerosol-generating device of Exl3 when dependent upon any one of ExlO to Exl2, wherein the air inlet is fluidly connected to the access opening.

[0063] Exl5. The aerosol-generating device of any one of Exl to Exl4, wherein the battery includes a pair of battery terminals and a body portion.

[0064] Exl6. The aerosol-generating device of Exl5, wherein the body portion of the battery extends between a first end portion and an opposing second end portion.

[0065] Exl7. The aerosol-generating device of any one of Exl to Exl6, further including a battery unit having a shell member with an outer surface, wherein the shell member is configured to be releasably attached to the housing of the aerosol-generating device, and wherein the battery is mounted to the battery unit .

[0066] Exl8. The aerosol-generating device of any one of Exl to Exl7, wherein the battery compartment opening is circumscribed by a compartment periphery, and wherein, in the use position, an outer surface of the shell member is flush with the compartment periphery.

[0067] Exl9. The aerosol-generating device of Exl7 or Exl8, wherein the housing has a contoured surface in the vicinity of the battery compartment opening and, in the use 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.

[0068] Ex20. The aerosol-generating device of any one of Exl7 to Exl9, wherein the battery unit includes a first connector and the aerosol-generating device 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 the second connector and draws the battery unit into the use position.

[0069] Ex21. A method of manufacturing an aerosol -generating device battery, the method including: providing a battery cell having a cell body portion; inserting the battery cell into an outer casing preform; inserting a sheet element between the cell body portion and the outer casing preform, wherein the sheet element includes a three -dimensionally patterned surface; and forming the outer casing preform around the sheet element and cell body portion so that an external surface portion of the outer casing conforms to the three -dimensionally patterned surface.

[0070] Ex22. The method of Ex21, wherein the forming step includes one or both of: vacuum-forming the outer casing preform around the sheet element and cell body portion, or heat-shrinking the outer casing preform around the sheet element and cell body portion.

[0071] Ex23. The method of Ex21 or Ex22, wherein the sheet element is a rigid plate.

[0072] Ex24. The method of any one of Ex21 to Ex23, further includes a step of sealing closed an open end of the outer casing preform.

[0073] Ex25. The method of any one of Ex21 to Ex24, further including a step of forming an elongate seam at least along at least a portion of a perimeter of the battery cell.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0074] Examples will now be described further with reference to the figures in which:FIG. 1A shows a perspective view of an example aero sol -generating device in which a battery unit is dismounted from the housing;FIG. IB shows the example aerosol-generating device of FIG. 1A with the battery unit mounted to the housing in a use position;FIG. 2 shows a perspective view of the battery unit of FIG. 1A and FIG. IB;FIG. 3 shows a perspective view of the battery interconnection assembly from the battery unit of FIG. 1A and FIG. IB;FIG. 4A shows a perspective view, and FIG. 4B shows a cross-sectional top view, of an example battery fully engaged within a housing;FIG. 5A shows a perspective view, and FIG. 5B shows a cross-sectional top view, of another example battery that is not fully engaged within a housing; andFIG. 6A to FIG. 6E show a series of views of steps in manufacturing an example battery.DETAILED DESCRIPTION

[0075] Certain terminology is used in the following description for convenience only and is not limiting. The words Tower’, ‘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.

[0076] 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.

[0077] 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.

[0078] Referring now to FIG. 1A to FIG. 2, 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. In FIG. 1A, the aerosol-generating device 100 is shown with a battery 150 dismounted from the aerosol-generating device 100 and ready for insertion into the aerosolgenerating device 100. The battery 150 is mounted to a battery unit 140.

[0079] 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 aerosol-generating article to the housing 110 in an engaged position for use.

[0080] 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 electrically connected to the aerosol-generating device. In the use position, the battery 150 provides electrical power to the heating element for heating the aerosol-forming substrate.

[0081] The battery 150 includes a first three-dimensionally patterned surface 121 (shown in FIG. 2). A second three-dimensionally patterned surface 122 is arranged at a side wall of the battery compartment. The first three-dimensionally patterned surface 121 and the second three-dimensionally patterned surface 122 are complementary to one another.

[0082] In the example shown, each of the first three-dimensionally patterned surface 121 and the second three-dimensionally patterned surface 122 extend in a respective lengthwise direction and a respective crosswise direction, perpendicular to the lengthwise direction. The first three-dimensionally patterned surface 121 is formed as a series of parallel ridges and grooves extending in a lengthwise direction. The second three-dimensionally patterned surface 122 is formed as a complementary series of parallel ridges and grooves extending in a lengthwise direction. The complementary series of ridges and grooves on the second three-dimensionally patterned surface 122 are offset in the crosswise direction so that when the first three-dimensionally patterned surface 121 and second three-dimensionally patterned surface 122 are engaged in the use position, the battery 150 rests in a central location within the battery compartment 112.

[0083] In this way, with the battery 150 received into the battery compartment 112, the first three- dimensionally patterned surface 121 and second three-dimensionally patterned surface 122 fit together in a predetermined lengthwise and crosswise location. This ensures that the user inserts the battery 150 with the correct alignment and positioning in the battery compartment 112.

[0084] The battery 150 is mounted to 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.

[0085] The battery 150 includes a pair of battery terminals 158 and a body portion 152. The body portion 152 of the battery 150 extends between a first end portion 153 and an opposing second end portion 154. The battery terminal 158 are located at the first end portion 153 of the battery 150.

[0086] The battery compartment 112 includes a first connector. The first connector is associated with a device terminal. The battery 150 includes a second connector 156 that has a pair of battery terminals 158 provided thereon. The pair of battery terminals 158 provide opposing battery terminals of thebattery 150. In the use position the second connector 156 engages against the first connector within the battery compartment 112 so that the pair of battery terminals 158 are electrically connected to the aerosol-generating device 100 through the device terminal.

[0087] The first three-dimensionally patterned surface and the second three-dimensionally patterned surface are configured such that the first connector contactingly engages the second connector 156 only when the battery 150 is fully engaged within the battery compartment 112. That is, the battery terminals 158 contactingly engages the device terminals only when the battery 150 is fully engaged within the battery compartment 112.,

[0088] In the example shown, the second connector 156 includes a magnetised portion configured, so that as the battery 150 is brought proximal to the battery compartment 112, the magnetised portion magnetically engages a complementary portion on the first connector and draws the battery 150 into the use position. In other examples, the first 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 150.

[0089] In addition, the magnetised portion ensures the battery unit 140 is drawn into and attached to the housing 110. The magnetised portion at least partly secures the battery unit 140 within the housing, although in certain examples, a fastener means may assist in securing the battery unit 140. Fastener means may include a clip, a lock, or interference elements formed with mutually compatible parts on the housing and on the battery unit.

[0090] If there first three-dimensionally patterned surface 121 and second three-dimensionally patterned surface 122 are not complementary than the battery 150 will not rest in the use position. Furthermore, if the battery 150 is inserted so that the first three-dimensionally patterned surface 121 is not facing the second three-dimensionally patterned surface 122, then the battery 150 also will not rest in the use position and the second connector 156 will not contact the device terminal. In this way, the battery 150 is only connectable to the aerosol-generating device 100 with the correct polarity to provide power to the aerosol-generating device heating element.

[0091] 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 aerosol-generating device 100. As shown in FIG. 3, the battery interconnection assembly 130 is a subunit 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 first connector and other components, for example a heating element and other electrical components, for convenient assembly within the aerosolgenerating device 100.

[0092] 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 opening118 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.

[0093] The housing 110 includes an article-receiving opening 116. The article -receiving opening 116 is configured to receive and secure an aero sol -generating article (not shown) to the aerosol-generating device 100 so that the aerosol-generating article is ready for use. In the example shown, the articlereceiving opening 116 is arranged at an opposing end of the housing 110 to the access opening 118.

[0094] 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.

[0095] Additionally, or alternatively, the aerosol-generating device may also include an air inlet configured to provide ingress of air into the aero sol -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 aerosolforming substrate of the aero sol -generating article.

[0096] Referring particularly to FIG. 4A and FIG. 4B, there is shown the aerosol-generating device of FIG. 1A to FIG. 3 in which the first three-dimensionally patterned surface 121 and second three- dimensionally patterned surface 122 are complementary to one another. In this way, once installed, the battery 150 engages the battery compartment 112 in the use position and the battery unit 140 is attached to the housing 110.

[0097] The battery compartment opening 114 is circumscribed by a compartment periphery. With the battery 150 in the use 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 surface that gives a comfortable fit in the user's hands. 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.

[0098] Furthermore, the complementary first three-dimensionally patterned surface 121 and second three-dimensionally patterned surface 122 are sufficiently interlinked that the shell member 142 seals the battery compartment opening 114. The battery 150 is installed in the use position is such a way that ingress of moisture into the battery compartment 112 is prevented.

[0099] Referring particularly to FIG. 5A and FIG. 5B, there is shown the aerosol-generating device of FIG. 1A to FIG. 3 in which the first three-dimensionally patterned surface 121 and second three- dimensionally patterned surface 122 are not complementary to one another. When installing the battery 150, the battery 150 cannot engage the battery compartment 112 in the use position. The battery 150sits away from the second three-dimensionally patterned surface 122. In this way, the battery unit 140 is not attached to the housing 110 and the outer surface of the shell member 142 sits away from the compartment periphery. The discontinuous contoured surface and raised edge provide both a visual indicator and a tactile indicator to the user that the battery 150 is not compatible with the aerosolgenerating device 100.

[0100] As will be apparent, the first three-dimensionally patterned surface and second three- dimensionally patterned surface may adopt any suitable form or configurations to ensure that a battery is received and located correctly within the battery compartment of an aerosol-generating device. The three-dimensionally patterned surfaces may be of any regular or irregular pattern so as to form a pair of complementary three-dimensionally patterned surfaces. In certain examples, the three-dimensionally patterned surfaces may be of any regular or irregular pattern so as to form a unique pair of complementary three-dimensionally patterned surfaces.

[0101] By incorporating the complementary three-dimensionally patterned surfaces it is possible to provide a mechanical encryption between the battery and the battery compartment. The mechanical encryption ensures only matching first and second three-dimensionally patterned surfaces conform to one another so that the battery is fully received into the battery compartment. Thus the use of counterfeit batteries is prevented because such batteries will not electrically connect to the aerosolgenerating device in the use position, and the battery will not provide electrical power to the heating element.

[0102] In certain examples, the first three-dimensionally patterned surface may include a first surface array of embossed regions and debossed regions, and the second three-dimensionally patterned surface includes a complementary second surface array of embossed regions and debossed regions. The embossed regions and the debossed regions may extend in one or both of a lengthwise direction and a crosswise direction. In certain examples, each of the first three-dimensionally patterned surface and the second three-dimensionally patterned surface includes a plurality of irregular surface features, that is of irregular areas on a patterned surface, and / or projecting or recessing irregular distances from a patterned surface.

[0103] 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 outer casing of the battery. In the example, the cross-sectional shape is rectangular, with uniform width and height along the battery length.

[0104] 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-sectionalshape 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.

[0105] Referring now to FIG. 6A to FIG. 6E, there are shown images of an aerosol-generating device battery 250 during manufacture. The battery 250 may be the same as the battery 150 shown in FIG. 1A to FIG. 5B.

[0106] Referring particularly to FIG. 6A, a cell 210 is provided includes a cell body portion 212 extending between a first end portion 213 and a second end portion 214. A second connector 216 is provided at the first end portion 213, including a pair of battery terminals 218. The second connector 216 and battery terminals 218 correspond to the second connector 156 and battery terminals 158 of the battery 150 described above, so are mounted to the cell body portion 212 ready to electrically connect the manufactured battery 250 to an aerosol-generating device.

[0107] A sheet element 220 is provided with the cell 210. The sheet element 220 is of substantially the same size as a face of the cell body portion 212 of the cell 210. In the example shown, the sheet element 220 is shaped as a flat plate, although any suitable shape may provided that conforms to a face of a cell.

[0108] The sheet element 220 includes a first three-dimensionally patterned surface 221. The three- dimensionally patterned surface 221 extends across a surface of the sheet element 220.

[0109] The sheet element 220 is formed from a suitable inert material. For example, the sheet element 220 may be include a ceramic material or any porcelain insulators. The sheet element 220 may include an insulating plastic material, such as a polycarbonate material, a polystyrene material, or a polyethylene material.

[0110] Referring particularly to FIG. 6B, the cell 210 and sheet element 220 are inserted into an outer casing preform 230. The outer casing preform 230 forms an enclosed sleeve for the cell 210 and sheet element 220. The cell 210 and sheet element 220 are inserted into an open end of the outer casing preform 230.

[0111] With the cell 210 inserted into the outer casing preform 230, the second end portion 214 is proximal to the enclosed end of the outer casing preform 230 and the second connector 216 is exposed at the open end of the outer casing preform 230.

[0112] With the sheet element 220 inserted into the outer casing preform 230, the three-dimensionally patterned surface 221 is oriented towards the outer casing preform 230.

[0113] With the cell 210 and sheet element 220 inserted into the outer casing preform 230, the outer casing preform 230 is formed around the sheet element 220 as well as the cell body portion 212 of thecell 210. In the example, the outer casing preform 230 includes an aluminum foil material and the outer casing preform 230 is formed around the sheet element 220 and cell body portion 212 by applying a vacuum within the outer casing preform 230. The open end of the outer casing preform 230 is sealed closed.

[0114] In this vacuum sealing process, the cell 210 is placed inside a sealed chamber, and the air is gradually removed to create a vacuum. This helps eliminate any moisture or air trapped within the battery 250, which could potentially lead to oxidation, corrosion, or thermal runaway during operation. Once the desired level of vacuum is achieved, the battery 250 is hermetically sealed to maintain the vacuum environment and prevent any external contaminants from entering the cell.

[0115] The forming process may be any suitable process for the material of the outer casing preform 230. In certain examples, for example where the outer casing preform is formed of heat-shrinking polymer, the forming process may include briefly apply heat to the outer casing preform, causing the outer casing preform to shrink over the sheet element and cell body portion.

[0116] The process allows the aluminum foil pouch to conform to the three-dimensionally patterned surface 221 of the sheet element 220. A battery 250 with a corresponding three-dimensionally patterned surface 221 is produced, as shown in FIG. 6C to FIG. 6E.

[0117] The battery 250 manufactured in this way provides the sealed cell 210 with the second connector 216, and corresponding battery terminal 218 exposed in order to electrically connect the battery 250 to an aerosol-generating device.

[0118] The battery 250 also includes an elongate seam 232. The elongate seam 232 extends around the perimeter of the battery 250. In the example, the elongate seam 232 is formed of the residual portions of the outer casing preform 230. In other examples, the elongate seam may be a welded seam that further improves conformity between the outer casing preform 230 and the cell 210 and sheet element 220.

[0119] Throughout the description and claims of this specification, the words “include” 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.

[0120] 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 stepsof 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.

[0121] 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 comprising a first three-dimensionally patterned surface; a battery compartment accessible by the battery compartment opening, wherein the battery compartment is configured to receive, in a use position, the battery so that the battery is electrically connected to the aerosol-generating device; and a second three-dimensionally patterned surface arranged at a side wall of the battery compartment; wherein the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are complementary to one another.

2. The aerosol-generating device of claim 1, wherein the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are configured so that, in the use position, the first three-dimensionally patterned surface conforms with the second three-dimensionally patterned surface.

3. The aerosol-generating device of claim 1 or 2, wherein the battery comprises at least one battery terminal configured to that, in the use position, the battery terminal is contactingly engages a corresponding device terminal to electrically connect the battery to the aerosol-generating device.

4. The aerosol-generating device of claim 3, wherein the battery comprises a battery terminal and the battery compartment comprises a device terminal, and wherein the first three-dimensionally patterned surface and the second three-dimensionally patterned surface are configured such that the device terminal contactingly engages the battery terminal only when the battery is fully engaged within the battery compartment.

5. The aerosol-generating device of any one of claims 1 to 4, wherein each of the first three- dimensionally patterned surface and the second three-dimensionally patterned surface extends in a respective lengthwise direction and a respective crosswise direction, perpendicular to the lengthwise direction, and wherein the embossed regions and the debossed regions each extend in both the lengthwise direction and the crosswise direction.

6. The aerosol-generating device of any one of claims 1 to 5, wherein the first three-dimensionally patterned surface is a mutually-inverse version of the second three-dimensionally patterned surface.

7. The aerosol-generating device of any one of claims 1 to 6, 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.

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

9. The aerosol-generating device of any one of claims 1 to 8, wherein the battery comprises a pair of battery terminals and a body portion.

10. The aerosol-generating device of claim 9, wherein the body portion of the battery extends between a first end portion and an opposing second end portion.

11. The aerosol-generating device of any one of claims 1 to 10, further comprising a battery unit having a shell member with an outer surface, wherein the shell member is configured to be releasably attached to the housing of the aerosol-generating device, and wherein the battery is mounted to the battery unit .

12. The aerosol-generating device of any one of claims 1 to 11, wherein the battery compartment opening is circumscribed by a compartment periphery, and wherein, in the use position, an outer surface of the shell member is flush with the compartment periphery.

13. The aerosol-generating device of claim 11 or 12, wherein the battery unit comprises a first connector and the aerosol-generating device 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 the second connector and draws the battery unit into the use position.

14. A method of manufacturing an aerosol-generating device battery, the method comprising: providing a battery cell having a cell body portion; inserting the battery cell into an outer casing preform; inserting a sheet element between the cell body portion and the outer casing preform, wherein the sheet element comprises a three-dimensionally patterned surface; and forming the outer casing preform around the sheet element and cell body portion so that an external surface portion of the outer casing conforms to the three-dimensionally patterned surface.

15. The method of claim 14, wherein the forming step includes one or both of: vacuum-forming the outer casing preform around the sheet element and cell body portion, orheat-shrinking the outer casing preform around the sheet element and cell body portion.

Images