An aerosol generating device

Abstract

An aerosol generating device (2) is described. The aerosol generating device (2) includes a space that may be defined by an interior space of a first support (8) and is adapted to receive an aerosol generating article (4) in use. The aerosol generating device (2) also includes an energy storage device (14) and a flexible printed circuit board (or PCB) (12) that is arranged to surround at least part of the space and / or the energy storage device (14). A controller that is adapted to control the aerosol generating device (2) is mounted on the flexible PCB (12). The flexible PCB (12) includes a plurality of elongate substrates. Each elongate substrate has a part that extends substantially along a longitudinal axis of the aerosol generating device (2). Circumferentially-adjacent elongate substrates are connected by one or more connecting substrates.

Description

[0001] AN AEROSOL GENERATING DEVICE

[0002] Technical Field

[0003] The present disclosure relates generally to an aerosol generating device, and in particular a device that is adapted to heat aerosol generating material to generate an aerosol for inhalation by a user. The aerosol generating device comprises a flexible printed circuit board, which is a printed circuit board that is designed to bend or flex.

[0004] The present disclosure is particularly applicable to a portable (hand-held) aerosol generating device.

[0005] Technical Background

[0006] Devices which heat, rather than bum, an aerosol generating material to produce an aerosol for inhalation have become popular with consumers in recent years. A commonly available reduced-risk or modified-risk device is the heated material aerosol generating device, or so-called heat-not-bum device. Devices of this type generate an aerosol or vapour by heating an aerosol generating material to a temperature typically in the range 150°C to 300°C, and in some cases as high as 350°C. This temperature range is quite low compared to an ordinary cigarette. Heating the aerosol generating material to a temperature within this range, without burning or combusting the aerosol generating material, generates a vapour which typically cools and condenses to form an aerosol for inhalation by a user of the device.

[0007] The aerosol generating material may be a solid or liquid. For example, the aerosol generating article may include a solid or semi-solid substrate of plant derived material, such as tobacco, or it may include a wick and a heater to produce vapour from aerosol generating liquid stored in a capsule or tank. When a user operates the aerosol generating device, liquid that has soaked into the wick is heated by the heater, producing a vapour which cools and condenses to form an aerosol which may then be inhaled. An aerosol generating article (sometimes called a pod or cartridge) may be received in the aerosol generating device and may include a liquid store, a liquid transfer element (e.g., a wick) and a heater. Electrical contacts may provide an electrical connection between the heater and an energy storage device of the aerosol generating device. The energy storage device may be a rechargeable battery that may be charged from an external power source by a charging assembly of the aerosol generating device.

[0008] The aerosol generating device will typically include a printed circuit board assembly (PCBA) with various electronic components mounted to a printed circuit board (PCB). The electronic components may be part of one or more circuits for operating the device. The electronic components may include a controller such as a microcontroller unit (MCU). The electrical contacts mentioned above may provide an electrical connection between the aerosol generating article and the PCBA, which in turn may be

[0009] P51791WO-6559 electrically connected to the energy storage device. Put another way, a charging circuit of the PCBA may be electrically connected to the energy storage device and to the aerosol generating article, e.g., to the heater or aerosol generator thereof. The charging circuit may provide power from the energy storage device and / or an external power source to the aerosol generating article.

[0010] The PCB is typically a rigid PCB - i.e., a conventional single-sided, double-sided, or multi-sided board that is not designed to bend or flex. Such rigid PCBs may be difficult to position within the housing of an aerosol generating device. Flexible PCBs are known. Such flexible PCBs are designed to bend or flex, which may make them easier to position within the housing of an aerosol generating device - particularly if the amount of space is restricted. Accordingly, there is a need for an improved way of mounting electronic components within the housing of an aerosol generating device.

[0011] Summary of the Disclosure

[0012] According to a first aspect of the present disclosure, there is provided an aerosol generating device comprising: a space adapted to receive an aerosol generating article in use; an energy storage device (e.g., a battery); a flexible printed circuit board (PCB) arranged to surround at least part of the space and / or the energy storage device; and a controller (e.g., a microcontroller unit (or MCU)) adapted to control the aerosol generating device, wherein the controller is mounted on the flexible PCB; wherein the flexible PCB comprises a plurality of elongate substrates, each elongate substrate having a part that extends substantially along a longitudinal axis of the aerosol generating device, and wherein circumferentially-adjacent elongate substrates are connected by one or more connecting substrates.

[0013] The “elongate substrates” mentioned above are also referred to herein as “mounting substrate sections”, and the “connecting substrates” mentioned above are also referred to herein as “connecting substrate sections”. Thus, put another way, the flexible PCB comprises a substrate having a plurality of connected elongate (i.e. substantially rectangular) mounting substrate sections arranged circumferentially around the at least part of the space and / or the energy storage device. At least part of each mounting substrate section has a long axis that extends substantially parallel with a longitudinal axis of the aerosol generating device and a short axis that extends substantially perpendicular to the long axis. Circumferentially-adjacent mounting substrate sections are connected by one or more connecting substrate sections of the substrate that are defined by gaps in the substrate. Thus, the mounting substrate sections and the connecting substrate sections together define a unitary flexible PCB including gaps defining through holes in the flexible substrate.

[0014] P51791WO-6559 Each connecting substrate section may extend substantially in a circumferential direction around the longitudinal axis of the aerosol generating device.

[0015] The flexible PCB may have any suitable construction. For example, the flexible PCB substrate may be made of any suitable flexible base material (e.g., polyimide or polyester). The flexible PCB may have one or more electrically conductive layers (e.g., copper layers applied to the base material that define electrically conductive traces that connect the various electronic components that are mounted to the flexible PCB).

[0016] The flexible PCB may include a protective layer or coverlay to provide insulation and protection.

[0017] The layers of the flexible PCB may be bonded by any suitable adhesive such as a thermoset adhesive, for example, which may be used for high-temperature applications.

[0018] Compared to a rigid PCB, a flexible PCB may be more easily arranged inside the housing of the aerosol generating device. For example, there may be more possibilities for how to arrange the flexible PCB within the aerosol generating device because it may be bent or folded as required. The space that is adapted to receive the aerosol generating article, and the energy storage device, will often occupy the most volume within the housing of the aerosol generating device. Put another way, they will often be the largest components of the aerosol generating device. Arranging the flexible PCB so that it surrounds at least part of the space and / or the energy storage device means that the inner volume of the aerosol generating device may be utilised more efficiently. As a result, a more physically compact aerosol generating device may be provided.

[0019] Forming the flexible PCB with a plurality of mounting substrate sections (elongate substrates) that are connected by connecting substrate sections may provide further advantages. For example, because the flexible PCB surrounds one or both of the space and the energy storage device, it may be more difficult to dissipate the heat generated by these components to the outside environment than if the flexible PCB was formed with a simple rectangular shape - e.g., where the space and / or the energy storage device are completely covered by the flexible PCB. However, the connecting substrate sections between the mounting substrate sections (elongate substrates) may provide gaps or spaces in the flexible PCB through which heat may be dissipated. The gaps or spaces may also be used to mount the flexible PCB. A rectangular-shaped flexible PCB may have a surface area that is too large for the electronic components that need to be mounted. In other words, a significant part of the surface of a rectangularshaped flexible PCB may remain uncovered. This is not very efficient. On the other hand, forming the flexible PCB as a plurality of connected mounting substrate sections (elongate substrates) will provide sufficient surface area for the electronic components to be mounted, but will also minimise the cost and / or weight of the aerosol generating device.

[0020] P51791WO-6559 The aerosol generating device may comprise a first support adapted to mechanically support the flexible PCB. The first support may be made of a plastics material, for example.

[0021] The flexible PCB may be arranged to surround at least part of the first support. The first support may have a substantially cylindrical outer surface, optionally defined by a plurality of flats - i.e., planar side surfaces. Some of the planar side surfaces may comprise a recess or locating features for receiving or locating a respective mounting substrate section (elongate substrate) of the flexible PCB.

[0022] A complex shape such as a combination of the plurality of mounting substrate sections (elongate substrates) and the connecting substrate sections may reduce the mechanical strength of the flexible PCB. The first support may reinforce and mechanically support the flexible PCB and therefore improve the durability of the aerosol generating device.

[0023] The first support may comprise an opening at a first end that is sized and shaped to receive the aerosol generating article. The aerosol generating article may be received in an interior space of the first support - i.e., the first support may have a tubular construction. The first support may be arranged at a first end of the aerosol generating device.

[0024] A second end of the first support, opposite the first end, may be substantially closed. The second end may include an air hole. The second end may include one or more openings for receiving one or more terminals (e.g., pogo or spring-loaded pins) of the flexible PCB - i.e., so that, if necessary, an electrical connection may be made between the flexible PCB and the aerosol generating article when it is received in the first support in use.

[0025] The aerosol generating article may further comprise a second support adapted to support the energy storage device. The second support may comprise an air hole. The air hole may be formed in a base of the second support. A substantially cylindrical wall may extend from the base and may surround a first end of the energy storage device.

[0026] The second support may be arranged at the first end of the energy storage device.

[0027] The second support may improve the durability of the aerosol generating device. The second support may also prevent direct contact between the energy storage device and the one or more terminals (e.g., pogo or spring-loaded pins) of the flexible PCB - thereby ensuring that an unwanted short-circuit does not occur.

[0028] P51791WO-6559 The aerosol generating device may further comprise a cover. The cover may be made of a suitable plastics material. The cover may be fixed (e.g., fixed to an outer housing of the aerosol generating device) or may be removable if it is necessary to provide access to the energy storage device, for example.

[0029] The cover may be arranged at a second end of the energy storage device, opposite the first end - i.e., so that the energy storage device is arranged between the second support and the cover. The cover may be arranged at the second end of the aerosol generating device, opposite the first end - i.e., the first support and the cover may be arranged at opposite ends of the aerosol generating device.

[0030] The energy storage device, the first support, and the second support may be surrounded by a housing. The cover may be fixed to the housing or may be removably located in an open end of the housing. The flexible PCB may be positioned between an outer surface of the first support and an inner surface of the housing, for example.

[0031] The controller may be mounted on an exterior surface of the flexible PCB, and in particular may be mounted on an exterior surface of a mounting substrate section of the flexible PCB. The temperature of the exterior surface of the flexible PCB may be relatively close to the ambient external temperature (e.g., room temperature) whereas the temperature at an interior surface may be higher. The bending stress may also be lower at the exterior surface. The exterior surface may therefore be more suitable for mounting the controller for more stable operation and durability of the aerosol generating device. Arranging all of the electronic components on the exterior surface (or at least those that are physically large) may minimise the gap between the flexible PCB and the space and / or the energy storage device that the flexible PCB surrounds.

[0032] A first elongate substrate may further comprise a first folded end part. In other words, the first mounting substrate section (elongate substrate) may comprise a main part that extends substantially along a longitudinal axis of the aerosol generating device, and a folded part at an end of the main part. The folded part may extend substantially perpendicular to the main part, for example. A first surface of the first folded end part that faces towards the energy storage device may have a normal that extends substantially parallel to the longitudinal axis of the aerosol generating device, and may comprise one or more terminals (e.g., battery terminals) electrically connected to the energy storage device. The one or more terminals provide a direct electrical connection between the flexible PCB and the energy storage device. This avoids the need for separate wires to electrically connect the flexible PCB to the energy storage device, which results in better efficiency - because of lower electrical losses - and higher tolerance to corrosion by avoiding bimetallic connections. It also simplifies the process of assembling the aerosol generating device. The first folded end part may be received in, or supported by, the second support - e.g., the first folded end part may be arranged between a surface of the second support and

[0033] P51791WO-6559 the end of the energy storage device. The first folded end part may also be beneficial for mounting the one or more terminals because the first folded end part may be wider than the main part of the first elongate substrate. This may allow the surface area of the one or more terminals to be increased - thereby reducing contact resistance. Reducing contact resistance may, in turn, reduce the amount of heat that is generated and reduce energy losses.

[0034] The aerosol generating device may further comprise a temperature sensor. The temperature sensor may be mounted on the first surface of the first folded end part. This provides a simple and convenient way of mounting the temperature sensor so that it may measure a temperature of the energy storage device. By arranging the temperature sensor on the first surface where it is close to the energy storage device, a more accurate measurement of the energy storage device temperature may be obtained.

[0035] The aerosol generating device may further comprise a puff sensor to detect when the user takes a puff - i.e., inhales the generated aerosol - during a vaping session. The puff sensor may be mounted on a second surface of the first folded end part, opposite the first surface - i.e., on a surface that may face towards the first support and optionally towards the base of the second support. This provides a simple and convenient way of mounting the puff sensor. The air hole in the second support may be substantially aligned with the puff sensor. A more accurate detection of a puff may therefore be obtained.

[0036] The flexible PCB may surround at least part of the space for receiving the aerosol generating article (e.g., surround at least part of the first support). A second mounting substrate section (elongate substrate) may further comprise a second folded end part that faces the first folded end part. In other words, the second elongate substrate may comprise a main part that extends substantially along a longitudinal axis of the aerosol generating device, and a folded part at an end of the main part. The folded part may extend substantially perpendicular to the main part, for example. The first folded end part and the second folded end part may be separated by the second support along the longitudinal axis of the aerosol generating device - i.e., the first folded end part may be located on the side of the second support facing the energy storage device and the second folded end part may be located on the side facing the first support. More particularly, the base of the second support may comprise a first surface that faces the first folded end part and from which the cylindrical wall extends, and second surface that faces towards the first support and a first surface of the second folded end part. A second surface of the second folded end part, opposite the first surface, may face towards the first support, and more particularly towards its closed second end. The second surface of the second folded end part may have a normal that extends substantially parallel to the longitudinal axis of the aerosol generating device, and may comprise one or more terminals (e.g., pogo or spring-loaded pins) electrically connectable to the aerosol generating article when received in the space in use. The one or more terminals may be received through the optional one or more openings in the second end of the first support. The second

[0037] P51791WO-6559 elongate substrate, and in particular the second folded end part, may further comprise an air hole that is substantially aligned with the puff sensor. The air hole may also be substantially aligned with the air hole in the second support. It will be understood that in some arrangements there is no need to make an electrical connection to the aerosol generating article and the one or more terminals may be omitted. The second folded end part may also be omitted in some arrangements.

[0038] The aerosol generating device may further comprise a charging circuit and / or a protection circuit mounted on the first elongate substrate. A charging circuit may be provided if the energy storage device is a rechargeable battery that may be charged from an external power source by a charging assembly of the aerosol generating device, for example. As mentioned above, the first elongate substrate may include a first folded end part that may include one or more terminals that are electrically connected to the energy storage device. A large current may flow through a conductive path connecting the energy storage device to the charging circuit and / or the protection circuit. To minimise electrical noise and losses, it is generally preferred that such a large current flows through a wide conductive path. If the charging circuit and / or the protection circuit are also mounted on the first elongate substrate, the physical distance between these components and the energy storage device may be minimised. This means that the area of the flexible PCB that is occupied by the wide conductive path will also be minimised.

[0039] At least two of the plurality of mounting substrate sections (elongate substrates) may have different lengths. The length of an elongate substrate will include a main part and a folded part, if appropriate. It may be preferred that each elongate substrate has a suitable length so that the one or more electronic components may be mounted in an appropriate way. Put another way, the length of each elongate substrate may be selected to provide sufficient surface area for mounting the electrical component(s) allocated to that particular elongate substrate. The size of each electronic component and any spacing requirements may also be taken into account when selecting the length of a particular elongate substrate. This may reduce the total surface area of the flexible PCB and therefore reduce the cost and weight of the aerosol generating device.

[0040] A circumferentially-adjacent pair of mounting substrate sections (elongate substrates) may be connected by a pair of connecting substrates that are spaced apart along the longitudinal axis of the aerosol generating device. A gap between a pair of spaced connecting substrates may be used to dissipate heat through the flexible PCB to the external environment.

[0041] At least one of the mounting substrate sections (elongate substrates) may comprise a supporting member or stiffener. A supporting member or stiffener may be added where some rigidity is required, e.g., to those areas of the flexible PCB to which one or more electronic components are mounted. The supporting members or stiffeners may help with cooling the elongate substrates by dissipating heat.

[0042] P51791WO-6559 The first mounting substrate section (elongate substrate) may not comprise a supporting member or stiffener - i.e., the first elongate substrate may be designed to be fully flexible without any supporting member or stiffener. The second elongate substrate may also not comprise a supporting member or stiffener - i.e., the second elongate substrate may also be designed to be fully flexible without any supporting member or stiffener.

[0043] The space and the energy storage device are preferably arranged along the longitudinal axis of the aerosol generating device. The first and second supports are also preferably arranged along the longitudinal axis of the aerosol generating device. A third mounting substrate section (elongate substrate) of the flexible PCB may extend over at least part of the space (e.g., over part of the first support) and at least part of the energy storage device. A plurality of semiconductor switches may be mounted on the third mounting substrate section (elongate substrate). The third mounting substrate section (elongate substrate) may have a long length so the plurality of semiconductor switches may be distributed or spaced apart along it. Being able to space the semiconductor switches apart may limit reciprocal interference between the semiconductor switches as a result of switching noise.

[0044] The controller may be mounted on a fourth mounting substrate section (elongate substrate) of the flexible PCB. In particular, the controller is preferably not mounted on the same mounting substrate section (elongate substrate) as the charging circuit or the semiconductor switches. This may protect the controller from unwanted electromagnetic noise or interference generated by the other components. A width of part of the fourth mounting substrate section (elongate substrate) may be wider than another part of the fourth mounting substrate section (elongate substrate). The controller may be mounted on the wider width part for a more convenient and simplified circuit arrangement. Because the controller generally has many terminals or pins, it may be easier to provide the necessary conductive paths if the controller is mounted on a wider part of the fourth elongate substrate.

[0045] Using a flexible PCB means the aerosol generating device has fewer separate components parts, which simplifies the assembly process. There are no wires or cables within the aerosol generating device, which also simplifies the assembly process and reduces electrical losses.

[0046] The size and weight of the aerosol generating device may be minimised.

[0047] The aerosol generating article may be removably received in the aerosol generating device, e.g., in the first support. The aerosol generating article may be of any suitable type and may include an aerosol generator adapted to heat aerosol generating material to generate an aerosol for inhalation by a user. The aerosol generator may include a heater. A heater may alternatively be part of the aerosol generating device.

[0048] P51791WO-6559 The aerosol generator may be adapted to heat aerosol generating material. The aerosol generating material may be a liquid which may be stored in the aerosol generating article. The liquid aerosol generating material may soak into a wick (e.g., a cotton wick) and is then heated by the heater to produce a vapour that cools and condenses to form an aerosol that may then be inhaled. The wick may be omitted in some cases and the liquid aerosol generating material may be directly stored in a cavity of the aerosol generating article. The aerosol generating article may be formed as an integrated component (or “pod”) that includes a liquid store, a liquid transfer element or wick, and a heater. The one or more terminals (e.g., pogo or spring-loaded pins) mentioned above may provide an electrical connection between the heater and the flexible PCB, which in turn is electrically connected to the energy storage device.

[0049] The aerosol generating article may be formed substantially in the shape of a stick, and may broadly resemble a cigarette, having a tubular region with an aerosol generating material or substrate arranged in a suitable manner. The space that is adapted to receive the aerosol generating article may be a heating space for example. In particular, the aerosol generating device may comprise a heater or heater assembly for heating the aerosol generating article when it is received in the heating space to generate an aerosol for inhalation by the user. The heater or heater assembly may be part of the first support, for example, and may be electrically connected to the flexible PCB, either directly or by wires. The heater or heater assembly may also be mounted directly on the flexible PCB. The aerosol generating article may include a filter segment, for example comprising cellulose acetate fibres, at a proximal end of the aerosol generating article. The filter segment may constitute a mouthpiece filter and may be in coaxial alignment with the aerosol generating material. One or more vapour collection regions, cooling regions, and other structures may also be included in some designs. For example, the aerosol generating article may include at least one tubular segment upstream of the filter segment. The tubular segment may act as a vapour cooling region. The vapour cooling region may advantageously allow the heated vapour generated by heating the aerosol generating material to cool and condense to form an aerosol with suitable characteristics for inhalation by a user, for example through the filter segment.

[0050] The aerosol generating material may comprise any type of solid or semi-solid material. Example types of aerosol generating solids include powder, granules, pellets, shreds, strands, particles, gel, strips, loose leaves, cut filler, porous material, foam material or sheets. The aerosol generating material may comprise plant derived material and in particular, may comprise tobacco. It may advantageously comprise reconstituted tobacco, for example including tobacco and any one or more of cellulose fibres, tobacco stalk fibres and inorganic fillers. The solid or semi-solid aerosol generating material may be heated by a heater that is provided as part of the aerosol generating device - e.g., arranged adjacent to a heating space of the aerosol generating device that is adapted to receive the aerosol generating article in use. The heater may be formed as part of the first support.

[0051] P51791WO-6559 The aerosol generating material may comprise an aerosol-former. Examples of aerosol-formers include polyhydric alcohols and mixtures thereof such as glycerine or propylene glycol. Typically, the aerosol generating material may comprise an aerosol-former content of between approximately 5% and approximately 50% on a dry weight basis. In some embodiments, the aerosol generating material may comprise an aerosol-former content of between approximately 10% and approximately 22% on a dry weight basis, and possibly approximately 15% on a dry weight basis.

[0052] The aerosol generating device may be adapted to heat the aerosol generating material or substrate, without burning the aerosol generating material, to volatise at least one component of the aerosol generating material and thereby generate a heated vapour which cools and condenses to form an aerosol for inhalation by a user of the aerosol generating device. The volatile compounds released from the aerosol generating material may include nicotine or flavour compounds such as tobacco flavouring.

[0053] 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 may 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.

[0054] When the aerosol generating material is depleted, the aerosol generating article may be removed from the aerosol generating device and a new article may be inserted.

[0055] The aerosol generating article may include a mouthpiece through which the generated aerosol may be inhaled.

[0056] Brief Description of the Drawings

[0057] Figure 1 is a diagrammatic view of an aerosol generating system with an aerosol generating device and an aerosol generating article;

[0058] Figures 2 and 3 are diagrammatic views of a first support of the aerosol generating device;

[0059] Figures 4 and 5 are diagrammatic views of a second support of the aerosol generating device;

[0060] Figure 6 is a diagrammatic view of an exterior surface of a flexible printed circuit board of the aerosol generating device in a flat configuration;

[0061] Figure 7 is a diagrammatic view of an interior surface of the flexible printed circuit board of Figure 6; and

[0062] Figure 8 is a diagrammatic view of the flexible printed circuit board of Figures 6 and 7 in a folded configuration.

[0063] P51791WO-6559 Detailed Description of Embodiments

[0064] Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.

[0065] Referring initially to Figure 1 there is shown diagrammatically an example of an aerosol generating system 1. The aerosol generating system 1 comprises an aerosol generating device 2 and an aerosol generating article 4 for use with the aerosol generating device 2. The aerosol generating device 2 comprises an outer housing 6 and is sized to be comfortably held by a user unaided, in a single hand. The body or housing 6 may be made of aluminium or another suitable metal or non-metal material, for example.

[0066] The aerosol generating device 2 includes a first support 8, a second support 10, a flexible printed circuit board (PCB) 12, a battery 14, and an end cover 16. The first support 8 is arranged at a first end (or proximal end) 2a of the aerosol generating device 2 and the end cover 16 is arranged at a second end (or distal end) 2b of the aerosol generating device 2 as shown.

[0067] The aerosol generating article 4 includes an aerosol generator (not shown) adapted to heat aerosol generating material (not shown) to generate an aerosol for inhalation by a user. The aerosol may be inhaled by a user through a mouthpiece 18 of the aerosol generating article 4.

[0068] Referring to Figures 2 and 3, the first support 8 may be made of a plastics material and is adapted to support the flexible PCB 12. In particular, the flexible PCB 12 is arranged around the outer surface of the first support 8. The first support 8 has a tubular construction with an interior space 20 and an opening 22 at a first end 8a that are sized and shaped to receive the aerosol generating article 4. The first support 8 has a substantially cylindrical outer surface defined by a plurality of flats - i.e., planar side surfaces 8c. Some of the planar side surfaces 8c include a recess for receiving a respective portion of the flexible PCB 12, as discussed further below. Other parts (labelled 8d) of the outer surface are received through gaps 62 in the flexible PCB 12 as described in more detail below. The parts 8d are shaped to protrude through the gaps 62. The flexible PCB 12 is therefore located and supported by the first support 8.

[0069] A shape of the opening 22 and a cross-sectional shape of the interior space 20 is not limited to a circle and it will be understood that other shapes, e.g., ellipse or polygon, may be used depending on the shape of the aerosol generating article 4.

[0070] A second end 8b of the first support 8 is substantially closed and includes an air hole 24. The second end 8b also includes a pair of openings 26a, 26b for receiving one or more terminals (e.g., pogo or

[0071] P51791WO-6559 spring-loaded pins 56a, 56b) of the flexible PCB 12 - see below. In another arrangement that is not shown, the aerosol generating article 4 may be formed substantially in the shape of a stick, and may broadly resemble a cigarette, having a tubular region with an aerosol generating material or substrate arranged in a suitable manner. The aerosol generating material may comprise any type of solid or semisolid material, e.g., tobacco. The aerosol generating article 4 may be inserted into a heating space of the first support 8, and the aerosol generating device 2 may include a heater or heater assembly for heating the aerosol generating material to generate an aerosol for inhalation by a user. In such an arrangement, the openings 26a, 26b may be omitted because there is no need to provide an electrical connection through the first support 8 to the aerosol generating article 4. The heater or heater assembly may be provided as part of the first support 8 and may be electrically connected to the flexible PCB 12 or may be mounted directly on the flexible PCB 12, for example.

[0072] Referring to Figures 4 and 5, the second support 10 may be made of a plastics material and is adapted to support an end of the battery 14. The second support 10 includes a base 28 and a cylindrical wall 30 that extends from the base 28 and defines an interior space for receiving the end of the battery 14. The cylindrical wall 30 includes a pair of slots 32, 34, each for receiving a respective portion of the flexible PCB 12 as described in more detail below. An air hole 36 is formed in the base 28.

[0073] The other end of the battery 14 is supported by the end cover 16. The end cover 16 may be made of a suitable plastics material.

[0074] Figures 6 and 7 show the flexible PCB 12 in a flat condition, before it is folded or bent to the folded condition shown in Figure 8. In Figure 8, the other components of the aerosol generating device 2 have been omitted for clarity. But it will be clear, e.g., from Figure 1, that the flexible PCB 12 is folded around, and supported by, the first support 8.

[0075] The flexible PCB 12 comprises a flexible substrate 57, also referred to herein as a flexible base material, such as polyimide or polyester. One or more electrically conductive layers (e.g., copper layers) are applied to the base material to define electrically conductive traces that connect electronic components that are mounted to the flexible PCB together in one or more electrical circuits. The flexible PCB additionally includes a protective layer or overlay to provide insulation and protection to the circuit.

[0076] The flexible substrate 57 comprises a first plurality of mounting substrate sections 58, which are connected together by a second plurality of connecting substrate sections 60. Together the mounting substrate sections 58 and the connecting substrate sections 60 form a unitary flexible PCB having a third plurality of gaps 62 defining through holes in the flexible substrate 57.

[0077] P51791WO-6559 Each mounting substrate section 58 is elongate, and comprises a respective long axis 59 and a short axis perpendicular to that long axis. In the example shown, the mounting substrate sections 58 are generally rectangular in shape and have substantially the same width as one another (with exceptions discussed below). Some of the mounting substrate sections 58 have different lengths, also as discussed in further detail below. The long axes 59 of the mounting substrate sections 58 are all parallel to one another. In the illustrated example there are five mounting substrate sections, though it will be understood that more or fewer mounting substrate sections could be provided if required by the geometry of the aerosol generating device.

[0078] Each mounting substrate section 58 is connected to either one or two neighbouring (i.e. adjacent) mounting substrate section(s) 58 via one or more connecting substrate sections 60. Put another way, the one or more gaps 62 or cutaway portions are provided through the flexible PCB at locations selected to define the mounting substrate sections 58 and the connecting substrate sections 60. The connecting substrate sections 60 each have a length (in the direction of the long axis of the mounting substrate sections) that is significantly less that the length of the mounting substrate sections. In the illustrated example there are eight connecting substrate sections, though it will be understood that more or fewer connecting substrate sections could be provided if required by the geometry of the aerosol generating device.

[0079] When the flexible PCB 12 is assembled into the aerosol generating device 2, the long axis 59 of each mounting substrate section 58 extends substantially parallel to a longitudinal axis of the aerosol generating device (which coextends with longitudinal axes of the interior space 20 of the first support 8 and of the battery 14). Each mounting substrate section 58 is supported by a respective flat portion 8c of the first support 8, whilst the protrusions 8d located between the flat portions are received in the gaps 62 through the flexible PCB 12.

[0080] Several electronic components are shown mounted on a first surface 12a of the flexible PCB 12, and more specifically on the mounting substrate portions 58 of the flexible PCB. The illustrated components include:

[0081] - a microcontroller unit (MCU) 38 adapted to control the aerosol generating device 2,

[0082] - capacitive sensors 40,

[0083] - semiconductor switches (e.g., MOSFETs) 42,

[0084] - a charging circuit 44 and a protection circuit 46, which may both be implemented as an integrated circuits (ICs), and

[0085] - temperature sensors 48, 50.

[0086] The first surface 12a also includes a pair of battery terminals 52a, 52b.

[0087] P51791WO-6559 A puff sensor 54 is mounted on a second surface 12b of the flexible PCB 12. A pair of terminals (e.g., pogo or spring-loaded pins) 56a, 56b are provided on the second surface 12b of the flexible PCB 12. The flexible PCB 12 and the various electronic components together define a printed circuit board assembly (PCB A) of the aerosol generating device 2.

[0088] As noted above, the flexible PCB 12 comprises five mounting substrate sections 58, also referred to herein as elongate substrates 58a, 58b, ..., 58e. The elongate substrates 58a, 58b, ..., 58e are spaced apart and are connected by respective substrate sections, also referred to herein as connecting substrates 60a, 60b, ..., 60d. In particular, the adjacent elongate substrates 58a and 58b are connected by a pair of connecting substrates 60a that are spaced apart along the longitudinal axis of the aerosol generating device 2, the adjacent elongate substrates 58b and 58c are connected by a pair of connecting substrates 60b that are spaced apart along the longitudinal axis of the aerosol generating device 2, the adjacent elongate substrates 58c and 58d are connected by a pair of connecting substrates 60c that are spaced apart along the longitudinal axis of the aerosol generating device 2, and the adjacent elongate substrates 58d and 58e are connected by a pair of connecting substrates 60d that are spaced apart along the longitudinal axis of the aerosol generating device 2. It will be understood that whilst adjacent elongate substrates are illustrated as linearly adjacent in Figures 6 and 7, those substrates are circumferentially adjacent when the flexible PCB 12 is assembled in the aerosol generating device, as shown in Figure 8.

[0089] Gaps 62 are defined between the various substrate sections as shown in Figures 6 and 7. The gaps 62 are sized and shaped to receive the parts 8d of the outer surface of the first support 8 to locate and retain the flexible PCB 12 on the first support 8. The gaps 62 may also allow heat to be dissipated through the flexible PCB 12.

[0090] As noted above, each elongate substrate 58a, 58b, ..., 58e has a respective long axis 59 that extends substantially parallel to a longitudinal axis of the aerosol generating device 2 and a short axis perpendicular to that long axis.

[0091] In general, the width of each elongate substrate is generally constant along its length. However, in the case of a central elongate substrate 58c, the MCU 38 is mounted on a wider, central part of the elongate substrate 58c as shown in Figures 6 and 7. This may make it easier to provide the conductive paths that are necessary to connect to the terminals or pins of the MCU 38. Furthermore, a first 58d of the elongate substrates comprises a wider end part 64 that is configured to fold (with respect to the long axis 59 of that elongate substrate) when the flexible PCB 12 is assembled into the aerosol generating device. A similar wider end part 66 is also comprised in a second 58a of the elongate substrates.

[0092] The capacitive sensors 40 are mounted on the second elongate substrate 58a. The capacitive sensors 40 may be used to provide the aerosol generating device 2 with one or more additional functions, for

[0093] P51791WO-6559 example, detecting the insertion and / or removal of the aerosol generating article 4, or sensing a manipulation of the aerosol generating device 2.

[0094] The semiconductor switches 42 and the temperature sensor 50 are mounted on elongate substate 58b. The semiconductor switches 42 may be used to regulate the power that is supplied to the electronic components mounted on the flexible PCB 12, the battery 14, or the aerosol generator of the aerosol generating article 4, for example.

[0095] The charging and protection circuits 44, 46 are mounted on the first elongate substrate 58d.

[0096] Other electronic components (e.g., other protection circuits) may be mounted on elongate substrate 58e.

[0097] As noted above, an end of the first elongate substrate 58d also includes a folded end part 64 that is folded to be substantially perpendicular to a main part of the first elongate substrate 58d. Put another way, the first elongate substrate 58d includes a fold line 61d that is perpendicular to the long axis 59 of the first elongate substrate 58d. The first elongate substrate 58d may thus be folded along the fold line 61 d to cause the end part 64 to extend at an angle to the remainder of the first elongate substrate 58d. When assembled into the aerosol generating device, the end part 64 is folded so that its long axis is normal to the long axis 59 of the remainder of the first elongate substrate 58d, and a normal of the folded end part 64 is parallel to the longitudinal axis of the aerosol generating device, as shown in Figure 8. The temperature sensor 48 and the battery terminals 52a, 52b are formed on a first surface of the 64a of the folded end part 64. The puff sensor 54 is formed on a second surface 64b of the folded end part 64.

[0098] The folded end part 64 is received in the interior space that is defined by the cylindrical wall 30 of the second part 10 - i.e., positioned between the base 28 and the end of the battery 14. The first elongate substrate 58d is received in the slot 32 in the cylindrical wall 30. The first surface 64a of the folded end part 64 faces towards the battery 14 so that the battery terminals 52a, 52b can make an electrical connection between the battery 14 and the flexible PCB 12. The temperature sensor 58 is also positioned next to the end of the battery 14 and can measure a temperature of the battery with high accuracy. The second surface 64b of the folded end part 64 faces towards the base 28 of the second support 10. The puff sensor 54 is substantially aligned with the air hole 36 in the base 28 of the second support 10. The folded end part 64 has a shape that is complementary to the interior space defined by the cylindrical wall 30 of the second part and, in the example shown, is generally circular in plan view.

[0099] An end of a second elongate substrate 58a also includes a folded end part 66 that is folded to be substantially perpendicular to a main part of the second elongate substrate 58a. Put another way, the second elongate substrate 58a includes a fold line 61a that is perpendicular to the long axis 59 of the

[0100] P51791WO-6559 second elongate substrate 58a. The second elongate substrate 58a may thus be folded along the fold line 61a to cause the end part 66 to extend at an angle to the remainder of the second elongate substrate 58a. When assembled into the aerosol generating device, the end part 66 is folded so that its long axis is normal to the long axis 59 of the remainder of the second elongate substrate 58a, and a normal of the folded end part 66 is parallel to the longitudinal axis of the aerosol generating device, as shown in Figure 8. A first surface 66a of the folded end part 66 faces towards the base 28 of the second support 10. The pair of terminals (e.g., pogo or spring-loaded pins) 56a, 56b are formed on a second surface 66b of the folded end part 66. The second surface 66b of the folded end part 66 faces towards the second end 8b of the first support 8 and the terminals 56a, 56b are received through the openings 26a, 26b of the first support 8 so that the ends of terminals 56a, 56b may make an electrical connection with corresponding terminals or contacts (not shown) of the aerosol generating article 4 when it is received in the space 20. The base 28 of the second support 10 may contact and support the folded end part 66 - particularly when electrical contact is being made between the terminals 56a, 56b and the aerosol generating article 4. The folded end part 66 includes an air hole 68 that is substantially aligned with the air hole 36 in the second support 10 that is positioned between the folded end parts 64, 66, and also with the puff sensor 54. In other words, the puff sensor 54 is substantially aligned with an axially extending passage formed through the second support 10 and the folded end part 66, where the passage is defined by the respective air holes 36, 68.

[0101] The elongate substrates 58b, 58c and 58e include a supporting member or stiffener 70. Each stiffener 70 may be formed as a strip of rigid material (e.g., a plastics material or metal) that extends along substantially the whole length of the elongate substrate to provide additional rigidity where required. If the stiffeners 70 are formed of a material with good thermal transfer properties, they may distribute heat and help cool the flexible PCB 12 and the mounted electronic components. The first and second elongate substrates 58d, 58a do not include a supporting member or stiffener and are designed to be fully flexible.

[0102] Figure 8 shows how the folded flexible PCB 12 may substantially surround the first support 8.

[0103] The elongate substrate 58b is received in the slot 34 in the cylindrical wall 30 of the second support 10. As shown in Figure 8, the elongate substrate 58b may overlap with the battery 14. (Although the battery 14 is not shown in Figure 8 for improved clarity, it will be clear that an end of the battery is positioned in electrical contact with the battery terminals 52a, 52b on the first surface 64a of the folded end part 64 so that the battery is overlapped by the end of the elongate substrate 58b that extends beyond the folded end part 64 of elongate substrate 58d.) The temperature sensor 50 at an end of the elongate substrate 58b will therefore be positioned adjacent the battery 14 and may be used to measure a temperature of the battery 14.

[0104] P51791WO-6559 Although not shown, the aerosol generating device 2 may further include a connector (e.g., a receptacle or socket such as Universal Serial Bus (USB-C) receptacle) that is configured to electrically and mechanically connect to the external power source. Such a connector may be arranged at a suitable position, e.g., on the end cover 16 or the outer housing 6 of the aerosol generating device 2.

[0105] 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. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

[0106] 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.

[0107] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

[0108] P51791WO-6559

Claims

Claims1. An aerosol generating device (2) comprising: a space (20) adapted to receive an aerosol generating article (4) in use; an energy storage device (14); a flexible printed circuit board PCB (12) arranged to surround at least part of the space (20) and / or the energy storage device (14); and a controller (38) adapted to control the aerosol generating device (2), wherein the controller (38) is mounted on the flexible PCB (12); wherein a substrate (57) of the flexible PCB (12) comprises a plurality of connected substantially rectangular mounting substrate sections (58a, 58b, ..., 58e) arranged circumferentially around the at least part of the space (20) and / or the energy storage device (14), at least part of each mounting substrate section (58a, 58b, ..., 58e) having a long axis (59) that extends substantially parallel with a longitudinal axis of the aerosol generating device (2) and a short axis that extends substantially perpendicular to the long axis, and wherein circumferentially-adjacent mounting substrate sections (58a, 58b, ..., 58e) are connected by one or more connecting substrate sections (60a, 60b, ..., 60d) of the substrate that are defined by gaps (62) in the substrate.

2. An aerosol generating device (2) according to claim 1, further comprising a first support (8) adapted to support the flexible PCB (12), the space (20) optionally being device by an interior space of the first support (8).

3. An aerosol generating device (2) according to claim 1 or claim 2, wherein the controller (38) is mounted on an exterior surface of a mounting substrate section (58c) of the flexible PCB (12).

4. An aerosol generating device (2) according to any preceding claim, wherein a first mounting substrate section (58d) further comprises a first folded end part (64), and wherein a first surface (64a) of the first folded end part (64) that faces towards the energy storage device (12) has a normal that extends substantially parallel to the longitudinal axis of the aerosol generating device (2) and comprises one or more terminals (52a, 52b) electrically connected to the energy storage device (14).

5. An aerosol generating device (2) according to claim 4, further comprising a temperature sensor (48) mounted on the first surface (64a) of the first folded end part (64).

6. An aerosol generating device (2) according to claim 4 or claim 5, further comprising a puff sensor (54) mounted on a second surface (64b) of the first folded end part (64), opposite the first surface (64a).P51791WO-65597. An aerosol generating device (2) according to claim 6, wherein the flexible PCB (12) surrounds at least part of the space (20), wherein a second mounting substrate section (58a) further comprises a second folded end part (66) that faces the first folded end part (64), and wherein a surface (66b) of the second folded end part (66) has a normal that extends substantially parallel to the longitudinal axis of the aerosol generating device (2) and comprises one or more terminals (56a, 56b) electrically connectable to the aerosol generating article (4) when received in the space (20) in use, and wherein the second mounting substrate section (58a) further comprises an air hole (68) that is substantially aligned with the puff sensor (54).

8. An aerosol generating device (2) according to any of claims 4 to 7, further comprising a charging circuit (44) and / or a protection circuit (46) mounted on the first mounting substrate section (58d).

9. An aerosol generating device (2) according to any preceding claim, wherein at least two of the plurality of mounting substrate sections (58a, 58b, ..., 58e) have different lengths.

10. An aerosol generating device (2) according to any preceding claim, wherein a circumferentially-adjacent pair of mounting substrate sections (58a, 58b) are connected by a pair of connecting substrates (60a) that are spaced apart along the longitudinal axis of the aerosol generating device (2).

11. An aerosol generating device (2) according to any preceding claim, wherein at least one of the mounting substrate sections (58b, 58c, 58e) comprises a supporting member or stiffener (70).

12. An aerosol generating device (2) according to any preceding claim, wherein the space (20) and the energy storage device (14) are arranged along the longitudinal axis of the aerosol generating device (2), wherein a third mounting substrate section (58b) extends over at least part of the space (20) and at least part of the energy storage device (14), and further comprising a plurality of semiconductor switches (42) mounted on the third mounting substrate section (58b).

13. An aerosol generating device (2) according to claim 12, further comprising a second support (10), wherein the second support (10) is arranged between the space (20) and the energy storage device (14) along the longitudinal axis of the aerosol generating device (2).

14. An aerosol generating device (2) according to any preceding claim, further comprising a fourth mounting substrate section (58c), wherein the controller (38) is mounted on the fourth mounting substrate second (58c).P51791WO-655915. An aerosol generating device (2) according to claim 14, wherein a width of part of the fourth mounting substrate section (58c) is wider than another part, and wherein the controller (38) is mounted on the wider width part.P51791WO-6559

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