WO2025233185A1

WO2025233185A1 - An aerosol generating device

Info

Publication number: WO2025233185A1
Application number: PCT/EP2025/061796
Authority: WO
Inventors: Pier Paolo MONTICONE; Alec WRIGHT
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2024-05-08
Filing date: 2025-04-29
Publication date: 2025-11-13
Anticipated expiration: 2026-11-08

Abstract

An aerosol generating device (10, 120). The aerosol generating device (10, 120) comprises a heating chamber (22) for receiving an aerosol generating substrate. The aerosol generating device (10, 120) further comprises a flow battery (28, 88, 90, 102, 106, 116, 118). The flow battery (28, 88, 90, 102, 106, 116, 118) comprises at least one negative electrolyte reservoir (48) and at least one positive electrolyte reservoir (50). The at least one negative electrolyte reservoir (48) and/or the at least one positive electrolyte reservoir (50) are arranged around the heating chamber (22) to absorb at least a proportion of heat emitted from the heating chamber (22) during heating of an aerosol generating substrate.

Description

AN AEROSOL GENERATING DEVICE

Technical Field

The present disclosure relates generally to an aerosol generating device, and more particularly to an aerosol generating device for heating an aerosol generating substrate to generate an aerosol for inhalation by a user.

Technical Background

The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) has grown rapidly in recent years as an alternative to the use of traditional tobacco products. Various devices and systems are available that heat or warm, rather than bum, an aerosol generating substrate to generate an aerosol for inhalation by a user.

A commonly available reduced-risk or modified-risk device is an aerosol generating device, or so-called heat-not-bum device. Devices of this type generate an aerosol or vapour by heating an aerosol generating substrate, for instance comprised in an aerosol generating article such as a heated tobacco stick, to a temperature typically in the range 150°C to 300°C, in a heating chamber. Heating the aerosol generating substrate to a temperature within this range, without burning or combusting the aerosol generating substrate, generates a vapour which typically cools and condenses to form an aerosol for inhalation by a user of the device.

Inadequate thermal insulation of the heating chamber of an aerosol generating device can lead to decreased heating efficiency of the device by increasing the energy needed to maintain a required operating temperature of the heating chamber. Furthermore, inadequate thermal insulation of the heating chamber of an aerosol generating device can result in an increased temperature of the external casing of the device so that the device can be too hot for a user to comfortably handle.

There is, therefore, a need to provide an aerosol generating device which mitigates these drawbacks. Summary of the Disclosure

According to a first aspect of the present disclosure, there is provided an aerosol generating device comprising: a heating chamber for receiving an aerosol generating substrate; a flow battery comprising at least one negative electrolyte reservoir and at least one positive electrolyte reservoir; wherein the at least one negative electrolyte reservoir and/or the at least one positive electrolyte reservoir are arranged around the heating chamber to absorb at least a proportion of heat emitted from the heating chamber during heating of an aerosol generating substrate.

Possibly, the at least one negative electrolyte reservoir and/or the at least one positive electrolyte reservoir are arranged to at least partially surround the heating chamber.

The absorption of at least a proportion of the heat emitted from the heating chamber by the at least one negative electrolyte reservoir and/or the at least one positive electrolyte reservoir improves thermal insulation of the heating chamber in use. The flow battery is acting as an insulator, wherein the specific heat capacity of the at least one negative electrolyte reservoir and/or the at least one positive electrolyte reservoir limits heat dissipation out of the heating chamber.

In examples of the disclosure, the at least one negative electrolyte reservoir is configured to hold a negative liquid electrolyte (i.e., an anolyte). The at least one positive electrolyte reservoir is configured to hold a positive liquid electrolyte (i.e., a catholyte). Each electrolyte (i.e., anolyte and catholyte) contains dissolved active species (atoms or molecules) that will electrochemically react to release or store electrons.

The negative/positive electrolyte reservoirs have been named because the negative electrolyte reservoir is in fluid communication with the anode side of a half cell (with negative electrode) of the battery and the positive electrolyte reservoir is in fluid communication with the cathode side of a half cell (with positive electrode) of the battery.

Improved thermal insulation of the heating chamber increases the heating efficiency of the device by decreasing the energy needed to maintain a required temperature of the heating chamber. Furthermore, improved thermal insulation of the heating chamber decreases the temperature of the external casing of the device so that the device can be comfortably held by a user. A further benefit is that the overall size of the device can be decreased.

Possibly, the at least one negative electrolyte reservoir and the at least one positive electrolyte reservoir are arranged around the heating chamber to absorb at least a proportion of heat emitted from the heating chamber during heating of an aerosol generating substrate. The at least one negative electrolyte reservoir and the at least one positive electrolyte reservoir may be arranged to at least partially surround the heating chamber.

Thermal insulation of the heating chamber, and thus the heating efficiency of the device, is further improved in examples where the at least one negative electrolyte reservoir and the at least one positive electrolyte reservoir are arranged around the heating chamber.

Possibly, the at least one negative electrolyte reservoir and the at least one positive electrolyte reservoir are arranged on opposite sides of the heating chamber.

Possibly, the heating chamber has a substantially circular cross-section, and the at least one negative electrolyte reservoir and the at least one positive electrolyte reservoir are arranged at substantially diametrically opposite positions around the heating chamber. In other examples, the at least one negative electrolyte reservoir and the at least one positive electrolyte reservoir may be stacked one on top of the other.

In examples of the disclosure, the heating chamber comprises a chamber wall. Possibly, the at least one negative electrolyte reservoir comprises a first reservoir wall and the at least one positive electrolyte reservoir comprises a second reservoir wall. A part of the first reservoir wall and a part of the second reservoir wall may contact the chamber wall. Alternatively, the chamber wall may be formed at least partially by at least part of the first reservoir wall and by at least part of the second reservoir wall. In such examples, there is direct contact between the electrolyte and the chamber wall to improve the insulation properties and further reduce the device size. In examples of the disclosure, the aerosol generating device comprises a device housing. The first reservoir wall and the second reservoir wall may be formed at least partially by the device housing.

Possibly, the at least one negative electrolyte reservoir or the at least one positive electrolyte reservoir are arranged around the heating chamber to absorb at least a proportion of heat emitted from the heating chamber during heating of an aerosol generating substrate. The at least one negative electrolyte reservoir or the at least one positive electrolyte reservoir may be arranged to at least partially surround the heating chamber.

Possibly, the aerosol generating device includes a heater for heating an aerosol generating substrate positioned in the heating chamber and the flow battery is electrically connected to the heater to supply electrical power to the heater.

Brief Description of the Drawings

Figure 1 is a diagrammatic cross-sectional view of an aerosol generating device according to examples of the disclosure;

Figure 2 is a diagrammatic view of another aerosol generating device according to examples of the disclosure;

Figure 3 is another diagrammatic view of the aerosol generating device of Figure 2;

Figure 4 is a simplified diagrammatic cross-sectional view of the flow battery arrangement of the aerosol generating device of Figures 2 and 3;

Figure 5 is a diagrammatic cross-sectional view of an example pump;

Figure 6 is a simplified diagrammatic cross-sectional view of another flow battery arrangement;

Figure 7 is a simplified diagrammatic cross-sectional view of another flow battery arrangement;

Figure 8 is a simplified diagrammatic cross-sectional view of another flow battery arrangement;

Figure 9 is a simplified diagrammatic cross-sectional view of another flow battery arrangement;

Figure 10 is a simplified diagrammatic cross-sectional view of another flow battery arrangement; and Figure 11 is a simplified diagrammatic cross-sectional view of another flow batery arrangement.

Detailed Description of Embodiments

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

Referring to the Figures, there is shown diagrammatically an aerosol generating device 10 according to the present disclosure.

The aerosol generating device 10 is configured to be used with an aerosol generating substrate. In the illustrated example, the aerosol generating substrate is comprised in an aerosol generating article 12. The aerosol generating device 10 and the aerosol generating article 12 together form an aerosol generating system 100.

The aerosol generating device 10 may equally be referred to as a “heated tobacco device”, a “heat-not-bum tobacco device”, a “device for vaporising tobacco products”, and the like, with this being interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices which are designed to vaporise any aerosol generating substrate.

The aerosol generating device 10 is a hand-held, portable, device, by which it is meant that a user is able to hold and support the device unaided, in a single hand. The aerosol generating device 10 has a first (or proximal) end 14 and a second (or distal) end 16 and comprises a device housing 18.

The aerosol generating device 10 comprises a heating assembly 20. The heating assembly 20 further comprises a heating chamber 22. In the illustrated example, the heating chamber 22 is arranged to receive an aerosol generating article 12 comprising the aerosol generating substrate. In some examples, for instance in the illustrated example, the heating chamber 22 has a substantially cylindrical cross-section. The heating chamber 22 defines a cavity. The aerosol generating device 10 includes a controller 24, which may comprise a PCBA 25. The aerosol generating device 10 may include a user interface for controlling the operation of the aerosol generating device 10 via the controller 24.

The controller 24 is configured to detect the initiation of use of the aerosol generating device 10, for example, in response to a user input, such as a button press to activate the aerosol generating device 10, or in response to a detected airflow through the aerosol generating device 10. As will be understood by one of ordinary skill in the art, an airflow through the aerosol generating device 10 is indicative of a user inhalation or ‘puff. The aerosol generating device 10 may, for example, include a puff detector, such as an airflow sensor (not shown), to detect an airflow through the aerosol generating device 10.

The controller 24 includes electronic circuitry. The aerosol generating device 10 includes a power source 26. In examples of the disclosure, the power source 26 is a flow battery 28.

The power source 26 and the electronic circuitry may be configured to operate at a high frequency in the case of an inductively heated vapour generating device 10. For example, the power source 26 and the electronic circuitry may be configured to operate at a frequency of between approximately 80 kHz and 500 kHz, possibly between approximately 150 kHz and 250 kHz, and possibly at approximately 200 kHz. The power source 26 and the electronic circuitry could be configured to operate at a higher frequency, for example in the MHz range, if required.

The heating chamber 22 has a first end 30 and a second end 32. The heating chamber 22 includes an opening 34 at the first end 30, which in the illustrated example is for receiving an aerosol generating article 12. In the illustrated example, the heating chamber 22 includes a chamber wall 36, which may be a substantially cylindrical side wall 36, i.e., a side wall 36 which has a substantially circular cross-section.

The aerosol generating substrate may be any type of solid or semi-solid material. Example types of aerosol generating solids include powder, granules, pellets, shreds, strands, particles, gel, strips, loose leaves, cut leaves, cut filler, porous material, foam material or sheets. The aerosol generating substrate may comprise plant derived material and in particular, may comprise tobacco. It may advantageously comprise reconstituted tobacco. The aerosol generating substrate may be a tobacco plug.

The aerosol generating substrate may comprise an aerosol-former. Examples of aerosolformers include polyhydric alcohols and mixtures thereof such as glycerine or propylene glycol. Typically, the aerosol generating substrate may comprise an aerosol-former content of between approximately 5% and approximately 50% on a dry weight basis. In some example, the aerosol generating substrate may comprise an aerosol-former content of between approximately 10% and approximately 20% on a dry weight basis, and possibly approximately 15% on a dry weight basis.

Upon heating, the aerosol generating substrate may release volatile compounds. The volatile compounds may include nicotine or flavour compounds such as tobacco flavouring.

The shape of the aerosol generating article 12 corresponds to the shape of the heating chamber 22. The aerosol generating article 12 may be generally cylindrical or rod-shaped. The aerosol generating article 12 may be formed substantially in the shape of a stick, and may broadly resemble a cigarette, having a tubular region with an aerosol generating substrate arranged in a suitable manner. The aerosol generating article 12 may be a disposable and replaceable article which may, for example, contain tobacco as the aerosol generating substrate. The aerosol generating article 12 may be a heated tobacco stick. The aerosol generating article 12 is a consumable.

The aerosol generating article 12 has a first end 38 (or mouth end), a second end 40, and comprises a filter 42 at the first end 38. The filter 42 acts as a mouthpiece and may comprise an air-permeable plug, for example comprising cellulose acetate fibres.

The aerosol generating substrate and filter 42 may be circumscribed by a paper wrapper and may, thus, be embodied as an aerosol generating article 12. One or more vapour collection regions, cooling regions, and other structure may also be included in some designs.

To use the aerosol generating device 10, a user inserts an aerosol generating article 12 through the opening 34 into the heating chamber 22, so that the second end 40 of the aerosol generating article 12 is positioned at the second end 32 of the heating chamber 22 and so that the filter 42 at the first end 38 of the aerosol generating article 12 projects from the first end 30 of the heating chamber 22 to permit engagement by a user’s lips.

The heating assembly 22 comprises a heater 44, i.e., a heating element, arranged to heat the aerosol generating substrate of an aerosol generating article 12 received in the heating chamber 22.

The heating assembly 20 may be an induction heating assembly (not shown). The induction heating assembly further comprises an induction coil (not shown). The induction coil is arranged to be energised to generate an alternating electromagnetic field for inductively heating an induction heatable susceptor (not shown). Accordingly, in such examples the heater 44 is an induction heatable susceptor.

The induction heatable susceptor may be arranged around the periphery of the heating chamber 22. Alternatively, the induction heatable susceptor may be arranged to project into the heating chamber 22 from the second end 32 (e.g., as a heating blade or pin) to penetrate the aerosol generating substrate when the aerosol generating article 12 is inserted into the aerosol generating device 10. In other examples, the induction heatable susceptor is instead provided in the aerosol generating substrate during manufacture of the aerosol generating article 12. In such examples, the aerosol generating article 12 comprises the induction heatable susceptor.

The induction coil can be energised by the power source 26 and controller 24. The induction coil may comprise a Litz wire or a Litz cable. It will, however, be understood that other materials could be used.

The induction coil may extend around the heating chamber 22. Accordingly, the induction coil may be annular. The induction coil may be substantially helical in shape. In some examples, the circular cross-section of a helical induction coil may facilitate the insertion of an aerosol generating article 12 and optionally one or more induction heatable susceptors, into the heating chamber 22 and ensure uniform heating of the aerosol generating substrate.

The induction heatable susceptor comprises an electrically conductive material. The induction heatable susceptor may comprise one or more, but not limited to, of graphite, molybdenum, silicon carbide, niobium, aluminium, iron, nickel, nickel containing compounds, titanium, mild steel, stainless steel, low carbon steel and alloys thereof, e.g., nickel chromium or nickel copper, and composites of metallic materials. In some examples, the induction heatable susceptor comprises a metal selected from the group consisting of mild steel, stainless steel, and low carbon stainless steel.

In use, with the application of an electromagnetic field in its vicinity, the induction heatable susceptor(s) generate heat due to eddy currents and magnetic hysteresis losses resulting in a conversion of energy from electromagnetic to heat.

The induction coil may be arranged to operate in use with a fluctuating electromagnetic field having a magnetic flux density of between approximately 20mT and approximately 2.0T at the point of highest concentration.

An alternative approach is to employ a resistive heating assembly (not shown). In such cases, the heater 44 is a resistive heater (not shown). The resistive heater may surround the aerosol generating substrate and transfer heat to an outer surface of the aerosol generating substrate, for instance, the resistive heater may be arranged around the periphery of the heating chamber 22. Alternatively, the resistive heater may be arranged to project into the heating chamber 22 from the second end 32 (e.g., as a heating blade or pin) to penetrate the aerosol generating substrate when the aerosol generating article 12 is inserted into the aerosol generating device 10. In use, current from the power supply 26 is supplied directly to the resistive heater to generate heat.

In use, heat from the heater 44 (i.e., induction heatable susceptor or resistive heater) is transferred to the aerosol generating substrate of an aerosol generating article 12 positioned in the heating chamber 22, for example by conduction, radiation and convection, to heat the aerosol generating substrate (without burning the aerosol generating substrate) and thereby generate a vapour which cools and condenses to form an aerosol for inhalation by a user of the aerosol generating device 10, for instance, through the filter 42. The vaporisation of the aerosol generating substrate is facilitated by the addition of air from the surrounding environment, e.g., through an air inlet (not shown).

In general terms, a vapour is a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms ‘aerosol’ and ‘vapour’ may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.

The aerosol generating device 10 further comprises a lid 46 configured to be moveable by a user to open and close the heating chamber 22. The lid 46 is a closure member. The lid 46 protects the heating chamber 22 when the aerosol generating device 10 is not in use. In the illustrated example, the lid 46 is slidably moveable by a user to open and close the heating chamber 22. In such examples, the lid 46 is a slider.

The lid 46 is moveable relative to the opening 34 between a closed position in which the lid 46 covers the opening 34, and an open position in which the opening 34 is unobstructed by the lid 46. In the open position, the opening 34 is unobstructed and an aerosol generating article 12 is receivable in the heating chamber 22.

The flow battery 28 comprises at least one negative electrolyte reservoir 48 and at least one positive electrolyte reservoir 50. The terms ‘negative electrolyte reservoir’ and ‘positive electrolyte reservoir’ are intended to cover all types and arrangements of liquid electrolyte batteries.

In some examples, the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 are arranged around the heating chamber 22 to absorb at least a proportion of the heat emitted from the heating chamber 22 during heating of an aerosol generating substrate. Such an arrangement is shown in Figures 1 to 4 and 6 to 9.

Accordingly, the reservoirs 48, 50 of the flow battery 28 are arranged to absorb at least a proportion of the heat (to act as an insulating element) generated during use of the aerosol generating device 10.

In examples of the disclosure, the power source 26 (i.e., flow battery 28) and heating chamber 22 are therefore arranged within the aerosol generating device 10 such that the power source 26 receives at least a part of heat emitted from the heating chamber 22 so that the power source 26 can act as an insulation element. The absorption of at least a proportion of heat emitted from the heating chamber 22 by the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 improves thermal insulation of the heating chamber 22 in use. The flow battery 28 is acting as an insulator, wherein the specific heat capacity of the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 limits heat dissipation out of the heating chamber 22.

In some examples, heat is mainly absorbed by the liquid electrolyte contained in the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50. In general terms, the specific heat capacity for a solid is typically a few hundred J/(kg °C), and for a liquid is typically a few thousand J/ (kg °C). Accordingly, a liquid material (such as the electrolyte in examples of the disclosure) is a better insulator than a solid material.

Improved thermal insulation of the heating chamber 22 increases the heating efficiency of the device 10 by decreasing the energy needed to maintain a required temperature of the heating chamber 22. Furthermore, improved thermal insulation of the heating chamber 22 decreases the temperature of the device housing (i.e., external casing 18) of the device 10 so that the device 10 can be comfortably held by a user. A further benefit is that the overall size of the device 10 can be decreased.

The at least one negative electrolyte reservoir 48 is configured to hold a negative liquid electrolyte (i.e., an anolyte). The at least one positive electrolyte reservoir 50 is configured to hold a positive liquid electrolyte (i.e., a catholyte).

In some examples of the disclosure, the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 are tanks.

Each electrolyte (i.e., anolyte and catholyte) contains dissolved active species (atoms or molecules) that will electrochemically react to release or store electrons. The negative liquid electrolyte (anolyte) and/or positive liquid electrolyte (catholyte) may comprise nanoparticles (e.g., nanofluids) to increase the energy density of the system, for example, achieving an energy density of at least about 400 watt-hours per kilogram. The use of nanoparticles (e.g., nanofluids) in the electrolytes allows an increased concentration within the aqueous solvent without increasing viscosity and without agglomeration taking place. In some examples, a surface of the nanoparticles is modified or treated to anchor an organic ion to form a self-suspended nanoelectrofuel. The anchor may be a silane, a phosphate a carboxylate or a thiol. The nanoparticles may have a metallic component. The nanoparticles may be between 1-500 nm. The nanoparticles may be suspended in an aqueous solution comprising a salt and/or a polar solvent.

Without being bound by theory, the treatment to a surface of the nanoparticles prevents agglomeration, allowing concentrations up to 60% volume fraction and with it a high energy density, e.g., of 620 watt-hours per kilogram.

A flow battery 28 according to examples of the disclosure can operate from -40°C to 80°C and therefore has a larger temperature threshold and less temperature-sensitivity than Li-ion batteries. This increases the operating freedom of an aerosol generating device 10 comprising a flow battery 28. Energy generation is also improved because the reaction rate (as well as the rate of diffusion of active species) is enhanced with temperature. This means that heat received by the flow battery 28 also contributes to good energy generation.

Furthermore, operating a Li-ion battery outside of its temperature range can cause significant safety concerns with the effects of thermal degradation of a Li-ion battery well reported. A flow battery 28 according to examples of the disclosure is therefore significantly safer and with no shorting possible between electrolyte solutions. This improves performance under drop tests, and if the device 10 is pierced with a sharp object, there is almost no risk from the direct effects on the user.

Figures 2 and 3 show another example aerosol generating device 120. The aerosol generating device 120 is similar to the aerosol generating device 10 described above and corresponding components are identified using the same reference numerals.

Referring to Figures 2 and 3, the flow battery 28 of the aerosol generating device 120 is illustrated in more detail. A simplified view of the flow battery 28 is shown in Figure 4 where only selected features of the flow battery 28 are shown. In the illustrated example, the negative electrolyte reservoir 48 comprises a charged electrolyte repository 52 and a discharged electrolyte repository 54. The positive electrolyte reservoir 50 also comprises a charged electrolyte repository 56 and a discharged electrolyte repository 58. Accordingly, the negative and positive electrolyte reservoirs 48, 50 each respectively comprise a charged electrolyte repository 52, 56 and a discharged electrolyte repository 54, 58.

In the example of Figures 2 to 4, each of the respective charged electrolyte repositories 52, 56 and discharged electrolyte repositories 54, 58 are separate and discrete tanks. Accordingly, the flow battery 28 of the aerosol generating device 120 of Figures 2 and 3 comprises four separate and discrete tanks. The four separate and discrete tanks are the charged electrolyte repository 52 of the negative electrolyte reservoir 48, the discharged electrolyte repository 54 of the negative electrolyte reservoir 48, the charged electrolyte repository 56 of the positive electrolyte reservoir 50, and the discharged electrolyte repository 58 of the positive electrolyte reservoir 50.

In the illustrated example (and as most clearly shown in Figure 4), the charged electrolyte repository 52 and the discharged electrolyte repository 54 of the negative electrolyte reservoir 48 are horizontally aligned either side of the heating chamber 22. The charged electrolyte repository 56 and the discharged electrolyte repository 58 of the positive electrolyte reservoir 50 are horizontally aligned either side of the heating chamber 22.

In the illustrated example, the flow battery 28 comprises respective pumps 60, 62 to circulate the two electrolytes (i.e., the anolyte and catholyte) through a fuel cell 64 via conduits 66, 68, 70, 72.

In the example illustrated in Figures 2 to 4, the at least one negative electrolyte reservoir 48 is associated with the pump 60 (anolyte pump 60) and conduits 66 and 68 (anolyte conduits 66, 68). The at least one positive electrolyte reservoir 50 is associated with the other pump 62 (catholyte pump 62) and conduits 70, 72 (catholyte conduits 70, 72).

During discharge of the flow battery 28, anolyte held in the charged electrolyte repository 52 of the negative electrolyte reservoir 48 is pumped into the fuel cell 64 through conduit 66 and pumped out of the fuel cell 64 through conduit 68 to the discharged electrolyte repository 54 of the negative electrolyte reservoir 48 by action of the anolyte pump 60. Concomitantly, catholyte held in the charged electrolyte repository 56 of the positive electrolyte reservoir 50 is pumped into the fuel cell 64 through conduit 70 and pumped out of the fuel cell 64 through conduit 72 to the discharged electrolyte repository 58 of the positive electrolyte reservoir 50 by action of the catholyte pump 62.

Accordingly, during discharge (i.e. , heating), electrolyte held in the respective charged electrolyte repositories 52, 56 is circulated through the fuel cell 64 to the discharged electrolyte repositories 54, 58.

The pumps 60, 62 can be endless screw, flexible membranes, piezoelectric or peristaltic, based on a plunger or spinning mechanics, or mems/electro-magnetic.

An example pump 60, 62 is illustrated in Figure 5. The pump of Figure 5 comprises a pair of drive coils 74, a diaphragm 76 with an embedded magnet 78, and a pump chamber 80 with an inlet port 82 and an outlet port 84. Respective valves 86 are associated with the inlet and outlet ports 82, 84 to control the flow of electrolyte into and out of the pump chamber 80.

In some examples, the fuel cell 64 comprises an anode and a cathode (not shown) separated by an ion exchange membrane. In use, when the flow battery 28 is being discharged, the anolyte is oxidised at the anode and the catholyte is reduced at the cathode. Oxidation of the anolyte releases electrons that flow through an external circuit to the cathode causing the catholyte to be reduced. The flow of these electrons through the external circuit provides a current which can power the heater 44. Accordingly, the flow battery 28 is electrically connected to the heater 44 to supply electrical power to the heater 44.

In addition to the movement of the electrons, supporting ions (other charged species in the electrolyte) pass through the ion exchange membrane to complete the reaction and keep the system electrically neutral. Electricity is therefore generated from a chemical reductionoxidation (redox) process.

During discharge (i.e., in heating mode), the pumps 60, 62 can be provided with power via the fuel cell 64 or via a secondary energy source (not shown) such as a Li-ion battery, capacitor or supercapacitor. In some examples, a secondary energy source initiates the pumps 60, 62. The pumps 60, 62 are subsequently powered by the fuel cell 64 after initiation. In some (non-limiting) examples, an example fuel cell 64 can use a solution containing lithium ions and surface modified metallic nanoparticles configured to support electrochemical reactions on a working/ counter electrode when the nanoparticles are contacted to the electrode.

In some examples, the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 can also be arranged around other internal components of the device 10, 120 such as the PCBA 25, to thermally insulate such internal components.

As described above, the flow battery 28 of the example of Figures 2 to 4 comprises four separate and discrete tanks. In other examples, the flow battery 28 may have a different number of separate and discrete tanks and/or a different arrangement, as described below with reference to Figures 6 to 9. With regard to Figures 6 to 9, only selected features of the flow batteries 28, 88, 90, 102, 106 are illustrated. In each case, the heating chamber 22 of the aerosol generating device 10, 120 is shown to provide context and orientation of the illustrated component parts of the respective flow batteries 28, 88, 90, 102, 106.

Figure 6 shows the arrangement of another flow battery 88. The flow battery 88 is similar to the flow battery 28 described above and corresponding components are identified using the same reference numerals.

In the example shown in Figure 6, the flow battery 88 comprises four separate and discrete tanks similar to the flow battery 28 of Figures 2 to 4.

The only difference between the flow battery 88 arrangement of Figure 6 and the flow battery 28 arrangement of Figures 2 to 4 is that the charged electrolyte repository 52 and the discharged electrolyte repository 54 of the negative electrolyte reservoir 48 are vertically aligned on one side of the heating chamber 22. The charged electrolyte repository 56 and the discharged electrolyte repository 58 of the positive electrolyte reservoir 50 are vertically aligned on the other side of the heating chamber 22.

Figure 7 shows the arrangement of another flow battery 90. The flow battery 90 is similar to the flow batteries 28, 88 described above and corresponding components are identified using the same reference numerals. With reference to Figure 7, the flow battery 90 comprise an anolyte tank 92 and a catholyte tank 94, wherein the anolyte tank 92 and catholyte tank 94 are separate and discrete tanks. Accordingly, the flow battery 90 comprises two separate and discrete tanks 92, 94 (rather than four separate and discrete tanks).

The anolyte tank 92 comprises the at least one negative electrolyte reservoir 48 and the catholyte tank 94 comprises the at least one positive electrolyte reservoir 50. The anolyte tank comprises a partition 96 separating the charged electrolyte repository 52 and the discharged electrolyte repository 54 of the negative electrolyte reservoir 48. The catholyte tank 94 comprises a partition 98 separating the charged electrolyte repository 56 and the discharged electrolyte repository 58 of the positive electrolyte reservoir 50. The partitions 96, 98 may be a moveable.

Accordingly, the respective charged electrolyte repositories 52, 56 and the discharged electrolyte repositories 54, 58 are separated by partitions 96, 98, which partitions may be moveable.

The respective moveable partitions 96, 98 permit a change in volume of the charged electrolyte repositories 52, 56 and the discharged electrolyte repositories 54, 58 according to whether the flow battery 90 is discharging or being charged. This makes the most efficient use of space by eliminating the possibility of air pockets forming as a fluid is depleted in a respective reservoir.

The moveable partitions 96, 98 maintain a seal between the respective charged electrolyte repositories 52, 56 and the discharged electrolyte repositories 54, 58. The moveable partitions 96, 98 may be driven by a pressure change caused by the action of the respective anolyte and catholyte pumps 60, 62 (not shown in Figure 7).

Figure 8 shows the arrangement of another flow battery 102. The flow battery 102 is similar to the flow batteries 28, 88, 90 described above and corresponding components are identified using the same reference numerals.

With reference to Figure 8, the flow battery 102 comprises an anolyte tank 92 and a catholyte tank 94, wherein the anolyte tank 92 and catholyte tank 94 are separate and discrete tanks (as per the example of Figure 7). The only difference between the flow battery 102 of Figure 8 and the flow battery 90 of Figure 7 is that the two electrolytes (i.e., the anolyte and catholyte) are circulated through the fuel cell 64 (not shown) via conduits 66, 68, 70, 72 (not shown) by at least one motor 104 acting on respective moveable partitions 96, 98 associated with the anolyte and catholyte tanks 92, 94. In such examples, separate pumps 60, 62, as described in relation to Figures 2 to 7 above, are not required. In such examples, the at least one motor 104 drives the respective moveable partitions 96, 98 to change the volume of the charged electrolyte repositories 52, 56 and the discharged electrolyte repositories 54, 58 according to whether the flow battery 102 is discharging or being charged. The action of the at least one motor 104 moves electrolyte through the fuel cell 64 (not shown) between the respective charged electrolyte repositories 52, 56 and the discharged electrolyte repositories 54, 58.

The at least one motor 104 can drive the moveable partitions 96, 98 by using an actuator or by rotating a screw. There can be separate motors 104 for each of the anolyte and catholyte tanks 92, 94, each motor 104 respectively acting on the moveable partition 96, 98 associated with that tank 92, 94. Alternatively, there can be a single motor 104 acting on the moveable partitions 96, 98 in each of the anolyte and catholyte tanks (i.e., the moveable partitions 96, 98 in both tank 92, 94 are driven by the same motor 104). If different flow rates are required this can be adjusted by gearing in the motor(s) 104, adjusting the cross-section of the tanks 92, 94, or changing the pitch of the screw.

Figure 9 shows the arrangement of another flow battery 106. The flow battery 106 is similar to the flow batteries 28, 88, 90, 102 described above and corresponding components are identified using the same reference numerals.

With reference to Figure 9, the flow battery 106 comprises an anolyte tank 92 and a catholyte tank 94, wherein the anolyte tank 92 and catholyte tank 94 are separate and discrete tanks (as per the example of Figures 7 and 8).

With regard to the flow battery 106, the respective charged electrolyte repositories 52, 56 and the discharged electrolyte repositories 54, 58 are comprised in separate and discrete bladders 108a, 108b, 108c, 108d within the anolyte and catholyte tanks 92, 94. The bladders 108a-d are configured to contract and expand according to the direction of flow of electrolyte (i.e., anolyte and catholyte) caused by the action of the respective anolyte and catholyte pumps 60, 62 (not shown). For instance, as electrolyte (i.e., anolyte) is pumped from one bladder 108a, that bladder 108a contracts whilst the bladder 108b to which the electrolyte (i.e., anolyte) is being pumped expands.

Referring again to Figure 1 in particular, the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 are arranged to at least partially surround the heating chamber 22.

In some examples, the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 are arranged on opposite sides of the heating chamber 22.

As described above, in some examples the heating chamber 22 has a substantially circular cross-section. The at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 can be arranged at substantially diametrically opposite positions around the heating chamber 22. In other examples, the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 can be stacked one on top of the other.

In examples of the disclosure, the heating chamber 22 comprises a chamber wall 36 (as described above). The at least one negative electrolyte reservoir 48 comprises a first reservoir wall 110 and the at least one positive electrolyte reservoir 50 comprises a second reservoir wall 112.

In some examples, a part of the first reservoir wall 110 and a part of the second reservoir wall 112 contact the chamber wall 36. In such examples, the negative and positive electrolyte reservoirs 48, 50 are separate components from the chamber wall 36 of the heating chamber 22.

In other examples, the chamber wall 36 of the heating chamber 22 is formed at least partially by at least part of the first reservoir wall 110 and by at least part of the second reservoir wall 112. In such examples, there is direct contact between the electrolyte and the chamber wall 36 to improve the insulation properties and further reduce the device size. Accordingly, the external surface of the heating chamber 22 may also be the internal walls (i. e. , first and second reservoir walls 110, 112) of the at least one negative electrolyte reservoir 48 and/or the at least one positive electrolyte reservoir 50. This allows direct contact between the electrolyte and the in use hot walls 110, 112 of the heating chamber 22 to improve the insulation properties and potentially to further reduce the overall size of the device 10.

In examples of the disclosure, the aerosol generating device 10 comprises a device housing 18, i.e., a body (as described above). In some examples, the first reservoir wall 110 and the second reservoir wall 112 are formed at least partially by the device housing 18. Accordingly, the body of the aerosol generating device (device housing 18) can also define part of the reservoir walls 110, 112.

In such examples, the device housing 18 provides the first reservoir wall 110 and the second reservoir wall 112 so that all internal components of the device, e.g., PCBA 25, heating chamber 22, etc. are contacting electrolyte. According, in such examples the device housing 18 is acting as the anolyte and catholyte tanks 92, 94. Such an arrangement permits the exploitation of any cube millimetre of free space existing in a device 10, e.g., in between PCB- mounted components.

Examples of the disclosure therefore permit the design of smaller devices 10 and/or longer battery duration due to the higher energy density of the energy storage, i.e., power source 26. Such devices 10 are safer because there are no risk of explosion or combustion as with conventional batteries. Smaller devices 10 have the best form factor because the liquid electrolyte of a flow battery can fill and fit any shape, contrary to conventional batteries that are either cylindrical or rectangular.

Figure 10 shows the arrangement of another flow battery 116. The flow battery 116 is similar to the flow batteries 28, 88, 90, 102, 106 described above and corresponding components are identified using the same reference numerals.

With reference to Figure 10, the flow battery 116 comprises at least one negative electrolyte reservoir 48 and at least one positive electrolyte reservoir 50, as per the flow batteries 28, 88, 90, 102, 106 described above. However, only the negative electrolyte reservoir 48 is arranged around the heating chamber 22 to absorb at least a proportion of heat emitted from the heating chamber 22 during heating of an aerosol generating substrate. The negative electrolyte reservoir 48 can be arranged to at least partially surround the heating chamber 22. The positive electrolyte reservoir 50 (which is not shown in the drawing) is not arranged around the heating chamber 22.

Figure 11 shows the arrangement of another flow battery 118. The flow battery 118 is similar to the flow batteries 28, 88, 90, 102, 106, 116 described above and corresponding components are identified using the same reference numerals.

With reference to Figure 11, and as per the flow batteries 28, 88, 90, 102, 106, 116 described above, the flow battery 118 comprises at least one negative electrolyte reservoir 48 and at least one positive electrolyte reservoir 50. However, only the positive electrolyte reservoir 50 is arranged around the heating chamber 22 to absorb at least a proportion of heat emitted from the heating chamber 22 during heating of an aerosol generating substrate. The positive electrolyte reservoir 50 can be arranged to at least partially surround the heating chamber 22. The negative electrolyte reservoir 48 (which is not shown in the drawing) is not arranged around the heating chamber 22.

Accordingly, in examples of the disclosure the at least one negative electrolyte reservoir 48 and/or the at least one positive electrolyte reservoir 50 are arranged around the heating chamber 22. In other words, either or both of the at least one negative electrolyte reservoir 48 and the at least one positive electrolyte reservoir 50 are arranged around the heating chamber 22.

In such examples, the at least one negative electrolyte reservoir 48 and/or the at least one positive electrolyte reservoir 50 can also be arranged around other internal components of the device 10, 120 such as the PCBA 25, to thermally insulate such internal components.

Referring to all the flow batteries 28, 88, 90, 102, 106, 116, 118 described above, once all the species have reacted and the flow battery 28, 88, 90, 102, 106, 116, 118 is fully discharged, the system can be recharged. In some examples, the flow battery 28, 88, 90, 102, 106, 116, 118 can be re-charged (i.e., charged) by providing an external power supply to the device, for example, via a USB-C connection 114 (as shown in Figures 1 to 3). The pumps 60, 62 are driven by the power supply in a direction opposite to during discharge to move the discharged electrolyte back from the discharged electrolyte repositories 54, 58 to the charged electrolyte repositories 52, 56 through the internal fuel cell 64.

Alternatively, the discharged electrolyte repositories 54, 58 can be replenished with charged electrolyte via liquid mass transfer from an external body in the form of a charger module (not shown), rather than via the internal fuel cell 64 as described above.

The charger module may be a handheld charging unit to create a combo-style vape device or docking station charger. In some examples, the charger module also has fuel cell arranged only to charge electrolyte. Power is provided to the fuel cell via an external USB-C cable. Liquid mass transfer of electrolyte takes place via a fluid transfer port. The fluid transfer port may be duck bill valves, ball lunge valves, deform valves or syringe valves.

The Figures also illustrate a method of manufacturing an aerosol generating device 10, 120 according to examples of the disclosure. The Figures also illustrate a method of providing an aerosol generating system 100 according to examples of the disclosure.

Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications may be made to those embodiments without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

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

Claims

1. An aerosol generating device (10, 120) comprising: a heating chamber (22) for receiving an aerosol generating substrate; a flow battery (28, 88, 90, 102, 106, 116, 118) comprising at least one negative electrolyte reservoir (48) and at least one positive electrolyte reservoir (50); wherein the at least one negative electrolyte reservoir (48) and/or the at least one positive electrolyte reservoir (50) are arranged around the heating chamber (22) to absorb at least a proportion of heat emitted from the heating chamber (22) during heating of an aerosol generating substrate.

2. An aerosol generating device according to claim 1, wherein the at least one negative electrolyte reservoir (48) and/or the at least one positive electrolyte reservoir (50) are arranged to at least partially surround the heating chamber (22).

3. An aerosol generating device according to claim 1, wherein the at least one negative electrolyte reservoir (48) and the at least one positive electrolyte reservoir (50) are arranged around the heating chamber (22) to absorb at least a proportion of heat emitted from the heating chamber (22) during heating of an aerosol generating substrate.

4. An aerosol generating device according to claim 3, wherein the at least one negative electrolyte reservoir (48) and the at least one positive electrolyte reservoir (50) are arranged to at least partially surround the heating chamber (22).

5. An aerosol generating device according to claim 3 or 4, wherein the at least one negative electrolyte reservoir (48) and the at least one positive electrolyte reservoir (50) are arranged on opposite sides of the heating chamber (22).

6. An aerosol generating device according to any of claims 3 to 5, wherein the heating chamber (22) has a substantially circular cross-section, and the at least one negative electrolyte reservoir (48) and the at least one positive electrolyte reservoir (50) are arranged at substantially diametrically opposite positions around the heating chamber (22).

7. An aerosol generating device according to any of claims 3 to 6, wherein the heating chamber (22) comprises a chamber wall (36), the at least one negative electrolyte reservoir (48) comprises a first reservoir wall (110) and the at least one positive electrolyte reservoir (50) comprises a second reservoir wall (112).

8. An aerosol generating device according to claim 7, wherein a part of the first reservoir wall (110) and a part of the second reservoir wall (112) contact the chamber wall (36).

9. An aerosol generating device according to claim 7, wherein the chamber wall (36) is formed at least partially by at least part of the first reservoir wall (110) and by at least part of the second reservoir wall (112).

10. An aerosol generating device according to any of claims 7 to 9, wherein the aerosol generating device (10) comprises a device housing (18), and wherein the first reservoir wall (110) and the second reservoir wall (112) are formed at least partially by the device housing (18).

11. An aerosol generating device according to claim 1, wherein the at least one negative electrolyte reservoir (48) or the at least one positive electrolyte reservoir (50) is arranged around the heating chamber (22) to absorb at least a proportion of heat emitted from the heating chamber (22) during heating of an aerosol generating substrate.

12. An aerosol generating device according to claim 11, wherein the at least one negative electrolyte reservoir (48) or the at least one positive electrolyte reservoir (50) is arranged to at least partially surround the heating chamber (22).

13. An aerosol generating device according to any preceding claim, wherein the aerosol generating device (10, 120) includes a heater (44) for heating an aerosol generating substrate positioned in the heating chamber (22) and the flow battery (28, 88, 90, 102, 106, 116, 118) is electrically connected to the heater (44) to supply electrical power to the heater (44).