Integrated pouch-type battery assembly

Abstract

An integrated pouch-type battery assembly comprises: a battery cell having electrodes; a PCM module comprising a PCM holder and a PCM board received in the PCM holder and electrically connected to said electrodes; and a wrapper that envelops the battery cell and the PCM module to mount the PCM module to the battery cell.

Description

[0001] INTEGRATED POUCH-TYPE BATTERY ASSEMBLY

[0002] TECHNICAL FIELD

[0003] The present invention relates to an integrated pouch-type battery assembly.

[0004] BACKGROUND

[0005] Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user’s mouth. Such tobacco heating devices may include a battery' to power a heater for heating the aerosol generating substrate. The battery may be removable from the device.

[0006] SUMMARY

[0007] According to a first aspect of the disclosure, there is provided an integrated pouch-type battery assembly, comprising: a battery cell having electrodes; a PCM module comprising a PCM holder and a PCM board received in the PCM holder and electrically connected to said electrodes; and a wrapper that envelops the batery cell and the PCM module to mount the PCM module to the battery cell.

[0008] The integrated pouch-type battery assembly may also be referred to as an “integrated pouchtype battery pack and PCM module”, an “integrated battery pack and PCM module”, a “pouch type battety pack and PCM module”, “a battery' and PCM”, “a combined battery’ and PCM”, “a battery' and PCM module”, or the like.

[0009] Optionally, the PCM holder comprises a recess to locate the PCM board.

[0010] Optionally, the PCM holder comprises a first receiving element configured to receive the PCM board.

[0011] Optionally, the first receiving element is configured to locate the PCM board. Optionally, the first receiving element comprises a recess, a slot, a groove, a channel or an aperture.

[0012] Optionally, the wrapper wraps the batery cell and the PCM module together.

[0013] Optionally, the wrapper is arranged to circumscribe at least a portion of the battery cell and at least a portion of the PCM module.

[0014] Optionally, the wrapper is arranged to cover at least a portion of the battery cell and at least a portion of the PCM module.

[0015] Optionally, the wrapper is arranged to hold the battery cell and the PCM module together.

[0016] Optionally, the wrapper is arranged to bind the PCM module to the battery cell.

[0017] Optionally, the integrated pouch-type battery assembly comprises a flat panel contact pad electrically connected to the PCM board, and the PCM holder also comprises a recess to locate the flat panel contact pad.

[0018] Optionally, the PCM holder is generally cuboidal.

[0019] Optionally, the PCM holder comprises a block shape.

[0020] Optionally, the recess to locate the PCM board is a first recess of the PCM holder, and the recess to locate the flat panel contact pad is a second recess of the PCM holder.

[0021] Optionally, the first recess is configured to receive the PCM board, and / or the second recess is configured to receive the flat panel contact pad.

[0022] Optionally, the first recess and / or the second recess each comprises a generally rectangular channel, slot, aperture or groove. Optionally, the first recess is arranged to extend in a first plane, and the second recess is arranged to extend in a second plane, wherein the second plane is generally perpendicular to the first plane.

[0023] Optionally, the integrated pouch-type battery assembly comprises a longitudinal axis, wherein the first recess is arranged to extend in a direction that is generally parallel to the longitudinal axis, and the second recess is arranged to extend in a plane that is generally normal to the longitudinal axis.

[0024] The flat panel contact pad may also be referred to as a “flat panel contact board”, an “FPC pad”, an “FPC board”, or the like.

[0025] Optionally, the flat panel contact pad comprises terminals configured to connect with corresponding terminals in an aerosol generating device to connect said aerosol generating device to the electrodes of the battery cell via the PCM board.

[0026] Optionally, the terminals on the flat panel contact pad lie in the same plane.

[0027] Optionally, the terminals on the flat panel contact pad are each generally rectangular and are oriented to be generally parallel to one another.

[0028] Optionally, the flat panel contact comprises a generally flat base element, and the terminals are arranged to be generally parallel to the generally flat base element.

[0029] Optionally, the terminals are arranged to be generally planar with one another.

[0030] Optionally, the flat panel contact pad comprises two or more terminals, wherein the terminals are arranged to equally spaced apart from one another.

[0031] Optionally, the flat panel contact pad comprises three terminals.

[0032] Optionally, each of the one or more terminals is configured to be generally rectangular. Optionally, the PCM holder is configured to mount the flat panel contact pad generally at a right angle to the PCM board.

[0033] Optionally, the flat panel contact pad is arranged to be generally perpendicular to the PCM board.

[0034] Optionally, the PCM holder is configured to mount the flat panel contact pad and the PCM board relative to one another in a generally perpendicular relationship.

[0035] Optionally, the flat panel contact pad is coupled to the PCM board by a connecting portion.

[0036] Optionally, the battery’ cell has a longitudinal axis and the PCM board extends in a first plane, the PCM board being received in the PCM holder so that said first plane extends along, or parallel to, the longitudinal axis.

[0037] Optionally, the flat panel contact pad extends in a second plane, the flat panel contact pad being received in the PCM holder so that it extends substantially at right angles to the longitudinal axis of the battery cell and to the PCM board.

[0038] Optionally, the PCM board and the flat panel contact pad are coupled to one another via a connecting portion.

[0039] Optionally, the connecting portion is generally flexible, to permit the PCM board and the flat panel contact pad to pivot relative to one another, to facilitate assembly of the PCM board and the flat panel contact pad into the PCM holder.

[0040] Optionally, the connecting portion is generally rigid.

[0041] Optionally, the connecting portion is integrally formed with the PCM board and / or the flat panel contact pad.

[0042] Optionally, the wrapper envelops the cell and the PCM module to leave the terminals of the flat panel contact pad exposed. Optionally, the terminals of the flat panel contact pad are uncovered by the wrapper.

[0043] Optionally, the integrated pouch-type battery assembly comprises an end portion comprising the terminals of the flat panel contact pad.

[0044] Optionally, the end portion is arranged to be generally normal to the longitudinal axis.

[0045] Optionally, the end portion is uncovered by the wrapper.

[0046] Optionally, the wrapper comprises a polymer material.

[0047] Optionally, the wrapper comprises a thermoplastic material.

[0048] Optionally, the wrapper comprises a thermoplastic sheet wrapped around the batery cell and the PCM module, said thermoplastic sheet having been deformed around the battery cell and the PCM module to mount the PCM module to the battery cell.

[0049] Optionally, the thermoplastic sheet has been deformed by heat treatment to form the wrapper.

[0050] Optionally, the thermoplastic sheet is wrapped around the battery cell and the PCM module using heat shrinking.

[0051] Optionally, the integrated pouch-type battery assembly comprises a longitudinal axis, and the wrapper is arranged to envelop the batery cell and the PCM module along substantially an entire length thereof along the longitudinal axis.

[0052] Optionally, the integrated pouch-type batery assembly comprises a longitudinal axis, and the wrapper is arranged to envelop the battery cell along substantially an entire length thereof along the longitudinal axis, and the wrapper is arranged to envelop the PCM module along at least a portion of the length thereof along the longitudinal axis.

[0053] Optionally, the wrapper is arranged to envelop the battery cell and the PCM module such that at a portion of the PCM module is uncovered by the wrapper. Optionally, the PCM holder comprises an opening or groove configured to bind the thermoplastic sheet to the PCM holder when the thermoplastic sheet is deformed.

[0054] Optionally, the PCM holder comprises a binding element configured to bind the wrapper to the PCM holder.

[0055] Optionally, the binding element comprises an opening, groove, channel or aperture.

[0056] Optionally, at least a portion of the wrapper is configured to be received in the binding element.

[0057] Optionally, the binding element comprises an undercut.

[0058] Optionally, the integrated pouch-type battery assembly comprises a pouch, the battery' cell being received within the pouch, with the PCM holder being located outside of the pouch.

[0059] Optionally, the pouch comprises a thermoplastic material.

[0060] Optionally, the pouch comprises a thermoplastic sheet having been deformed by heat treatment.

[0061] Optionally, the pouch comprises a thermoplastic sheet wrapped around at least a portion of the battery cell by heat shrinking.

[0062] Optionally, the pouch comprises one or more folded edges each extending in a longitudinal direction along the pouch.

[0063] Optionally, each of the one or more folded edges is arranged to be generally parallel to the longitudinal axis.

[0064] Optionally, the PCM holder comprises one or more openings, each of the one or more openings being configured to receive a respective one of the one or more folded edges of the pouch, to mount the PCM holder to the pouch.

[0065] Optionally, the integrated pouch-type battery assembly comprises a first shaped feature on the PCM holder configured to cooperate with a corresponding second shaped feature in an aerosol generating device when the integrated pouch-type batery pack is received in an aerosol generating device.

[0066] Optionally, the pouch comprises one or more protruding elements.

[0067] Optionally, the PCM holder comprises one or more receiving elements, for example one or more openings, each of the one or more receiving elements being configured to receive a respective one of the one or more protruding elements of the pouch, to mount the PCM holder to the pouch.

[0068] Optionally, each of the one or more protruding elements is arranged to extend generally in a longitudinal direction along the pouch.

[0069] Optionally, each of the one or more protruding elements comprises an edge of the pouch.

[0070] Optionally, the integrated pouch-type battery assembly comprises a plurality of first shaped features on the PCM holder configured to cooperate with a plurality of corresponding second shaped features in an aerosol generating device when the integrated pouch-type battery pack is received in an aerosol generating device.

[0071] Optionally, each of the one or more first shaped features comprises a receiving element configured to receive a respective one of the one or more second shaped features.

[0072] Optionally, the integrated pouch-type battery assembly comprises two first shaped features.

[0073] Optionally, each of the one or more first shaped features comprises a receiving element, and each of the one or more second shaped features comprises a protruding element configured to be received by a respective one of the receiving elements.

[0074] Optionally, each of the one or more first shaped features comprises a protruding element, and each of the one or more second shaped features comprises a receiving element configured to receive a respective one of the protruding elements.

[0075] Optionally, each of the first shaped features is integrally formed with or in the PCM holder. Optionally, each of the second shaped features is integrally formed with or in a compartment of the aerosol generating device, the compartment being configured to receive the integrated pouch-type battery assembly.

[0076] Optionally, the one or more first and second shaped features are configured to cooperate with one another when the integrated pouch-type battery assembly is inserted into a compartment of an aerosol generating device in one particular orientation, to prevent, or at least discourage, incorrect insertion of the integrated pouch-type battery assembly into the aerosol generating device in an incorrect orientation that is different to said particular orientation.

[0077] Optionally, each of the one or more first shaped features comprises a cut-out, groove, recess, aperture or channel, which may be generally quadrilateral in shape.

[0078] Optionally, the PCM holder comprises two first shaped features arranged on opposite sides of the PCM holder along a common edge of the PCM holder.

[0079] Optionally, the PCM holder comprises a first face and a second face opposite to the first face, wherein the one or more first shaped features are each arranged on the first face, and no first shaped features are arranged on the second face.

[0080] Optionally, the integrated pouch-type battery assembly is generally elongate.

[0081] Optionally, the integrated pouch-type battery assembly is generally cuboidal, and may comprise one or more rounded edges and / or rounded corners.

[0082] Optionally, the integrated pouch-type battery assembly is generally in the shape of an elliptical prism.

[0083] Optionally, the integrated pouch-type battery assembly is generally cylindrical.

[0084] Optionally, the integrated pouch-type battery assembly comprises a longitudinal axis, and the battery cell and the PCM module are arranged adj cent to one another along the longitudinal axis. Optionally, the wrapper is arranged to extend about the longitudinal axis around the perimeter of the battery cell and the PCM module.

[0085] Optionally, the integrated pouch-type battery assembly further comprises a label, wherein at least a portion of the label is attached to the wrapper, to the pouch, or to the battery cell.

[0086] Optionally, the label is generally elongate and rectangular.

[0087] Optionally, the label is arranged to extend generally parallel to the longitudinal axis, along at least a portion of the length of the battery cell.

[0088] Optionally, the label comprises a coupling portion attached to the wrapper, the pouch, or the batery cell.

[0089] Optionally, the coupling portion comprises an adhesive layer configured to be affixed to the wrapper, the pouch, or the battery cell.

[0090] Optionally, the label comprises a tail portion attached to the coupling portion and configured to protrude from the batery cell and extend away therefrom.

[0091] Optionally, the tail portion is configured to be held by a user, and a pulling force applied thereto, in order to facilitate removal of the integrated pouch-type battery assembly from an aerosol generating device.

[0092] Optionally, the integrated pouch-type battery assembly comprises a first end portion comprising the terminals of the flat panel contact pad, and a second end portion opposite to the first end portion along the longitudinal axis.

[0093] Optionally, the tail portion of the label is arranged to extend away from the battery cell and protrude therefrom at the second end portion of the integrated pouch-type battery assembly.

[0094] Optionally, the battery cell comprises a rechargeable batery cell. Optionally, the battery cell comprises a soft pouch cell.

[0095] Optionally, the wrapper is configured to fixedly mount the PCM module to the battery' cell.

[0096] Optionally, the wrapper is configured to envelop the battery cell and the PCM module such that the battery' cell and the PCM module are not removable from one another when the wrapper envelops them.

[0097] Optionally, the wrapper is not removable from the battery- cell and the PCM module.

[0098] Optionally, the wrapper is configured to contain the batery- cell and the PCM module.

[0099] Optionally, the wrapper is configured to hold the battery cell and the PCM module together such that the wrapper prevents the battery cell and the PCM module from being removable from one another.

[0100] According to a second aspect of the disclosure, there is provided an aerosol delivery device comprising a compartment to receive an integrated pouch-type battery assembly according to any preceding claim.

[0101] Optionally, the integrated pouch-type battery- assembly comprises any one or more of the optional features recited above in relation to the first aspect of the disclosure.

[0102] Optionally, the aerosol delivery device is an aerosol generating device.

[0103] Optionally, the aerosol delivery' device comprises any one or more of the features of the aerosol generating device described above in relation to the first aspect of the disclosure.

[0104] Optionally, the integrated pouch-type battery' assembly is configured to be removable from the compartment.

[0105] Optionally, the aerosol delivery device comprises electrical connectors for connection to the terminals on the flat panel contact pad upon insertion of the integrated pouch-type battery assembly into said compartment. Optionally, the aerosol delivery device comprises a shrapnel connect module comprising one or more electrical connectors for connection to the terminals on the flat panel contact pad upon insertion of the integrated pouch-type battery assembly into said compartment.

[0106] Optionally, each of the one or more connectors is configured to be electrically connected to a respective one of the terminals of the flat panel contact pad of the integrated pouch-type battery assembly.

[0107] Optionally, the flat panel contact pad comprises three terminals and the aerosol delivery device comprises three electrical connectors.

[0108] Optionally, each of the one or more electrical connectors is arranged to protrude from a connect board of the shrapnel connect module.

[0109] Optionally, the connect board is arranged to extend in a plane generally parallel to or along the longitudinal axis of the integrated pouch-type battery assembly and generally parallel to the PCM board.

[0110] Optionally, the shrapnel connect module is configured to be coupled to the integrated pouchtype battery assembly.

[0111] Optionally, when the shrapnel connect module is coupled to the integrated pouch-type battery assembly, the one or more electrical connectors are electrically connected to the terminals on the flat panel contact pad.

[0112] Optionally, the aerosol delivery device comprises a locating feature in the compartment of the aerosol generating delivery device and a shaped feature on the PCM holder, the locating and shaped features being configured to cooperate when the integrated pouch-type battery assembly is inserted into the compartment in one orientation.

[0113] Optionally, the aerosol delivery device comprises a housing, and a consumable holder configured to receive a consumable.

[0114] Optionally, the aerosol delivery device comprises a housing, and a bottom case. Optionally, the consumable comprises an aerosol generating material.

[0115] Optionally, the aerosol delivery device is configured to heat the aerosol generating material to produce an aerosol therefrom.

[0116] Optionally, the integrated pouch-type battery' assembly is configured to power the aerosol delivery device.

[0117] Optionally, the aerosol delivery' device comprises a charging port, for example a USB type connector port, for charging the integrated pouch-type battery assembly.

[0118] Optionally, the battery cell comprises a rechargeable battery.

[0119] Optionally, the aerosol delivery device comprises a charging port seal arranged to protect the charging port against the ingress of moisture, debris, and other fluids or foreign objects.

[0120] Optionally, the aerosol delivery device comprises a release button configured to decouple the housing from the consumable holder or the bottom case.

[0121] Optionally, the aerosol delivery device comprises one or more snap fit elements configured to mechanically couple the housing to the consumable holder or the bottom case.

[0122] Optionally, the release button is configured to release one or more of the snap fit elements upon the application of a force to the release button.

[0123] Optionally, the housing is configured to slidably receive at least a portion of the consumable holder or the bottom case, or the consumable holder or the bottom case is configured to slidably receive at least a portion of the consumable holder.

[0124] Optionally, the release button is arranged in a region of overlap between the housing and the consumable holder or in a region of overlap between the housing and the bottom case. Optionally, upon application of a force to the release button, the release button is configured to permit the housing and the consumable holder or the housing and the bottom case to axially move relative to one another, to permit their decoupling.

[0125] Optionally, the release button is integrally formed with the housing.

[0126] Optionally, the release button is integrally formed with the consumable holder or the bottom case, and the release button is configured to be received in and protrude through an aperture in the housing.

[0127] Optionally, the release button is arranged on a major face of the aerosol delivery device, for example on a front or rear face thereof.

[0128] Optionally, the release button is arranged on a minor face of the aerosol delivery device, for example on a left or right side face thereof.

[0129] Optionally, the aerosol delivery device comprises a battery holder which comprises the compartment.

[0130] Optionally, the battery holder comprises at least one open face or surface to permit the integrated pouch-type battery assembly to be inserted into and removed from the compartment.

[0131] Optionally, the aerosol delivery device comprises a fastening element configured to couple the housing to the consumable holder or bottom case.

[0132] Optionally, the fastening element comprises a screw, a bolt, or a lock pin.

[0133] Optionally, the housing and the consumable holder or bottom case each comprises an aperture configured to receive the fastening element.

[0134] Optionally, the housing comprises an aperture, which may define an open surface of the housing. Optionally, the aerosol delivery device comprises a snap fit panel configured to be arranged in the aperture of the housing, to cover and close the open surface of the housing.

[0135] Optionally, the compartment is configured to be accessed via the open surface of the housing, such that when the snap fit panel is arranged in the aperture of the housing, the compartment is enclosed, and when the snap fit panel is not arranged in the aperture of the housing, the compartment is open and accessible such that the integrated pouch-type battery assembly may be inserted into and removed from the compartment.

[0136] Optionally, the snap fit panel is generally rectangular.

[0137] Optionally, when the snap fit panel is received in the aperture, the snap fit panel is arranged to be generally flush with the housing.

[0138] Optionally, the snap fit panel is removable from the housing.

[0139] Optionally, the snap fit panel comprises at least one snap element configured to mechanically connect with the main body of the housing.

[0140] Optionally, the housing comprises at least one snap element configured to mechanically connect with the snap fit panel.

[0141] Optionally, the aerosol delivery device comprises a seal configured to seal the interface between the housing and the snap fit panel, to protect against the ingress of moisture, debris, and other fluids or foreign objects from entering into the housing.

[0142] According to a third aspect of the disclosure, there is provided a method of manufacturing an integrated pouch-type battery assembly, the method comprising: providing a battery cell having electrodes; providing a PCM module comprising a PCM holder and a PCM board received in the PCM holder and electrically connected to said electrodes; and providing a wrapper that envelops the battery cell and the PCM module to mount the PCM module to the battery cell. Optionally, the method comprises manufacturing an integrated pouch-type battery assembly having any one or more of the optional features recited above in relation to the first and second aspects of the disclosure.

[0143] Optionally, the method comprises circumscribing at least a portion of the battery cell and at least a portion of the PCM module with the wrapper.

[0144] Optionally, the wrapper comprises a thermoplastic material, and the method comprises applying a heat treatment to the thermoplastic material to envelop the wrapper around the battery cell and the PCM module.

[0145] Optionally, the method comprises deforming the wrapper around at least a portion of the battery cell and around at least a portion of the PCM module.

[0146] Optionally, the method comprises heat shrinking the wrapper around at least a portion of the battery cell and around at least a portion of the PCM module.

[0147] Optionally, the method comprises providing a sheet of wrapper material and deforming the sheet of wrapper material by heat treatment to form the wrapper that envelops the battery cell and the PCM module

[0148] Optionally, deforming the sheet of wrapper material by heat treatment comprises heat shrinking the sheet of wrapper material around the battery cell and the PCM module.

[0149] Optionally, the sheet of wrapper material comprises a thermoplastic sheet.

[0150] According to a fourth aspect of the disclosure, there is provided a method of assembling an aerosol delivery system comprising an aerosol delivery’ device according to the second aspect of the disclosure, and an integrated pouch-type battery assembly according to the first aspect of the disclosure, wherein the method comprises arranging the integrated pouch-type battery assembly in the compartment of the aerosol delivery7device.

[0151] Optionally, the aerosol delivery device comprises any one or more of the optional features recited above in relation to the second aspect of the di sclosure.

[0152] Optionally, the integrated pouch-type battery assembly comprises any one or more of the opti onal features recited above in relation to the first aspect of the disclosure. According to a fifth aspect of the disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device according to the second aspect of the disclosure, and an integrated pouch-type battery assembly according to the first aspect of the disclosure.

[0153] Optionally, the aerosol delivery device comprises any one or more of the optional features recited above in relation to the second aspect of the disclosure.

[0154] Optionally, the integrated pouch-type battery assembly comprises any one or more of the optional features recited above in relation to the first aspect of the disclosure.

[0155] BRIEF DESCRIPTION OF THE DRAWINGS

[0156] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0157] Figure 1 shows an integrated pouch-type battery assembly;

[0158] Figure 2 shows an integrated pouch-type battery assembly;

[0159] Figure 3 shows a portion of an integrated pouch-type battery assembly;

[0160] Figure 4 shows an exploded view of an integrated pouch-type battery assembly;

[0161] Figure 5 shows a PCM board and a flat panel contact pad;

[0162] Figure 6 shows a PCM holder;

[0163] Figure 7 shows a PCM board and a flat panel contact pad received in a PCM holder;

[0164] Figure 8 shows a battery cell and a pouch;

[0165] Figure 9 shows a portion of an integrated pouch-type battery assembly;

[0166] Figure 10 shows an exploded view of an integrated pouch-type battery assembly;

[0167] Figure 11 shows an integrated pouch-type battery assembly;

[0168] Figure 12 shows an integrated pouch-type battery assembly;

[0169] Figure 13 shows an integrated pouch-type battery assembly and a shrapnel connect module; Figure 14 shows an integrated pouch-type battery assembly coupled to a shrapnel connect module;

[0170] Figure 15A shows an aerosol generating device;

[0171] Figure 15B shows an exploded view of an aerosol generating device containing an integrated pouch-type battery assembly;

[0172] Figure 15C shows a portion of a disassembled aerosol generating device and an integrated pouch-type battery assembly; Figure 16A shows an aerosol generating device;

[0173] Figure 16B shows an aerosol generating device;

[0174] Figure 16C shows an exploded view of an aerosol generating device containing an integrated pouch-type battery assembly;

[0175] Figure 16D shows a portion of a disassembled aerosol generating device and an integrated pouch-type battery assembly;

[0176] Figure 17A shows an aerosol generating device;

[0177] Figure 17B shows an exploded view of an aerosol generating device containing an integrated pouch-type battery assembly;

[0178] Figure 17C shows a portion of a disassembled aerosol generating device and an integrated pouch-type battery assembly;

[0179] Figure 18A shows an aerosol generating device;

[0180] Figure 18B shows an aerosol generating device;

[0181] Figure 18C shows an exploded view of an aerosol generating device containing an integrated pouch-type battery assembly;

[0182] Figure 18D shows a portion of a disassembled aerosol generating device and an integrated pouch-type battery assembly;

[0183] Figure 19A shows an aerosol generating device;

[0184] Figure 19B shows an aerosol generating device;

[0185] Figure 19C shows an exploded view of an aerosol generating device containing an integrated pouch-type battery assembly;

[0186] Figure 19D shows a portion of a disassembled aerosol generating device and an integrated pouch-type battery assembly;

[0187] Figure 20A shows an aerosol generating device;

[0188] Figure 20B shows a disassembled aerosol generating device containing an integrated pouchtype battery assembly

[0189] Figure 20C shows a disassembled aerosol generating device and an integrated pouch-type battery assembly; and Figure 21 shows a flowchart depicting a method of manufacturing an integrated pouch-type battery assembly.

[0190] DETAILED DESCRIPTION As used herein, the term “delivers' system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol generating material without combusting the aerosol generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0191] According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate deliver ’ of at least one substance to a user. In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar. In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

[0192] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

[0193] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol generating material is not a requirement. In some embodiments, the non- combustible aerosol provision system is an aerosol generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol generating materials, one or a plurality of which may be heated. Each of the aerosol generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material may comprise, for example, tobacco or a non-tobacco product.

[0194] Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.

[0195] In some embodiments, the disclosure relates to consumables comprising aerosol generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

[0196] In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device tobacco heated product, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol generating material or to a heat transfer material in proximity to the exothermic power source.

[0197] In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine..

[0198] In some embodiments, the substance to be delivered may be an aerosol generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials. In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0199] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0200] In some embodiments, the substance to be delivered comprises an active substance.

[0201] The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco or another botanical. In one embodiment the active substance is a legally permissible recreational drug

[0202] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0203] As noted herein, the active substance may comprise one or more constituents, derivatives or extracts, such as one or more cannabinoids or terpenes.

[0204] The active substance may be CBD or a derivative thereof

[0205] As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), raatcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata cnspa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

[0206] In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

[0207] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

[0208] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

[0209] In some embodiments, the substance to be delivered comprises a flavour.

[0210] As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognacjasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0211] In some embodiments, the flavour comprises menthol, spearmint and / or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco.

[0212] In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to, eucalyptol, WS-3.

[0213] Aerosol generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and / or flavourants. The aerosol generating material may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material. The aerosol generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and / or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol generating material may or may not be soluble in the solvent. In some embodiments, the aerosol generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol generating material is substantially tobacco free.

[0214] The aerosol generating material may comprise or be in the form of an aerosol generating film. The aerosol generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and / or filler may also be present. The aerosol generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol generating material is substantially tobacco free.

[0215] The aerosol generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

[0216] The aerosol generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol generating material.

[0217] The aerosol generating film may be discontinuous. For example, the aerosol generating film may comprise one or more discrete portions or regions of aerosol generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

[0218] The aerosol generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol generating film.

[0219] The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent. The aerosol generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol generating material comprises an aerosol generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid. The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

[0220] The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, di ethylene glycol, tri ethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0221] The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0222] The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

[0223] A consumable is an article comprising or consisting of aerosol generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

[0224] An aerosol-modifying agent is a substance, typically located down stream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent

[0225] The aerosol -modifying agent may, for example, be an additive or a sorbent. The aerosolmodifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosolmodifying agent may be free from filtration material.

[0226] An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating material to heat energy, so as to release one or more volatiles from the aerosol generating material to form an aerosol. In some embodiments, the aerosol generator is confi gured to cause an aerosol to be generated from the aerosol generating materi al without heating. For example, the aerosol generator may be configured to subject the aerosol generating material to one or more of vibration, increased pressure, or electrostatic energy. Figures 1 and 2 show an integrated pouch-type battery assembly 100 comprising a battery cell 101 and a PCM (protection circuit module) holder 103 which are wrapped together by a wrapper 104, such that the wrapper 104 envelops the battery cell 101 and the PCM holder 103 to mount the PCM holder 103 to the battery cell 101. Figure 2 depicts the wrapper 104 as being transparent, purely for illustrative purposes, the wrapper 104 circumscribing the battery cell 101 and at least a portion of the PCM holder 103 to couple the battery cell 101 to the PCM holder 103, thus binding the PCM holder 103 to the battery cell 101. The integrated pouch-type battery assembly 100 further comprises a PCM board 105 (see Figures 4 and 7 for example) received in the PCM holder 103 and electrically connected to electrodes 102 of the battery cell 101 (see Figures 3 and 4 for example). The PCM holder 103 and the PCM board 105 may be collectively referred to as a “PCM module”. Accordingly, it is to be understood that the wrapper 104 may also be described as enveloping the battery cell 101 and the PCM module, the PCM module comprising the PCM holder 103 and the PCM board 105 received in the PCM holder 103.

[0227] Advantageously, the integrated pouch-type batiery assembly 100 can provide for improved ease of removability of the combined battery cell 101 and PCM board 105 from an aerosol generating device 200 or other device, with improved manufacturing ease and cost. Furthermore, the integrated pouch-type battery assembly 100 can provide for reduced dimensions of the combined battery cell 101 and PCM board 105 and PCM holder 103, thus reducing the packaging space required therefor, and further reducing manufacturing cost, by providing a more compact arrangement.

[0228] In the example shown in Figure 1, the integrated pouch-type battery assembly 100 is generally elongate and is in the form of a generally cuboidal shape with rounded edges, or in the form generally of an elliptical prism. Though, it is envisaged that the integrated pouch-type battery assembly 100 may have any other suitable shape. Referring now to Figure 3 (which shows the integrated pouch-type battery assembly 100 with the wrapper 104 removed, purely for illustrative purposes) and Figure 4 (which shows an exploded view of the integrated pouchtype battery assembly 100), the integrated pouch-type battery assembly 100 has a longitudinal axis 110 and the PCM holder 103 and the battery cell 101 are arranged adjacent to one another along the longitudinal axis 110, with the wrapper 104 being arranged to extend about the longitudinal axis 110 around the perimeter of the battery cell 101 and the PCM holder 103. As shown in Figure 1, the wrapper 104 is arranged to fit tightly around the battery cell 101 and the PCM holder 103, such that it holds the battery cell 101 and the PCM holder 103 together. The wrapper 104 may comprise a thermoplastic sheet wrapped around the battery cell 101 and the PCM holder 103 and then deformed, for example by heat treatment such as heat shrinking, around the battery cell 101 and the PCM holder 103 to mount the PCM holder 103 to the battery cell 101. In the example shown, the wrapper 104 is arranged to envelop the battery cell 101 and the PCM holder 103 along substantially an entire length thereof along the longitudinal axis 110. Though, it is envisaged that the wrapper 104 need not necessarily envelop the battery cell 101 and the PCM holder 103 along substantially the whole length thereof, but may envelop at least a portion of the battery cell 101 and the PCM holder 103 along their lengths. For example, the wrapper 104 may be sized and positioned to envelop substantially an entire length of the battery cell 101 and a portion of the PCM holder 103, such that a portion of the PCM holder 103 is uncovered by the wrapper 104.

[0229] Referring now to Figure 5, the integrated pouch-type battery assembly 100 further comprises a flat panel contact pad 107 electrically connected to the PCM board 105. The flat panel contact pad 107 comprises one or more terminals 108 (see Figure 3) configured to connect with one or more corresponding terminals in an aerosol generating device 200 (see Figures 15Ato 20C for example), to connect the aerosol generating device 200 to the electrodes 102 of the batery' cell 101 via the PCM board 105. In the example shown, the flat panel contact pad 107 comprises three terminals 108 arranged to be equally spaced apart from one another in a plane that is generally normal to the longitudinal axis 110. Though, it is envisaged that the flat panel contact pad 107 may have any other suitable number of terminals 108, for example one, two, three, four, five, six, seven, eight or more terminals.

[0230] Advantageously, arranging the one or more terminals 108 in the same plane as one another, for example in a plane that is generally normal to the longitudinal axis, such that they are arranged on a flat surface of the flat panel contact pad 107, can provide for an improved flat panel contact pad 107 design to facilitate a universal connection interface for compatibility with a range of devices. Furthermore, this can also facilitate easy removal of the integrated pouch-type battery assembly 100 from a device, such as an aerosol generating device 200.

[0231] Referring back to the example of Figure 1, the wrapper 104 is arranged to envelop the battery cell 101 and the PCM holder 103 such that the terminals 108 of the flat panel contact pad 107 are uncovered by the wrapper 104 and are thus exposed. In other words, the wrapper 104 circumscribes and envelops the battery cell 101 and the PCM holder 103 to couple them together by binding them together, but does not cover or envelop an end portion of the PCM holder 103 which is oriented to be generally normal to the longitudinal axis 110, thus leaving the terminals 108 unwrapped.

[0232] As shown in Figure 6, the PCM holder 103 is generally cuboidal and comprises a first recess 106 and a second recess 109. As shown in Figures 3 and 7 for example, the first recess 106 is configured to receive and to locate the PCM board 105, and the second recess 109 is configured to receive and to locate the flat panel contact pad 107. In the example shown, the first recess 106 and the second recess 109 are each in the form of a generally rectangular slot, channel, aperture or groove, although it is envisaged that the first and second recesses 106, 109 may have any other suitable form. It is also envisaged that the PCM holder 103 need not necessarily be generally cuboidal or block shaped, but that it may have any other suitable shape or form. The PCM holder 103 may comprise a polymer material, and may be manufactured by injection moulding for example.

[0233] The first and second recesses 106, 109 are sized and positioned relative to one another such that the PCM holder 103 is configured to mount the flat panel contact pad 107 generally at a right angle to the PCM board 105. That is, the PCM board 105 and the flat panel contact pad 107 are arranged to be generally perpendicular to one another, as shown in Figures 5 and 9 for example. When mounted in the PCM holder 103, the PCM board 105 is arranged to extend in a first plane that extends along, or parallel to, the longitudinal axis 110; and the flat panel contact pad 107 is arranged to extend in a second plane that extends substantially perpendicul rly to the first plane and substantially normal to the longitudinal axis 110. Thus, the flat panel contact pad 107 is arranged to extend substantially at right angles to the longitudinal axis 110 and to the PCM board 105. The PCM board 105 and the flat panel contact pad 107 may be mechanically coupled to one another via a connecting portion 119, as shown in Figure 5, which may be generally flexible to permit the flat panel contact pad 107 and the PCM board 105 to be pivoted relative to one another to facilitate their assembly into the PCM holder 103, or which may be generally rigid.

[0234] Exemplary geometric features of the PCM holder 103 shall now be described, with further reference to Figures 2, 6 and 7. In the example shown, the PCM holder 103 comprises a binding element 111, which may for example comprise an undercut, slot, opening, groove, channel or aperture. The binding element 111 is configured to bind the wrapper 104, which, may for example comprise a thermoplastic sheet heat shrunk around the battery cell 101 and the PCM holder 103, to the PCM holder 103, when the wrapper material is deformed therearound. For example, the wrapper 104 may be configured to fit tightly around the PCM holder 103, with a portion of the wrapper 104 configured to follow' the contours of an external surface of the PCM holder 103, snugly extending into the binding element 111 and then out of the binding element 111 along the longitudinal axis 110, via neighbouring portions of the external surface of the PCM holder 103. The PCM holder 103 may also comprise one or more first shaped features 115 each configured to cooperate with a corresponding second shaped feature 201 of an aerosol generating device 200 when the integrated pouch-type battery assembly 100 is received in an aerosol generating device 200, as shall be described below in more detail. For example, the one or more first shaped features 115 may each comprise a receiving element configured to receive a respective one of the second shaped features 201, which may each comprise a protruding element, which may be integrally formed with a housing 202 or a compartment 225 of the device 200 for example.

[0235] In the example shown in Figure 2, the PCM holder 103 comprises two first shaped features 115 arranged on opposite sides of the PCM holder 103 along an edge thereof. Each of the two first shaped features 115 is in the form of a generally quadrilateral shaped cut-out, groove, recess, aperture or channel. Though, it is envisaged that the PCM holder 103 may have any other suitable number of first shaped features 115, for example one, two, three, four, five, six or more first shaped features 115, and that each of these may have any other suitable shape.

[0236] The first and second shaped features 115, 201 may be configured to cooperate when the integrated pouch-type battery assembly 100 is inserted into a compartment 225 of an aerosol generating device 200 in one particular orientation, to prevent, or at least discourage, incorrect insertion of the integrated pouch-type battery assembly 100 into the device 200 in an incorrect orientation. Advantageously, the one or more first shaped features 115 can thus act as a foolproof feature to prevent the positive and negative electrodes from being reversed, to ensure that the user inserts the integrated pouch-type battery assembly 100 into the device 200 in the correct orientation. The one or more first shaped features 115 can also advantageously provide for improved support and fixing of the integrated pouch-type battery' assembly 100 in a device 200, which can result in improved reliability.

[0237] Turning now to Figure 8, in the example shown, the integrated pouch-type battery assembly 100 further comprises a pouch 112, the battery' cell 101 being received within the pouch 112, and at least a portion of the PCM holder 103 being located outside of the pouch 112. The pouch 112 comprises one or more folded edges 113 each extending in a generally longitudinal direction along the pouch 112, such that each of the one or more folded edges 113 is arranged to be generally parallel to the longitudinal axis 110. The PCM holder 103 may comprise one or more openings 114 (see Figure 3 for example), each for receiving a respective one of the one or more folded edges 113 of the pouch 112, to mount the PCM holder 103 to the pouch 112, with the wrapper 104 then being arranged to envelop the battery cell 101 and the PCM holder 103 to mount the PCM holder 103 to the battery cell 101.

[0238] Figures 10 to 12 show an example of an integrated pouch-type battery assembly 100, in which like reference numerals denote like elements as described above and shown in earlier figures. Figure 10 show's an exploded view of the integrated pouch-type battery assembly 100, and Figures 11 and 12 show’ the integrated pouch -type batteiy assembly 100 in an assembled state. The integrated pouch-type battery assembly 100 is substantially similar to those described above, other than that the integrated pouch-type battery assembly 100 further comprises a label 116 attached to the wrapper 104, or directly to the pouch 112 or the battery cell 101. In the example shown, the label 116 is generally elongate and rectangular and is arranged to extend generally parallel to the longitudinal axis 110, along at least a portion of the length of the battery cell 101. Though, it is envisaged that other shapes, positions and orientations of label 116 may also be employed.

[0239] The label 116 comprises a coupling portion 117 configured to be attached to the wrapper 104, or directly to the pouch 112 or the battery cell 101. The coupling portion 117 may for example comprise an adhesive layer and be configured to be affixed to the wrapper 104, pouch 112, or battery cell 101. The label 116 also comprises a tail portion 118 attached to the coupling portion 117 configured to protrude from the battery cell 101 and extend away therefrom. Advantageously, the tail portion 118 may be held by a user and a pulling force applied thereto, in order to facilitate removal of the integrated pouch-type battery assembly 100 from an aerosol generating device 200.

[0240] Figure 13 shows an exemplary integrated pouch-type battery assembly 100 and an exemplary shrapnel connect module 219 which forms part of an aerosol generating device 200. The shrapnel connect module 219 comprises one or more connectors 220. Each of the one or more connectors 220 is configured to be electrically connected to a respective one of the terminals 108 of the flat panel contact pad 107. In the example shown, the flat panel contact pad 107 comprises three terminals 108 and the shrapnel connect module 219 correspondingly comprises three connectors 220 which are sized and spaced apart from one another to correspond with the three terminals 108 to electrically connect therewith. Though, it is envisaged that there may be any other suitable number of terminals 108 and connectors 220, for example one, two, three, four, five, six or more terminals 108 and connectors 220. In the example shown, the connectors 220 are each arranged to protrude from a connect board 221 of the shrapnel connect module 219, the connect board 221 being arranged to extend in a plane generally parallel to or along the longitudinal axis 110 and generally parallel to the PCM board 105. Figure 13 shows the integrated pouch -type batters' assembly 100 and the shrapnel connect module 219 in an uncoupled state, in which the connectors 220 are spaced apart from and are not electrically connected to the terminals 108. Figure 14 shows the module 110 and the shrapnel connect module 219 in a coupled state, in which the connectors 220 are electrically connected to the terminals 108.

[0241] With reference to Figures 15Ato 20C, exemplars aerosol generating devices 200 shall now be described, which may be configured to receive an integrated pouch-type battery assembly 100, for example an integrated pouch-type batery assembly 100 as described above, and which may comprise a shrapnel connect module 219 as described above.

[0242] In the example of Figures 15A to 15C, the aerosol generating device 200 comprises a housing 202, and a consumable holder 203 configured to receive a consumable, for example a consumable comprising an aerosol generating material, wherein the aerosol generating device 200 is configured to heat the aerosol generating material contained in the consumable, to produce an aerosol therefrom. The integrated pouch-type battery assembly 100 is configured to be received in the housing 202 of the aerosol generating device 200 and to power the device 200, to power the heating of the aerosol generating material thereby. The device 200 comprises one or more electrical connectors for electrically connecting to the terminals 108 of the flat panel contact pad 107 upon insertion of the integrated pouch-type battery assembly 100 into a compartment 225 of the device 200. The housing 202 comprises a charging port 211, for example a USB type connector port, for charging the integrated pouch-type battery assembly 100, in which the battery cell 101 may for example comprise a rechargeable battery. A charging port seal 212 may be arranged to seal the charging point 211, to protect against the ingress of moisture, debris, and other fluids or foreign objects. Another seal 210 may be arranged to seal the boundary between the housing 202 and the consumable 203 when coupled thereto, to protect against the ingress of moisture, debris, and other fluids or foreign objects into the housing 202.

[0243] The device 200 comprises a release button 205, which may be arranged on a major face, for example a front or rear face, of the housing 202, as shown in the example of Figure 15 A. For example, the consumable holder 203 may be slidably receivable in the housing 202 and connected thereto via one or more snap fit elements 209, which may be released by pressing the release button 205. The release button 205 may be integrally formed with the consumable holder 203 and may be configured to protrude therefrom through an aperture 223 formed in the housing 202. Thus, by pressing the release button 205, the user may thus be permitted to axially slide the housing 202 off from the consumable holder 203, for example by pulling the housing 202 away from and off the consumable holder 203, or by pulling the consumable holder 203 out of the housing 202, or by pulling the housing 202 and the consumable 203 away from each other simultaneously in opposite directions as indicated by the arrows in Figure 15B. The housing 202 and the consumable holder 203 can thus be disassembled from the position shown in Figure 15A into the position shown in Figure 15B.

[0244] One or more internal components of the aerosol generating device 200, for example including a battery7holder or internal housing 222, which may define the compartment 225, may be coupled to the consumable holder 203, such that said one or more internal components are configured to be retained inside the housing 202 when the housing 202 is coupled to the consumable holder 203. The battery holder 222 is configured to receive the integrated pouch¬ type battery- assembly 100 as shown in Figure 15B. The battery7holder 222 may comprise at least one open surface 223 to permit the integrated pouch-type battery assembly 100 to be inserted into and removed from the battery holder 222. The integrated pouch-type battery7assembly 100 may thus be removed from the aerosol generating device 200, as in the disassembled position shown in Figure 15C. The integrated pouch-type battery7assembly 100 may7then be reinserted into the aerosol generating device 200 if required, or a new7replacement integrated pouch-type batteiy assembly 100 may be inserted as a replacement, as in the position shown in Figure 15B. The housing 202 and the consumable holder 203 may7then be recoupled together into the position shown in Figure 15A, to close the device 200.

[0245] Figures 16A to 16D show another example of an aerosol generating device 200 and an integrated pouch-type battery7assembly 100, which are substantially similar to those described above and shown in Figures 15 A to 15C, such that like reference numerals denote like elements. The aerosol generating device 200 differs from that shown in Figures 15Ato 15C in that the rel ease button 205 is arranged on a minor face of the housing 202, for example on a left or right side face thereof, rather than on a major face, such as a front or rear face thereof. Otherwise, the structure and operation of the device 200 is generally similar to that described above in relation to Figures 15Ato 15C. Figures 17A to 17C show another example of an aerosol generating device 200 and an integrated pouch-type battery assembly 100, which are substantially similar to those described above and shown in Figures 15A to 16D, such that like reference numerals denote like elements. The aerosol generating device 200 differs from those shown in Figures 15Ato 16D in that it comprises a housing 202 and a bottom case 204, rather than a housing 202 and a consumable holder 203. The housing 202 may be configured to receive a consumable comprising an aerosol generating material. In the example shown, the bottom case 204 comprises the charging port 211, as well as one or more snap fit elements 213 for coupling to the housing 202. A seal 214 may be arranged to seal the interface between the bottom case 204 and the housing 202.

[0246] Like in the examples of Figures 15A to 16D, the device 200 comprises a release button 205, The release button 205 is integrally formed with the bottom case 204. The bottom case 204 is configured to be slidably received inside the housing 202, and for the release button 205 to protrude from the bottom case 204 and through an aperture 223 in the housing 202, A seal 216 may be arranged to seal the aperture 223 in the housing 202 to prevent against the ingress of moisture, debris, and other fluids or foreign objects into the housing 202. In a similar manner to the example described above in relation to Figures 15A to 15C, the release button 205 may be pressed to facilitate decoupling of the housing 202 and the bottom case 204, such that the integrated pouch-type batte / assembly 100 may then be removed from the battery holder 222. As described above, the integrated pouch-type battery' assembly 100 may comprise a label comprising a protruding tail portion 118. The tail portion 118 may be pulled by a user to facilitate removal of the integrated pouch-type battery' assembly 100 from the compartment 225.

[0247] In the example shown in Figures 18A to 18D, the aerosol generating device 200 is generally similar to that described above in relation to Figures 17A to 17C and similarly includes a housing 202 and a bottom case 204. The bottom case 204 may comprise one or more snap fit elements 215 configured to removably couple the housing 202 thereto. The example of Figures 18A to 18D differs from that described above in relation to Figures 17A to 17C in that rather than the housing 202 being fixedly coupleable to the bottom case 204 via a release button 205, they are instead coupleable to one another via a screw 206, The screw 206 is configured to be received through an aperture 223 in the housing 202 and into a corresponding aperture in the bottom case 204, to removably couple the housing 202 to the bottom case 204. For example, Figure 18A shows the device 200 in an assembled state in which the housing 202 is screwed to the bottom case 204 by the screw 206. As shown in Figure 18B, the screw 206 may be unscrewed and removed, to permit the decoupling of the housing 202 and the bottom case 204 into the position shown in Figure 18C. As in the aforementioned examples, the integrated pouch-type batery assembly 100 may then be removed from the battery holder 222 into the position shown in Figure 18D.

[0248] The example of Figures 19Ato 19D is substantially identical to the example of Figures 18Ato 18D, other than that instead of the screw 206, a lock pin 207 is arranged to couple the housing 202 to the bottom case 204. The lock pm 207 may be removed, as shown in Figure 19B, in order to facilitate the decoupling of the housing 202 and the bottom case 204 into the position shown in Figure 19C. It is envisaged that any other suitable fastening means or mechanical fixing element other than a screw 206 or a lock pin 207 may be employed to couple the housing 202 to the bottom case 204, such as a bolt for example.

[0249] In the example shown in Figures 20A to 20C, the aerosol generating device 200 also comprises a housing 202 and a bottom case 204, as in the examples of Figures 18 / X to 19D, albeit the integrated pouch-type batery assembly 100 is not removed from the device 200 by decoupling the housing 202 and the bottom case 204 from one another to permit access to the integrated pouch-type battery assembly 100. Instead, the housing 202 comprises a snap fit panel 208 which is removable from a main body 224 of the housing 202. The snap fit panel 208 comprises at least one snap element 218 configured to mechanically connect with the main body 224 of the housing 202. The snap fit panel 208 may be sized and positioned to generally correspond with the size and positioning of the battery holder 222, such that removal of the snap fit panel 208 causes the housing 202 to be placed into an open state (see Figure 20B) in which the battery holder 222 is exposed and the integrated pouch-type battery assembly 100 may be removed, into the position shown in Figure 20C. A seal 217 may be arranged to seal the interface between the main body 224 and the snap fit panel 208, to protect against the ingress of moisture, debris, and other fluids or foreign objects from entering into the housing 202, and in particular, into the battery holder 222 thereof and the integrated pouch-type battery' assembly 100.

[0250] Figure 21 show's a flowchart depicting the steps of a method 300 of manufacturing an integrated pouch-type battery assembly 100, for example an integrated pouch-type battery pack as described above and shown in Figures 1 to 20C. The method comprises a step 301 of providing a battery cell 101 having electrodes 102, and a PCM holder 103. In step 302, a PCM board 105 is also provided, and the PCM board 105 is arranged to be electrically connected to the electrodes 102, and to be received in the PCM holder 103. In step 303, a wrapper 104 is provided that envelops the battery cell 101 and the PCM holder 103 to mount the PCM holder 103 to the battery cell 101.

[0251] Step 303 may comprise providing a sheet of wrapper material and deforming the sheet of wrapper material by heat treatment to form the wrapper 104 that envelops the baiters- cell 101 and the PCM holder 103. For example, the sheet of wrapper material may be deformed by heat shrinking the sheet of wrapper material around the bat.teiy cell 101 and the PCM holder 103. The sheet of wrapper material may comprise a thermoplastic sheet for example.

[0252] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. CLAIMS1. An integrated pouch-type battery assembly, comprising:3.a battery cell having electrodes;4.a PCM module comprising a PCM holder and a PCM board received in the PCM holder and electrically connected to said electrodes; and5.a wrapper that envelops the battery cell and the PCM module to mount the PCM module to the battery cell.

2. An integrated pouch-type battery assembly according to claim 1, wherein the PCM holder comprises a recess to locate the PCM board.

3. An integrated pouch-type battery assembly according to claim 2, comprising a flat panel contact pad electrically connected to the PCM board, the PCM holder also comprising a recess to locate the flat panel contact pad.

4. An integrated pouch-type battery assembly according to claim 3, wherein the flat panel contact pad comprises terminals configured to connect with corresponding terminals in an aerosol generating device to connect said aerosol generating device to the electrodes of the battery cell via the PCM board.

5. An integrated pouch-type battery assembly according to claim 4, wherein the terminals on the flat panel contact pad lie in the same plane.

6. An integrated pouch-type battery assembly according to any of claims 3 to 5, wherein the PCM holder is configured to mount the flat panel contact pad generally at a right angle to the PCM board.

7. An integrated pouch-type battery assembly according to claim 6, wherein the battery cell has a longitudinal axis and the PCM board extends in a first plane, the PCM board being received in the PCM holder so that said first plane extends along, or parallel to, the longitudinal axis.

8. An integrated pouch-type battery assembly according to claim 7, wherein the flat panel contact pad extends in a second plane, the flat panel contact pad being received in the PCM holder so that it extends substantially at right angles to the longitudinal axis of the battery cell and to the PCM board.

9. An integrated pouch-type battery assembly according to any of claims 4 to 8, wherein the wrapper envelops the cell and the PCM module to leave the terminals of the flat panel contact pad exposed.

10. An integrated pouch-type battery assembly according to any preceding claim, wherein the wrapper comprises a thermoplastic sheet wrapped around the battery cell and the PCM module, said thermoplastic sheet having been deformed around the battery cell and the PCM module to mount the PCM module to the battery cell.

11. An integrated pouch-type battery assembly according to claim 10, wherein the PCM holder comprises an opening or groove configured to bind the thermoplastic sheet to the PCM holder when the thermoplastic sheet is deformed.

12. An integrated pouch-type battery assembly according to any preceding claim, comprising a pouch, the battery cell being received within the pouch, with the PCM holder being located outside of the pouch.

13. An integrated pouch-type battery assembly according to claim 12, wherein the pouch comprises one or more folded edges each extending in a longitudinal direction along the pouch.

14. An integrated pouch-type battery assembly according to claim 13, wherein the PCM holder comprises one or more openings, each of the one or more openings being configured to receive a respective one of the one or more folded edges of the pouch, to mount the PCM holder to the pouch.

15. An integrated pouch-type battery assembly according to any preceding claim, comprising a first shaped feature on the PCM holder configured to cooperatewith a corresponding second shaped feature in an aerosol generating device when the integrated pouch-type battery pack is received in an aerosol generating device16. An aerosol delivery device comprising a compartment to receive an integrated pouch-type battery assembly according to any preceding claim.

17. An aerosol delivery device according to claim 16, comprising electrical connectors for connection to the terminals on the flat panel contact pad upon insertion of the integrated pouch-type battery assembly into said compartment.

18. An aerosol delivery device according to claim 17, comprising a locating feature in the compartment of the aerosol generating delivery device and a shaped feature on the PCM holder, the locating and shaped features being configured to cooperate when the integrated pouch-type battery assembly is inserted into the compartment in one orientation.

19. An aerosol delivery device according to claim 16, comprising a housing, and: a bottom case, and / or a consumable holder configured to receive a consumable comprising an aerosol generating material.

20. An aerosol delivery device according to claim 19, comprising a release button configured to decouple the housing from the consumable holder or the bottom case.

21. An aerosol delivery device according to claim 20, comprising one or more snap fit elements configured to mechanically couple the housing to the consumable holder and / or the bottom case.

22. An aerosol delivery device according to claim 21, wherein the release button is configured to release one or more of the snap fit elements upon application of a force to the release button.

23. An aerosol delivery device according to claim 19, comprising a fastening element configured to couple the housing to the consumable holder or the bottom case, the fastening element comprising a screw, a bolt, or a lock pin.

24. An aerosol delivery device according to claim 19, wherein the housing comprises an aperture defining an open surface of the housing, wherein the aerosol delivery device further comprises a snap fit panel configured to be arranged in the aperture of the housing, to cover and close the open surface of the housing.

25. A method of manufacturing an integrated pouch-type battery assembly, the method comprising:28.providing a battery cell having electrodes;29.providing a PCM module comprising a PCM holder and a PCM board received in the PCM holder and electrically connected to said electrodes; and30.providing a wrapper that envelops the battery cell and the PCM module to mount the PCM module to the battery cell.

26. A method according to claim 25, comprising providing a sheet of wrapper material and deforming the sheet of wrapper material by heat treatment to form the wrapper that envelops the battery cell and the PCM module.

27. A method according to claim 26, wherein deforming the sheet of wrapper material by heat treatment comprises heat shrinking the sheet of wrapper material around the battery cell and the PCM module.

28. A method according to claim 26 or claim 27, wherein the sheet of wrapper material comprises a thermoplastic sheet.

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