EP4669144A1

EP4669144A1 - AEROSOL GENERATION SYSTEM WITH IMPROVED ELECTRONICS ORGANIZATION

Info

Publication number: EP4669144A1
Application number: EP24703223.8A
Authority: EP
Inventors: Rory Andrew Bruce MCDONALD; Christopher John Wright; Ben Charles Emmanuel MEUNIER
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2023-02-23
Filing date: 2024-02-08
Publication date: 2025-12-31
Also published as: CN120693077A; JP2026504453A; WO2024175372A1; KR20250150123A

Abstract

An aerosol-generating system, comprising: a case comprising a moldable material, processing circuitry comprising at least one controller and at least one electrically conductive trace, wherein at least one of the controller and the trace is at least partly embedded in the moldable material of the case.

Description

AEROSOL-GENERATING SYSTEM WITH IMPROVED ELECTRONICS ARRANGEMENT

The present disclosure relates to an aerosol-generating system.

Aerosol-generating devices are typically designed as handheld devices that can be used by a user for consuming or experiencing, for instance in one or more usage sessions, aerosol generated by heating an aerosol-generating substrate or an aerosol-generating article. The aerosol-generating devices the present disclosure pertains to are commonly referred to as heated tobacco products (HTP), heat-not-burn devices, electronic cigarettes and/or vaporisers.

Exemplary aerosol-generating substrates can comprise solid substrate material, such as tobacco material or tobacco cast leaves (TCL) material. The substrate material can, for example, be assembled, often with other elements or components, to form a substantially stick-shaped aerosol-generating article. Such a stick or aerosol-generating article can be configured in shape and size to be inserted at least partially into the aerosol-generating device. The aerosolgenerating system may comprise a heating element or heater device for heating the aerosolgenerating article and/or the aerosol-generating substrate. The heating element or heater device may be part of the aerosol-generating article and/or the aerosol-generating device. Alternatively or additionally, aerosol-generating substrates can comprise one or more liquids and/or solids, which can, for example, be supplied to the aerosol-generating device in the form of a cartridge or container. Corresponding exemplary aerosol-generating articles can, for example, comprise a cartridge containing or tillable with the liquid and/or solid substrate, which can be vaporized during aerosol consumption by the user based on heating the substrate and/or liquid. Usually, such cartridge or container can be coupled to, attached to or at least partially inserted into the aerosolgenerating device. Alternatively, the cartridge may be fixedly mounted to the aerosol-generating device and refilled by inserting liquid and/or solid into the cartridge. The aerosol generated from the aerosol-generating substrate or article may comprise or include one or more of nicotine, aroma, sugar, moisturising agent, preservative, flavouring, for example cocoa, liquorice, menthol and lactic acid or other additives.

For generating the aerosol during use or consumption, heat can be supplied by a heating element, heater device or heat source to heat at least a portion or part of the aerosol-generating substrate. The heating element, heater device or heat source can be arranged in the handheld device or a handheld part of the aerosol-generating device. Alternatively or additionally, at least a part of or the entire heating element or heater device or heat source can be fixedly associated with or arranged within an aerosol-generating article, for instance in the form of a stick or cartridge, which can be attached to and/or powered by the handheld device or handheld part of the aerosolgenerating device. Exemplary heating elements or heater devices can be based on one or more of resistive heating, inductive heating and microwave heating using electrical energy supplied via, drawn from or stored in battery of the aerosol-generating device. As used herein, a battery of the aerosolgenerating device can generally refer to an energy storage of the aerosol-generating device configured to store electrical energy. Accordingly, the term battery can include one or more capacitors, one or more accumulators or other types of energy storage. Also, any reference to a battery herein can include a plurality of batteries.

Typically, aerosol-generating devices comprise an energy storage, for example a battery, providing the electrical energy needed to operate the aerosol-generating device and especially for heating the aerosol-generating substrate and/or article, for example to generate aerosol in one or more usage sessions using one or more aerosol-generating articles. The battery may, for example, be a lithium-ion battery.

As used herein, a usage session may refer to a period of time, during which a user may use the device to generate, consume, experience or inhale aerosol using the aerosol-generating device. Therein, a usage session may be finite. In other words, a usage session may have a start, an end and a duration. The duration of the usage session as measured by time may be influenced by use during the usage session. The duration of the usage session may have a maximum duration determined by a maximum time from the start of the usage session. The duration of the usage session may be less than the maximum time if one or more monitored parameters reaches a predetermined threshold before the maximum time from the start of the usage session. By way of example, the one or more monitored parameters may comprise one or more of: i) a cumulative puff count of a series of puffs drawn by a user since the start of the usage session, and ii) a cumulative volume of aerosol evolved from the aerosol-forming substrate since the start of the usage session.

A battery capacity may typically be chosen so that the aerosol-generating device can provide a user with at least a minimum number, for example at least two or more, consecutive usage sessions or experiences without having to recharge the battery or the aerosol-generating device in between. To improve user experience, aerosol-generating devices are usually configured to only allow a user to start a usage session if the battery contains enough electrical energy to fully complete the usage session. Battery capacity can degrade over time with accumulating charge/discharge-cycles. Generally, it is desirable to provide the user with as many usage sessions as possible without having to recharge the device, even when the battery may already be degraded. It is therefore desirable to implement an energy storage, for example a battery, with the highest possible capacity in the aerosol-generating device. The capacity is typically limited by the size of the energy storage and/or the aerosol-generating device. If the energy storage is increased, for example by providing a bigger battery, the aerosol-generating device may become bulky and/or unwieldy, which impairs user experience.

It may therefore be desirable to provide for an aerosol-generating device with an improved user experience, for example by optimising the relation of energy storage capacity to overall size of the aerosol-generating device.

This is achieved by the subject-matter of the independent claim. Optional features are provided by the dependent claims and by the description.

According to an aspect of the present invention, there is provided an aerosol-generating system, comprising: a case or housing comprising a moldable material, processing circuitry comprising at least one controller and at least one electrically conductive trace, wherein at least one of the controller and the trace is at least partly embedded in the moldable material of the case.

The aerosol-generating system may comprise an energy storage for storing electrical energy, for example a battery or a battery pack, wherein the case at least partly encases the energy storage, preferable wherein the energy storage is removable and/or replaceable by a user. For this, the case may comprise an opening, preferably with a removable lid, through which the energy storage may be removed or inserted. The case may further comprise electrical contacts configured to electrically connect the energy storage to the rest of the system when the battery is inserted into the case through the opening.

The aerosol-generating system may have a longitudinal axis in the direction of the largest extension of the aerosol-generating system. The longitudinal axis may be parallel to the direction in which an aerosol-generating article is inserted into and/or extracted from the aerosolgenerating system. The case may comprise at least one wall surface. The wall surface may surround the energy storage at least partly or completely, for example in at least one of an axial direction and a radial direction of the longitudinal axis. The wall surface of the case may comprise or include or may at least partially be made of the moldable material. The moldable material may not need to be moldable during operation of the aerosol-generating system, but may only be moldable during manufacture of the aerosol-generating system. In other words, the case may at least partly be formed from a moldable material during production of the aerosol-generating system. The moldable material may then be hardened to provide a case that can withstand the physical strain of the operation of the aerosol-generating system and does not break or deform easily. The moldable material may, for example, comprise or include or be at least one of a thermosetting plastic, for example a thermoplastic material, and a ceramic material.

The controller may for example comprise or include or be a microcontroller. It may comprise or include at least one of a data storage, for example memory, and programmable input/output peripherals. The electrically conductive trace may be configured to electrically connect the controller to other electrical components of the aerosol-generating system, for example via the input/output peripherals.

In conventional aerosol-generating systems, at least one of the controller and the electrically conductive trace is typically arranged on a printed circuit board (PCB). The PCB comprises the electrical components, namely at least the controller and the electrically conductive trace, and a substrate on which the electrical components are arranged. Such a PCB is therefore a separate component that needs to be inserted into the case of the aerosol-generating system. Typically, the PCB and its components, for example the controller, is so big that an arrangement of the PCB and the energy storage of the aerosol-generating system at the same spot along the longitudinal axis is mutually exclusive. In other words, in a sector along the longitudinal axis in which the PCB is arranged, conventionally there is not enough room for parts of the energy storage and vice versa. Therefore, for a given total size of the aerosol-generating system, the size of the energy storage is limited by the space used for the PCB.

According to the present disclosure, a PCB may not be needed anymore. At least one or both of the controller and the electrically conductive trace is at least partly arranged on and/or embedded in the moldable material of the case itself. The case of the aerosol-generating system may therefore directly act as the substrate on and/or in which the electrical components, namely the controller and/or the electrically conductive trace, are arranged. By embedding the electrical components in the moldable material of the case, no separate substrate, for example in the form of a PCB, may be needed to arrange these components in the aerosol-generating system. Therefore, the aerosol-generating system according to the present disclosure may be implemented without using a separate substrate to arrange the electrical components on, namely without a PCB. The space saved hereby may be used to house a bigger energy storage, for example.

Also according to the present disclosure, by at least partly embedding at least one of the controller and the trace in the moldable material of the case, the extent to which these electrical components protrude from the case or the surface of the case may be reduced. In other words, the dimensions of the parts of the electrical components that protrude from the case or the surface of the case may be smaller because the electrical components are at least partly arranged inside of the material of the case or the thickness of the case. The electrical components may therefore be recessed into the material and/or the thickness of the case. Thus, at least one of the controller and the electrically conductive trace may be embedded in the moldable material of the case. This may be achieved by a process comprising molding these components into the moldable material of the case. Specifically, at least one of the controller and the electrically conductive trace may be molded into the material of the case. The term “embedding” or “embedded” as used herein may mean that the respective components are arranged at least partly surrounded by the material of the case. This arrangement may be achieved by forming and/or molding the case at least partly around the respective electrical components in a state in which the material of the case is still moldable. Through this process, the contacting surfaces of the material of the case and the electrical components may be in intimate contact with each other. This intimate contact is not achieved, however, by inserting parts of the electrical components into the case when the material of the case is not moldable. For example, a component glued, clamped, soldered, welded, fused, screwed, bolted or nailed into and/or onto the case is not “embedded” in the moldable material of the case in the meaning of the present disclosure. The electrical components may be partly or fully embedded in the moldable material of the case. Partly embedded may mean that the electrical components are recessed or sunk into the material, for example so that they are surrounded by the material on at least two sides. At least one side of the components may be free of the moldable material and therefore accessible from the outside of the material. Fully embedded may mean that the electrical components are surrounded by the material on all sides. The components may therefore be arranged completely covered by the moldable material and thus inaccessible from outside of the moldable material.

The electrical components, namely the controller and/or the electrically conductive trace, therefore may be arranged in the case of the aerosol-generating system in a space-efficient manner. This is further improved in that the electrical components may be arranged on and/or in the case in a way that follows the shape of the wall surface of the case. For example, the case may include curved and/or angled wall surfaces. The electrical components may therefore be arranged on and/or in the case following this curved and/or angled surface of the case.

Especially the controller may have significant spatial extensions, for example in one or more of thickness, width and length. At least partly embedding the controller in the material of the case may therefore free space inside the case that is conventionally used up by the bulky controller and/or the PCB. The arrangement according to the present disclosure may save space to such an extent that the at least one controller and the energy storage may overlap each other in a radial direction of the longitudinal axis of the aerosol-generating system. That the controller and the energy storage overlap each other in a radial direction of the longitudinal axis may mean that the controller and the energy storage follow upon each other in a radial direction of the longitudinal axis, preferably with the controller being arranged further from the longitudinal axis than the energy storage. In other words, the at least one controller and the energy storage may be arranged at the same height or level in the direction of the longitudinal axis of the aerosolgenerating system. The energy storage may therefore extend along the longitudinal axis of the aerosol-generating system even in a section along the longitudinal axis in which the controller may be arranged. For a given total size of the aerosol-generating system, this may lead to a significantly larger energy storage, increasing its capacity.

Of all the electrical components of the aerosol-generating system, the controller may be the one with the largest spatial dimensions. Typically, the controller may have a rectangular base shape with a variable thickness, although any other shape may be possible. The controller may have a direction of greatest extension, for example the direction of the longer sides of the rectangular base shape. As already mentioned, the case may have a wall surface that is curved or angled. The most space may be saved by the present disclosure when the electrical components and especially the controller follows the shape of the case as closely as possible. To this end, it may be provided that the at least one controller of the processing circuitry is arranged on the case, preferably an interior wall of the case, such that the direction of the greatest extension of the controller is oriented in parallel to the longitudinal axis of the aerosol-generating system. In the present disclosure, the greatest extension may be directed along one of the sides of the base shape of the component in question. This means that diagonals may be exempt from being the direction of the greatest extension in the sense of the present disclosure, even if, for example, the diagonal of a rectangular base shape is longer than the longer side of the rectangle. In a rectangular base shape, the longer side of the rectangle may still be the greatest extension in the sense of the present disclosure. This feature may also apply to further electrical components of the aerosol-generating system mentioned herein, for example one or more of a sensor, controller subunits and any of the heater devices. These components may also be arranged on the case, preferably an interior wall of the case, such that a direction of the greatest extension of the respective component is oriented in parallel to a longitudinal axis of the aerosol-generating system.

To maximize the space saved in the interior of the case, it may be provided that other electrical components of the aerosol-generating system, preferably all electrical components except the energy storage and a heater blade, are also at least partly embedded in the moldable material of the case. For each of these components, all of the features as explained herein for the controller and/or the electrically conductive trace may also be applicable. For example, it may be provided that the processing circuitry comprises at least one sensor, preferably one or more of a temperature sensor, a strain sensor and an accelerometer, and wherein the at least one sensor is at least partly embedded in the moldable material of the case.

As already mentioned, the controller may be the electrical component with the biggest dimensions (except the energy storage). It may therefore be provided that the controller is broken down into smaller subunits of smaller spatial dimensions. These subunits may be arranged on the case separately and independently from each other, but may be connected, for example through traces, so that they together may form and/or function as one single controller. It may therefore be provided that the controller comprises at least two controller subunits, and wherein each of the at least two controller subunits are individually at least partly embedded in the moldable material of the case. By splitting the controller into subunits of smaller dimensions, more space in the interior of the case can be saved. Additionally, by splitting the controller into subunits, the subunits may be arranged on the surface wall of the case following the shape of the case more closely than possible with one single bigger controller.

The capacity of the energy storage may be highly dependent on its temperature. As the aerosol-generating system comprises a heater device for heating an aerosol-generating article during the production of aerosol, the energy storage of the aerosol-generating system may be adapted to high temperatures. It may therefore be that especially low temperatures impair the performance of the energy storage. To prevent the temperature of the energy storage to become too low, it may be provided that the aerosol-generating system comprises an energy storage heater, for example a resistive energy storage heater, configured to heat the energy storage, wherein the energy storage heater is at least partly embedded in the moldable material of the case. The aerosol-generating system may also comprise at least one temperature sensor, which may sense the temperature of the energy storage. If the sensed temperature of the energy storage becomes too low or falls below a predetermined lower threshold temperature, the energy storage heater is activated to heat the energy storage, preferably until the temperature of the energy storage reaches a predetermined higher threshold temperature. The predetermined lower and higher threshold temperatures may be chosen so that the energy storage is kept in an optimal temperature range for optimal performance.

To increase the efficiency of the energy storage heater, the moldable material of the case may comprise a heat spreader. The heat spreader may comprise a thermally conductive material. The heat spreader may, for example, comprise at least one of a moldable ceramic material, a metal, preferably copper, and a coating, preferably a non-electrically conductive coating and/or a non-thermally conductive coating. The heat spreader may be arranged at least partly surrounding the energy storage so that the heat generated by the energy storage heater may be distributed into the energy storage as uniformly as possible. The heat spreader may be part of the moldable material of the case, so that the electrical components as described herein may also be at least partly embedded in the heat spreader. It is therefore possible that the hear spreader may be part of the case and of the moldable material of the case. The heat spreader may thus be produced and molded along with the case in the same production step as the case. This ensures a uniform shape and uniform distribution of the heat, for example the heat from the energy storage heater. On the other hand, some of the electrical components of the aerosol-generating system, especially the controller, may have better performance when not heated or heated as little as possible by the energy storage heater. It may therefore be provided that the case comprises nonheated areas free from and/or spaced apart from the energy storage heater and/or the heat spreader, and wherein at least one of the controller and further electrical components are arranged in the non-heated areas. The further electrical components may be any of the electrical components of the aerosol-generating system as mentioned in the present disclosure. In other words, in the non-heated areas, the moldable material of the case may not comprise a heat spreader. Furthermore, in the non-heated areas, there may not be an energy storage heater embedded in the moldable material of the case. By arranging temperature-sensitive electrical components like the controller in the non-heated areas, the performance of these components may be improved.

The case of the aerosol-generating system may at least partly encase an interior space for the energy storage of the aerosol-generating system. The case and/or the wall surfaces of the case may be formed in such a way that the interior space may be a cylinder, an elliptic cylinder, a cube, a rectangular cuboid, a polyhedron or any other suitable shape or mixture of shapes. At least one of the controller and the trace may be at least partly embedded in a surface of the case facing the interior space and/or the energy storage. At least one of the controller and the trace may, in other words, be at least partly embedded in the inner wall surface of the case. Electrical components protruding from the case may thus protrude towards the interior space, for example towards the energy storage.

The case may, for example, be formed in such a way that the interior space may have the shape of a cylinder or an elliptic cylinder with an additional flat surface extending in the direction of the cylinder axis. The cylinder axis may be parallel to the longitudinal axis of the aerosolgenerating system. In such an arrangement, the electrical components may be arranged and at least partly embedded in the flat surface of the case. In other words, the case may comprise, in a plane perpendicular to the longitudinal axis of the aerosol-generating system, a rounded surface and a flat surface, wherein the rounded surface and the flat surface are connected to one another and together encase the interior space, and wherein at least one of the controller and the trace is at least partly embedded in the flat surface. It may be especially beneficial to arrange the electrical components, preferably the controller, on the flat surface next to the connection to the rounded surface. The electrical components may therefore be arranged eccentrically on the flat surface, for example offset in the direction of where the flat surface and the rounded surface meet. As the aerosol-generating system may use a cylindrical energy storage, the area in which the flat surface and the rounded surface meet may provide room that can be beneficially used by electrical components at least partially protruding from the case.

Especially with controllers of large dimensions, it may be beneficial to arrange the controller axially offset from the energy storage along the longitudinal axis of the aerosol-generating system, wherein the controller is oriented such that its plane or surface of greatest extension is perpendicular to said longitudinal axis. In other words, the controller and the energy storage may not overlap in a radial direction of the longitudinal axis. In contrast, the controller and the energy storage may follow upon one another in the direction of the longitudinal axis. The controller may be oriented such that its greatest extension is perpendicular to the longitudinal axis. For example, the controller may be embedded in the moldable material of a part of the case that is also oriented perpendicular to the longitudinal axis. In this arrangement, the controller may be embedded or recessed in the moldable material of the case in the direction of the longitudinal axis, thereby increasing the available space for the energy storage.

The aerosol-generating system may comprise a heating element for heating an aerosolgenerating substrate or article, for example to generate aerosol for consumption by a user. The heating element may comprise a heating blade configured to be inserted into the aerosolgenerating substrate or article and a resistive heater or an induction coil. The heating blade may therefore be arranged extending into the interior space of the case so that it may enter into an aerosol-generating substrate or article that is inserted into the interior space. The heating blade may be configured to heat the aerosol-generating substrate or article from inside of the substrate or article. The heating blade may comprise a moldable material and the resistive heater or the induction coil may be at least partly embedded in the moldable material of the heating blade. In this way, the heating blade may be slimmer than usual, allowing for bigger aerosol-generating substrates or articles.

Additionally or alternatively, the aerosol-generating system may comprise a heating element for heating an aerosol-generating substrate or article, wherein the heating element may comprise a resistive heater or an induction coil, and wherein the resistive heater or the induction coil may be at least partly embedded in the moldable material of the case. This heating element may thus be arranged in the case at least partly surrounding the interior space. It may therefore be configured to heat an aerosol-generating substrate or article from outside of the substrate or article. An aerosol-generating substrate or article that is inserted into the interior space of the case is therefore also at least partly inserted into and/or surrounded by the heating element.

The heat generated by the heating element or heating elements for heating an aerosolgenerating substrate or article has to be directed at the substrate or article while a transfer of the heat to the outside of the case is to be avoided so as not to lead to uncomfortable temperatures of the case for a user holding the aerosol-generating system or even burning their hand. The case may therefore comprise a heat insulating material, wherein the heat insulating material may be arranged at least partly surrounding the heating element or heating elements. The heat insulating material may therefore be arranged between the heating element or heating elements and the outer surface of the case.

The heating element or the heating elements and the case may be configured as one integral unit. For example, the heating blade and/or the heating element embedded in the heating blade may be configured as one integral unit with the case. This means that the heating element or the heating elements, for example the heating blade, may be produced together with and in the same molding step as the case. The moldable material of the case and the heating element or the heating elements, for example the heating blade, may thus be one continuous unit. This may, on the one hand, reduce production costs. On the other hand, as the heating element or heating elements are not produced as separate units, they do not need to be separately mounted in the case of the aerosol-generating system, rendering separate, additional attachment means superfluous. This also leads to a saving of space in the interior space of the case which is then available for other components, for example the energy storage.

Another electrical component that may be advantageously embedded in the moldable material of the case may be an input device, for example for receiving control signals from a user. The aerosol-generating system may therefore comprise an input device for receiving control signals, wherein the input device may be configured as a capacitive button and wherein the input device may be at least partly embedded in the moldable material of the case. The input device may be arranged on the outer surface of the case facing away from the interior space.

Another electrical component that may be advantageously embedded in the moldable material of the case may be an electrical connector for establishing electrical connections to external devices. The aerosol-generating system may therefore comprise an electrical connector for establishing electrical connections to external devices, wherein the electrical connector may be at least partly embedded in the moldable material of the case. The electrical connector may, for example, be configured to establish an electrical connection to a companion device or a smartphone or a personal computer or other suitable devices.

Another electrical component that may be advantageously embedded in the moldable material of the case may be a field generating component. The aerosol-generating system may therefore comprise at least one field generating component, preferably a wireless charging coil or antenna, wherein the field generating component may be at least partly embedded in the moldable material of the case. The at least one field generating component may be configured to establish a wireless data connection to an external device, for example to a companion device or a smartphone or a personal computer or other suitable devices. The at least one field generating component may thus be part of a communications arrangement of the aerosol-generating system.

To further simplify the production of the aerosol-generating system, the processing circuitry may comprise printed components. For example, the traces may be printed using an electrically conductive and flexible ink. But also more complex electrical components, for example the capacitive button as explained above, may be provided as printed components. The printed components may be printed directly onto the moldable material of the case. There may be no need for a separate PCB. As printed components typically have a reduced thickness in comparison to conventional components, this may also save space in the interior of the case.

As explained above, the use of a PCB may lead to an unnecessary waste of space in the interior space of the case. While it is already advantageous to reduce the size of the PCB by embedding some of the electrical components of the aerosol-generating system directly into the moldable material of the case, it may be desirable to dispense of a PCB altogether. It may therefore be provided that the processing circuitry is exclusively arranged on the case of the aerosol-generating system. The aerosol-generating system may thus be free from a separate printed circuit board. All of the electrical components of the aerosol-generating system may be arranged on the case and no separate, additional substrate for the electrical components may be necessary. This may lead to the biggest possible saving of space in comparison to conventional systems.

In the direction of the longitudinal axis of the aerosol-generating system, the energy storage cannot extend over the whole aerosol-generating system, because room may be needed for other components as well. However, by the arrangement according to the present disclosure, it may be provided that the energy storage extends over at least one of 50%, 55%, 60%, 65%, 70%, 75%, or 80% of the entire extension of the aerosol-generating system along the longitudinal axis of the aerosol-generating system. The energy storage may, for example, be configured as a cylindrical battery, preferably with the cylinder axis of the battery arranged in parallel to the longitudinal axis of the aerosol-generating system.

According to an aspect of the present disclosure, the aerosol-generating system comprises one or more of an aerosol-generating device configured to generate aerosol and a companion device configured to supply electrical energy to an aerosol-generating device. The companion device may, for example, comprise an energy storage of bigger capacity than the aerosolgenerating device so that the companion device may be used to recharge the aerosol-generating device several times. The companion device may comprise an opening into which the aerosolgenerating device may be at least partly received while charging. One or more of the energy storage, the processing circuitry along with the controller and the trace, the case as well as any or all of the further components and electrical components mentioned in the present disclosure for the aerosol-generating system may be part of the aerosolgenerating device and/or the companion device. The specific arrangement of the electrical components in the aerosol-generating system as explained in the present disclosure may also apply to the aerosol-generating device and/or the companion device.

In a specific case, for example, the aerosol-generating system may comprise the aerosolgenerating device. All of the arrangements, features, functions and advantages described for the aerosol-generating system herein may in this case apply to the aerosol-generating device and vice versa. In another specific case, for example, the aerosol-generating system may comprise the companion device. All of the arrangements, features, functions and advantages described for the aerosol-generating system herein may in this case apply to the companion device and vice versa. In another specific case, for example, the aerosol-generating system may comprise the aerosol-generating device and the companion device. All of the arrangements, features, functions and advantages described for the aerosol-generating system herein may in this case apply to the aerosol-generating device and/or to the companion device and vice versa.

The aerosol-generating system may further comprise an aerosol-generating article, wherein the aerosol-generating system may be configured to generate aerosol from the article. The aerosol-generating article may be configured as described herein, for example comprising an aerosol-generating substrate or a cartridge comprising an aerosol-generating liquid.

The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

Example 1 . An aerosol-generating system, comprising: a case comprising a moldable material, processing circuitry comprising at least one controller and at least one electrically conductive trace, wherein at least one of the controller and the trace is at least partly embedded in the moldable material of the case.

Example 1 A. The aerosol-generating system according to Example 1 wherein the system comprises an energy storage for storing electrical energy, wherein the case at least partly encases the energy storage, preferable wherein the energy storage is removable and/or replaceable by a user.

Example 2. The aerosol-generating system according to any of the preceding Examples, wherein the at least one controller and an energy storage of the aerosol-generating system overlap each other in a radial direction of a longitudinal axis of the aerosol-generating system.

Example 3. The aerosol-generating system according to any of the preceding Examples, wherein the at least one controller of the processing circuitry is arranged on the case, preferably an interior wall of the case, such that a direction of the greatest extension of the controller is oriented in parallel to a longitudinal axis of the aerosol-generating system.

Example 4. The aerosol-generating system according to any of the preceding Examples, wherein the processing circuitry comprises at least one sensor, preferably one or more of a temperature sensor, a strain sensor and an accelerometer, and wherein the at least one sensor is at least partly embedded in the moldable material of the case.

Example 5. The aerosol-generating system according to any of the preceding Examples, wherein the controller comprises at least two controller subunits, and wherein each of the at least two controller subunits are individually at least partly embedded in the moldable material of the case.

Example 6. The aerosol-generating system according to any of the preceding Examples, comprising an energy storage heater configured to heat an energy storage of the aerosol-generating system, wherein the energy storage heater is at least partly embedded in the moldable material of the case.

Example 7. The aerosol-generating system according to the preceding Example, wherein the moldable material of the case comprises a heat spreader, preferably wherein the heat spreader comprises at least one of a moldable ceramic material, a metal, preferably copper, and a coating.

Example 8. The aerosol-generating system according to any of the preceding Examples 6-7, wherein the case comprises non-heated areas free from and/or spaced apart from the energy storage heater and/or the heat spreader, and wherein at least one of the controller and further electrical components are arranged in the non-heated areas.

Example 9. The aerosol-generating system according to any of the preceding Examples, wherein the case at least partly encases an interior space for an energy storage of the aerosol-generating system, and wherein at least one of the controller and the trace is at least partly embedded in a surface of the case facing the interior space.

Example 10. The aerosol-generating system according to the preceding Example, wherein the case comprises, in a plane perpendicular to a longitudinal axis of the aerosolgenerating system, a rounded surface and a flat surface, wherein the rounded surface and the flat surface are connected to one another and together encase the interior space, and wherein at least one of the controller and the trace is at least partly embedded in the flat surface. Example 1 1. The aerosol-generating system according to any of the preceding Examples, wherein the controller is arranged axially offset from an energy storage of the aerosolgenerating system along a longitudinal axis of the aerosol-generating system and wherein the controller is oriented such that its plane of greatest extension is perpendicular to said longitudinal axis.

Example 12. The aerosol-generating system according to any of the preceding Examples, comprising a heating element for heating an aerosol-generating substrate or article, wherein the heating element comprises a heating blade configured to be inserted into the aerosolgenerating substrate or article and a resistive heater, wherein the heating blade comprises a moldable material and wherein the resistive heater is at least partly embedded in the moldable material of the heating blade.

Example 13. The aerosol-generating system according to any of the preceding Examples, comprising a heating element for heating an aerosol-generating substrate or article, wherein the heating element comprises a resistive heater, and wherein the resistive heater is at least partly embedded in the moldable material of the case.

Example 14. The aerosol-generating system according to any of the preceding Examples 12-13, wherein the case comprises a heat insulating material, wherein the heat insulating material is arranged at least partly surrounding the heating element.

Example 15. The aerosol-generating system according to any of the preceding

Examples 12-14, wherein the heating element and the case are configured as one integral unit.

Example 16. The aerosol-generating system according to any of the preceding

Examples, comprising an input device for receiving control signals, wherein the input device is configured as a capacitive button and wherein the input device is at least partly embedded in the moldable material of the case.

Example 17. The aerosol-generating system according to any of the preceding Examples, comprising an electrical connector for establishing electrical connections to external devices, wherein the electrical connector is at least partly embedded in the moldable material of the case.

Example 18. The aerosol-generating system according to any of the preceding Examples, comprising at least one field generating component, preferably a wireless charging coil or antenna, wherein the field generating component is at least partly embedded in the moldable material of the case.

Example 19. The aerosol-generating system according to any of the preceding Examples, wherein the processing circuitry comprises printed components. Example 20. The aerosol-generating system according to any of the preceding Examples, wherein the processing circuitry is exclusively arranged on the case of the aerosolgenerating system and preferably is free from a separate printed circuit board.

Example 21. The aerosol-generating system according to any of the preceding Examples, wherein the energy storage is configured as a cylindrical battery and extends over at least one of 50%, 55%, 60%, 65%, 70%, 75%, or 80% of the entire extension of the aerosolgenerating system along a longitudinal axis of the aerosol-generating system.

Example 22. The aerosol-generating system according to any one of the preceding Examples, comprising one or more of: an aerosol-generating device configured to generate aerosol; and a companion device configured to supply electrical energy to an aerosol-generating device.

Example 23. The aerosol-generating system according to any of the preceding Examples, wherein one or more of an energy storage of the aerosol-generating system, the processing circuitry, and the case is part of the aerosol-generating device or the companion device.

Example 24. The aerosol-generating system according to any of the preceding Examples, further comprising an aerosol-generating article, wherein the aerosol-generating system is configured to generate aerosol from the article.

Examples will now be further described with reference to the figures in which:

Figure 1 shows an aerosol-generating system comprising an aerosol-generating device and a companion device;

Figure 2 shows an arrangement of an energy storage and processing circuitry of an aerosolgenerating system according to prior art;

Figure 3 shows an arrangement of processing circuitry of an aerosol-generating system;

Figure 4 shows the arrangement of the energy storage of the aerosol-generating system according to Figure 3;

Figure 5 shows a cross section of an aerosol-generating system;

Figure 6 shows a cross section of an aerosol-generating system according to prior art;

Figure 7 shows a cross section of an alternative aerosol-generating system;

Figure 8 shows an arrangement of processing circuitry of an aerosol-generating system with a heater device;

Figure 9 shows the arrangement of the energy storage of the aerosol-generating system according to Figure 8; Figure 10 shows an arrangement of processing circuitry of an aerosol-generating system with a different heater device;

Figure 1 1 shows the arrangement of the energy storage of the aerosol-generating system according to Figure 10;

Figure 12 shows an arrangement of processing circuitry of an aerosol-generating system with an energy storage heater; and

Figure 13 shows the arrangement of the energy storage of the aerosol-generating system according to Figure 12.

The figures are schematic only and not to scale.

Figure 1 shows an aerosol-generating system 1 for generating aerosol, for example for consumption by a user in one or more usage sessions. The system 1 may comprise an aerosolgenerating device 2 for generating aerosol and a companion device 3 for at least partially receiving the aerosol-generating device 2. The companion device 3 may be a charging device for charging the aerosol-generating device 2 and/or an energy storage or battery thereof. Both the aerosol-generating device 2 and the companion device 3 may comprise a case 22 or housing. The case 22 may encase or house the further components of the devices 2, 3 as explained herein. The case 22 may comprise or be made from a moldable material, for example a thermosetting plastic material like a thermoplastic material or a moldable ceramic material.

The aerosol-generating device 2 may comprise an insertion opening 4 for at least partially inserting an aerosol-generating article 17. The aerosol-generating article 17 may comprise an aerosol-forming substrate, such as a tobacco containing substrate, and/or a cartridge comprising a liquid.

The aerosol-generating device 2 may further include processing circuitry 30 or control circuitry 30 with at least one controller 5 and one or more processors 6. For generating the aerosol during use or consumption of the aerosol-generating article 17, the aerosol-generating device 2 may comprise at least one heating element 7 or heater device for applying heat to at least a portion of the aerosol-generating article 17. The processing circuitry 30 and/or the controller 5 may be configured to control actuation, activation and/or deactivation of at least one heating element 7.

For powering the at least one heating element 7 with electrical power, the aerosolgenerating device 2 may further comprise at least one energy storage 15, for example in the form of a battery, for storing electrical energy or power. The aerosol-generating device 2 may further comprise at least one electrical connector 12 for coupling to a corresponding at least one electrical connector 13 of the companion device 3. For example, when the aerosol-generating device 2 is at least partially inserted into the opening 14 of the companion device 3, the one or more electrical connectors 12 of the aerosol-generating device 2 may be coupled with the one or more electrical connectors 13 of the companion device 3 to charge the at least one energy storage 15 of the aerosol-generating device 2.

The aerosol-generating device 2 may further comprise user interface components, for example comprising an input element or input device 8, for example in the form of a pushbutton. The input device 8 may be used as a power button to activate or deactivate the heating element 7 for aerosol generation thereby to activate or deactivate the aerosol-generating device 2. Upon activation of the aerosol-generating device 2, the heating element 7 may be activated and heat may be applied to at least a part of the aerosol-generating article 17, such that aerosol can be generated for consumption by the user, for example in a usage sessions. The aerosol generating device 2 and the companion device 3 may each comprise a user interface comprising one or more output elements, such as LED(s), for outputting a signal to a user.

The aerosol-generating device 2 may further comprise a communications arrangement 9 or communication circuitry 9 with one or more communications interfaces 10 for communicatively coupling the aerosol-generating device 2 with the companion device 3, for example, via an Internet connection, a wireless LAN connection, a WiFi connection, a Bluetooth connection, a mobile phone network, a 3G/4G/5G connection, an edge connection, an LTE connection, a BUS connection, a wireless connection, a wired connection, a radio connection, a near field connection, and/or an loT connection.

The aerosol-generating device 2 may further comprise a data storage 11 for storing information, program code or data. One or more sensors 16 may be arranged on, at or in the aerosol-generating device 2 to collect data. One or more of the sensors 16 may for example be temperature sensors, strain sensors, accelerometers or any other suitable sensors.

Both the aerosol-generating device 2 and the companion device 3 may comprise a longitudinal axis 28. Longitudinal axis 28 may extend in the direction of greatest extension of the respective device 2, 3. In the case of the aerosol-generating device 2, the longitudinal axis 28 may extend in or be parallel to the direction in which an aerosol-generating article 17 is inserted into or extracted from the insertion opening 4 of the aerosol-generating device 2. In the case of the companion device 3, the longitudinal axis 28 may extend in the same direction as or be parallel to the longitudinal axis 28 of the aerosol-generating device 2 when the aerosol-generating device 2 is inserted into the opening 14 of the companion device 3.

While the further figures focus on explaining the content of the present disclosure implemented in an aerosol-generating device 2, the whole description of figures 2-13 is similarly applicable to a companion device 3. Figure 2 shows an aerosol-generating device 2 according to prior art. Processing circuitry 30, comprising controller 5 and further electrical components 18 are typically arranged on a PCB 19, specifically on a separate substrate of the PCB 19. The electrical components 18 and the controller 5 are connected to each other through traces 20 also arranged on the PCB 19. PCB 19 is manufactured as a separate component from the case 22 and needs to be mounted in the case 22 during the manufacture of the aerosol-generating device 2. Also, because PCB 19 comprises a separate substrate on which the controller 5, the electrical components 18 and the traces 20 are arranged, PCB 19 is large and bulky. As can be seen in figure 2, PCB 19 fills up the case 22 of the aerosol-generating device 2 in such a way that it precludes the arrangement of the energy storage 15 in the same area along the axial direction of the longitudinal axis 28 as the PCB 19. In other words, in the area of the aerosol-generating device 2 in which the PCB 19 is located, there is no room for energy storage 15. This is a drastic restriction for the total space available for the energy storage 15 which significantly limits the capacity of the energy storage 15.

This problem may be alleviated by the arrangement according to the present disclosure shown in figures 3 and 4. The aerosol-generating system 1 , exemplarily represented by the aerosol-generating device 2 shown in figures 3 and 4, may not comprise a separate PCB. Instead, processing circuitry 30, specifically one or more of the controller 5, the sensor 16, further electrical components 18 and electrically conductive trace 20 may be arranged directly on the case 22, and may specifically be at least partly embedded in the moldable material of the case 22. The processing circuitry 30 may therefore be included in the production process of the case 22 and may be produced in the molding step in which case 22 is formed from moldable material. The mentioned components may, for example, be arranged on the interior surface of case 22. By at least partly embedding one or more of the electrical components in the moldable material of the case 22, no separate substrate is needed to mount these components. A separate PCB may therefore be completely dispensed with. As basically the entire surface of the case 22 may be available for embedding the components, they can be arranged in a manner more widely distributed than on a conventional PCB, where the components are concentrated in one smaller area. Both the lack of a separate substrate, separate from the case 22, for mounting the components and the possibility to distribute the components more widely over the surface of the case 22 may contribute to the saving of space in the interior space of the case 22. Additionally, by embedding the components into the moldable material of the case 22, the extent to which the components protrude from the wall surface of the case 22 can be reduced. This may leave more room in the interior of the case 22, even in an area of the interior space of the case 22 directly adjacent to the electrical components, for example the controller 5. In contrast to the prior art shown in figure 2, it may therefore be possible to arrange the energy storage 15 even in an area along the longitudinal axis 28 of the aerosol-generating device 2 in which the processing circuitry 30, for example including the controller 5, is located. For clarity reasons, the energy storage 15 of the aerosol-generating device 2 is not shown in figure 3. However, figure 4 shows the arrangement and the extension of the energy storage 15 of the aerosol-generating device 2 according to figure 3. For equal clarity reasons, the processing circuitry 30 is not shown in figure 4. As can be seen in figure 4, the energy storage 15 may extend along most of the aerosol-generating device 2 in the direction of the longitudinal axis 28. The energy storage 15 may be arranged in the same areas as the processing circuitry 30, including the controller 5. In other words, the processing circuitry 30, including the controller 5, may overlap the energy storage 15 in the radial direction of the longitudinal axis 28 of the aerosol-generating device 2. The energy storage 15 may therefore extend through most of the extension of the aerosol-generating device 2 along the longitudinal axis 28. Through this increase in the size of the energy storage 15, its capacity may be significantly increased.

Figure 5 shows a cross-section perpendicular to the longitudinal axis 28 through an aerosolgenerating system 1 , exemplarily represented by an aerosol-generating device 2. As shown, the aerosol-generating device 2 may have a circular or elliptical cross-section, although other shapes are also possible. Figure 5 exemplifies how embedding of the electrical components, specifically the controller 5, traces 20 and further electrical components 18 into the moldable material of the case 22 may increase the space available for the energy storage 15 in the interior of the case 22. First, the electrical components may be arranged on the case 22 in a way that closely follows the shape of the case 22 itself. As the interior surface of the case 22 as shown in figure 5 may be rounded, the components of the processing circuitry 30 are arranged following this rounded shape. This would not be possible with a conventional PCB, which is typically planar and would therefore require a lot more room to be installed in the case 22 as shown in figure 5. Additionally, figure 5 shows that the electrical components may be embedded into the moldable material of the case 22 itself. In other words, the electrical components are recessed or sunk into the material of the wall of the case 22. Some of the thickness of the electrical components is therefore absorbed by the thickness of the case 22 so that the electrical components may protrude less into the interior space of the case 22. This leaves more room in the interior of the case 22 so that an energy storage 15 with increased radius or circumference may be used despite the fact that the energy storage 15 may be arranged directly adjacent to the electrical components, especially the controller 5.

Figures 6 and 7 show a similar cross-section as figure 5 through an exemplary aerosolgenerating device 2 with a circular or cylindrical base shape of the case 22 and an additional flat sidewall 23. Figure 6 shows a device according to prior art and figure 7 shows an improved device according to the present disclosure. In the device of prior art according to figure 6, the components of the processing circuitry 30 are again arranged on a PCB 19. As the PCB 19 is usually planar, it may be typically arranged on the flat sidewall 23 of the case 22. In this arrangement, the components of the processing circuitry 30, for example the controller 5 and further electrical components 18 are distanced from the flat sidewall 23 by the thickness of the substrate of the PCB 19. Additionally, as the components of the processing circuitry 30 are arranged on the outer surface of the PCB 19 substrate, they extend into the interior space of the case 22 with their full thickness. From the flat sidewall 23, the components therefore extend into the interior space of the case 22 with both their full thickness and the thickness of the PCB 19 substrate. As can be seen in figure 6, this significantly limits the radius or circumference and the size of an energy storage 15 that may be used in the interior space of the case 22.

Figure 7 shows a cross-section through an aerosol-generating system 1 , exemplarily represented by an aerosol-generating device 2, according to the present disclosure. The processing circuitry 30 and its components may be directly arranged on the flat sidewall 23 of the case 22, without the use of an additional PCB substrate. Through this arrangement, the components of the processing circuitry 30 may not be distanced from the flat sidewall 23 by an additional layer of PCB substrate. Additionally, the components of the processing circuitry 30 may be at least partially embedded in the moldable material of the flat sidewall 23 of the case 22. All in all, the extension of the components according to the arrangement of figure 7 above the surface of the sidewall 23 may even be smaller than the thickness of the components themselves. As can be seen in figure 7, this may facilitate the use of an energy storage 15 with an increased radius or circumference and therefore an increased size and capacity. It may also be provided that the components of the processing circuitry 30, for example the controller 5 and the further electrical components 18, may be arranged at the edge of the flat sidewall 23, where the flat sidewall 23 is connected to the rounded part of the case 22. When an energy storage 15 with a cylindrical or elliptic cylindrical shape is used, this may lead to another possible increase of the size of the energy storage 15, because the shape of the case 22 may automatically lead to unused interior space in the region where the flat sidewall 23 and the rounded part of the case 22 are connected. It may therefore be advantageous to arrange the components of the processing circuitry 30 in this region.

Figures 8 and 9 show another example of an aerosol-generating system 1 , exemplarily represented by an aerosol-generating device 2. The example is generally similar to the one shown in figures 3 and 4, so that only the aspects differing from those figures will be described to avoid repetitions. As shown in figure 8, the controller 5 may be split into at least two or more separate controller subunits 21. The controller subunits 21 may be connected to each other, for example by traces 20, and may together form the controller 5. Each controller subunit 21 may have smaller spatial dimensions than controller 5 made up from one single unit. The controller subunits 21 may be arranged on the case 22 such that the direction of their greatest extension is parallel to the longitudinal axis 28 of the aerosol-generating device 2. While this has been shown exemplarily for the controller subunits 21 in figure 8, this may also apply to all the other electrical components mentioned in this disclosure, for example also to a controller 5 made up from a single unit. In this way, the controller subunits 21 or the other electrical components may follow the shape of the wall of the case 22 as closely as possible, as also shown in figure 5.

Figure 9 shows an alternative arrangement of the controller 5. As shown, the controller 5 may be arranged axially offset to the energy storage 15 along the longitudinal axis 28. In this case, the controller 5 may be at least partially embedded in part of the case 22 that extends perpendicularly to the longitudinal axis 28. The controller 5 may also be arranged such that the direction of its smallest extension is parallel to the longitudinal axis 28. In other words, a flat controller 5 may be arranged perpendicularly to the longitudinal axis 28. A flat controller 5 may be a controller 5 that has at least one direction of extension in which it extends less than in other directions. Such an arrangement may be advantageous when the controller 5 is too big to be arranged in the case 22 next to the energy storage 15 in a radial direction from the longitudinal axis 28. By embedding the controller 5 at least partly in the moldable material of the case 22 in this position, the interior space available for the energy storage 15 may be increased.

Figures 8 and 9 also show an exemplary heating element 7 of the aerosol-generating device 2. The heating element 7 may be configured so that an aerosol-generating article 17 can be inserted into the heating element 7 through the insertion opening 4. The heating element 7 may include a resistive heater 24 or an induction coil configured to heat the aerosol-generating article 17. The resistive heater 24 or the induction coil may be at least partly embedded in the moldable material of the case 22. By this arrangement, the resistive heater 24 or the induction coil may surround an interior space into which the aerosol-generating article 17 may be inserted through the insertion opening 4. The moldable material of the case 22 may also include insulating material 25, which may be arranged at least partly surrounding the resistive heater 24 or the induction coil in a radial direction of the longitudinal axis 28. Insulating material 25 ensures that the heat of heating element 7 is mainly conducted to the aerosol-generating article 17 and not to the outside through the case 22, where the heat might be uncomfortable for a user. The heating element 7 may be produced in the same production step as the molding of the case 22 and may be produced as a single integral unit with the case 22. Figures 10 and 1 1 show another example of an aerosol-generating system 1 , exemplarily represented by an aerosol-generating device 2. The example is generally similar to the one shown in figures 3, 4, 8 and 9, so that only the aspects differing from those figures will be described to avoid repetitions.

Specifically, figures 10 and 1 1 show another type of heating element 7. The heating element 7 may be configured as a heating blade. The heating blade may be configured to enter into an aerosol-generating article 17 that is inserted into the aerosol-generating device 2 through the insertion opening 4. It may therefore be configured to heat the aerosol-generating article 17 from inside of the article 17 itself. The heating blade may comprise a resistive heater 24 or an induction coil configured to heat the aerosol-generating article 17. Additionally, the heating blade may comprise a moldable material, for example a moldable material similar to the material of the case 22. The resistive heater 24 or the induction coil may be at least partly embedded in the moldable material of the heating blade. The heating element 7 configured as a heating blade may be produced in the same production step as the molding of the case 22 and may be produced as a single integral unit with the case 22.

Figures 12 and 13 show another example of an aerosol-generating system 1 , exemplarily represented by an aerosol-generating device 2. The example is generally similar to the one shown in figures 3, 4, 8, 9, 10 and 11 , so that only the aspects differing from those figures will be described to avoid repetitions.

As shown in figure 12, the aerosol-generating device 2 may include a battery heater 27 configured to heat the energy storage 15. The battery heater 27 may include a resistive heater 24 or an induction coil. Battery heater 27 may be at least partially embedded in the moldable material of the case 22. Battery heater 27 may be arranged to cover the whole extension of the energy storage 15 along the longitudinal axis 28. Specifically, the battery heater 27 may be arranged so as to surround the energy storage 15 in a radial direction of the longitudinal axis 28. To facilitate the heating of the energy storage 15, the case 22 may include a heat spreader 29. Heat spreader 29 may for example include a moldable material that is heat conductive, for example a moldable heat conductive ceramic material. The heat spreader 29 may be included into the case 22 during the molding step in the production of case 22 so that the heat spreader 29 and the case 22 may be molded together. Also in this same step, the battery heater 27 may be at least partly embedded in the material of the case 22 and the heat spreader 29.

The battery heater 27 and the heat spreader 29 may be configured to cover the energy storage 15 completely in a radial direction of the longitudinal axis 28. However, as shown in figure 13, there may be provided non-heated areas 26, in which the case 22 does not comprise or is free from the battery heater 27 and/or the heat spreader 29. The non-heated areas 26 are arranged at locations of the case 22 in which electronic components that may be heat sensitive or whose performance may be impaired by high temperatures are arranged. For example, a nonheated area 26 may be arranged around the controller 5. A non-heated area 26 may also be arranged around further electrical components 18. By providing a battery heater 27 along with a heat spreader 29 but then also providing non-heated areas where temperature sensitive components are installed, it may be ensured that the energy storage 15 may be kept at an optimal temperature while simultaneously making sure that other temperature sensitive components are not overly heated. Furthermore, by at least partly embedding the battery heater 27 in the moldable material of the case 22 and by providing the heat spreader 29 as additional moldable material of the case 22, the whole arrangement may be very space-efficient and may allow for an energy storage 15 of increased size and capacity.

For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

1 . An aerosol-generating system, comprising: a case comprising a moldable material, processing circuitry comprising at least one controller and at least one electrically conductive trace, wherein at least one of the controller and the trace is at least partly embedded in the moldable material of the case.

2. The aerosol-generating system according to claim 1 , wherein the at least one of the controller and the trace is at least partly embedded in the moldable material of the case so that the at least one of the controller and the trace is recessed into the material of the case.

3. The aerosol-generating system according to any of the preceding claims, wherein the system comprises an energy storage for storing electrical energy, wherein the case at least partly encases the energy storage, preferable wherein the energy storage is removable and/or replaceable by a user, and/or wherein the at least one controller and an energy storage of the aerosol-generating system overlap each other in a radial direction of a longitudinal axis of the aerosol-generating system.

4. The aerosol-generating system according to any of the preceding claims, wherein the at least one controller of the processing circuitry is arranged on the case, preferably an interior wall of the case, such that a direction of the greatest extension of the controller is oriented in parallel to a longitudinal axis of the aerosol-generating system.

5. The aerosol-generating system according to any of the preceding claims, wherein the processing circuitry comprises at least one sensor, preferably one or more of a temperature sensor, a strain sensor and an accelerometer, and wherein the at least one sensor is at least partly embedded in the moldable material of the case.

6. The aerosol-generating system according to any of the preceding claims, wherein the controller comprises at least two controller subunits, and wherein each of the at least two controller subunits are individually at least partly embedded in the moldable material of the case.

7. The aerosol-generating system according to any of the preceding claims, comprising an energy storage heater configured to heat an energy storage of the aerosol-generating system, wherein the energy storage heater is at least partly embedded in the moldable material of the case.

8. The aerosol-generating system according to the preceding claim, wherein the moldable material of the case comprises a heat spreader, preferably wherein the heat spreader comprises at least one of a moldable ceramic material, a metal, preferably copper, and a coating.

9. The aerosol-generating system according to any of the preceding claims 7-8, wherein the case comprises non-heated areas free from and/or spaced apart from the energy storage heater and/or the heat spreader, and wherein at least one of the controller and further electrical components are arranged in the non-heated areas.

10. The aerosol-generating system according to any of the preceding claims, wherein the case at least partly encases an interior space for an energy storage of the aerosol-generating system, and wherein at least one of the controller and the trace is at least partly embedded in a surface of the case facing the interior space, preferably wherein the case comprises, in a plane perpendicular to a longitudinal axis of the aerosol-generating system, a rounded surface and a flat surface, wherein the rounded surface and the flat surface are connected to one another and together encase the interior space, and wherein at least one of the controller and the trace is at least partly embedded in the flat surface.

1 1 . The aerosol-generating system according to any of the preceding claims, comprising a heating element for heating an aerosol-generating substrate or article, wherein the heating element comprises a heating blade configured to be inserted into the aerosol-generating substrate or article and a resistive heater, wherein the heating blade comprises a moldable material and wherein the resistive heater is at least partly embedded in the moldable material of the heating blade.

12. The aerosol-generating system according to any of the preceding claims, comprising a heating element for heating an aerosol-generating substrate or article, wherein the heating element comprises a resistive heater, and wherein the resistive heater is at least partly embedded in the moldable material of the case.

13. The aerosol-generating system according to any of the preceding claims, wherein the processing circuitry is exclusively arranged on the case of the aerosol-generating system and preferably is free from a separate printed circuit board.

14. The aerosol-generating system according to any one of the preceding claims, comprising one or more of: an aerosol-generating device configured to generate aerosol; and a companion device configured to supply electrical energy to an aerosol-generating device, preferably wherein one or more of an energy storage of the aerosol-generating system, the processing circuitry, and the case is part of the aerosol-generating device or the companion device.

15. The aerosol-generating system according to any of the preceding claims, further comprising an aerosol-generating article, wherein the aerosol-generating system is configured to generate aerosol from the article.