RU2842805C2 - Aerosol-generating device with battery with plurality of contact taps - Google Patents

Abstract

FIELD: aerosol-generating devices.

SUBSTANCE: invention relates to an aerosol-generating device with a battery for supplying power for heating. Aerosol-generating device comprises a battery with a cathode-anode unit. Cathode and anode of cathode-anode unit are wound around longitudinal direction with formation of multiple turns. At least one of cathode and anode is equipped with at least two contact taps, which are located at some distance from each other. Besides, number of contact taps is less than number of turns.

EFFECT: increasing the energy capacity and volumetric energy density of the battery of a compact aerosol generating device.

14 cl, 11 dwg

Description

The present invention relates to an aerosol generating device with a battery for supplying power for heating. The present invention also relates to a method of operating the aerosol generating device and the use of the aerosol generating device with a battery with an increased discharge capacity.

Known portable electric smoking systems typically include an aerosol generating device that includes a battery, control electronics, and an electric heating element for heating an aerosol generating article that is designed specifically for use with the aerosol generating device. In some examples, the aerosol generating article includes an aerosol generating substrate, such as a tobacco rod or tobacco plug, and a heating element contained within the aerosol generating device is inserted into the aerosol generating substrate or is located around it when the aerosol generating article is inserted into the aerosol generating device. In an alternative electric smoking system, the aerosol generating article may include a capsule that includes an aerosol generating substrate, such as loose tobacco.

In some aerosol generating devices, prior art uses batteries with a single contact lead to ensure compactness. However, the time required to heat the substrate that forms the aerosol is relatively long, since the flow of electric current is limited to a single contact lead. Increasing the flow of electric current would lead to rapid wear of the battery. As a result, either slow heating or inaccurate temperature control results in a weakened user experience or a shortened battery life.

It would be advantageous to provide the aerosol generating device with a battery that is capable of supplying a significant amount of electrical energy in a short time and is small enough to be used in a very compact aerosol generating device.

According to the first aspect of the invention, an aerosol generating device is proposed, which comprises a battery, wherein the battery is designed with the possibility of supplying power for heating. The battery comprises a cathode-anode unit. The cathode-anode unit comprises a cathode and an anode. At least one of the cathode and the anode is provided with at least two contact leads. These at least two contact leads can be located at a distance from each other.

In general, the contact leads in the battery are located on the anode or cathode, providing a flow of electric current to or from the anode or cathode. The contact leads can be made as a single unit with the anode or cathode or attached directly to the anode or cathode. These at least two contact leads allow a significant amount of electric power to be supplied in a short time in order to quickly heat the heating element to the operating temperature. These at least two contact leads allow a loss of temperature that occurs during the intermittent formation of the aerosol to be quickly compensated for. The battery, however, can be compact.

The battery may have an energy capacity in the range of at least 1600 joules to 2400 joules, in particular from 1800 joules to 2200 joules. The energy capacity of the battery may be limited by a given number of intermittent aerosol generating actions. In particular, the energy capacity of the battery may be adapted to ensure at least 2, preferably from 2 to 5, in particular from 2 to 3 aerosol generating cycles with one full battery charge. An aerosol generating cycle corresponds to the consumption of the aerosol generating article by the aerosol generating device. Each aerosol generating cycle may include from at least 5 to no more than 30, preferably from at least 7 to no more than 20 intermittent aerosol generating actions, namely puffs, performed by the consumer. The aerosol generating device may be adapted to perform only the specified number or the specified maximum number of aerosol generating actions, either by signaling the consumer that an aerosol generating cycle has been completed, or by supplying power only for aerosol generating actions that do not exceed the specified number or the specified maximum number of aerosol generating actions.

In particular, the distance between these at least two contact leads is a continuation of the cathode or anode between these at least two contact leads. These at least two contact leads can be made with the possibility of transmitting power from the battery to the electrical circuit of the aerosol generating device. These at least two contact leads can be made with the possibility of transmitting power from an external voltage source to the battery. These at least two contact leads can be made of a material having electrically conductive properties, in particular of a metal or metal alloys, more specifically of copper or aluminum.

To generate the aerosol, power may be taken from a battery and supplied to the heating element via an electronic power supply circuit containing a controller. The controller may be adapted so that power is supplied to the heating element only when the temperature of the heating element or the substrate forming the aerosol falls below a threshold value.

The use of at least two contact leads allows the electrons to travel a shorter distance along the cathode or anode before reaching the contact leads. Therefore, compared with a design that provides for one contact lead, the discharge capacity of the battery is higher. At low polarization, even with high current loads, a significant amount of electrical energy can be generated in a short time, which is what is required for the discharge heating pulse.

The main direction of the battery extension, namely the direction in which the battery has the greatest length, may be the longitudinal direction. The transverse direction may be perpendicular to the longitudinal direction. In the vertical orientation of the aerosol-generating device or battery, the longitudinal direction may be the height direction, and the transverse direction may be the horizontal direction. The transverse direction may be perpendicular to the width direction of the aerosol-generating device or battery. Any such subsequent indications as "upper", "top", "lower" and "bottom" refer to the longitudinal direction being the height direction.

The aerosol generating device may be portable. Its longest side may be less than 20 cm, less than 15 cm, or less than 10 cm. Its longest side may be more than 5 centimeters.

The battery may be a lithium iron phosphate (LFP) battery, wherein the battery cathode comprises LFP. Additionally or alternatively, the cathode may comprise nickel manganese cobalt oxide (NMC), lithium cobalt oxide (LCO), nickel cobalt aluminum oxide (NCA), or any combination thereof.

The contact leads can be located at the edge of the cathode. All contact leads can be located at the same edge of the cathode.

In particular, the cathode-anode block additionally contains a separator. The separator is located between the cathode and the anode. The separator may contain a polymer.

The battery may comprise a cap. The cap may provide an output for an electrical circuit of the aerosol generating device. The cap may have an end cap wall and a side cap wall. The cap may be electrically connected to the contact leads of the cathode or anode.

The battery may comprise a shell. The shell may provide a cavity for a cathode-anode unit. The cathode-anode unit may be completely located in the shell. The shell may provide an output for an electrical circuit of an aerosol generating device.

The shell may comprise a shell side wall and a shell end wall. The shell end wall may be electrically connected to the shell side wall. The shell side wall surface may be larger than the cap side wall. The shell side wall may be cylindrical.

The cap can be isolated from the shell.

The shell can be electrically connected to the anode.

These at least two cathode contact leads may be attached to the cap. The cap may be electrically connected to the cathode.

At least two of these anode contact leads may be attached to the shell.

The battery, in particular, has a housing. The housing, in particular, contains a shell and a cap for closing the shell.

These at least two contact leads can be folded and attached, in particular welded or soldered, to the cap.

These at least two contact leads or more than two contact leads may form a stack of overlapping contact leads. The stack may be formed from overlapping contact leads in layers. The stack may be laid in the longitudinal direction.

Preferably, the battery is a roll battery. The cathode and anode of the cathode-anode unit may be made in the form of a roll having a plurality of turns. The cathode and anode may be wound in the longitudinal direction to form a roll. Alternatively, the cathode and anode of the cathode-anode unit may form a cell in the form of a package.

The cathode and the anode may be wound in the longitudinal direction to form a plurality of turns. If necessary, at least one of the cathode and the anode may be provided with contact leads in a quantity smaller than the number of turns. This may reduce the height of the stack compared to batteries having a contact lead in each turn and provide more space for the cathode and the anode. This may increase the energy capacity and volumetric energy density of the battery.

The plurality of turns may have a height of from 11 millimeters to 110 millimeters, preferably from 25 millimeters to 45 millimeters, in particular from 37 millimeters to 39 millimeters.

The plurality of turns may have a diameter from 5 millimeters to 20 millimeters, in particular from 8 millimeters to 13 millimeters, in particular less than 10.5 millimeters.

The plurality of turns can be cylindrical in shape.

The plurality of turns may be prismatic in shape. This may increase the outer surface of the plurality of turns and thus reduce the generation of heat inside the battery.

The battery may contain carbonate-based electrolytes.

The cathode-anode block or battery may be from 11 millimeters to 110 millimeters high, preferably from 25 millimeters to 45 millimeters, in particular from 37 millimeters to 39 millimeters.

The cathode-anode block or battery may have a diameter from 5 millimeters to 20 millimeters, in particular from 8 millimeters to 13 millimeters, in particular less than 10.5 millimeters.

At least one of the cathode and the anode may be provided with only one contact lead for at least 2, at least 5 or at least 15 turns. At least one of the cathode and the anode may be provided with at least one contact lead for 30, 25 or 15 turns.

At least one of the cathode and the anode may be provided with at least three contact leads.

At least one of the cathode and the anode may be provided with contact leads in a quantity of from two to eight, in particular contact leads in a quantity of from two to five, more specifically contact leads in a quantity of from two to four.

At least two or three contact leads may be provided on the cathode.

Both the cathode and the anode may be provided with at least two or three contact leads. Alternatively, both the cathode and the anode may be provided with four contact leads.

The cathode contact leads and the anode contact leads may be provided on opposite sides of the battery. The cathode contact leads and the anode contact leads may extend from opposite longitudinal end surfaces of the cathode-anode block.

In the case where exactly two contact leads are provided on the cathode or the anode or on both the cathode and the anode, the distance between the contact leads of the anode may be from 330 millimeters to 480 millimeters, preferably from 380 millimeters to 480 millimeters, in particular from 430 millimeters to 480 millimeters. The distance between the contact leads of the cathode may be from 200 millimeters to 400 millimeters, preferably from 250 millimeters to 350 millimeters, in particular from 280 millimeters to 320 millimeters. It is preferable that the two contact leads are located at opposite ends of one edge of the anode or cathode, in particular at the two horizontal ends of the anode or cathode.

In the case where exactly three contact leads are provided on the cathode or the anode or on both the cathode and the anode, the distance between the contact leads of the anode may be from 165 millimeters to 240 millimeters, preferably from 190 millimeters to 240 millimeters, in particular from 215 millimeters to 240 millimeters. The distance between the contact leads of the cathode may be from 100 millimeters to 200 millimeters, preferably from 125 millimeters to 175 millimeters, in particular from 140 millimeters to 160 millimeters. It is preferable that two of the three contact leads are located at opposite ends of one edge of the anode or cathode, and one contact lead is located between two contact leads on the same edge. In particular, the contact leads are located at two horizontal ends and in the middle of the anode or cathode.

In the case where exactly four contact leads are provided on the cathode or the anode or on both the cathode and the anode, the distance between the contact leads of the anode may be from 110 millimeters to 160 millimeters, preferably from 125 millimeters to 160 millimeters, in particular from 143 millimeters to 160 millimeters. The distance between the contact leads of the cathode may be from 65 millimeters to 130 millimeters, preferably from 85 millimeters to 115 millimeters, in particular from 92 millimeters to 107 millimeters.

If more than two contact leads are provided on the anode or cathode, two contact leads are located at opposite ends of one edge of the anode or cathode, and subsequent contact leads are located between two contact leads on the same edge.

The width of the contact leads may be from 1 millimeter to 5 millimeters, preferably from 2 millimeters to 4 millimeters, in particular from 3 millimeters to 4 millimeters.

In particular, the cathode comprises a cathode current collector and a cathode active material. In particular, the anode comprises an anode current collector and an anode active material.

The cathode may be formed from a multilayer sheet material comprising a layer of a cathode current collector and a layer of a cathode active material. The layer of the cathode active material may be a coating on one side of the cathode current collector. The thickness of the coating forming the layer of the cathode active material may be from 30 micrometers to 60 micrometers, preferably from 40 micrometers to 50 micrometers. This thickness range may prevent a reduction in service life, while allowing high discharge currents of above 1, 2 or 3 amperes to be maintained during heating. This thickness range may provide energy to maintain two consecutive aerosol generation cycles, each of which provides for 7 to 18 puffs taken by the consumer. The aerosol generation cycle may require battery power of at least 700 joules and less than 1500 joules, in particular at least 900 joules, more particularly approximately 1000 joules.

The anode can be formed from a multilayer sheet material comprising a layer of anode current collector and a layer of anode active material. The layer of anode active material can be a coating on one of the sides of the anode current collector. The thickness of the coating forming the layer of anode active material can be from 20 micrometers to 50 micrometers, preferably from 25 micrometers to 40 micrometers. This thickness range can prevent a reduction in service life, while allowing the charging current values to be maintained at a level of from 1 ampere to 2 amperes, preferably about 1.6 amperes. This thickness range can maintain a stable and uniform coating.

At least one of the anode and the cathode may comprise a conductive region and a non-conductive region extending in the horizontal direction of the multilayer sheet material. The horizontal direction may correspond to the main direction of the extension of the multilayer sheet material, namely the direction in which the multilayer sheet material has the greatest length in the unfolded state.

The conductive region may comprise a region with active material and a region without active material. The non-conductive region may be provided with adhesive tape to fix the position of the cathode-anode unit.

The length of the conductive region of the anode may be from 350 millimeters to 500 millimeters, preferably from 400 millimeters to 500 millimeters, in particular from 450 millimeters to 500 millimeters. The width of the conductive region of the anode may be from 25 millimeters to 40 millimeters, preferably from 30 millimeters to 40 millimeters, in particular from 30 millimeters to 35 millimeters.

The length of the conductive region of the cathode may be from 350 millimeters to 450 millimeters, preferably from 375 millimeters to 450 millimeters, in particular from 400 millimeters to 450 millimeters. The width of the conductive region of the cathode may be from 25 millimeters to 40 millimeters, preferably from 30 millimeters to 40 millimeters, in particular from 30 millimeters to 35 millimeters.

These at least two contact leads can be made as a single unit with the cathode current collector. These at least two contact leads can be made as a single unit with the anode current collector. These at least two contact leads can be made as a single unit with at least one of the cathode current collector and the anode current collector. This can reduce the electrical resistance between the contact leads and the current collector. At least one of the cathode current collector and the anode current collector can be formed by cutting.

The cathode active material layer may comprise lithium iron phosphate LiFePO4 (LFP). Alternatively, the cathode active material layer may comprise nickel manganese cobalt oxides (NCM). The use of cathodes with LFP may improve the cyclic stability of the battery and thus the service life of the aerosol generating device, especially compared to batteries with NCM. Compared to other cathode materials, such as NCM, cathodes with LFP may have low conductivity. Therefore, the use of at least two contact leads on the cathode with LFP may increase the capacity of the battery even more significantly than the use of at least two contact leads on the cathode with NCM.

The anode active material layer may comprise graphite, silicon and/or lithium titanate oxide (LTO).

At least one of the at least two contact leads can be attached to the cathode current collector, in particular by means of ultrasonic or resistance welding.

At least one of these at least two contact leads may be attached to the anode current collector, in particular by means of ultrasonic or resistance welding. This at least one contact lead attached to the anode current collector may be made of nickel. This at least one contact lead attached to the cathode current collector may be made of aluminum.

The contact leads can be rectangular, trapezoidal or needle-shaped. This can reduce the height of the stack of contact leads compared to the height of the stack of rectangular contact leads. More space can be left for the cathode-anode unit. This can increase the energy capacity and volumetric energy density of the battery. The contact leads of the needle shape can have increased mechanical strength. Thus, the durability of the contact leads when stacked can be increased.

The contact leads may extend from the cathode or anode toward the periphery of the battery. This may reduce the stack height compared to the stack height of batteries whose contact leads are bent toward the center of the battery, and provide more space for the cathode-anode assembly. This may increase the energy capacity and volumetric energy density of the battery.

The contact leads can extend from the cathode or anode towards the center of the battery.

Contact leads can be trapezoidal in shape and bent inward.

Contact leads can be trapezoidal or rectangular in shape and bent outward.

Contact leads can be needle-shaped and bent outward or inward.

It is preferable that the contact leads are needle-shaped. The needle-shaped form increases the mechanical strength of the contact leads. Thus, the probability of breakage of the contact leads, especially when folding, can be reduced.

Preferably, the cathode contact leads are at least one of the following: rectangular in shape and bent outward in the direction from the center of the battery, trapezoidal in shape and bent inward in the direction from the center of the battery, trapezoidal in shape and bent outward in the direction from the center of the battery, needle-shaped and bent inward in the direction from the center of the battery, or needle-shaped and bent outward in the direction from the center of the battery.

Alternatively or additionally, the anode contact leads may be at least one of the following: rectangular in shape and bent inward toward the center of the battery, or trapezoidal in shape and bent inward toward the center of the battery.

The battery may be provided with an electrically conductive structure with connection ports intended for contact leads. The electrically conductive structure makes it easier to connect the contact leads to the battery terminals. In particular, this makes it easier to assemble relatively small batteries. The electrically conductive structure may allow the contact leads to be attached to the connection ports rather than to the cap. This may avoid the formation of a stack of contact leads and provide more space for the cathode-anode unit. This may increase the energy capacity and volumetric energy density of the battery. In addition, attaching the contact leads to the electrically conductive structure makes it possible to reduce the number of bends and bending angles of the contact leads. This may reduce the risk of breakage of the contact leads during their bending.

The conductive structure may span the distance in the longitudinal direction between the cathode or anode and the battery terminal. The conductive structure may have a longitudinal projection of 2 millimeters to 8 millimeters.

The terminal may be located on the battery cap, electrically isolated from the battery shell.

The conductive structure may provide parallel electrical connection of the contact leads. The conductive structure may connect the contact leads of the cathode.

Attaching the contact leads to the connection ports may involve soldering or welding.

The conductive structure may comprise a non-conductive structure designed to insulate the contact leads from the battery terminal. The terminal may provide an electrical potential different from the electrical potential of the contact leads.

The conductive structure may be secured to the longitudinal end surface of the cathode-anode block. Preferably, the conductive structure is hermetically secured to the shell so that the position of the battery is fixed through its longitudinal end surface. Prior art batteries have a thinned portion for fixing the position of the cathode-anode block. Fastening the conductive structure to the longitudinal end surface of the cathode-anode block may eliminate the need for such a thinned portion. More space remains for the cathode-anode block. This may increase the energy capacity and volumetric energy density of the battery.

The connection ports of the conductive structure may be holes for placing contact leads. The holes may be in the form of cutouts or grooves.

The size and shape of the holes may correspond to the size and shape of the contact leads. Round holes may be provided when using needle-shaped contact leads. Slots may be provided when using trapezoidal or rectangular contact leads.

The cathode contact leads may be provided on the conductive structure, representing at least one of the following: being rectangular in shape and bent outward in the direction from the center of the battery, trapezoidal in shape and bent inward in the direction from the center of the battery, trapezoidal in shape and bent outward in the direction from the center of the battery, needle-shaped and bent inward in the direction from the center of the battery, or needle-shaped and bent outward in the direction from the center of the battery.

Alternatively or additionally, the anode contact leads may be provided on the conductive structure, being at least one of the following: rectangular in shape and bent inward toward the center of the battery, or trapezoidal in shape and bent inward toward the center of the battery.

The aerosol generating device may further comprise a means for generating the aerosol, in particular a heating element. The means for generating the aerosol or the heating element may have an electrical connection to the battery.

The heating element may be an induction coil.

The heating element may be an electrically resistive heating means.

The aerosol generating device may further comprise an electronic power supply circuit. The electronic power supply circuit may be adapted to supply power from a battery for the purpose of heating. The electronic power supply circuit may be an electrical circuit of the aerosol generating device. The electronic power supply circuit may control the power supplied to the heating element.

The power supply electronic circuit may contain a power converter. The power converter may be electrically connected to the battery terminals.

The power converter may comprise a DC-to-AC converter or a DC-to-DC converter.

The aerosol generating device may further comprise a sensor for obtaining a heating temperature. The heating temperature may indicate the temperature of the heating element or the substrate forming the aerosol.

The aerosol generating device may further comprise a control device adapted to control the electronic circuit of the power supply for supplying power from the battery for the purpose of heating. The control device may comprise a controller in the form of a microcontroller, a field programmable gate array (FPGA) or an application-specific integrated circuit (ASIC).

The control device can be operatively connected to a sensor for obtaining the heating temperature and a power converter in a configuration with a feedback loop.

The controller may be configured to receive a feedback signal from a sensor indicating a heating temperature and to control the power converter in response to the received feedback signal in order to obtain power from the battery.

The control device may comprise a two-position controller. In particular, the two-position controller is adapted to be switched on when the feedback signal is below a lower threshold value and switched off when the feedback signal exceeds a higher threshold value. The control device may be part of the electronic circuit of the power supply.

The aerosol generating device may further comprise a means for accommodating an aerosol generating article. The means for accommodating an aerosol generating article is adapted for accommodating the aerosol generating article. The means for accommodating an aerosol generating article may be a cavity.

According to a second aspect of the invention, an aerosol generating system may be provided, comprising an aerosol generating device according to the first aspect of the invention. The aerosol generating system may also comprise an aerosol generating article.

An aerosol generating product may contain a current collector.

An aerosol-generating article may contain an aerosol-generating substrate.

The aerosol generating substrate may be made from aerosol generating sheet material.

The aerosol generating sheet material may be corrugated, folded or cut.

The current collector can be embedded in the aerosol generating substrate.

According to a third aspect of the present invention, a method for producing a battery for an aerosol generating device may be provided. The method may include the step of providing a cathode-anode unit comprising one or more contact leads on a longitudinal end surface of the cathode-anode unit. The method may also include the step of arranging an electrically conductive structure on the longitudinal end surface of the cathode-anode unit so that one or more contact leads contact (contact) one or more connection ports of the electrically conductive structure.

The provided cathode-anode block may contain at least two contact leads on the longitudinal end surface.

The step of providing the cathode-anode block may include the step of cutting the layer of the cathode or anode current collector to obtain one or more contact leads. The step of providing the cathode-anode block may further include the step of winding the cathode-anode block with the cut cathode or anode current collector around the longitudinal axis to form a roll.

The conductive structure may be located on the longitudinal end surface of the cathode-anode block in such a way that the conductive structure is completely located inside the battery.

The step of arranging the conductive structure may include the step of passing one or more contact leads through one or more corresponding openings forming one or more ports of the conductive structure.

The step of arranging the conductive structure may include the step of attaching the conductive structure to the shell. The conductive structure may be hermetically attached to the shell.

It is preferable that the needle-shaped contact leads are provided and pass through the holes. The mechanical strength of the needle-shaped contact leads can allow the contact leads to pass through the holes easily.

The method may further include the step of arranging the cathode-anode unit and the conductive structure in the shell. The method may further include the step of closing the shell with a cap. The cap may be electrically connected to one or more contact leads by means of the conductive structure and may be electrically isolated from the shell.

The capping step may additionally include fastening the conductive structure to the cap, in particular by soldering, ultrasonic or resistance welding.

The step of arranging the conductive structure may include the step of bending one or more contact leads in the direction of the conductive structure. The step of arranging the conductive structure may further include fastening one or more contact leads to the conductive structure, in particular by soldering, ultrasonic or resistance welding.

According to the fourth aspect of the invention, an aerosol generating device may be provided, comprising a battery. The battery may be configured to supply power for heating. The battery comprises a cathode-anode unit, wherein the cathode-anode unit may be provided with one or more contact leads on the longitudinal end surface of the cathode-anode unit. The battery may additionally comprise an electrically conductive structure. The electrically conductive structure may be placed on the longitudinal end surface of the cathode-anode unit and may comprise one or more connection ports for one or more contact leads. One or more connection ports may contact one or more contact leads.

The conductive structure may span the distance in the longitudinal direction between the cathode-anode block and the battery terminal.

The conductive structure may have a longitudinal protrusion from 3 millimeters to 8 millimeters.

The conductive structure may comprise a pad and a connector.

The pad may have a peripheral section corresponding to the inner edge of the battery shell.

The platform can be located on the longitudinal end surface of the cathode-anode block.

The platform can be made of a conductive structure and a non-conductive structure.

The conductive structure may comprise one or more connection ports in the form of one or more cutouts for receiving one or more contact leads. The one or more openings may be cutouts. In other examples, one or more slots may be provided. The size and shape of the one or more openings may complement the size and shape of the one or more contact leads. The conductive structure of the pad may be made of one or more metals such as iron, copper, aluminum, and nickel; most preferably, nickel.

The non-conductive structure may be formed in a peripheral section of the conductive structure in such a way that the conductive structure is electrically isolated from the shell. The pad may be attached to the shell in such a way that the cathode-anode unit is fixed in a longitudinal position relative to the shell.

The thickness of the pad may be from 0.05 millimeters to 0.5 millimeters, preferably from 0.1 millimeters to 0.2 millimeters.

A connector may be provided between the platform and the battery cap. The connector may span the distance in the longitudinal direction between the cathode-anode block and the cap.

The connector may comprise a conductive structure for electrically connecting the contact leads to the cap and a non-conductive structure for insulating the conductive material from the shell.

The conductive structure of the connector may have three connector sections, wherein at least one of the first connector section and the second connector section may be connected to the third connector section at an angle of 60 to 120 degrees, preferably 80 to 100 degrees. The first connector section and the second connector section may extend in the same transverse direction.

The first section of the connector may be attached to the cap. The second section of the connector may be attached to the conductive structure of the pad. The conductive structure of the connector may be made of one or more metals such as iron, copper, aluminum and nickel, most preferably aluminum or nickel.

Below are examples of contact tap designs in the case of contact tap attachment to an electrically conductive structure.

The contact lead may project in the vertical direction to a height of 1 millimeter to 5 millimeters, preferably 2 millimeters to 4 millimeters. The contact lead projecting in the height direction may correspond to the length of a portion of one or more contact leads extending from the layer of the anode or cathode current collector in the height direction.

If there is one or more rectangular contact leads, the width of the contact lead may be from 1 millimeter to 5 millimeters, preferably from 2 millimeters to 4 millimeters, in particular from 3 millimeters to 4 millimeters. The thickness of the one or more rectangular contact leads may be approximately 0.1 millimeter.

If there is one or more trapezoidal contact leads, the width of the contact lead on the side of the current collector may be from 1 millimeter to 5 millimeters, preferably from 2 millimeters to 4 millimeters, in particular from 3 millimeters to 4 millimeters. The width of the contact lead on the far side may be from 1 millimeter to 4.5 millimeters, preferably from 1 millimeter to 3.5 millimeters, in particular from 1 millimeter to 2.5 millimeters. The thickness of the one or more trapezoidal contact leads may be about 0.1 millimeters. The far side may correspond to the side of the contact lead with the greatest distance to the current collector in the height direction.

If there is one or more needle-shaped contact leads, the diameter of the one or more contact leads may be from 0.5 millimetres to 3 millimetres, preferably from 0.5 millimetres to 2 millimetres, in particular from 0.5 millimetres to 1 millimetre.

According to a fifth aspect of the invention, a method is proposed for operating an aerosol generating device, comprising the step of determining whether a consumer requests the supply of an aerosol, and supplying power from a battery to the aerosol generating means through at least two contact leads in the battery, wherein the contact leads are arranged in parallel in an electrical circuit of which the battery is a part.

These at least two contact leads may be connected to or provided on the cathode of the battery. These at least two contact leads may be connected to or provided on the anode of the battery. The at least two contact leads may be connected to or provided on both the cathode and the anode of the battery.

The step of determining whether the consumer requests delivery of an aerosol may include determining whether the consumer applies a pressure lower than the ambient pressure to the mouthpiece of the aerosol generating device.

The step of supplying power from the battery to the aerosol generating means via at least two battery terminals may provide for consuming a discharge current from the battery only after the heating temperature has dropped below a threshold level. In particular, the threshold level is preset; preferably stored in the memory of the aerosol generating device.

The consumed discharge current may be a pulse current that has at least one on-cycle and at least one off-cycle.

The duration of at least one of the on-cycle and the off-cycle may be from 0.5 seconds to 4 seconds, preferably from 0.75 seconds to 2 seconds, in particular approximately 1 second.

The duration of at least one of the on-cycle and the off-cycle may be from 0.01 seconds to 3 seconds, preferably from 0.1 seconds to 2 seconds, in particular approximately 0.3 seconds. It is preferable that the on-cycle and the off-cycle have substantially the same duration.

The peak value of the discharge current may be from 2 to 5 amperes, preferably from 2.5 amperes to 4 amperes, in particular approximately 3.15 amperes.

The method can be carried out, at least in part, by a control device of an aerosol generating device.

According to a sixth aspect of the invention, it is envisaged to use at least two contact leads provided on the cathode or anode in the aerosol generating device for the purpose of increasing the discharge capacity of the battery for intermittent heating.

Battery power can only be consumed after the heating element temperature drops below the threshold level.

The aerosol generating device according to the first or fourth aspect of the invention and the system according to the second aspect of the invention can operate according to the method of the fifth aspect of the invention.

The aerosol generating device according to the first or fourth aspect of the invention and the system according to the second aspect of the invention can be manufactured according to the method of the third aspect of the invention.

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

Example Ex1. An aerosol generating device comprising a battery, wherein the battery is configured to supply power for heating, wherein the battery comprises a cathode-anode unit, wherein the cathode-anode unit comprises a cathode and an anode, wherein at least one of the cathode and anode is provided with at least two contact leads, wherein these at least two contact leads are located at a distance from each other.

Example Ex2. An aerosol generating device according to example Ex1, wherein the battery has an energy capacity in the range of at least 1600 joules to 2400 joules, in particular from 1800 joules to 2200 joules.

Example Ex3. An aerosol generating device according to any of the examples Ex1-Ex2, wherein the aerosol generating device is portable.

Example Ex4. An aerosol generating device according to any of examples Ex1-Ex3, wherein the battery is a lithium iron phosphate battery.

Example Ex5. An aerosol generating device according to any of the examples Ex1 to Ex4, wherein the contact leads are located at the edge of the cathode.

Example Ex6. An aerosol generating device according to any of the examples Ex1-Ex5, wherein the battery further comprises a separator, wherein the separator is located between the cathode and the anode.

Example Ex7. An aerosol generating device according to any of the examples Ex1 to Ex6, wherein the battery comprises a cap, wherein the cap is provided with a terminal for the electrical circuit of the aerosol generating device.

Example Ex8. An aerosol generating device according to example Ex7, wherein the cap is electrically connected to the contact leads of the cathode or anode.

Example Ex9. An aerosol generating device according to any of the examples Ex7-Ex8, wherein the battery further comprises a shell, wherein the shell comprises a cavity for a cathode-anode unit, and wherein the shell is provided with a terminal for an electrical circuit of the aerosol generating device.

Example Ex10. An aerosol generating device according to example Ex9, wherein the casing comprises a casing side wall and a casing end wall, wherein the casing end wall is electrically connected to the casing side wall.

Example Ex11. An aerosol generating device according to any of the examples Ex9 to Ex10, wherein the cap is electrically insulated from the enclosure.

Example Ex12. An aerosol generating device according to any of the examples Ex9-Ex11, wherein the cathode contact leads are attached to the cap.

Example Ex13. An aerosol generating device according to any of the examples Ex9-Ex12, wherein the anode contact leads are attached to the shell. Example Ex14. An aerosol generating device according to any of the examples Ex1-Ex13, wherein these at least two contact leads or more than two contact leads form a stack of overlapping contact leads.

Example Ex15. An aerosol generating device according to any of the examples Ex1-Ex14, wherein the cathode and the anode are wound in the longitudinal direction to form a plurality of turns, wherein the number of contact leads is less than the number of turns.

Example Ex16. An aerosol generating device according to example Ex15, wherein the height of the plurality of turns is from 11 millimetres to 110 millimetres, preferably from 25 millimetres to 45 millimetres, in particular from 37 millimetres to 39 millimetres.

Example Ex17. An aerosol generating device according to any of examples Ex15-Ex16, wherein the diameter of the plurality of turns is from 5 millimetres to 20 millimetres, in particular from 8 millimetres to 13 millimetres, in particular less than 10.5 millimetres.

Example Ex18. An aerosol generating device according to any of examples Ex15-Ex17, wherein the plurality of turns have a cylindrical shape.

Example Ex19. An aerosol generating device according to any of examples Ex15-Ex17, wherein the plurality of turns have a prismatic shape.

Example Ex20. An aerosol generating device according to any of the examples Ex1-Ex19, wherein there is only one contact lead per at least 2 turns, at least 5 turns or at least 15 turns.

Example Ex21. An aerosol generating device according to any of the examples Ex1-Ex20, wherein at least one of the cathode and the anode is provided with at least three contact leads.

Example Ex22. An aerosol generating device according to any of the examples Ex1-Ex20, in which at least two or three contact leads are provided on the cathode.

Example Ex23. An aerosol generating device according to any of the examples Ex1-Ex20, wherein both the cathode and the anode are provided with at least two or at least three contact leads.

Example Ex24. An aerosol generating device according to any of the examples Ex1-Ex23, wherein the cathode contact leads and the anode contact leads are located on opposite sides of the battery.

Example Ex25. An aerosol generating device according to any of the examples Ex1-E24, wherein the cathode is formed from a multilayer sheet material comprising

cathode current collector layer and

layer of cathode active material,

wherein the layer of cathode active material is a coating on one side of the cathode current collector, wherein the thickness of the coating forming the layer of cathode active material is from 30 micrometers to 60 micrometers, preferably from 40 micrometers to 50 micrometers.

Example Ex26. An aerosol generating device according to example Ex25, wherein the anode is formed from a multilayer sheet material comprising a layer of anode current collector and a layer of anode active material, wherein the layer of anode active material is a coating on one of the sides of the anode current collector, wherein the thickness of the coating forming the layer of anode active material is from 20 micrometers to 50 micrometers, preferably from 25 micrometers to 40 micrometers.

Example Ex27. An aerosol generating device according to any of the examples Ex25-Ex26, in which at least one of the at least two contact leads is formed as a single unit with the cathode current collector.

Example Ex28. An aerosol generating device according to any of the examples Ex26-Ex27, in which at least one of the at least two contact leads is formed as a single unit with the anode current collector.

Example Ex29. An aerosol generating device according to any of examples Ex25-Ex28, wherein the cathode active material layer comprises lithium iron phosphate (LiFePO4).

Example Ex30. An aerosol generating device according to any of the examples Ex25-Ex29, in which at least one of the at least two contact leads is attached to the cathode current collector, in particular by means of ultrasonic or resistance welding.

Example Ex31. An aerosol generating device according to any of the examples Ex26-Ex30, in which at least one of the at least two contact leads is attached to the anode current collector, in particular by means of ultrasonic or resistance welding.

Example Ex32. An aerosol generating device according to any of the examples Ex1-Ex31, wherein the contact leads have a rectangular, trapezoidal or needle shape.

Example Ex33. An aerosol generating device according to any of the examples Ex1-Ex32, in which the contact leads extend from the cathode or the anode in the direction of the periphery of the battery.

Example Ex34. An aerosol generating device according to any of the examples Ex1-Ex33, wherein the cathode contact leads are at least one of the following:

have a rectangular shape and are bent outward in the direction from the center of the battery;

have a trapezoidal shape and are bent inward towards the center of the battery;

have a trapezoidal shape and are bent outward in the direction from the center of the battery;

have a needle-like shape and are bent inward towards the center of the battery;

have a needle-like shape and are bent outward in the direction from the center of the battery.

Example Ex35. An aerosol generating device according to any of the examples Ex1-Ex34, wherein the anode contact leads are at least one of the following:

have a rectangular shape and are bent inward towards the center of the battery;

have a trapezoidal shape and are bent inward towards the center of the battery.

Example Ex36. An aerosol generating device according to any of the examples Ex1-Ex35, wherein the battery further comprises an electrically conductive structure with connection ports for contact leads.

Example Ex37. An aerosol generating device according to example Ex36, in which the conductive structure spans the distance in the longitudinal direction between the cathode or anode and the battery terminal.

Example Ex38. An aerosol generating device according to any of examples Ex36-Ex37, wherein the terminal is located on the battery cap, wherein the cap is electrically isolated from the battery shell.

Example Ex39. An aerosol generating device according to any of examples Ex36-Ex38, wherein the electrically conductive structure comprises a non-conductive structure intended to insulate the contact leads from the battery terminal, wherein the terminal provides an electrical potential different from the electrical potential of the contact leads.

Example Ex40. An aerosol generating device according to any of examples Ex36-Ex39, wherein the electrically conductive structure provides parallel electrical connection of the contact leads.

Example Ex41. An aerosol generating device according to any of the examples Ex36-Ex40, in which the connecting ports of the conductive structure are openings for receiving contact leads, in particular cutouts or grooves.

Example Ex42. An aerosol generating device according to any of the examples Ex1-Ex41, further comprising a means for generating an aerosol, in particular a heating element, wherein the means for generating an aerosol is electrically connected to a battery.

Example Ex43. An aerosol generating device according to example Ex42, wherein the heating element is an induction coil.

Example Ex44. An aerosol generating device according to example Ex42, wherein the heating element is an electrically resistive heating means.

Example Ex45. An aerosol generating device according to any of the examples Ex1-Ex44, further comprising an electronic power supply circuit, wherein the electronic power supply circuit is adapted to supply power from a battery for the purpose of heating.

Example Ex46. An aerosol generating device according to example Ex45, in which the electronic circuit of the power supply unit comprises a power converter electrically connected to the terminals of the battery.

Example Ex47. An aerosol generating device according to example Ex46, wherein the power converter comprises a DC-to-AC converter or a DC-to-DC converter.

Example Ex48. An aerosol generating device according to any of the examples Ex1-Ex47, further comprising a control device, wherein this control device is adapted to control the electronic circuit of the power supply for supplying power from the battery for the purpose of heating.

Example Ex49. An aerosol generating device according to any of the examples Ex1-Ex48, further comprising a sensor for obtaining a heating temperature, where the heating temperature indicates the temperature of the heating element.

Example Ex50. An aerosol generating device according to any of examples Ex1-Ex49, further comprising a means for accommodating an aerosol generating article, wherein the means for accommodating an aerosol generating article is adapted to accommodate the aerosol generating article.

Example Ex51. An aerosol generating device according to example Ex50, wherein the means for accommodating the aerosol generating article is a cavity.

Example Ex52. An aerosol generating system comprising an aerosol generating device according to any of the examples Ex1-Ex51, and also an aerosol generating article.

Example Ex53. An aerosol generating system according to example Ex52, wherein the aerosol generating article comprises a current collector.

Example Ex54. An aerosol generating system according to any of examples Ex52-Ex53, wherein the aerosol generating article comprises an aerosol generating substrate.

Example Ex55. An aerosol generating system according to example Ex54, wherein the aerosol generating substrate is made of an aerosol generating sheet material.

Example Ex56. An aerosol generating system according to example Ex55, wherein the aerosol generating sheet material is corrugated, folded or cut.

Example Ex57. An aerosol generating system according to example Ex53, in which the current collector is integrated into the aerosol generating substrate.

Example Ex58. A method for producing a battery for an aerosol generating device, which comprises the following steps:

providing a cathode-anode block containing one or more contact leads on a longitudinal end surface of the cathode-anode block;

arranging the conductive structure on the longitudinal end surface of the cathode-anode block in such a way that one or more contact leads contact one or more connecting ports of the conductive structure.

Example Ex59. The method according to example Ex58, in which a cathode-anode block is provided, which contains at least two contact leads on the longitudinal end surface.

Example Ex60. The method according to any of examples Ex58-Ex59, wherein the step of providing a cathode-anode unit comprises the following steps:

cutting a layer of the cathode or anode current collector to obtain one or more contact leads; and

winding of a cathode-anode block with a cut cathode or anode current collector around the longitudinal axis to form a roll.

Example Ex61. The method according to any of examples Ex58-Ex60, in which the conductive structure is located on the longitudinal end surface of the cathode-anode block in such a way that the conductive structure is completely located inside the battery.

Example Ex62. The method according to any of examples Ex58-Ex61, wherein the step of arranging the conductive structure includes the step of one or more contact leads passing through one or more corresponding openings, to form one or more ports of the conductive structure.

Example Ex63. A method according to any of the examples Ex58-Ex62, additionally comprising the following steps:

the location of the cathode-anode block and the conductive structure in the shell;

closing the shell with a cap,

wherein the cap is electrically connected to one or more contact leads by means of an electrically conductive structure and is electrically insulated from the shell.

Example Ex64. The method according to example Ex63, in which the step of closing with a cap further comprises fastening the conductive structure to the cap, in particular by soldering, ultrasonic or resistance welding.

Example Ex65. The method according to any of the examples Ex58-Ex64, wherein the step of arranging the conductive structure comprises the following steps:

bending one or more contact leads in the direction of the conductive structure; and

fastening one or more contact leads to an electrically conductive structure, in particular by soldering, ultrasonic or resistance welding.

Example Ex66. An aerosol generating device comprising

battery,

wherein the battery is configured to supply power for heating,

the battery contains

cathode-anode block,

wherein the cathode-anode block is provided with one or more contact leads on the longitudinal end surface of the cathode-anode block, and

conductive structure,

wherein the electrically conductive structure is located on the longitudinal end surface of the cathode-anode block,

wherein the conductive structure comprises one or more connecting ports for one or more contact leads,

wherein one or more connection ports are in contact with one or more contact leads.

Example Ex67. An aerosol generating device according to example Ex66, in which the electrically conductive structure spans the distance in the longitudinal direction between the cathode-anode unit and the battery terminal.

Example Ex68. An aerosol generating device according to any of examples Ex66-Ex67, wherein the conductive structure has a longitudinal projection of 2 millimeters to 8 millimeters

Example Ex69. A method for operating an aerosol generating device comprising the following steps: determining whether a consumer has requested the supply of an aerosol; supplying power from a battery to the aerosol generating means through at least two contact leads in the battery, wherein the contact leads are arranged parallel to an electrical circuit of which the battery is a part.

Example Ex70. The method according to example Ex69, in which the step of determining whether the consumer requests the supply of an aerosol comprises determining whether the consumer applies a pressure lower than the ambient pressure to the mouthpiece of the aerosol generating device.

Example Ex71. The method according to any of examples Ex69-Ex70, in which the step of supplying power from the battery to the aerosol generating means through these at least two battery terminals comprises consuming current from the battery only after the heating temperature falls below a threshold level.

Example Ex72. The method according to any of the examples Ex69-E71, wherein the discharge current is a pulse current that has at least one on-cycle and at least one off-cycle.

Example Ex73. The method according to example Ex72, wherein the duration of at least one of the on-cycle and the off-cycle can be from 0.01 seconds to 3 seconds, preferably from 0.1 seconds to 2 seconds, in particular approximately 0.3 seconds.

Example Ex74. The method according to any of the examples Ex72-Ex73, wherein the on-cycle and the off-cycle have substantially the same duration.

Example Ex75. The method according to any of the examples Ex71-E73, wherein the peak value of the discharge current is from 2 to 5 amperes, preferably from 2.5 amperes to 4 amperes, in particular approximately 3.15 amperes.

Example Ex76. The use of at least two contact leads provided on the cathode or anode in an aerosol generating device for the purpose of increasing the discharge capacity of a battery for intermittent heating.

Example Ex77: Application according to example Ex76, in which power from the battery is only consumed after the temperature of the heating element has fallen below the threshold level.

Below, the examples will be further described with reference to the figures.

Fig. 1 shows a schematic cross-sectional view of an embodiment of an aerosol generating system with an aerosol generating device according to an embodiment of the invention.

Fig. 2 shows a schematic perspective view of the cathode-anode unit used in the first embodiment of the aerosol generating device according to Fig. 1.

Fig. 3 shows a schematic partial perspective view of the cathode and anode of the cathode-anode unit according to Fig. 2 in an unfolded state.

Fig. 4 shows a schematic top view of an unfolded cathode current collector with a plurality of contact leads that can be used in the cathode-anode unit according to Fig. 2 and Fig. 3.

Fig. 5 shows a schematic perspective view of a battery for a second embodiment of the aerosol generating system according to Fig. 1.

Fig. 6 shows a schematic perspective view of a cathode-anode unit used in a third embodiment of the aerosol generating device according to Fig. 1.

Fig. 7 is a schematic perspective view of a cathode-anode assembly used in a fourth embodiment of the aerosol generating device according to Fig. 1.

Fig. 8 shows a schematic perspective view of a cathode-anode unit used in a fifth embodiment of the aerosol generating device according to Fig. 1.

Fig. 9 is a schematic perspective view of a cathode-anode unit used in a sixth embodiment of the aerosol generating device according to Fig. 1.

Fig. 10 is a schematic perspective view of a battery for a seventh embodiment of the aerosol generating device of Fig. 1.

Fig. 11 is a schematic perspective view of a battery for an eighth embodiment of the aerosol generating device according to Fig. 1.

Fig. 1 schematically shows an embodiment of an aerosol generating system 1. The system 1 comprises an aerosol generating device 2 according to an embodiment of the invention, and an aerosol generating article 3 for use with the aerosol generating device 2. The aerosol generating article 3 comprises an aerosol generating substrate 9 that is to be heated to form an inhalable aerosol.

The aerosol-generating article 3 is a consumable article in the form of a rod, containing four elements sequentially aligned coaxially: a segment 4 of the aerosol-generating rod, a support element 5 containing a central air passage, an element 6 cooling the aerosol, and a mouthpiece element 7 containing a filter. The segment 4 of the aerosol-generating rod is located at the far end of the article 3 and contains a current collector 8 in the form of a strip and a substrate 9 to be heated, forming the aerosol. The mouthpiece element 7 is located at the near end of the article 3, allowing the user to puff through it. The support element 5 and the element 6 cooling the aerosol are located between them. Each of these four elements is a substantially cylindrical element, while they all have substantially the same diameter. The four elements are surrounded by an outer wrapper 10 in order to hold these four elements together and to maintain the required circular cross-sectional shape of the rod-shaped article 3. It is preferable that the wrapper 10 is made of paper.

The aerosol generating device 2 comprises a cylindrical containing cavity formed inside the proximal part 1 of the device 2 for accommodating at least the distal part of the article 3 therein. The device 2 further comprises a heating element 11 comprising an inductor for generating an alternating high-frequency magnetic field. In the present embodiment, the inductor is a helical coil surrounding the cylindrical containing cavity along the circumference. In alternative embodiments, the heating element may be an electroresistive heating means. The coil is arranged so that the current collector 8 of the aerosol generating article 3 is exposed to the alternating magnetic field when the article 3 is coupled to the device 2. Thus, when the heating element 11 is activated, the current collector 8 is heated due to eddy currents and hysteresis losses, which are caused by the alternating magnetic field in the current collector 8, depending on the magnetic and electrical properties of its material. The current collector 8 is heated until it reaches a working temperature sufficient for evaporation of the substrate 9 forming the aerosol surrounding the current collector 8 inside the article 3. Inside the distant part, the device 2 generating the aerosol additionally contains a battery 12 and an electronic circuit 13 of the power supply unit, intended for power supply and control of the heating process.

In the use of the aerosol generating system 1, when the user takes a puff through the mouthpiece element 7 of the article 3, air is drawn into the containing cavity near the edge of the cavity. The air flow then passes in the direction of the distal end of the cavity through a passage formed between the inner surface of the cylindrical cavity and the outer surface of the article 3. At the distal end of the cavity, the air flow enters the aerosol generating article 3 through the substrate element 4, then passes through the support element 5, the aerosol cooling element 6, and the mouthpiece element 7, from where it eventually leaves the article 3. In the substrate element 4, the evaporated material from the aerosol forming substrate 9 is entrained in the air flow. Then, when passing through the support element 5, the cooling element 6 and the mouthpiece element 7, the air flow containing the evaporated material is cooled to form an inhalable aerosol, which exits the article 3 through the mouthpiece element 7.

In the first embodiment of the aerosol generating device 2, the battery 12 comprises a cathode-anode block 14, shown in Fig. 2. The cathode-anode block 14 is shown in a vertical position with a longitudinal axis extending in the vertical direction. The cathode-anode block 14 is made in the form of a roll. The cathode-anode block 14 comprises a plurality of contact leads 15. The plurality of contact leads 15 extend from the upper longitudinal end surface of the cathode-anode block 14.

Although three contact leads are shown in Fig. 2, any number of contact leads, but not less than two, may be provided on the upper longitudinal end surface of the cathode-anode block 14. Preferably, the number of contact leads may be two or three.

Although not shown in Fig. 2, one or more contact leads are provided on the opposite lower longitudinal end surface of the cathode-anode block 14. The number of contact leads on both longitudinal end surfaces of the cathode-anode block 14 may be equal.

Fig. 3 shows the cathode-anode block 14 according to Fig. 2 in an unfolded state. The cathode-anode block 14 contains two electrodes, namely a cathode 16 and an anode 17.

The cathode 16 is formed from a multilayer sheet material. The multilayer sheet material of the cathode comprises a layer 18 of a cathode current collector. The layer 18 of the cathode current collector is formed from a sheet material and comprises two large opposite surfaces. In order to form a layer 19 of cathode active material on both surfaces of the layer 18 of the cathode current collector, both surfaces of the layer 18 of the cathode current collector are coated with a cathode active material. In some examples, only one surface of the layer 18 of the cathode current collector may be coated with a cathode active material.

The anode 17, like the cathode 16, is formed from a multilayer sheet material. The multilayer sheet material of the anode 17 contains a layer 21 of an anode current collector. The layer 21 of an anode current collector is formed from a sheet material and contains two large opposite surfaces. In order to form a layer 22 of anode active material on both surfaces of the layer 21 of anode current collector, both surfaces of the layer 21 of anode current collector are coated with a cathode active material. In some examples, only one surface of the layer 21 of anode current collector can be coated with anode active material.

The cathode-anode block 14 additionally contains a separator 24. The separator 24 is formed from a sheet material. The separator is located between the cathode and the anode.

An example of a layer 18 of the cathode current collector is shown in Fig. 4, a top view. The vertical extension of the layer 18 of the cathode current collector shown in Fig. 4 corresponds to the height of the cathode-anode block 14 shown in Fig. 2. The horizontal extension of the layer 18 of the cathode current collector corresponds to the length of the layer 18 of the cathode current collector and is perpendicular to the vertical extension.

The layer 21 of the anode current collector can be made with a structure similar or identical to the structure of the layer 18 of the cathode current collector.

A plurality of contact leads 15 of the cathode-anode unit 14, shown in Fig. 2, are arranged at a distance from each other on the edge of the layer 18 of the cathode current collector. This distance represents the length between the plurality of contact leads 15 relative to the horizontal length of the layer 18 of the cathode current collector in the unfolded state.

A plurality of contact leads 15 are arranged on the edge in such a way that the plurality of contact leads 15 extend from the edge of the layer 18 of the current collector, and so that the contact leads protrude vertically to a height of 25.

In Fig. 4, the black dot schematically indicates an electron. This electron is one of a large number of electrons that are part of the layer 18 of the cathode current collector. Since the length of the layer 18 of the current collector is large, the electrons have to travel large distances when using a design with a single contact lead. With multiple contact leads, the travel distances are reduced, due to which the discharge capacity of the battery increases. The use of multiple contact leads allows the battery 12 to generate a significant amount of energy in a short time with a small polarization even under large current loads.

As further shown in Fig. 4, each of the plurality of contact leads 15 has a rectangular shape.

In the second embodiment of the aerosol generating device 2, the battery 12 has a design for fastening the contact leads shown in Fig. 5. The battery 12 contains a cathode-anode block 14 according to Fig. 2, an insulating structure 26 and a housing with two terminals 27 and 28 for connecting the electrical circuit of the aerosol generating device 2.

The upper terminal 27 is connected to the cathode, acting as a positive terminal (+), and the lower terminal 28 is connected to the anode, acting as a negative terminal (-). The battery 12 has a cylindrical shape. Alternatively, the polarity of terminals 27 and 28 may be reversed; the battery 12 may have a cylindrical shape; both terminals 27, 28 may be located on the same longitudinal end surface of the battery; the battery 12 may have a shape and terminal arrangement similar to a battery known as a "9V block battery".

The body contains a shell 29 and a cap 30 covering the shell 29.

The shell 29 comprises a side wall, an upper opening for accommodating the cathode-anode unit 14 during manufacture, and a lower end wall. The side wall of the shell may be in the form of a cylindrical section extending in the longitudinal direction and forming a cavity for the cathode-anode unit 14. The end wall of the shell forms the lower part of the shell 29.

Both the end wall of the shell and the side wall of the shell are made of a conductive material such as aluminum. The end wall of the shell and the side wall of the shell are electrically connected, thus providing the same electrical potential. The end wall of the shell serves as a negative terminal (-).

The cap 30 has a round shape with a raised part in the middle, which serves as a positive terminal (+). The cap 30 closes the opening of the shell. A second insulating structure (not shown in the figure) is provided, which insulates the cap 30 from the shell 29. The second insulating structure may be located on the cap 30 or on the shell 29.

The shell 29 additionally comprises a thinned portion 31, which fixes the position of the cathode-anode block 14 in the longitudinal direction. The thinned portion 31 forms a part of the cylindrical portion of the shell 29. The thinned portion 31 is located above the upper longitudinal end surface of the cathode-anode block 14 and corresponds to a cone on the cylindrical portion of the shell 29.

Between the neck 31 and the cathode-anode block 14, an insulating structure 26 is provided, which insulates from the shell 29 a plurality of contact leads 15 extending from the upper longitudinal end surface of the cathode-anode block 14. As shown in the figure, the insulating structure 26 has a central cutout for accommodating a plurality of contact leads 15.

A plurality of contact leads 15 are attached to the cap 30. Preferably, the plurality of contact leads 15 are welded or soldered to the cap 30. As shown in Fig. 5 and Fig. 6, the plurality of contact leads 15 are bent inward in the direction of the center of the battery 12, until they pass through the central cutout of the insulating structure 26 to reach the cap 30, as a result of which a stack of overlapping contact leads is formed, extending in the longitudinal direction.

Since the dimensions of the battery 12 used in the portable aerosol generating device 2 are limited, the space required for the overlapping contact leads reduces the space allocated for the cathode-anode unit 14, which results in a decrease in the energy capacity of the battery 12.

In embodiments of the aerosol generating device 2 with cathode-anode blocks or batteries according to Figs. 7-11, the overlapping space 32 caused by the use of a plurality of contact leads 15 can be reduced.

In a fourth embodiment of the aerosol generating device 2, the battery 12 comprises a cathode-anode unit 14, shown in Fig. 7. According to the fourth embodiment, a plurality of leads 15 are bent outward. In this way, the overlapping space 32 formed by the plurality of contact leads 15 after their bending can be reduced.

In the fifth and sixth embodiments of the aerosol generating device 2, the battery 12 comprises a cathode-anode unit 14, shown in Fig. 8 and Fig. 9.

In contrast to the cathode-anode block 14 shown in Fig. 2, the plurality of contact leads 15 according to Fig. 8 have a trapezoidal shape. The width of the plurality of contact leads 15 decreases as the distance to the longitudinal end surface of the cathode-anode block 14 increases. In this way, the overlapping space 104 formed by the plurality of contact leads 15 after their bending is reduced.

In contrast to the cathode-anode block 14 shown in Fig. 2, the plurality of contact leads 15 according to Fig. 9 have a needle-like shape. In this way, the overlapping space 104 formed by the plurality of contact leads 15 after their bending is reduced.

Referring to Fig. 5, an embodiment of a method for manufacturing a battery 12 for an aerosol generating device 2 may include one or more of the following steps.

First, a cathode-anode block 14 is provided. The cathode-anode block 14 contains three contact leads 15 extending from the upper longitudinal end surface of the cathode-anode block 14.

Secondly, a cathode-anode block 14 is placed in the shell 29. The cathode-anode block 14 can be positioned in such a way that it adjoins the end wall of the shell.

Thirdly, three contact leads 15, coming out of the lower end surface of the cathode-anode block 14, are attached to the lower end wall of the shell. It is preferable that the three contact leads coming out of the lower end surface of the cathode-anode block 14 are attached by welding the three contact leads 15 to the lower end wall of the shell. For example, a welding needle is passed through the center of the cathode-anode block 14 and three contact leads 15 are welded to the end wall of the shell with its help.

Fourthly, the shell 29 is at least partially filled with electrolyte.

Fifthly, the insulating structure 26 is positioned above the cathode-anode block 14 so that the three contact leads 15 pass through the central cutout of the insulating structure 26. The fifth step further includes bending the three contact leads 15 in accordance with one of the methods discussed in connection with Fig. 6 and Fig. 7.

Sixthly, three contact leads 15 are attached to cap 30 by welding or soldering.

Typically, the three contact tabs 15 are long enough to facilitate fastening. For example, the height 25 of the contact tab projection in the vertical direction for a battery of the 11390 design may be from 14 millimeters to 16 millimeters.

In the seventh and eighth embodiments of the aerosol generating device 2, the battery 12 comprises a contact lead fastening structure shown in Fig. 10 and Fig. 11. Since the battery 12 has the same features as the battery 12 according to Fig. 4, or features similar to them, the same reference numerals are used.

Instead of fixing the plurality of contact leads 15 directly to the cap 30, the battery 12 according to Fig. 10 and Fig. 11 is equipped with an electrically conductive structure 33 having connection ports 34 for the plurality of contact leads 15. In essence, the electrically conductive structure 33 allows the plurality of contact leads 15 to be fixed to the connection ports 34, and not to the cap 30, which in turn reduces their length and, therefore, the space they occupy. The electrically conductive structure 33 can, in addition, allow less bending of the contact leads and, therefore, reduce the likelihood of their breakage. Finally, the electrically conductive structure 33 allows the thinned part 31 to be removed.

The conductive structure 33 comprises a platform 35 and a connector 36. The platform 35 has a periphery corresponding to the inner edge of the shell 29. The platform 35 is located on the longitudinal end surface of the cathode-anode block 14. The platform 35 is made of a conductive structure 37 and a non-conductive structure 38. The conductive structure 37 comprises connecting ports 34 in the form of a plurality of cutouts for accommodating a plurality of contact leads 15. The number of connecting ports 34 is equal to the number of contact leads 15. The openings are made in the form of cutouts. In other examples, grooves may be provided.

As shown in Fig. 10, slots are provided when using rectangular contact leads. Similarly, slots can be provided when using trapezoidal contact leads.

As shown in Fig. 11, cutouts are provided when the contact leads of a needle shape are used. In the manufacturing process, a plurality of contact leads 15 are passed through the holes, bent inward or outward, and then welded or soldered to the conductive structure 37. Due to the mechanical strength of the needles, a plurality of contact leads 15 are easily passed through the holes without forming cracks.

The non-conductive structure 38 is formed on the periphery of the conductive structure 37, and in such a way that the conductive structure 37 is electrically isolated from the shell 29. The platform replaces the insulating structure 26 shown in Fig. 4.

The platform 35 is attached to the shell 29 in such a way that the cathode-anode block 14 is fixed in a longitudinal position relative to the shell 29. In particular, the non-conductive structure 26 is hermetically attached to the side wall of the shell. This allows the cathode-anode block 14 to be fixed in the longitudinal direction and eliminates the need for the thinned part 31. This allows the space for the cathode-anode block 14 to be increased and, thus, the volumetric energy density of the battery 12.

Between the platform 35 and the cap 30, a connector 36 is provided. The connector 36 covers the distance in the longitudinal direction between the cathode-anode block 14 and the cap 30. The connector 36 contains a conductive structure 39 for electrically connecting a plurality of contact leads 15 to the cap 30 and a non-conductive structure 40 for insulating the conductive structure 39 from the shell 29.

The conductive structure 39 of the separator 36 has a U-shape. In particular, the connector has three sections, wherein both the first section of the connector and the second section of the connector are connected to the third section of the connector at an angle of 90 degrees. The first section of the connector and the second section of the connector extend in the same transverse direction. The first section of the connector is attached to the cap 30. The second section of the connector is attached to the conductive structure 37 of the platform 35.

With reference to the method for manufacturing the battery 12 according to Fig. 4, the method for manufacturing the battery 12 according to Fig. 10 and Fig. 11 may also include the first to fourth steps.

Instead of the fifth step of arranging the insulating structure 26 and the sixth step of attaching the plurality of contact leads 15 to the cap 30, the method of manufacturing the battery 12 according to Fig. 10 and Fig. 11 includes one or more of the following steps:

Fifthly, the conductive structure 33 is arranged on the longitudinal end surface of the cathode-anode block 14 in such a way that three contact leads 15 contact three connection ports 34 of the conductive structure 33. The fifth stage additionally includes one or more of the following stages:

Each of the three contact leads 15 is passed through one of the three cutouts corresponding to it, forming three connecting ports 34.

The conductive structure 33 is attached to the shell 29. It is preferable that the conductive structure 33 is hermetically attached to the side wall of the shell.

Three contact leads 15 are bent inward or outward and attached to the conductive structure 33.

Sixthly, the conductive structure 33 is secured to the shell 30. Preferably, the conductive structure 33 is welded or soldered to the cap 30.

Claims (18)

1. An aerosol generating device comprising a battery, wherein the battery is configured to supply power for heating, wherein the battery comprises a cathode-anode unit, wherein the cathode-anode unit comprises a cathode and an anode, wherein the cathode and anode are wound around a longitudinal direction to form a plurality of turns, wherein at least one of the cathode and anode is provided with at least two contact leads, wherein these at least two contact leads are located at a distance from each other, wherein the number of contact leads is less than the number of turns. 2. An aerosol generating device according to claim 1, characterized in that the contact leads are placed on the cathode or anode in such a way that there is only one contact lead for at least 2 turns, at least 5 turns, or at least 15 turns. 3. An aerosol generating device according to any of the preceding paragraphs, characterized in that the cathode is formed from a multilayer sheet material containing: cathode current collector layer; and a layer of cathode active material, wherein the layer of cathode active material is a coating on one side of the cathode current collector, wherein the thickness of the coating forming the layer of cathode active material is from 30 to 60 micrometers, preferably from 40 to 50 micrometers. 4. An aerosol generating device according to claim 3, characterized in that at least one of the at least two contact leads is attached to the cathode current collector, in particular by means of ultrasonic or resistance welding. 5. An aerosol generating device according to any of the preceding claims, characterized in that the contact leads extend from the cathode or anode in the direction of the periphery of the battery. 6. An aerosol generating device according to any of the preceding claims, characterized in that the battery additionally comprises an electrically conductive structure with connecting ports for contact leads. 7. An aerosol generating device according to claim 6, characterized in that the electrically conductive structure covers the distance in the longitudinal direction between the cathode or anode and the battery terminal. 8. An aerosol generating device according to claim 6 or 7, characterized in that the connecting ports of the electrically conductive structure are openings for accommodating contact leads, in particular cutouts or grooves. 9. A method for controlling an aerosol generating device, comprising the steps of: determine whether the consumer requests aerosol delivery; supplying power from a battery to an aerosol generating means through at least two battery terminals, wherein the battery comprises a cathode and an anode, wherein the cathode and anode are wound around a longitudinal direction to form a plurality of turns, wherein the terminals are arranged in parallel in an electrical circuit of which the battery is a part, wherein the number of terminals is less than the number of turns. 10. The method according to claim 9, characterized in that the step of supplying power from the battery to the aerosol generating means through these at least two battery terminals provides for the consumption of current from the battery only when the heating temperature drops below the threshold level. 11. The method according to claim 10, characterized in that the discharge current is a pulsed current having at least one on-cycle and at least one off-cycle. 12. The method according to claim 11, characterized in that the duration of at least one of the on-cycle and the off-cycle is from 0.01 to 3 seconds, preferably from 0.1 to 2 seconds, in particular approximately 0.3 seconds. 13. The method according to any one of paragraphs. 10-12, characterized in that the peak value of the discharge current is from 2 to 5 amperes, preferably from 2.5 to 4 amperes, in particular approximately 3.15 amperes. 14. The use of at least two contact leads provided on the cathode or anode in an aerosol generating device to increase the discharge capacity of a battery for intermittent heating, wherein the cathode and anode are wound around a longitudinal direction to form a plurality of turns, wherein the number of contact leads is less than the number of turns.