Variable-Thickness Battery Module for Compact Aerosol Devices
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Solution Overview
Problem
Existing aerosol generating systems, such as e-cigarettes, face challenges in spatial optimization of their battery modules, leading to elongated shapes that are not pocket-friendly and inefficient use of volume, which affects the portability and convenience of the devices.
Innovation Solution
The battery module is designed with a battery having portions of different thicknesses, allowing the printed circuit board assembly to be connected on the thinner portion, reducing the overall thickness and enabling other components to be superimposed without increasing the system's length, using a flexible printed circuit for electrical connections and a ferromagnetic sheet for charging contacts, optimizing both thickness and length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery module uses a conventional uniform thickness design, then the battery capacity is sufficient, but the overall system becomes elongated and not pocket-friendly
Solution Approach 1:
The battery is divided into two portions along the longitudinal direction: a first portion with a first thickness and a second portion with a second thickness that is less than the first thickness. This segmentation allows the printed circuit board assembly to be connected to the thinner second portion, reducing the overall system length while maintaining sufficient battery capacity in the thicker first portion.
Solution Approach 2:
The invention transitions from a uniform thickness design to a variable thickness design along the longitudinal axis. By creating a thickness gradient (first portion thicker than second portion), the design optimizes space utilization in the longitudinal dimension, allowing the printed circuit board assembly to fit within the thinner region without increasing overall system length.
2Reliability
If the printed circuit board assembly is connected to the battery, then electrical connection is established, but the system thickness increases
Solution Approach 1:
The battery is designed with different thicknesses at different locations along its longitudinal axis. The second portion has a reduced thickness specifically at the location where the printed circuit board assembly needs to be connected. This local quality variation allows the printed circuit board assembly to be superimposed on the second portion without significantly increasing the overall system thickness, while maintaining reliable electrical connection.
3Length of stationary object
If the battery module is optimized for compactness, then portability is improved, but the battery capacity may be reduced
Solution Approach 1:
By segmenting the battery into a thicker first portion and a thinner second portion, the design concentrates the battery capacity in the first portion while using the thinner second portion only for electrical connection. This segmentation ensures that the reduced thickness in the connection region does not significantly compromise overall battery capacity, while achieving the compactness needed for portability.
Data Source
AI summary
The invention relates to a battery module for an aerosol generating system. It comprises a battery extending substantially in a longitudinal direction and a printed circuit board assembly connected to the battery. The battery comprises along the longitudinal direction a first portion of a first thickness, and a second portion comprising opposite faces defining a second thickness, the second thickness being less than the first thickness. The printed circuit board assembly is electrically connected to the second portion of the battery on one of said opposite faces. This allows spatial optimization of the battery module. The invention also relates to a corresponding aerosol generating system, and to a corresponding set comprising a battery charger.