EP4669155A1

EP4669155A1 - POWER SUPPLY SYSTEM FOR AEROSOL GENERATION DEVICE

Info

Publication number: EP4669155A1
Application number: EP24704875.4A
Authority: EP
Inventors: Grzegorz Aleksander PILATOWICZ; Jörg Füglistaller
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2023-02-21
Filing date: 2024-02-20
Publication date: 2025-12-31
Also published as: KR20250150130A; JP2026504466A; WO2024175580A1; CN120640994A

Abstract

An aerosol generation device power system (300) is provided. The power system comprises a first power module (104) and a second power module (106). A first voltage converter (310) is configured to be connected between the first power module and a heater component (108) of an aerosol generation device to step-up a voltage of a power flow from the first power module to the heater component. A second voltage converter (312) is connected between the second power module and the first power module.

Description

AEROSOL GENERATION DEVICE POWER SYSTEM

FIELD OF THE INVENTION

The present invention relates to aerosol generation devices, and more specifically aerosol generation device power systems.

BACKGROUND

Aerosol generation devices such as electronic cigarettes and other aerosol inhalers or vaporisation devices are becoming increasingly popular consumer products.

Heating devices for vaporisation or aerosolisation are known in the art. Such devices typically include a heating chamber and heater. In operation, an operator inserts the product to be aerosolised or vaporised into the heating chamber. The product is then heated with an electronic heater to vaporise the constituents of the product for the operator to inhale. In some examples, the product is a tobacco product similar to a traditional cigarette. Such devices are sometimes referred to as “heat not bum” devices in that the product is heated to the point of aerosolisation, without being combusted.

Problems faced by known aerosol generation devices include providing effective power management and heating.

SUMMARY OF INVENTION

In a first aspect, there is provided an aerosol generation device power system, the power system comprising a first power module, a second power module, a first voltage converter configured to be connected between the first power module and a heater component of an aerosol generation device to step-up a voltage of a power flow from the first power module to the heater component, and a second voltage converter connected between the second power module and the first power module. In this way, by stepping up the voltage from the first power module, a smaller first power module can be utilised in the power system whilst achieving a continuous power delivery to the heater component. In turn, this can reduce the overall size of an aerosol generation device comprising the power system. The first voltage converter allows for a lower voltage to be used, which helps to stabilise power delivery, and improve the quality of the aerosolisation session.

Preferably, the second voltage converter is controlled with input current control.

Preferably, the second voltage converter uses the input current control to provide substantially constant power to the heater from each of the second power module and the first power module as a function of voltage of the first power module.

In this way, the second power module provides a continuous power flow that is independent of the voltage of the first power module. This stabilises the power system and reduces losses at the first power module as the voltage of the first power module drops. Consequently, higher energy efficiency is achieved, especially for low voltages, helping to use more energy stored in the first power module and allowing for a reduced component size.

Preferably, the aerosol generation device power system is connectable to an auxiliary power source, and the input current control at the second voltage converter controls a power flow to the heater from the auxiliary power source for an aerosolisation session.

In this way, through the use of the input current control at the second voltage converter, other sources of power (including external power sources) can be used in place of the second power module. This increases the flexibility of the power system.

Preferably, the second power module is configured to recharge the first power module. In this way, the first power module can power an aerosolisation session for longer, and/or be adequately charged for a subsequent aerosolisation session. This improves the use of power in the power system.

Preferably, the second voltage converter is configured to step-up the voltage of a power flow from the second power module to the first power module when recharging the first power module from the second power module.

In this way, a lower voltage second power module can be used.

Preferably, the first power module is a supercapacitor module comprising one or more supercapacitors, or the first power module is a battery module comprising one or more high power batteries.

A high-power battery is a battery with a high discharge rate, capable of providing a high power.

Preferably, the first power module can comprise one or more electrochemical double-layer capacitors.

Preferably, the first power module is capable of providing a high power / discharge rate that is for example greater than or equal to 10 W/Wh, or more preferably greater than or equal to 40 W/Wh. It is particularly preferable to have discharge rate of greater than or equal to 40 W/Wh for the duration of the pre-heating.

In this way, through the use of supercapacitors or high-power batteries, energy can be rapidly transferred to the heater component from the first power module.

Preferably, the second power module is a battery module comprising at least one battery, or wherein the second power module is a supercapacitor module comprising one or more supercapacitors, or wherein the second power module is a supercapacitor module comprising one or more hybrid supercapacitors.

In this way, a high energy content can be stored in the second power module to recharge the first power module and/or power the heater component. In a second aspect, there is provided an aerosol generation device comprising the aerosol generating device power system of the first aspect.

Preferably, the aerosol generation device comprises a heating chamber that is configured to receive an aerosol generating consumable, and to heat without burning the aerosol generating consumable to generate an aerosol in an aerosolisation session.

In this way, a consumer can perform an aerosolisation session that provides an experience similar to traditional smoking.

Preferably, the heating chamber has a substantially circular cross section, and defines a cavity that is substantially cylindrical in shape for receiving the aerosol generating consumable.

In this way, a rod-shaped aerosol generating consumable can be used for an aerosolisation session that provides the operator with a similar experience to traditional smoking.

Preferably, the aerosol generating consumable is a tobacco rod.

In this way, a tobacco rod can be used for an aerosolisation session that provides the operator with a similar experience to traditional smoking.

Preferably, the heating chamber has a substantially rectangular cross section, and defines a cavity that is substantially cuboidal in shape for receiving the aerosol generating consumable.

In this way, the heating chamber can be of a compact configuration thereby reducing the overall device size.

Preferably, the aerosol generating consumable is a substantially planar in shape.

In this way, the aerosol generating substrate is compact, thereby allowing for a smaller overall device size. Preferably, the aerosol generating consumable comprises tobacco.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:

Figure 1 is a block diagram of the components of an aerosol generation device;

Figure 2 is a flow diagram of the steps of an aerosolisation session;

Figure 3 a circuit diagram of an aerosol generation device power system;

Figure 4 is a plot of heater temperature against time, with a first data set representing heater temperature as a function of time for the power system of Figure 3 including the first voltage converter, and a second data set representing heater temperature as a function of time for the power system of Figure 3 but not including the first voltage converter;

Figure 5 is a plot of preheating time as a function of the current limiting value of the second voltage converter for the power system of Figure 3;

Figure 6A is a plot of power against supercapacitor voltage with the second voltage converter using output current control in the power system of Figure 3;

Figure 6B is a plot of power against supercapacitor voltage with the second voltage converter using input current control in the power system of Figure 3;

Figure 7 is a plot of supercapacitor losses as a function of supercapacitor voltage;

Figure 8A is a plot of heater voltage as a function of time for the power system of Figure 3 with input current limitation not used at the second voltage converter;

Figure 8B is a plot of heater voltage as a function of time for the power system of Figure 3 with input current limitation used at the second voltage converter; Figure 9A is a plot of current measured at the second power module as a function of time for the power system of Figure 3 with input current limitation not used at the second voltage converter;

Figure 9B is a plot of current measured at the second power module as a function of time for the power system of Figure 3 with input current limitation used at the second voltage converter;

Figure 10A is a plot of voltage measured at the first power module as a function of time for the power system of Figure 3 with input current limitation not used at the second voltage converter;

Figure 10B is a plot of voltage measured at the first power module as a function of time for the power system of Figure 3 with input current limitation used at the second voltage converter;

Figure 11 A is a plot of current measured at the first power module as a function of time for the power system of Figure 3 with input current limitation not used at the second voltage converter;

Figure 11 B is a plot of current measured at the first power module as a function of time for the power system of Figure 3 with input current limitation used at the second voltage converter;

Figure 12A is a diagram of a planar aerosol generating consumable;

Figure 12B is a diagram of the aerosol generating consumable of Figure 12A inserted into a heating chamber; and

Figure 12C is a diagram of a mouthpiece region of an aerosol generation device comprising the heating chamber of Figure 12B configured to receive the planar aerosol generating consumable of Figure 12A. DETAILED DESCRIPTION

Figure 1 shows a block diagram of the components of an aerosol generation device 100 or a vapor generation device, also known as an electronic cigarette. For the purposes of the present description, it will be understood that the terms vapor and aerosol are interchangeable.

The aerosol generation device 100 has a body portion 112 containing controller 102, and a power system comprising a first power module 104 and a second power module 106. The power system is discussed in more detail with respect to Figure 3.

Herein only one first power module 104 and one second power module 106 are referred to; the skilled person will however understand that the power system can comprise one or more first power modules and one or more second power modules as appropriate.

The controller 102 is configured to control power flows of the first power module 104 and the second power module 106 based on the operating mode of the aerosol generation device, as will be subsequently described.

The controller 102 can be at least one microcontroller unit comprising memory, with instructions stored thereon for operating the aerosol generation device 100 including instructions for executing the selectable operating modes and controlling the power flows, and one or processors configured to execute the instructions.

In an example, a heater 108 (or heater component) is contained with the body portion 112. In such an example, as shown in Figure 1 , the heater 108 is arranged in a heating chamber 110 or cavity in the body portion 112. The heating chamber 110 is accessed by an opening 110A in the body portion 112. The heating chamber 110 is arranged to receive an associated aerosol generating consumable 114. The aerosol generating consumable can contain an aerosol generating material, such as a tobacco rod containing tobacco. A tobacco rod can be similar to a traditional cigarette. The heating chamber 110 can have a substantially cross-sectional shape, thereby defining a cavity that is substantially cylindrical in shape for receiving the aerosol generating consumable 114.

The heating chamber 110 has cross-section approximately equal to that of the aerosol generating consumable 114, and a depth such that when the associated aerosol generating consumable 114 is inserted into the heating chamber 110, a first end portion 114Aof the aerosol generating consumable 114 reaches a bottom portion 11 OB of the heating chamber 110 (that is, an end portion 11 OB of the heating chamber 110 distal from the heating chamber opening 110A), and a second end portion 114B of the aerosol generating consumable 114 distal to the first end portion 114A extends outwardly from the heating chamber 110. In this way, a consumer can inhale upon the aerosol generating consumable 114 when it is inserted into the aerosol generation device 100. In the example of Figure 1 , the heater 108 is arranged in the heating chamber 110 such that the aerosol generating consumable 114 engages the heater 108 when inserted into the heating chamber 110. In the example of Figure 1 , the heater 108 is arranged as a tube in the heating chamber such that when the first end portion 114A of the aerosol generating consumable is inserted into the heating chamber the heater 108 substantially or completely surrounds the portion of the aerosol generating consumable 114 within the heating chamber 110. The heater 108 can be a wire, such as a coiled wire heater, or a ceramic heater, or any other suitable type of heater. The heater 108 can comprise multiple heating elements sequentially arranged along the axial length of the heating chamber that can be independently activated (i.e., powered up) in a sequential order.

In an alternative embodiment (not shown), the heater can be arranged as an elongate piercing member (such as in the form of needle, rod, or blade) within the heating chamber; in such an embodiment the heater can be arranged to penetrate the aerosol generating consumable and engage the aerosol generating material when the aerosol generating consumable is inserted into the heating chamber.

In another alternative embodiment (not shown), the heater may be in the form of an induction heater. In such an embodiment, a heating element (i.e., a susceptor) can be provided in the consumable, and the heating element is inductively coupled to the induction element (i.e., induction coil) in the heating chamber when the consumable is inserted into the heating chamber. The induction heater then heats the heating element by induction.

The heater 108 is arranged to heat the aerosol generating consumable 114 to a predetermined temperature to produce an aerosol in an aerosolisation session. An aerosolisation session can be considered as when the device is operated to produce an aerosol from the aerosol generating consumable 114. In an example in which the aerosol generating consumable 114 is a tobacco rod, the aerosol generating consumable 114 comprises tobacco. The heater 108 is arranged to heat the tobacco, without burning the tobacco, to generate an aerosol. That is, the heater 108 heats the tobacco at a predetermined temperature below the combustion point of the tobacco such that a tobacco-based aerosol is generated. The skilled person will readily understand that the aerosol generating consumable 114 does not necessarily need to comprise tobacco, and that any other suitable substance for aerosolisation (or vaporisation), particularly by heating without burning the substance, can be used in place of tobacco.

In an alternative, the aerosol generating consumable can be a vaporisable liquid. The vaporisable liquid can be contained in a cartridge receivable in the aerosol generation device, or can be directly deposited into the aerosol generation device.

The controller 102 is arranged to control the power flow of the first power module 104 and the second power module 106 based upon a selected operating mode of the aerosolisation session. The operating modes of an aerosolisation session can include a preheating mode and a heating mode. The progression from the preheating mode to the heating mode in an aerosolisation session can be understood from Figure 2.

In the preheating mode 202, the heater 108 associated with the aerosol generation device 100 is heated to a predetermined temperature for the generation of an aerosol from the aerosol generating consumable 114. A preheating phase can be considered the time during which the preheating mode is being executed, for example the time it takes for the heater 108 to reach the predetermined temperature. The preheating mode occurs during a first time period of the aerosolisation session. In an example, the first time period can be a fixed predetermined time period. In other examples, the first time period can vary corresponding to the length of time needed to heat the heater 108 to the predetermined temperature.

When the heater reaches the predetermined temperature, the controller 102 ends the preheating mode 202 and controls the power system to perform the heating mode 204. In the heating mode 204 the controller 102 controls the power flow from the power system to maintain the heater 108 substantially at the predetermined temperature so that an aerosol is generated for the consumer to inhale. A heating phase can be considered the time during which the heating mode is being executed, for example the time during which the heater 108 is aerosolising one (or at least part of one) aerosol generating consumable 114 after the preheating phase. The controller 102 can control the power system to operate the heating mode for a second time period of the aerosolisation session. The second time period can be predetermined and stored at the controller 102.

In the preheating and heating modes, the controller 102 can control the power flow from the power system to the heater such that the power flow is a pulse width modulated power flow having one or more pulse width modulation cycles. A pulse width modulated power flow comprises one or more pulse width modulation (PWM) cycles (also known as pulse width modulation switching periods). A single PWM cycle, or switching period, comprises one PWM cycle “on period” D and one PWM cycle “off period” 1-D. The combination of the PWM cycle on period D and the PWM cycle off period 1-D forms the overall PWM cycle or switching period.

During the PWM on period of the PWM cycle, power is applied to the heater; that is, a power line to heater is closed by a switch that implements the PWM control. During the PWM off period power is not applied to heater; that is, the power line to the heater is opened by a switch that implements the PWM control. As such, one pulse width modulation cycle comprises the power being switched once between an on state and an off state, and a pulse width modulated power flow therefore comprises continuously powering the heater with a power flow which is rapidly switched between PWM on periods and off periods with a duty cycle.

The pulse width modulation duty cycle corresponds to the on period (D) as a proportion of the total period (D + (1-D)) of the cycle (i.e., the combined “on period” and “off period” of the switching period). The pulse width modulated power flow, comprising a plurality of PWM cycles, continuously powers the heater with the average power of the PWM on period and the PWM off period based upon the duty cycle. Controlling the duty cycle controls the amount of power delivered to the heater. A higher duty cycle for the pulse width modulated power flow delivers a higher average power; a lower duty cycle for the pulse width modulated power flow delivers a lower average power. That is, for a higher duty cycle a greater proportion of the cycle is the “on period” D than for a lower duty cycle. In this way, careful control of the level of power applied to the heater can be achieved by controlling the duty cycle of the pulse width modulated power flow.

In the heating mode, the controller 102 is configured to control the power system to apply the pulse width modulated power flow to the heater with a first duty cycle regime to maintain the heater substantially at the predetermined aerosol generation temperature. In the preheating mode, the controller 102 is configured to control the power system to apply the pulse width modulated power flow to the heater with a second duty cycle regime, different to the first duty cycle regime, to heat the heater to the aerosol generation temperature. The second duty cycle regime can have a higher duty cycle than the first duty cycle regime, in this way a greater amount of power is applied to the heater to rapidly heat it to the predetermined temperature, whilst a lower amount of power is used to maintain the heater at the predetermined temperature. The first duty cycle regime comprises one or more PWM cycles with a first duty cycle ratio D1 , and the second duty cycle regime comprises one or more PWM cycles with a second duty cycle ratio D2; the relationship between D1 and D2 can be considered as D2 = D1*K, where K is a coefficient that is » 1 and can be selected as an implementation choice; the theoretical maximum duty cycle is 1 with no off period, or close to but less than 1 with a very short off period. In examples, the first duty cycle regime comprises one or more duty cycles with duty cycle ratios much less than 1 and the second duty cycle regime comprises one or more duty cycles with duty cycle ratios near to but less than 1. In other examples, the first duty cycle regime comprises one or more duty cycles with duty cycle ratios « 0.5 and the second duty cycle regime comprises one or more duty cycles with duty cycle ratios > 0.5. In further examples, the first duty cycle is configured such that < 3 W is applied in the heating mode, and the second duty cycle is configured such that approximately 16 W is applied in the preheating mode. More generally, 2 W to 6 W could be applied during the heating mode, and 10 W to 30 W could be applied during the pre-heating mode.

Figure 3 presents a circuit diagram of a power system 300 that may be used in the aerosol generation device described with reference to Figure 1 , or any other suitable type of aerosol generation device.

The power system 300 of Figure 3 comprises the first power module 104 and the second power module 106.

The first power module 104 can be implemented as a supercapacitor module that comprises one or more supercapacitors. Such a plurality of supercapacitors can connected in series for the first power module 104. Connecting a plurality of smaller supercapacitors in series, rather than using a single larger supercapacitor, is advantageous in allowing greater design flexibility. In another example, the first power module 104 can be implemented as a battery module that comprises one or more high power batteries, that discharge with a high power rate, such as lithium-titanate (LTO) batteries.

In a specific example, the first power module 104 can be implemented as a supercapacitor module that comprises two supercapacitors connected in series. These supercapacitors can be traditional-type supercapacitors and each can have a voltage of 2.5 V thereby providing the first power module 104 with a total voltage of 5 V. In another such example, the supercapacitors can each have a voltage of 3 V thereby providing the first power module 104 with a total voltage of 6 V. In another such example, the supercapacitors can each have a voltage of 3.3 V thereby providing the first power module 104 with a total voltage of 6.6 V. More generally, the supercapacitors can each have a voltage of 2.5 V to 3.3 V, thereby providing the first power module 104 with a total voltage of 5 V to 6.6 V. In other examples, a plurality of supercapacitors can be connected in series to meet the voltage requirements needed for powering the heater 108.

The use of one or more supercapacitors, or high-power batteries, as the first power module 104 is beneficial for powering the energy intensive pre-heating phase of the aerosolisation session, due to the high-power characteristics of such components. This allows for the preheating to be achieved rapidly.

The second power module 106 can be implemented as a battery module comprising one or more batteries. These batteries can be high energy batteries, that store high amounts of energy, such as a battery using lithium-ion technology, aluminium-ion technology, or zinc-ion technology, or any other suitable type of battery. Alternatively, the second power module 106 can be implemented as one or more hybrid supercapacitors.

In a specific example, the second power module 106 can be implemented as a battery module that comprises a lithium-ion battery. Such a battery can have a voltage of 3.7 V.

The use of one or more high energy batteries or hybrid supercapacitors as the second power module 106 is beneficial for powering multiple aerosolisation sessions due to the high energy storage capacity. In particular, the high energy storage capacity allows for the second power module 106 to both supplement the power flow from the first power module 104, and also recharge the first power module 104 (as will be discussed).

The first power module 104 is connectable to the heater 108, for example in a parallel configuration. The heater 108 need not itself be a component of the power system 300, but rather is powered by the power system 300.

A first voltage converter 310 is arranged between the first power module 104 and the heater 108. The first voltage converter 310 can be a DC/DC voltage converter, with a low minimum voltage input, and can be arranged to step up or boost the voltage of first power module 104 for the power flow from the first power module 104 to the heater 108.

If the first voltage converter 310 is not included in the power system 300, the first power module 104 may have a limited usable energy content as, with falling voltage, the required power can no longer be delivered to the heater 108. Continuous power delivery may, therefore, not be possible. This can negatively impact the quality of the aerosolisation session. The energy content issue could be addressed by oversizing the first power module 104, to have a higher energy content. However, this leads to a higher size of the aerosol generation device, which may be disadvantageous to the consumer. By including the first voltage converter 310 between the first power module 104 and the heater 108, to step-up the voltage of a power flow from the first power module 104 to the heater 108, these issues are obviated. That is to say, the first voltage converter 310 is beneficial as, by stepping up the voltage from the first power module 104, a smaller first power module 104 can be utilised in the power system whilst achieving a continuous power delivery to the heater 108; in turn, this can reduce the overall size of an aerosol generation device comprising the power system. The first voltage converter 310 allows for a lower voltage to be used, which helps to stabilise power delivery, and improve the quality of the aerosolisation session.

This is evidenced by Figure 4 which shows a plot 400 of heater temperature 402 against time 404, including a first data set 406 and a second data set 408. The first data set 406 represents heater temperature as a function of time for the power system 300 including the first voltage converter 310 (as described with reference to Figure 3). For the purposes of comparison, the second data set 408 represents heater temperature as a function of time for the same power system but without the first voltage converter 310. For the first data set 406, with the inclusion of the fist voltage converter, heater temperature increases more rapidly, reaching the target temperature of 210°C at approximately 27.5 seconds (compared to approximately 40 seconds for the second data set 408), and stabilises at this temperature at approximately 55 seconds (compared to approximately 85 seconds for the second data set).

Furthermore, by inclusion of the first voltage converter 310, the preheating time for an aerosolisation session is independent of the current limiting value of the second voltage converter 312 (the second voltage converter 312 is discussed later). Figure 5 shows a plot 500 of preheating time 502 as a function of the current limiting value 504 of the second voltage converter 312. As can be seen, the preheating time 504 is approximately consistent at around 22 seconds regardless of the changing current limiting value 504 of the second voltage converter 312. As such, improved control is achieved in the preheating, thereby improving the aerosolisation session.

Returning to Figure 3, the first power module 104 and the second power module 106 are connected with one another in the power system, for example connected in parallel configuration. The second power module 106 can be configured to charge the first power module 104.

The controller 102 can control the second power module 106 to recharge the first power module 104. The controller 102 can control a power flow from the second power module 106 to the first power module 104 after an aerosolisation session, to recharge the first power module 104. In this way, the first power module 104 is adequately charged between aerosolisation sessions to power the power intensive preheating phase of the subsequent aerosolisation session. Alternatively, or additionally, the controller 102 can control a power flow from the second power module 106 to the first module during an aerosolisation session. In this way, the first power module 104 is recharged during the aerosolisation session so that it can power the aerosolisation session for longer. How this control is brought about is discussed subsequently.

A second voltage converter 312 is arranged between the first power module 104 and the second power module 106. The second voltage converter 312 can be configured to step-up the voltage of a power flow from the second power module 106 to the first power module 104 when recharging the first power module 104 from the second power module 106. The second voltage converter 312 can be a DC/DC voltage converter and can be arranged to step up, or boost, the voltage of the second power module 106 in order to charge the first power module 104 from the second power module 106.

When powering the heater with both the first power module 104 and the second module 106, the first voltage converter 310 can step-up the voltage of the power flow from each of the first power module 104 and the second power module 106. The power flow from the second power module 106 can be stepped-up by the second voltage converter 312, and then stepped-up again by the first voltage converter 310. Constant current support can be provided from the second power module 106. Therefore, the second voltage converter 312 controls the power flow in a way that the input current for the second voltage converter 312 from the second power module 106 is constant. Depending on the state of the first power module 104 this can mean both stepping-up voltage on the second voltage converter 312 (if the first power module 104 is relatively full) or stepping-down (if the first power module 104 is relatively empty and very high current charges are not wanted). The first voltage converter 310 can manage the power flow to the heater 108. It could be that a very little part of the current from second power module 106 goes to the heater 108 (whilst the major part recharges the first power module104). The resistance of the heater 108 will increase during the aerosolisation session, therefore the first voltage converter 310 will need to continuously step-up the voltage. The power delivery can be changed by changing the duty cycle (low power, lower duty cycle).

A first switching means 320 (or first switch) is arranged between the power system (i.e. , the first power module 104 and the second power module 106) and the heater 108. This first switching means 320 can be configured to switch the power flow to the heater 108 from the power system such that power flows to the heater 108 when the first switching means 320 is in a closed state, and power does not flow to the heater 108 when the first switching means 320 is in an open state. The first switching means 320 can be used to either switch off the heater 108, or control the power flow to the heater 108 using PWM to control the heater temperature. A second switching means 322 (or second switch) can optionally be arranged between the second power module 106 and the second voltage converter 312. The second switching means 322 can be configured to control the power flow from second power module 106 to the first power module 104, to charge the first power module 104. The second switching means 322 can also be configured to control the power flow from the second power module 106 to the heater 108 in examples in which the second power module 106 contributes to powering the heater 108. In some examples, the second switching means 322 need not be included as, for example, the size considerations of the second power module 106 and the first power module 104 mean that the second power module 106 can always support the first power module 104.

The first switching means 320 and the second switching means 322 can be transistors connected to the controller 102 (not shown in Figure 5A).

As has been mentioned, the second power module 106 can be configured and controlled to recharge the first power module 104.

In some examples, the second power module 106 can be controlled to recharge the first power module 104 after an aerosolisation session. This can be brought about by the controller 102 controlling the first switching means 320 to be open, so that power does not flow to the heater 108, and the second switching means 322 to be closed, so that power flows from the second power module 106 to the first power module 104 thereby recharging the first power module 104.

In other examples, the second power module 106 can be controlled to recharge the first power module 104 during an aerosolisation session, using PWM control, in addition or alternatively to charging the first power module 104 between aerosolisation sessions.

In a first example of the second power module 106 charging the first power module 104 during the aerosolisation session, the second power module 106 charges the first power module 104 during both the pre-heating mode and the heating mode. During the PWM cycle on periods of the PWM power flow to the heater 108, the first power module 104 (or both the first power module 104 and second power module 106) powers the heater 108. During the PWM cycle off periods of the PWM power flow to the heater 108, the second power module 106 recharges the first power module 104. In a second example of the second power module 106 charging the first power module 104 during the aerosolisation session, the second power module 106 charges the first power module 104 during the heating mode as described in the previous example. However, the second power module 106 does not charge the first power module 104 during the pre-heating mode. As a higher duty cycle is used in the pre-heating mode, not charging the first power module 104 during the pre-heating mode reduces the complexity of the system.

An exemplary manner for bringing about this charging during the aerosolisation session can involve the controller 102, the first switching means 320, and the second switching means 322 controlling the heating and charging. During the PWM cycle on periods of the pulse width modulated power flow, the controller 102 controls the first switching means 320 to be closed and the second switching means 322 to be open. In this way, power flows from the first power module 104 to the heater 108 during the PWM on period whilst the second power module 106 is isolated from the first power module 104 and the heater 108. During the PWM cycle off periods of the pulse width modulated power flow, the controller 102 controls the first switching means 320 to be open and the second switching means 322 to be closed. In this way, power flows from the second power module 106 into the first power module 104 to recharge the first power module 104 whilst the first power module 104 is isolated from the heater 108. As such, during the pulse width modulated power flow, a rapid switching occurs between powering the heater 108 in the PWM cycle on periods and recharging the first power module 104 in the PWM cycle off periods.

In some examples, the heater 108 is only powered by the first power module 104 during an aerosolisation session. In such examples, the second power module 106 is isolated from the heater 108 whilst power flows from the first power module 104 to the heater 108 (e.g., with the second switching means 322), and the first switching means 320 is controlled to switch the power flow from the first power module 104 to the heater 108. In such examples, the second power module 106 is used to recharge the first power module 104 either between aerosolisation sessions, or during the aerosolisation session, as has been discussed.

However, in other examples, the heater 108 can be powered during the aerosolisation session by both the first power module 104 and the second power module 106. In such examples, the second power module 106 supports the first power module 104 during the preheating and/or heating phase. The second voltage converter 312 can be advantageously configured to improve the support provided to the first power module 104 by the second power module 106. This can be brought about by controlling the second voltage converter 312 with input current control, also known as input current limitation. Input current control controls the current limit at the input of the second voltage converter 312, rather than output current control in which the output current of a voltage converter is controlled.

To appreciate the beneficial impact of controlling the second voltage converter 312 with input current control compared to output current control, Figures 6A and 6B are referred to. In the example of Figures 6A and 6B, the first power module 104 can be considered a supercapacitor, and the second power module 106 can be considered a battery. However, the same teaching can apply to the first power module 104 being any of the other examples described herein, and the second power module 106 being any of the other examples described herein.

Controlling the second voltage converter 312 with input current control allows for the second power module 106 to be a less robust or powerful by design energy source. The limitation from input current control helps to protect the second power module 106, for example so that it never draws higher a current than allowed. It also protects alternative energy sources to the second power module, e.g., a USB port, AA batteries, or a power adaptor. The first power module 104 can be more robust and more powerful by nature, and therefore it does not need such protection. Figure 6A shows a plot 600A of power 602A against supercapacitor voltage 604A with the second voltage converter 312 using output current control. The first data set 606A corresponds to the power output from the supercapacitor (i.e. , the first power module 104) as a function of supercapacitor voltage (i.e., first power module voltage). The second data set 608A corresponds to the power output from the second voltage converter 312 as a function of supercapacitor voltage (i.e., first power module voltage). If the voltage of the output from the second voltage converter 312 goes down, e.g. due to the voltage on the battery or second power module 106 dropping, the power goes down as well. The output current needs to be kept constant, so P output ^— I output (constant) * V_0Ut_Put (which is going down linearly as the discharge curve of the supercapacitor is linear as well). In this case, as a certain power is needed at the heater, and the second power module 106 and second voltage converter 312 cannot deliver this, more is drawn from the supercapacitor or first power module 104, leading to a higher voltage and higher power output from the supercapacitor or first power module 104. Furthermore, the low internal resistance of a supercapacitor further promotes this.

Figure 6B shows a plot 600B of power 602B against supercapacitor voltage 604B with the second voltage converter 312 using input current control. The first data set 606B corresponds to the power output from the supercapacitor (i.e., the first power module 104) as a function of supercapacitor voltage (i.e., first power module voltage). The second data set 608B corresponds to the power output from the second voltage converter 312 as a function of supercapacitor voltage (i.e., first power module voltage). The power output from the second voltage converter 312 (i.e., the power from the battery or second power module 106) is constant due to the input current control. This is because the input current control forces the battery or second power module 106 to provide continuous support for the power the heater 108 by continuously providing the maximum power needed from the battery or second power module 106. The supercapacitor (i.e., the first power module) therefore also provides a constant output so that the desired power is directed to the heater 108. This stabilises the power system and reduces losses on the supercapacitor. Regarding reducing losses, Figure 7 shows a plot 700 of supercapacitor losses 702 as a function of supercapacitor voltage 704 for a supercapacitor with an internal resistance of 10 mQ. The first data set 706 shows the supercapacitor losses as a function of supercapacitor voltage when using an input current control limit of 3A at the second voltage converter 312. The second data set 708 shows the supercapacitor losses as a function of supercapacitor voltage when using an output current control limit of 2A at the second voltage converter 312. As can be seen, there are considerably lower supercapacitor losses when using input current control at the second voltage converter 312.

Consequently, higher energy efficiency is achieved, especially for low voltages, helping to use more energy stored in the supercapacitor. This allows for a reduced supercapacitor size. The input current control allows for the power splitting to be independent of the supercapacitor voltage.

Further advantages of controlling the second voltage converter 312 with input current control are discussed with reference to Figure 8 to Figure 11 .

Figure 8A shows a plot of 800A of heater voltage 802A as a function of time 804A for the power system 300 if input current limitation is not used at the second voltage converter 312. Figure 8B shows a plot of 800B of heater voltage 802B as a function of time 804B for the power system 300 if input current limitation is used at the second voltage converter 312. As can be seen, the application of input current control does not affect the voltage on the heater 108.

Figure 9A shows a plot 900A of current 902A measured at the second power module 106 as a function of time 904A for the power system 300 if input current limitation is not used at the second voltage converter 312. Figure 9A shows a plot 900B of current 902B measured at the second power module 106 as a function of time 904B for the power system 300 if input current limitation is used at the second voltage converter 312. As can be seen, with the application of input current limitation, the current levels of the second power module 106 are more consistent and can be controlled to not exceed the maximum specified current range. Less stress is applied to the second power module 106, thereby improving the life expectancy.

Figure 10A shows a plot 1000A of voltage 1002A measured at the first power module 104 as a function of time 1004Afor the power system 300 if input current limitation is not used at the second voltage converter 312. Figure 10B shows a plot 1000B of voltage 1002B measured at the first power module 104 as a function of time 1004B for the power system 300 if input current limitation is used at the second voltage converter 312. With the application of input current limitation, a lower voltage drop is seen on the first power module 104. These leads to lower losses and improved stability.

Figure 11 A shows a plot 1100A of current 1102A measured at the first power module 104 as a function of time 1104Afor the power system 300 if input current limitation is not used at the second voltage converter 312. Figure 11 B shows a plot 1100B of current 1102B measured at the first power module 104 as a function of time 1104B for the power system 300 if input current limitation is used at the second voltage converter 312. As can be seen, with the application of input current limitation, the current at the first power module 104 is more consistent, thereby stressing the first power module 104 less.

The benefits of the second voltage converter 312 are therefore two-fold. Firstly, the second voltage converter 312 can advantageously step-up the voltage of the power flow from the second power module 106 to the first power module 104 when charging the first power module 104, allowing for a lower voltage second power module 106 to be used. Secondly, through input control of the power flow from the second power module 106 at the second voltage converter 312, losses and stress are reduced at the first power module 104 and stress is reduced at the second power module 106.

The use of the input current control also allows for external or auxiliary power sources to be used, for example if the energy level at the second power module 106 is depleted, or in place of the second power module 106. In a first example, a low-cost power adapter with a low maximum current (for example up to 3A, 5V) can be used as an external power source to perform an aerosolisation session without needing power from the second power module 106. In a second example, a USB connector, such as from a power bank, car lighter socket, portable PC, stationary PC or the like could be used in a similar manner to the first example. In a third example, primary batteries (such as 3 or 4 AA batteries) could be used as a back-up, in place of the second power module 106, for an aerosolisation session to be performed.

Returning to Figure 3, the power system 300 can further comprise a temperature sensor 332 or temperature sensing subcircuit configured to monitor the temperature of the first power module 104. The power system can also comprise a temperature sensor 334 or temperature sensing subcircuit configured to monitor the temperature of the second power module 106. A further temperature sensor 330 or temperature sensing subcircuit can be included at the heater 108 to measure the heater temperature or heating chamber temperature. The aforementioned temperature sensors can be controlled by the controller 102.

The power system 300 can further comprise a voltage sensor 342 or voltage sensing subcircuit configured to monitor the voltage of the first power module 104. The power system can also comprise a voltage sensor 344 or voltage sensing subcircuit configured to monitor the voltage of the second power module 106. A further voltage sensor 340 or voltage sensing subcircuit can be included at the heater 108 to measure heater voltage. The aforementioned voltage sensors can be controlled by the controller 102.

The power system 300 can further comprise a current sensor 352 or current sensing subcircuit configured to monitor the current output by the first power module 104. The power system can also comprise a current sensor 354 or current sensing subcircuit configured to monitor the current output by the second power module 106. A further current sensor 540 or current sensing subcircuit can be included at the heater 108 to measure the heater current. The aforementioned current sensors can be controlled by the controller 102. The power system 300 can be connected to an external power source, such as a mains supply, battery, power bank or the like. The external power source can be connected at connection node 370. The controller 102 can control the charging of the second power module 106 and/or first power module 104 using a third switching means 324 (or third switch) between the power system and the connection node 370. In an example, the third switching means 324 can be a transistor switch controlled by the controller 102.

Whilst in the foregoing description, the aerosol generation device has been described with reference to the aerosol generation device 100 of Figure 1 , alternative arrangements of aerosol generation device can readily be used with the power system 300 described with reference to Figure 3. Figures 12A to 12C present an example of an aerosol generation device configured with an alternative heating chamber 1210 for use with an alternative aerosol generating consumable 1214.

In such an alternative embodiment, the aerosol generating consumable 1214 can be substantially flat or planar in shape. Figures 12A to 12C show diagrams of an arrangement by which such a planar aerosol generating consumable 1214 and corresponding heating chamber 1210 can be implemented. Figure 12A is a diagram of a planar aerosol generating consumable 1214, and Figure 12B is a diagram of the aerosol generating consumable 1214 inserted into the heating chamber 1210. Figure 12C is a diagram of a mouthpiece region of an aerosol generation device comprising the heating chamber 1210 configured to receive such a planar aerosol generating consumable 1214, with a mouthpiece 1260 fitted. The power system 300 as described herein, as well as the operation and control of the aerosol generation device as already described, can be used with this embodiment of an aerosol generation device, and these details are not repeated for brevity.

Referring to Figure 12A, the aerosol generating consumable 1214 can be planar or flat in shape, for example in the form of a flat-shaped cuboid. In a specific example, the length of the consumable 1214 according to the consumable axis is substantially 33 mm, and the width and depth are substantially 12 mm and 1.2 mm, respectively. That is to say, the consumable 1214 can be considered planar in shape in that it has a depth that is much shorter than the length and width. However, in other examples, the aerosol generating consumable 1214 and corresponding heating chamber 1210 can be of other suitable shapes or dimensions.

The aerosol generating consumable 1214 can comprise a heating portion 1239 and a mouthpiece portion 1238. The heating portion 1239 is received in the heating chamber 1210, and the mouthpiece portion 1238 is received in the mouthpiece 1260. That is, the heating portion 1239 defines an abutting end of the consumable 1214 that can abut or be proximal to the bottom 1250 of the heating chamber 1210, and the mouthpiece portion 1238 defines a mouth end of the consumable 1214.

The heating portion 1239 is configured to be heated by a heater 1208 in the heating chamber 1210 and comprises an aerosol generating material. The aerosol generating material can be a material that may for example comprise nicotine or tobacco and an aerosol former. Tobacco may take the form of various materials such as shredded tobacco, granulated tobacco, tobacco leaf and/or reconstituted tobacco. Suitable aerosol formers include: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, acids such as lactic acid, glycerol derivatives, esters such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin or vegetable glycerin. In some embodiments, the aerosol generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The consumable 1214 may also comprise at least one of a gelling agent, a binding agent, a stabilizing agent, and a humectant. When the aerosol generating material is heated, an aerosol or vapour is formed.

The mouthpiece portion 1238 is intended to be received inside the mouthpiece 1260. The mouthpiece portion 1238 comprises a core 1264 that can provide a filtering functionality. In some examples, the core 1264 can be a foam, or packed strands of fibres. The mouthpiece portion 1238 can have a plurality of venting holes 1262 arranged on walls of the consumable 1214 allowing fresh air entering inside the consumable 1214 to achieve particular vaping/tasting effects.

Referring to Figure 12C, the mouthpiece 1260 has a through-hole designed to receive the mouthpiece portion 1238 of the aerosol generating consumable 1214. The through-hole can have the same cross-sectional shape as the aerosol generating consumable 1214 with internal dimensions slightly greater than the external dimensions of the mouthpiece portion 1238 of the aerosol generating consumable 1214. As can be seen, the mouthpiece 1260 fits over the mouthpiece portion 1238 of the aerosol generating consumable 1214 that extends from the heating chamber 1210 so that an opening in the mouthpiece 1260 coincides with the end of the aerosol generating consumable 1214 through which the generated aerosol is drawn when the operator inhales upon the mouthpiece 1260.

In some cases, the consumable 1214 may not include the venting holes 1262; in such cases the air can flow into the consumable 1214 by being drawn in through the abutting end. For example, air can be drawn into the device through a flow inlet 1266 in the mouthpiece 1260, or sidewalls of the device, to counteract a pressure drop caused by the operator inhaling upon the mouthpiece 1260.

Turning to Figure 12B, the heating chamber 1210 can be cup-shaped with an open end 1248 into which the aerosol generating consumable 1214 is inserted, and an opposing sealed end 1250. The heating chamber 1210 receives the heating portion 1239 of the aerosol generating consumable 1214. The heating chamber 1210 has substantially the same cross-sectional shape as the aerosol generating consumable 1214. That is, the heating chamber 1210 can have a substantially rectangular cross section defining a cavity that is substantially cuboidal in shape for receiving the planar aerosol generating consumable 1214.

Walls of the heating chamber 1210 can comprise one or more heating elements of the heater 1208 therein or thereon. Each, or one or more of, the walls of the heating chamber 1210 have a heating element therein or thereon. Walls of the heating chamber 1210 can be ceramic with heater wires or tracks embedded therein or thereon. In an example, the heating elements can be arranged in contact with one of the heating chamber walls outside of the heating chamber 1210. As depicted in the example of Figure 12B, the heating element is arranged on an outer surface of the chamber wall. Likewise, a second heating element can be arranged on an outer surface of the opposing chamber wall (not shown). Thus, the chamber walls transfer heat from the heating elements to the aerosol generating consumable 1214. In other examples, the heating elements can be embedded within the chamber walls. In a further example, the heating elements can be on the chamber walls, internal to the heating chamber 1210. As explained, the chamber walls can be a ceramic material with a heater track or wire therein or thereon. In an alternative, each heating element may comprise a polyimide film heater extending along substantially the total area of the outer surface of the corresponding heating wall or only along a part of this surface.

In a preferable example, the heating chamber 1210 has two major internal faces corresponding to the opposing wider faces of the planar aerosol generating consumable 1214, and two minor internal faces corresponding to the opposing narrower faces of the planar aerosol generating consumable 1214. The minor internal faces can be perpendicular to the major internal faces, and connect the major internal faces. The walls of the heating chamber 1210 corresponding to the major internal faces can be arranged with heater wires or tracks embedded therein or thereon forming two ceramic heaters. In some examples, walls of the heating chamber 1210 corresponding to the minor internal faces can also be ceramic. Such ceramic heaters can provide a compact heating chamber 1210 with well- distributed heat directed to the planar aerosol generating consumable 1214. However, such ceramic heaters can require considerably more power to heat (e.g., »10 W and/or » 1600 J) than the heater of an aerosol generation device that is configured to receive a more traditional cigarette or cigarette-like consumable. Such heaters therefore greatly benefit from the heating power management utilising one or more supercapacitors or high power batteries, as described in herein. In other examples, each of the walls can be of a thermally conductive material, such as a metal, notably a stainless steel. Additionally, at least some of the walls or all of these walls can form one single piece.

The internal dimensions of the heating chamber 1210 can be defined so that an airflow channel is formed between the walls of the heating chamber 1210 and the aerosol generating consumable 1214 when inserted therein. That is, when the heating portion 1239 of the aerosol generating consumable 1214 is inserted in the heating chamber 1210, an airflow channel is formed along the axial length of the consumable 1214. It will be readily understood to the skilled person that the preceding embodiments in the foregoing description are not limiting; features of each embodiment may be incorporated into the other embodiments as appropriate.

In the preceding examples, processing steps described herein carried out by the controller 102 or control electronics may be stored in a non-transitory computer- readable medium, or storage, associated with the respective controller or control electronics. A computer-readable medium can include non-volatile media and volatile media. Volatile media can include semiconductor memories and dynamic memories, amongst others. Non-volatile media can include optical disks and magnetic disks, amongst others.

Claims

1. An aerosol generation device power system, the power system comprising: a first power module; a second power module; a first voltage converter configured to be connected between the first power module and a heater component of an aerosol generation device to step- up a voltage of a power flow from the first power module to the heater component; and a second voltage converter connected between the second power module and the first power module.

2. The aerosol generation device power system of claim 1 , wherein the second voltage converter is controlled with input current control.

3. The aerosol generation device power system of claim 2, wherein the second voltage converter uses the input current control to provide substantially constant power to the heater from each of the second power module and the first power module as a function of voltage of the first power module.

4. The aerosol generation device power system of claim 2 or claim 3, wherein the aerosol generation device power system is connectable to an auxiliary power source, and the input current control at the second voltage converter controls a power flow to the heater from the auxiliary power source for an aerosolisation session.

5. The aerosol generation device power system of any preceding claim, wherein the second power module is configured to recharge the first power module.

6. The aerosol generation device power system of claim 5, wherein the second voltage converter is configured to step-up the voltage of a power flow from the second power module to the first power module when recharging the first power module from the second power module.

7. The aerosol generation device power system of any preceding claim, wherein the first power module is a supercapacitor module comprising one or more supercapacitors, or wherein the first power module is a battery module comprising one or more high power batteries.

8. The aerosol generation device power system of any preceding claim, wherein the second power module is a battery module comprising at least one battery, or wherein the second power module is a supercapacitor module comprising one or more supercapacitors, or wherein the second power module is a supercapacitor module comprising one or more hybrid supercapacitors.

9. An aerosol generation device comprising the aerosol generating device power system of any preceding claim.

10. The aerosol generation device of claim 9, wherein the aerosol generation device comprises a heating chamber that is configured to receive an aerosol generating consumable, and to heat without burning the aerosol generating consumable to generate an aerosol in an aerosolisation session.

11 . The aerosol generation device of claim 10, wherein the heating chamber has a substantially circular cross section, and defines a cavity that is substantially cylindrical in shape for receiving the aerosol generating consumable.

12. The aerosol generation device of claim 11 , wherein the aerosol generating consumable is a tobacco rod.

13. The aerosol generation device of claim 10, wherein the heating chamber has a substantially rectangular cross section, and defines a cavity that is substantially cuboidal in shape for receiving the aerosol generating consumable.

14. The aerosol generation device of claim 13, wherein the aerosol generating consumable is a substantially planar in shape.

15. The aerosol generation device of any one of claims 10 to 14, wherein the aerosol generating consumable comprises tobacco.