Aerosol generating systems

Abstract

A battery component (120) for an aerosol generating device, the battery component (120) having a longitudinal axis (34) and comprising: a chassis (24, 24a, 24b, 24c) configured to house a battery (22), control circuitry (26), and at least one surface-mount device, SMD, component (28) electrically connected to the control circuitry, wherein the chassis (24, 24a, 24b, 24c) comprises a structural support, said structural support comprising a through hole in which the at least one SMD component (28) is located. Also described are aerosol generating systems 10 including the battery component (120).

Description

[0001] AEROSOL GENERATING SYSTEMS

[0002] Technical Field

[0003] The present invention relates to aerosol generating systems, and particularly, but not exclusively, to battery components for aerosol generating systems.

[0004] Technical Background

[0005] Aerosol generating systems are an alternative to conventional cigarettes. Instead of generating a combustion smoke, they comprise a heating assembly configured to heat an aerosol-forming substrate to generate a vapour or aerosol that may be inhaled by a user. Such aerosol generating systems may be also referred to as reduced-risk or modified-risk devices.

[0006] In general terms, a vapour is a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms “aerosol” and “vapour” may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.

[0007] An aerosol-forming substrate may comprise a liquid comprising an aerosol-forming substance, such as glycerine or propylene glycol, that creates the vapour when heated. Other common substances in the liquid are nicotine and various flavourings. In alternative arrangements, the aerosol-forming substrate may be a tobacco-based substrate, which may be shaped, contained or wrapped in the form of a stick or a pod.

[0008] Liquid-based aerosol generating systems, commonly termed electronic cigarettes, typically comprise a reservoir configured to hold liquid aerosol-forming substrate in a reservoir chamber. Vaporisation is achieved in a vaporisation region, such as a vaporisation chamber, by a heating assembly which typically comprises a heating element and a fluid transfer medium such as a wick. Vaporisation occurs when the heating element heats the liquid in the wick until the liquid is transformed into vapour. Such systems often take the form of a multipart aerosol generating device having a base part including control electronics and a separable cartridge or cartomiser including the reservoir. The cartridge or cartomiser may be disposable, whilst the base part may be reusable multiple times. Other types of aerosol generating system include heated-substrate aerosol generating devices, also known as heat-not-burn devices. Devices of this type generate an aerosol or vapour by heating a non-liquid (e.g. solid) aerosol-forming substrate to a temperature typically in the range 150°C to 300°C. Heating a solid aerosol-forming substrate to a temperature within this range, without burning or combusting the aerosol-forming substrate, generates a vapour which typically cools and condenses to form an aerosol for inhalation by a user of the device. The aerosol-forming substrate may be provided as a consumable that is receivable in a heating chamber of the aerosol generating device.

[0009] Aerosol generating systems are typically hand-held, meaning that they can be comfortably held by a user during use, usually in a single hand. Such systems typically comprise a battery, which may be rechargeable, in order to provide power to the heater or heating assembly together with portability. The battery may be included in a battery component of the system, such as the base part of a liquid-based aerosol generating system or the aerosol generating device of a heated substrate system. Control circuitry may also be included in the battery component, to control the operation and charging of the battery, together with other functions of the aerosol generating system.

[0010] Summary

[0011] According to a first aspect of the invention, we provide a battery component for an aerosol generating system, the battery component having a longitudinal axis and comprising: a chassis configured to house a battery, control circuitry, and at least one surface-mount device (SMD) component electrically connected to the control circuitry, wherein the battery component further comprises a structural support, said structural support comprising a through hole in which the SMD component is located.

[0012] As noted above, aerosol generating systems are typically hand-held, and as such must be sufficiently robust to withstand transportation and use. To this end, some aerosol generating systems include a chassis in order to locate a battery within a battery component of the system, and to maintain a position of the battery in the event that an orientation of the system changes. The chassis may also serve to locate and house at least some of the control circuitry included in the battery component. We have found that it can be desirable to include a structure in a battery component for an aerosol generating device that operates to provide mechanical support to control circuitry included in the battery component, in order to provide reinforcing to the control circuity in the event of mechanical stress. Such a structure is referred to herein as a “structural support”, and is preferably comprised in the chassis of the battery component, for example by being integrally formed with the chassis or rigidly connected to the chassis.

[0013] In some cases, we have found that such a structural support may undesirably transfer mechanical force from the chassis to components of the control circuitry, particularly SMD components. This may displace the SMD components and / or cause damage to the control circuitry or SMD components, either of which may adversely affect the ability of the control circuitry to function correctly.

[0014] To this end, the chassis of the battery component described herein includes a structural support having a through hole in which an SMD component electrically connected to the control circuitry is located. By providing a through hole in a structural support of the chassis, a space or void may be maintained around the SMD component, which may reduce, and may preferably substantially prevent, the transmission of mechanical force between the chassis and the SMD component in the event of an unexpected impact to the aerosol generating system, whilst still providing mechanical reinforcement to the control circuitry via the structural support.

[0015] Where more than one SMD component is included in the control circuitry, the structural support may comprise a plurality of through holes, where each through hole is located in the structural support so as to receive one or more of the SMD components.

[0016] The control circuitry may comprise a flexible printed circuit board (FPCB). The at least one SMD component may be located on the FPCB, and electrically connected to the FPCB. Printed circuit boards (PCBs) are often used in the manufacture of electrical devices, such as aerosol generating systems of the type described herein. PCBs can be damaged by mechanical shock, such as a shock caused by an impact to the electrical device containing the PCB, for example if the device is accidentally dropped. Such an impact can lead to damage to the circuitry of the PCB, as well as fatigue, cracks, and eventual failure in joints between the PCB and one or more surface-mount device (SMD) components electrically connected, for example via soldering, to the PCB. Flexible PCBs, referred to herein as FPCBs, are sometimes used in applications that require frequent bending or flexing. However, repeated mechanical stress to such FPCBs can reduce the overall durability and reliability of the FPCB and its components. A structural support of the type described herein thus has particular utility in battery components including an FPCB.

[0017] It can sometimes be desirable to monitor the temperature of a battery included in a battery component of an aerosol generating system during use, in order to avoid a situation in which the battery temperature becomes unacceptably high. The battery component may therefore include a mechanism for monitoring a battery temperature, such as a temperature sensor. At least one SMD component may thus be a temperature sensor that is operable to sense a temperature of a battery housed by the chassis. For example, the temperature sensor may be located so as to be in thermal proximity to a battery that is housed by the chassis. Temperature sensors are particularly delicate and prone to damage by mechanical stress. Furthermore, such sensors can output inaccurate readings if displaced from their intended position. Use of a structural support of the type described herein thus has particular utility in the protection of a surface mounted temperature sensor.

[0018] The chassis may comprise a first end piece, a second end piece longitudinally separated from the first end piece, a first side piece, and a second side piece transversely separated from the first side piece. “Longitudinal” as used herein refers to a direction that is parallel to the longitudinal axis of the aerosol generating system, whereas “transverse” refers to a direction perpendicular to the longitudinal direction.

[0019] A battery may be locatable in a space defined between the first end piece, the second end piece, the first side piece and the second side piece, such that the structural support extends alongside the battery. In use, the chassis may operate to maintain a battery housed in the chassis in a predefined location within the chassis, and to provide at least some mechanical protection to the battery.

[0020] The structural support may comprise a longitudinal portion extending between the first and second end pieces. Such a structural support may increase the mechanical strength of the chassis without substantially increasing the overall bulk of the chassis. Where the control circuitry comprises an FPCB, the FPCB may comprise a longitudinal axis, which may be aligned so as to be substantially parallel with the longitudinal axis of the battery component. When the structural support comprises a longitudinally extending portion, that portion may thus be aligned with the longitudinal axis of the FPCB, so as to provide mechanical reinforcement to the FPCB along its full length. This may increase the mechanical strength of the FPCB in the axis in which it is most likely to experience bending or flexation. The structural support may be located centrally with respect to the longitudinal axis of the FPCB, such that the structural support extends along the longitudinal axis of the FPCB.

[0021] Alternatively, or additionally, the structural support may comprise a transverse portion extending between the first and second side pieces. Such a structural support may increase the mechanical strength of the chassis without substantially increasing the overall bulk of the chassis, and may reduce the susceptibility of the chassis to twisting forces.

[0022] The structural support may comprise a longitudinal portion extending between the first and second end pieces and a transverse portion extending between the first and second side pieces. The structural support may comprise a cruciform (cross) shape. The through hole may be located at a junction between the longitudinal and transverse portions. Locating the through hole at a junction between two portions of a structural support may increase the mechanical stability of the structural support at the location of the through hole and / or may permit a larger through hole to be formed in a structural support having a given width than would be possible at locations away from the junction. Providing the through hole at a junction between two portions of a structural support may therefore improve the mechanical isolation of an SMD component, such as a temperature sensor in an economical manner.

[0023] The structural support may comprise a raised portion adjacent the through hole. The raised portion may encircle a perimeter of the through hole, and may extend continuously around the perimeter of the through hole. By providing a raised portion in the vicinity of the through hole, additional protection may be provided to an SMD component located in the through hole. The raised portion may have a height that is greater than the height of the SMD component. This may provide further isolation to the SMD component, for example by preventing contact between the SMD component and another component that is located adjacent the structural support within the battery component (such as, for example, an outer housing).

[0024] The through hole may define a first area A1. For example, the through hole may comprise a perimeter, and the first area may be defined as the area enclosed by the perimeter. The SMD component may define a second area A2. For example, the SMD component may comprise a footprint, and the second area may be defined as the area enclosed by the footprint. The first area may be an order of magnitude larger than the second area, such that a ratio A2:A1 between the second area and the first area is greater than 1 :10. In this way the space maintained around the SMD component, such as a temperature sensor, may be relatively large when compared with the dimensions of the SMD component, thus further reducing the likelihood of unwanted force being transmitted to the SMD component from elsewhere in the battery component.

[0025] The ratio A2:A1 between the second area and the first area may be greater than 1 :25, and may be greater than 1 :30, or 1 :40, or 1 :50. The ratio between the second area and the first area may preferably be in the range 1 :30 to 1 :100, or 1 :30 to 1 :80, or 1 :30 to 1 :60. The ratio between the second area and the first area is most preferably approximately 1 :38. Such dimensions provide good protection to the SMD component whilst maintaining structural support to the battery and control circuitry and minimising the materials used in the construction of the chassis.

[0026] The through hole may be elongate, such that said through hole has a transverse dimension that is greater than a longitudinal dimension of said through hole. The transverse dimension may preferably be between 1 .5 and 4 times greater than the longitudinal dimension, and most preferably may be between 2 and 3 times greater than the longitudinal dimension. The SMD component, such as a temperature sensor, may also be elongate, and the through hole may be shaped to complement (e.g. to have a similar ratio between its transverse and longitudinal dimensions as) the SMD component.

[0027] The control circuitry may be housed by the chassis. The control circuitry may have a first side and a second side. The control circuitry may be received in the chassis such that the second side faces and / or abuts the structural support. The SMD component may be located on the second side, and may be received in the through hole in the structural support when the control circuitry is received in the chassis. Where there is a plurality of SMD components, each SMD component may be located on the second side, and may be received in the or a through hole in the structural support when the control circuitry is received in the chassis. In this way, the control circuitry may be provided with additional support and / or protection by the chassis, whilst ensuring space around the SMD component(s) is maintained.

[0028] The battery component may further comprise an outer housing. The outer housing may be configured to contain the chassis, control circuitry and the at least one SMD component, and so may provide protection to the internal components as well as an attractive external appearance to the overall device. The battery component may further comprise a battery. The battery may be located within the chassis. Where the control circuitry is housed in the chassis, the battery may be located in the chassis such that the first side of the control circuitry faces and / or abuts the battery, such that the control circuitry is sandwiched between the battery and the structural support. This may provide for a compact battery component which is straightforward to assemble, and, where the (or one of the) SMD component(s) is a temperature sensor, may also help to ensure that the temperature sensor is located in thermal proximity to the battery.

[0029] According to a second aspect of the invention, we provide an aerosol generating system comprising the battery component of the first aspect of the invention. The aerosol generating system may comprise a base part that is operable to be removably connected to a cartridge.

[0030] It is to be appreciated that the aerosol generating system may include any one or more components conventionally included in such a system, as discussed in the background section above or the description below.

[0031] The features set out in the above aspects of the invention may be combined together in any combination that is not explicitly excluded, and also with features selected from the background section above or the detailed description below.

[0032] Brief Description of the Drawings

[0033] There now follows a detailed description of the invention, by way of example only, with reference to the accompanying drawing, in which:

[0034] Figure 1 schematically shows an aerosol generating system including a base part and disposable cartridge;

[0035] Figure 2 illustrates an aerosol generating system in exploded perspective view;

[0036] Figure 3 illustrates a first example of a chassis for a battery component from a first side;

[0037] Figure 4 illustrates a second example of a chassis for a battery component from a first side;

[0038] Figure 5 illustrates a third example of a chassis for a battery component from a second side, opposite the first side, assembled together with control circuitry, as well as an inset detail showing a temperature sensor;

[0039] Figure 6 illustrates a battery component including the chassis of Figure 5 from the second side; and Figure 7 illustrates a cross section through a battery component including the chassis of Figure 5, as well as an inset detail showing a raised portion.

[0040] Detailed Description

[0041] Figure 1 schematically shows one example of an aerosol generating system 10, such as an electronic cigarette. The aerosol generating system 10 includes a base part 12 and a cartridge 14 (also referred to in the art as a “capsule” or “pod”). The cartridge 14 is removably connectable to the base part 12, and may be disposable. The base part 12 thus forms the main body of the aerosol generating system 10, and is generally re-usable. When assembled, the aerosol generating system 10 is sized to be comfortably held by a user unaided, in a single hand.

[0042] In the example shown in Figure 1 , the cartridge 14 includes a liquid storage reservoir (not visible) defining a reservoir chamber configured for containing therein a liquid to be vaporised. The liquid may comprise an aerosol-forming substance such as propylene glycol and / or glycerine and may contain other substances such as nicotine and acids. The liquid may also comprise flavourings such as tobacco, menthol or fruit flavour.

[0043] The cartridge 14 further includes a vaporising unit 16. In the example shown in Figure 1 , the vaporising unit 16 comprises a heating element, such as a resistive heating wire, and a fluid transfer element, such as a ceramic or fibrous wick. The fluid transfer element is located in fluid communication with the reservoir chamber, and is configured to draw vaporisable liquid from the reservoir chamber towards the heating element in a vaporisation zone. A vapour transfer channel (not visible) extends from one or more air inlets (not shown) through and / or past the vaporisation zone, to one or more aerosol outlets 18 provided in a mouthpiece region 20 of the cartridge.

[0044] The base part 12 accommodates therein a power supply unit in the form of a rechargeable battery 22. The base part 12 may thus be considered a battery component 120 of the aerosol generating system 10. The base part 12 additionally includes control circuitry 26 electrically connected to the rechargeable battery 22, as well as to a user interface (not shown) for permitting a user to control the operation of the aerosol generating system 10 via the control circuitry 26.

[0045] A housing 32 encloses the internal components of the base part 12, such as the control circuitry 26 and battery 22. A longitudinal axis 34 extends from a first, distal end 36 of the base part 12 to a second, proximal end 38 of the base part 12. In use, the cartridge 14 may be connected to the base part 12 at the proximal end 38 via any suitable connection mechanism.

[0046] When the base part 12 is attached to the cartridge 14, power may be supplied to the vaporisation unit 16 from the battery 22 to heat up liquid in the vaporisation zone, thereby generating a vapour. A user of the system may draw on the mouthpiece 20 to encourage air to flow along an airflow path from the inlet(s) towards the vaporisation zone. In the vaporisation zone vapour is entrained in the airflow, and cools and condenses to form an aerosol for inhalation by the user through the outlet(s) 18.

[0047] It will be understood that the aerosol generating system 10 illustrated in Figure 1 is just one example of an aerosol generating system, and that other types of system are available, including single part systems and multipart systems. A commonality between most such aerosol generating systems is that the majority of such systems include a battery, such as a rechargeable battery, in order to allow for portable operation. The term “battery component” is used herein to refer to the portion of an aerosol generating system that is operable, in use, to house a battery. For example, in the case of the system shown in Figure 1 , the base part 12 may be considered a battery component.

[0048] Referring now to Figures 2 to 7, battery components 120 suitable for use in a system of the type shown in Figure 1 are illustrated in more detail. It will be understood, however, that the battery components 120 shown in Figures 2 to 7 have a wider application, and are suitable for use in other types of aerosol generating system, such as heat-not-burn systems or liquidbased systems having a differing structure to that shown in Figure 1 .

[0049] Each battery component 120 described herein includes a chassis 24 configured to house a battery 22, control circuitry 26, and at least one surface-mount device (SMD) component 28 electrically connected to the control circuitry 26. Each chassis 24 comprises a structural support 40 that includes a through hole 42 in which the temperature sensor 28 is located.

[0050] Three different example chassis 24 are shown in Figure 3 (first example chassis 24a), Figure 4 (second example chassis 24b) and Figures 5 to 6 (third example chassis 24c). In each case, the chassis 24a, 24b, 24c includes a first end piece 44 and a second end piece 46. The first and second end pieces 44, 46 are spaced apart along the longitudinal axis 34 so as to be longitudinally separated from one another. When assembled into a base part 12 of the type shown in Figure 1 , the first end piece 44 is located at or near the proximal end 38 of the base part 12, whilst the second end piece 46 is located at or near the distal end 36 of the base part 12. The chassis 24a, 24b, 24c further include a first side piece 48 and a second side piece 50. The first and second side pieces are spaced apart in a direction that is perpendicular to the longitudinal axis 34, so as to be transversely separated from one another.

[0051] The spaces separating the first and second end pieces 44, 46 and the first and second side pieces 48, 50 from the structural support 40 can be considered as defining windows 49 through the chassis 24. In the example shown in Figure 3 the chassis 24a includes two windows 49a, each of which defines a hole or opening through the chassis between the first and second end pieces 44, 46 and between the first and second side pieces 48, 50. A first one of the windows 49a is bounded by the first and second end pieces 44, 46, the first side piece 48 and the structural support 40, whilst a second one of the windows 49a is bounded by the first and second end pieces 44, 46, the second side piece 50 and the structural support 40. In contrast, the alternative example chassis 24b, 24c shown in Figures 4 to 6 each include four windows 49b, each of which defines a hole through the chassis between the first and second end pieces 44, 46 and between the first and second side pieces 48, 50. A first one of the windows 49b is bounded by the first end piece 44, the first side piece 48 and the structural support 40, whilst a second one of the windows 49b is bounded by the first end piece 44, the second side piece 50 and the structural support 40. Similarly, a third one of the windows 49b is bounded by the second end piece 46, the first side piece 48 and the structural support 40, whilst a fourth one of the windows 49b is bounded by the second end piece 46, the second side piece 50 and the structural support 40. The windows 49 reduce the bulk of the chassis and promote airflow through the chassis, whilst the structural support 40 provides additional rigidity, reducing the likelihood of twisting or bending that might otherwise occur if it was not present.

[0052] When assembled together with a battery 22, said battery is housed by the chassis 24 in a space defined between the first end piece 44, the second end piece 46, the first side piece 48 and the second side piece 50, with the structural support 40 extending around one side of the battery 22 so as to provide additional mechanical support to the battery. The chassis may be formed (e.g. moulded) such that the battery 22 fits closely within the space, so that the battery is maintained securely in a fixed position inside the battery component 120 once assembled.

[0053] In the specific examples shown in Figures 2 to 7, the control circuitry 26 includes a flexible printed circuit board (FPCB) 30. The FPCB 30 comprises the at least one SMD component 28, which is mounted on a flexible substrate. In the examples shown, the FPCB 30 includes a plurality of SMD components, one of which is a temperature sensor 62, such as an NTC thermistor (negative temperature coefficient thermistor).

[0054] As can be best seen in Figures 5, 6 and 7, some of the control circuitry 26, and specifically the FPCB 30, is also housed by the chassis 24. The FPCB 30 has a first side 52 and a second side 54, and is received in the chassis 24 such that the first side faces towards the space reserved for housing the battery, and the second side 24 faces towards the structural support 40. In the specific example shown, the first side 52 of the FPCB 30 abuts the battery 22, and the second side 54 of the FPCB 30 abuts the structural support 40, such that the FPCB 30 is sandwiched between the battery 22 and the structural support 40.

[0055] The at least one SMD component 28 is located on the second side 54 of the FPCB 30. When the FPCB 30 is received in the chassis 24, the at least one SMD component 28 is received in the through hole 42 in the structural support 40. In this way, the FPCB 30 and the battery 22 are provided with mechanical support and / or protection by the chassis 24, whilst avoiding mechanical pressure being placed on the at least one SMD component 28 by the chassis 24.

[0056] As well as serving to locate and house the battery 22 and the FPCB 30, the chassis 24 with structural support 40 functions to provide at least some mechanical support to the battery 22 and FPCB 30 in the event that the aerosol generating system experiences an unexpected shock or impact (e.g. the system may be dropped accidentally by a user). In some circumstances, however, this can have the unwanted consequence of transmitting mechanical force towards the SMD component(s) 28, particularly in the event of an impact to the battery component 120. Such a force may be vibrational and / or torsional and can potentially act to dislodge or damage the SMD component(s) 28. Locating an SMD component 28 within a through hole 42 in the support structure 40 creates a buffer space around that SMD component 28, which can reduce and / or avoid mechanical force being transferred from the chassis 24 to the SMD component28. The through hole 42 thus provides an SMD component 28 with improved mechanical isolation as compared with a situation in which the SMD component is instead in direct contact with the structural support 30.

[0057] In the first example chassis 24a shown in Figure 3, the structural support 40 comprises a generally rectangular structure that extends longitudinally between the first and second end pieces 44, 46. The through hole 42 is provided in the structural support 40 at a location that corresponds to the location at which the SMD component 28 is intended to be electrically connected to the second side of the FPCB 30, such that when the FPCB 30 is received in the chassis 24a the SMD component 28 is received in the through hole 42. When the FPCB 30 and battery 22 are located within the chassis 24a the structural support 40 extends longitudinally adjacent to both the FPCB 30 and battery 22 for substantially their full lengths, so providing increased mechanical support to both components. The structural support 40 is centrally located with respect to the longitudinal axis of the FPCB 30 so as to provide maximum support to the FPCB 30 and minimise the effect of bending forces on the FPCB 30. In this way the structural support is strategically placed and oriented along the axis of maximum bending, so as to optimise its effectiveness in stress distribution and protection of SMD components.

[0058] In the second and third example chassis 24b, 24c shown in Figures 4 to 7, the structural support 40 extends longitudinally between the first and second end pieces 44, 46 as well as transversely between the first and second side pieces 48, 50. The structural support 40 thus comprises one or more transverse arm portions 40b as well as a generally rectangular longitudinal body portion 40a, and has a generally cruciform shape. The provision of a transverse portion 40b in addition to a longitudinal portion 40a may reduce the ability for the chassis 24 to twist under impact, so providing further protection to the internal components of the battery component, including the FPCB 30. In the examples shown, the transverse portion and the longitudinal portion cross at or near their respective midpoints, but this is not necessary.

[0059] In the second and third exemplary chassis 24b, 24c illustrated in Figures 4 to 7, the through hole 42 is located at a junction 56 between the longitudinal and transverse portions 40a, 40b. Locating the through hole 42 at a junction between two portions of the structural support permits a larger through hole 42 to be formed in the structural support than would be possible at locations away from the junction.

[0060] In the third example chassis 24c, shown in Figure 5 to 7, the structural support 40 further includes a second through hole 42. As in the case of the second example chassis, the first through hole 42 is located so as to receive, and hence provide protection to, a first SMD component 28, at or near the centre of the FPCB 30. In the specific example shown in Figures 5 to 7, the first SMD component is a temperature sensor 62. In contrast, the second through hole is located so as to receive and provide protection to a group of different SMD components 28 which are located at or near the proximal end 38 of the FPCB 30. The structural support 40 includes a central longitudinal portion 40a and a pair of transverse portions 40b, one of which is located to cross the longitudinal portion adjacent the first through hole, and the other of which is located so as to cross the longitudinal portion adjacent the second through hole 42.

[0061] As noted above, the purpose of the through hole 42 is to create a space around an SMD component 28, such as a temperature sensor 62, to prevent contact between the SMD component 28 and the chassis 24 in the event of an impact to the device, without compromising the ability of the structural support 40 to provide additional strength and / or rigidity to the chassis 24 in the event of such an impact. The space is preferably large enough to define a buffer region around the SMD component 28 that a minimum clearance distance d is maintained between the SMD component 28 and a closest point of the chassis (put another way, this could be considered as being a distance between the SMD component 28 and a closest point on a perimeter 58 of the through hole 42). The minimum clearance distance d should be at least as large as the largest dimension of the SMD component 28, and in the example shown is approximately twice as large as the largest dimension of the SMD component 28. Nevertheless, it is important to ensure that the through hole is not so large as to compromise the structural integrity of the structural support 40, since this could hinder the ability of the chassis 24 to provide mechanical support to the battery 22 and FPCB 30.

[0062] In this context, it can be useful to consider the through hole 42 as defining a first area A1, and the SMD component 28 as defining a second area A2. For example, the first area A1 may be considered as being the area enclosed by the perimeter 58 of the through hole 42, and the second area A2 may be considered as being the area enclosed by a footprint 60 of the SMD component (where the footprint is the area occupied by the SMD component, e.g. the area occupied by the SMD component 28 on the FPCB 30 when viewed in plan view). To ensure a suitably sized buffer region, the first area A1 should be an order of magnitude larger than the second area A2, such that a ratio A2:A1 between the second area A2 and the first area A1 is greater than 1 :10. In all three examples shown, the ratio between the second area and the first area is greater than 1 :25 but less than 1 :100. In the example shown in Figures 5 to 7, the first area A1 is approximately 28.45mm2and the second area A2 is approximately 0.75mm2, such that the ratio A2:A1 between the second area and the first area is in the range 1 :30 to 1 :45, and, more specifically, is approximately 1 :38.

[0063] The through hole 42 may have any shape. In the first example chassis 24a shown in Figure 3, the through hole is generally square in shape, whilst in the second and third example chassis 24b, 24c shown in Figures 4 to 7, the through holes 42 are elongate, and in particular, each has a transverse dimension that is greater than its longitudinal dimension. The elongate shape of the first through hole 42 in the third example chassis 24c is selected to complement (e.g. to have a similar ratio between its transverse and longitudinal dimensions as) the shape of the temperature sensor 62. Furthermore, the temperature sensor 62 is oriented so as to have its largest dimension aligned with the longitudinal axis 34, so as to minimise the impact of any torsional forces which may be transferred to the FPCB 30.

[0064] As shown most clearly in Figures 5, 6 and 7, the structural support in the third example chassis 24c includes a raised portion 64 adjacent the first through hole 42. In the particular example shown, the structural support 40 includes a ramped surface between the longitudinal and transverse portions 40a, 40b of the structural support, which transitions into the raised portion 64. The raised portion 64 extends around the perimeter 58 of the through hole 42, so as to fully encircle the through hole. The raised portion has a height which is greater than that of the SMD component 28 (e.g. temperature sensor 62) that is received in the through hole 42, such that the SMD component 28 does not protrude from the through hole when the FPBC 30 is assembled inside the chassis 24c. This avoids contact between the SMD component 28 and the outer housing 32 of the battery component 120, when the chassis 24c is assembled inside the housing 32. In the example shown, the thickness of the raised portion 64 is greater than the thickness of the longitudinal and transverse portions 40a, 40b of the structural support adjacent the raised portion, although this need not be the case.

[0065] We have described herein battery components designed to improve the structural integrity and reliability of control circuity housed within said components, particularly flexible printed circuit boards (FPCBs). The battery components incorporate a structural support with openings that is designed to distribute and mitigate bending forces, thereby reducing mechanical stress on surface-mount device (SMD) components soldered to the FPCB. The support structures described herein introduce a centrally located rectangular reinforcement to the control circuitry, with the openings provided therein for the SMD components. This arrangement distributes bending forces across a larger area, so minimising localised stress concentrations. The support structures described herein may protect SMD components from mechanical stress induced by bending, thereby improving the reliability and longevity of solder joints and component leads. Furthermore, the support structures described herein may extend the lifespan of FPCBs by reducing the likelihood of mechanical failure during repeated bending cycles, making them more suitable for use in applications where flexibility and durability are critical. Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications may be made to those embodiments without departing from the scope of the appended claims. For example, it will be understood that the through hole 42 may be provided at a different location, or may have a different shape, to that shown in the examples in the Figures. Similarly, the SMD component(s) 28 may be located in a different position or orientation, so long as each is maintained within the perimeter of (and preferably near or at the centre of) a respective through hole 42 when the battery component is in an assembled state. It will be appreciated that a battery component of the type that is described herein need not be supplied assembled together with a battery, and that a battery could instead be provided, removed and / or replaced by a user of the system. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments. Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

CLAIMS1. A battery component (120) for an aerosol generating system (10), the battery component having a longitudinal axis (34) and comprising: a chassis (24, 24a, 24b, 24c) configured to house a battery (22), control circuitry (26), and at least one surface-mount device, SMD, component (28) electrically connected to the control circuitry (26), wherein the chassis (24, 24a, 24b, 24c) comprises a first end piece (44), a second end piece (46) longitudinally separated from the first end piece, a first side piece (48), and a second side piece (50) transversely separated from the first side piece, and wherein the battery component (120) further comprises a structural support (40), said structural support comprising a through hole (42) in which the SMD component (28) is located.

2. The battery component (120) of claim 1 , wherein the control circuitry (26) comprises a flexible printed circuit board, FPCB, (30), and the SMD component (28) is located on the FPCB (30).

3. The battery component (120) of claim 1 or claim 2, wherein the SMD component (28) is a temperature sensor (62) operable to sense a temperature of a battery (22) housed by the chassis (24, 24a, 24b, 24c).

4. The battery component (120) of any preceding claim, wherein the structural support (40) comprises a longitudinal portion (40a) extending between the first and second end pieces (44, 46), and / or wherein the structural support (40) comprises a transverse portion (40b) extending between the first and second side pieces (48, 50).

5. The battery component (120) of any one of claims 1 to 3, wherein the structural support (40) comprises a longitudinal portion (40a) extending between the first and second end pieces (44, 46) and a transverse portion (40b) extending between the first and second side pieces (48, 50), wherein the through hole (42) is located at a junction (56) between the longitudinal and transverse portions (40a, 40b), wherein the structural support (40) preferably comprises a cruciform shape.

6. The battery component (120) of any preceding claim, wherein the chassis (24, 24a, 24b, 24c) further comprises at least two windows (49) provided adjacent the structural support and between the first and second end pieces (44, 46) and the first and second side pieces (48, 50).

7. The battery component (120) of any preceding claim, wherein a battery (22) is locatable in the chassis (24, 24a, 24b, 24c) in a space defined between the first end piece (44), the second end piece (46), the first side piece (48) and the second side piece (50), with the structural support (40) extending alongside the battery.

8. The battery component (120) of any preceding claim, wherein the structural support (40) comprises a raised portion (64) adjacent the through hole (42), and preferably wherein the raised portion encircles a perimeter (58) of the through hole (42).

9. The battery component (120) of any preceding claim, wherein the through hole defines a first area A1 and the SMD component (28) defines a second area A2, the first area being an order of magnitude larger than the second area, such that a ratio A2:A1 between the second area and the first area is greater than 1 :10, and preferably greater than 1 :30.

10. The battery component (120) of any preceding claim, wherein the through hole (42) is elongate, such that said through hole (42) has a transverse dimension that is greater than a longitudinal dimension of said through hole (42), wherein the transverse dimension is preferably between 1.5 and 4 times greater than the longitudinal dimension, and is most preferably between 2 and 3 times greater than the longitudinal dimension.

11. The battery component (120) of any preceding claim, wherein the control circuitry (26) comprises an FPCB (30), and the FPCB (30) is housed by the chassis (24, 24a, 24b, 24c).

12. The battery component (120) of claim 11 , wherein the FPCB (30) comprises a longitudinal axis, and wherein the longitudinal axis of the FPCB (30) is substantially parallel with the longitudinal axis (34) of the battery component (120) and with the structural support (40), wherein the structural support (40) is preferably centrally located with respect to the longitudinal axis of the FPCB (30).

13. The battery component (120) of any preceding claim, further comprising an outer housing (32) configured to contain the chassis (24, 24a, 24b, 24c), control circuitry (26) and the at least one SMD component (28).

14. The battery component (120) of any preceding claim, further comprising a battery (22) located within the chassis (24, 24a, 24b, 24c).

15. An aerosol generating system (10) comprising the battery component (120) of any preceding claim.

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