Field of the Invention
[0001] The present invention relates to an aerosol delivery device, and, more particularly
but not exclusively, to an aerosol delivery device for a smoking substitute system.
Background
[0002] The smoking of tobacco is generally considered to expose a smoker to potentially
harmful substances. It is generally thought that a significant amount of the potentially
harmful substances are generated through the heat caused by the burning and/or combustion
of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.
[0003] Combustion of organic material such as tobacco is known to produce tar and other
potentially harmful by-products. There have been proposed various smoking substitute
devices in order to avoid the smoking of tobacco.
[0004] Such smoking substitute devices can form part of nicotine replacement therapies aimed
at people who wish to stop smoking and overcome a dependence on nicotine.
[0005] Smoking substitute devices, which may also be known as electronic nicotine delivery
systems, may comprise electronic systems that permit a user to simulate the act of
smoking by producing an aerosol, also referred to as a "vapour", which is drawn into
the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically
bears nicotine and/or flavourings without, or with fewer of, the odour and health
risks associated with traditional smoking.
[0006] In general, smoking substitute devices are intended to provide a substitute for the
rituals of smoking, whilst providing the user with a similar experience and satisfaction
to those experienced with traditional smoking and tobacco products.
[0007] The popularity and use of smoking substitute devices has grown rapidly in the past
few years. Some smoking substitute devices are designed to resemble a traditional
cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking
substitute devices do not generally resemble a cigarette (for example, the smoking
substitute device may have a generally box-like form).
[0008] There are a number of different categories of smoking substitute devices, each utilising
a different smoking substitute approach. A smoking substitute approach corresponds
to the manner in which the substitute system operates for a user.
[0009] One approach for a smoking substitute device is the so-called "vaping" approach,
in which a vaporisable liquid, typically referred to (and referred to herein) as "e-liquid",
is heated by a heater to produce an aerosol vapour which is inhaled by a user. An
e-liquid typically includes a base liquid as well as nicotine and/or flavourings.
The resulting vapour therefore typically contains nicotine and/or flavourings. The
base liquid may include propylene glycol and/or vegetable glycerine.
[0010] A typical vaping smoking substitute device includes a mouthpiece, a power source
(typically a battery), a tank or liquid reservoir for containing e-liquid, as well
as a heater. In use, electrical energy is supplied from the power source to the heater,
which heats the e-liquid to produce an aerosol (or "vapour") which is inhaled by a
user through the mouthpiece.
[0011] Vaping smoking substitute devices can be configured in a variety of ways. For example,
there are "closed system" vaping smoking substitute devices which typically have a
heater and a sealed tank which is pre-filled with e-liquid and is not intended to
be refilled by an end user. One subset of closed system vaping smoking substitute
devices include a main body which includes the power source, wherein the main body
is configured to be physically and electrically coupled to a consumable including
the tank and the heater. In this way, when the tank of a consumable has been emptied,
the main body can be reused by connecting it to a new consumable. Another subset of
closed system vaping smoking substitute devices are completely disposable, and intended
for one-use only.
[0012] There are also "open system" vaping smoking substitute devices which typically have
a tank that is configured to be refilled by a user, so the device can be used multiple
times.
[0013] An example vaping smoking substitute device is the myblu
™ e-cigarette. The myblu
™ e cigarette is a closed system device which includes a main body and a consumable.
The main body and consumable are physically and electrically coupled together by pushing
the consumable into the main body. The main body includes a rechargeable battery.
The consumable includes a mouthpiece, a sealed tank which contains e-liquid, as well
as a vaporiser, which for this device is a heating filament coiled around a portion
of a wick which is partially immersed in the e-liquid. The device is activated when
a microprocessor on board the main body detects a user inhaling through the mouthpiece.
When the device is activated, electrical energy is supplied from the power source
to the vaporiser, which heats e-liquid from the tank to produce a vapour which is
inhaled by a user through the mouthpiece.
[0014] Another example vaping smoking substitute device is the blu PRO
™ e-cigarette. The blu PRO
™ e cigarette is an open system device which includes a main body, a (refillable) tank,
and a mouthpiece. The main body and tank are physically and electrically coupled together
by screwing one to the other. The mouthpiece and refillable tank are physically coupled
together by screwing one into the other, and detaching the mouthpiece from the refillable
tank allows the tank to be refilled with e-liquid. The device is activated by a button
on the main body. When the device is activated, electrical energy is supplied from
the power source to a vaporiser, which heats e-liquid from the tank to produce a vapour
which is inhaled by a user through the mouthpiece.
[0015] In prior art smoking substitute devices, some of the unvaporised e-liquid passes
through the wick and to the mouthpiece. This may result in unvaporised e-liquid passing
into the user's mouth, which may be unpleasant for the user. Further leakage occurs
due to leakage paths present between the components of the consumable.
[0016] The present invention has been devised in light of the above considerations. Additionally,
it is desirable to provide consumables which are easier and cheaper to manufacture
Summary of the Invention
[0017] At its most general, the present invention relates to an aerosol delivery device
in which an airflow path around an airflow-directing member (baffle) within a vaporising
chamber has a reduced cross-sectional area to match a minimum upstream cross-sectional
area of the airflow path in the vaporising chamber.
[0018] In a first aspect, there is provided an aerosol delivery device having a chamber
airflow path through a vaporising chamber housing a vaporiser, the chamber airflow
path extending through at least one aperture defined by an upstream edge of a transverse
baffle mounted downstream from the vaporiser, wherein the chamber airflow path through
the at least one aperture has a transverse cross-sectional area that is substantially
equal or less than a minimum transverse cross-sectional area of the chamber airflow
path downstream from the at least one aperture.
[0019] The inclusion of a baffle downstream from the vaporiser may help to reduce (or prevent)
un-vaporised liquid from the vaporiser passing to the user. The un-vaporised liquid
may collect on an upstream surface of the baffle facing the vaporiser, whilst vapour
is able to pass through the aperture(s) defined by the upstream edge of the baffle.
Reducing the size of the aperture so that it has an equal or smaller transverse cross-sectional
area (perpendicular to the chamber airflow path) than the chamber airflow path downstream
of the aperture(s), effectively reduces the surface area of a downstream end wall
of the chamber that is exposed to the air flow in the chamber airflow path through
the aperture. In this way, it is possible to reduce or eliminate the chance of unvaporised
liquid depositing on this chamber end wall and thus being carried into the airflow
downstream of the aperture(s).
[0020] The terms "transversely" and "transverse" are used herein in relation to the cross-sectional
area of the airflow path to describe a direction that is substantially perpendicular
to the airflow path. The terms "transversely" and "transverse" are used herein in
relation to components of the device to describe a direction that is substantially
perpendicular to the axial (longitudinal) direction of the device.
[0021] The device has a device airflow path extending from at least one inlet of the device
to an outlet of the device with the vaporising chamber interposed between the inlet(s)
and the outlet. The term "upstream" is used to define a direction towards the inlet(s)
of the device. The term "downstream" is used to define a direction towards the outlet
of the device.
[0022] Optional features of the present disclosure will now be set out. These are applicable
singly or in any combination with any aspect of the present disclosure.
[0023] In some embodiments, the chamber airflow path has a portion extending from the aperture
to a downstream edge of the transverse baffle wherein the chamber airflow path at
the downstream edge of the transverse baffle has a transverse cross-sectional area
that is substantially equal or less than a minimum transverse cross-sectional area
of the chamber airflow path downstream from the downstream edge of the transverse
baffle.
[0024] In some embodiments, the portion of the chamber airflow path extending from the aperture
to the downstream edge of the transverse baffle has a constant transverse cross-sectional
area.
[0025] The chamber airflow path is partly defined by one or more walls of the vaporising
chamber. For example, the at least one aperture may be defined by the upstream edge
of the baffle and the opposing sidewall of the chamber.
[0026] Where there is a constant transverse cross-sectional area between the aperture and
the downstream edge of the baffle, the transverse width of the aperture (i.e. the
transverse spacing between the upstream edge of the baffle and the sidewall of the
chamber) equals the transverse spacing between the downstream edge of the baffle and
the sidewall of the vaporising chamber.
[0027] In some embodiments, the transverse width of the aperture(s) (i.e. the transverse
spacing between the upstream edge of the baffle and the sidewall of the chamber) equals
(or is less than) the longitudinal spacing between the downstream edge of the baffle
and the end wall of the vaporising chamber.
[0028] In some embodiments, the device comprises a passage extending longitudinally from
the vaporising chamber to the outlet of the device. In these embodiments, the chamber
airflow path extends to a passage opening which may be provided in a downstream end
wall of the vaporising chamber.
[0029] The aperture (and the upstream/downstream edges of the baffle) may be offset transversely
(i.e. laterally) from the longitudinal axis of the passage (e.g. may be radially outwards
of the passage opening).
[0030] In some embodiments, the transverse width of the downstream end wall of the vaporising
chamber between the passage opening and the sidewall of the vaporising chamber (measured
between the radially outermost limit of the passage opening and the proximal sidewall)
is less than the length of the chamber airflow path between the upstream edge and
the downstream edge of the baffle.
[0031] In some embodiments, the chamber airflow path, between the vaporiser and the passage,
may comprise at least one deflection. For example, a first portion of the chamber
airflow path may extend in a generally longitudinal direction from the vaporiser to
the aperture and/or the downstream edge of the baffle. A second portion of the airflow
path between the first portion and the passage, may extend generally radially (laterally)
e.g. generally parallel to a planar upper surface of the baffle, such that there may
be a deflection between the first and second portions.
[0032] The device airflow path may comprise a third portion in the passage extending in
a generally longitudinal direction. Thus, the device airflow path may deflect between
the lateral direction (of the second portion) to a longitudinal direction (of the
third portion) at or proximate to the passage opening.
[0033] The baffle may have two laterally opposed upstream edges that at least partly define
two laterally opposed apertures (e.g. between the upstream edges and opposed sidewalls
of the chamber). In this way, the chamber airflow path may be bifurcated as it passes
downstream of the vaporiser. In these embodiments, it is preferable that the transverse
cross-sectional area of the chamber airflow path in both branches of the bifurcated
flow is as described above.
[0034] Accordingly, both branches of the bifurcated chamber airflow path may have a transverse
cross-sectional area that is substantially equal or less than a minimum transverse
cross-sectional area of the chamber airflow path downstream from the apertures.
[0035] In some embodiments, both branches of the bifurcated chamber airflow path have an
equal transverse cross-sectional area downstream from the apertures.
[0036] The baffle may be configured (i.e. shaped and positioned) such that there is no direct
longitudinal line of sight between the vaporiser and the passage. A transverse width
of the baffle may be substantially the same or greater than a corresponding transverse
width (or diameter) of the passage. A transverse cross-sectional area of the baffle
may be substantially the same or greater than a transverse cross-sectional area of
the passage. A transverse width of the baffle may be greater than 30% of a corresponding
transverse width of the chamber, or may e.g. be greater than 40%, or 50%.
[0037] The passage opening (i.e. the opening from the vaporising chamber into the passage)
may have a transverse cross-sectional area of more than 5 mm
2. The passage opening may have a transverse cross-sectional area of no more than 10mm
2. The passage opening may have an internal diameter of more than 2.5 mm. The passage
opening may have an internal diameter of no more than 4 mm. The transverse cross-sectional
area of the or each aperture may be less than the cross-sectional area of the passage
opening.
[0038] There may be an inlet substantially transversely aligned with the baffle (i.e. both
may be aligned along a shared longitudinal axis). The inlet may be substantially transversely
aligned with the passage opening (e.g. the inlet may be aligned on the longitudinal
axis). The inlet, baffle and passage opening may be aligned along the longitudinal
axis.
[0039] The vaporising chamber may comprise opposing parallel sidewalls that are substantially
parallel to the longitudinal axis, and a downstream (e.g. end) wall extending transversely
between the sidewalls. The passage opening may be formed in the downstream wall of
the chamber.
[0040] The device may comprise a tank (reservoir) for containing the vaporisable liquid
(e.g. an e-liquid) with the vaporiser being in fluid communication with the tank.
The e-liquid may, for example, comprise a base liquid and e.g. nicotine. The base
liquid may include propylene glycol and/or vegetable glycerine.
[0041] The tank may be defined by a tank housing. At least a portion of the tank housing
may be translucent. For example, the tank housing may comprise a window to allow a
user to visually assess the quantity of e-liquid in the tank. The tank may be referred
to as a "clearomizer" if it includes a window, or a "cartomizer" if it does not.
[0042] The passage may extend longitudinally within the tank and a passage wall may define
the inner wall of the tank. In this respect, the tank may surround the passage e.g.
the tank may be annular. The passage wall may comprise longitudinal ribs extending
therealong. These ribs may provide support to the passage wall. The ribs may extend
for the full length of the passage wall. The ribs may project (e.g. radially outwardly)
into the tank.
[0043] The device may comprise an insert defining the device inlet(s). The insert may be
inserted into an open end of the tank so as to seal against the tank housing. The
insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s)
of the vaporising chamber and seals against the passage (e.g. seals against outer
surfaces of the passage wall). The insert may be configured to support the vaporiser
within the vaporising chamber. The insert may be formed of silicone. The baffle may
be formed of silicone. The insert and the baffle may be integrally formed.
[0044] The vaporiser may comprise a heater and a wick (e.g. comprising a porous material).
The wick may be elongate and extend transversely across the chamber between wall(s)
(e.g. sidewalls) of the chamber (which may be defined by the inner sleeve). In order
to be in fluid communication with the tank, the wick extends into the tank, e.g. one
or both of its opposing transverse ends may extend into the tank, e.g. through the
wall(s) of the chamber/through the inner sleeve. In this way e-liquid may be drawn
(e.g. by capillary action) along the wick, from the tank to the exposed (central)
portion of the wick. The wick may be oriented so as to align (in a direction of the
longitudinal axis) with the or each aperture at least partly defined by the baffle
(e.g. defined between the upstream edges and wall(s) of the chamber). In this respect,
the chamber airflow path may pass around, through or proximal the wick and through
the aperture(s). The upstream edge(s) (and downstream edge(s) of the baffle) may extend
across the chamber in a direction that is substantially perpendicular to the direction
of the extension of the wick.
[0045] The heater may comprise a heating element, which may be in the form of a filament
wound about the wick (e.g. the filament may extend helically about the wick). The
filament may be wound about the exposed portion of the wick. The heating element may
be electrically connected (or connectable) to a power source. Thus, in operation,
the power source may supply electricity to (i.e. apply a voltage across) the heating
element so as to heat the heating element. This may cause liquid stored in the wick
(i.e. drawn from the tank) to be heated so as to form a vapour and become entrained
in the chamber airflow path. This vapour may subsequently cool to form an aerosol
in the vaporising chamber.
[0046] The device may be in the form of a consumable. The consumable may be configured for
engagement with a main body (i.e. so as to form a smoking substitute system). For
example, the consumable may comprise components of the system that are disposable,
and the main body may comprise non-disposable or non-consumable components (e.g. power
supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable.
In such an embodiment, the aerosol former (e.g. e-liquid) may be replenished by replacing
a used consumable with an unused consumable.
[0047] The main body and the consumable may be configured to be physically coupled together.
For example, the consumable may be at least partially received in a recess of the
main body, such that there is snap engagement between the main body and the consumable.
Alternatively, the main body and the consumable may be physically coupled together
by screwing one onto the other, or through a bayonet fitting.
[0048] Thus, the consumable may comprise one or more engagement portions for engaging with
a main body. In this way, one end of the device (i.e. the inlet end) may be coupled
with the main body, whilst an opposing end (i.e. the outlet end) of the consumable
may define a mouthpiece.
[0049] The main body or the consumable may comprise a power source or be connectable to
a power source. The power source may be electrically connected (or connectable) to
the heater. The power source may be a battery (e.g. a rechargeable battery). An external
electrical connector in the form of e.g. a USB port may be provided for recharging
this battery.
[0050] The consumable may comprise an electrical interface for interfacing with a corresponding
electrical interface of the main body. One or both of the electrical interfaces may
include one or more electrical contacts. Thus, when the main body is engaged with
the consumable, the electrical interface may be configured to transfer electrical
power from the power source to a heater of the consumable. The electrical interface
may also be used to identify the consumable from a list of known types. The electrical
interface may additionally or alternatively be used to identify when the consumable
is connected to the main body.
[0051] The main body may alternatively or additionally be able to detect information about
the consumable via an RFID reader, a barcode or QR code reader. This interface may
be able to identify a characteristic (e.g. a type) of the consumable. In this respect,
the consumable may include any one or more of an RFID chip, a barcode or QR code,
or memory within which is an identifier and which can be interrogated via the interface.
[0052] The consumable or main body may comprise a controller, which may include a microprocessor.
The controller may be configured to control the supply of power from the power source
to the heater (e.g. via the electrical contacts). A memory may be provided and may
be operatively connected to the controller. The memory may include non-volatile memory.
The memory may include instructions which, when implemented, cause the controller
to perform certain tasks or steps of a method.
[0053] The consumable or main body may comprise a wireless interface, which may be configured
to communicate wirelessly with another device, for example a mobile device, e.g. via
Bluetooth
®. To this end, the wireless interface could include a Bluetooth
® antenna. Other wireless communication interfaces, e.g. WiFi
®, are also possible. The wireless interface may also be configured to communicate
wirelessly with a remote server.
[0054] As is provided above, an airflow (i.e. puff) sensor may be provided that is configured
to detect a puff (i.e. inhalation from a user). The airflow sensor may be operatively
connected to the controller so as to be able to provide a signal to the controller
that is indicative of a puff state (i.e. puffing or not puffing). The airflow sensor
may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller
may control power supply to the heater in response to airflow detection by the sensor.
The control may be in the form of activation of the heater in response to a detected
airflow. The airflow sensor may form part of the consumable or the main body.
[0055] In an alternative embodiment the device may be a non-consumable device in which an
aerosol former (e.g. e-liquid) of the system may be replenished by re-filling the
tank of the device (rather than replacing the consumable). In this embodiment, the
consumable described above may instead be a non-consumable component that is integral
with the main body. Thus the device may comprise the features of the main body described
above. In this embodiment, the only consumable portion may be e-liquid contained in
the tank of the device. Access to the tank (for re-filling of the e-liquid) may be
provided via e.g. an opening to the tank that is sealable with a closure (e.g. a cap).
[0056] The device may be a smoking substitute device (e.g. an e-cigarette device) and, when
in the form of a consumable, may be a smoking substitute consumable (e.g. an e-cigarette
consumable).
[0057] In a second aspect there is disclosed a smoking substitute system comprising a main
body having a power source, and a consumable as described above with respect to the
first aspect, the consumable being engageable with the main body such that vaporiser
of the consumable is connected to the power source of the main body.
[0058] The consumable may be an e-cigarette consumable. The main body may be as described
above with respect to the first aspect. The main body may, for example, be an e-cigarette
device for supplying power to the consumable.
[0059] The invention includes the combination of the aspects and preferred features described
except where such a combination is clearly impermissible or expressly avoided.
Summary of the Figures
[0060] So that the invention may be understood, and so that further aspects and features
thereof may be appreciated, embodiments illustrating the principles of the invention
will now be discussed in further detail with reference to the accompanying figures,
in which:
Figure 1A is a front schematic view of a smoking substitute system;
Figure 1B is a front schematic view of a main body of the system;
Figure 1C is a front schematic view of a consumable of the system;
Figure 2A is a schematic of the components of the main body;
Figure 2B is a schematic of the components of the consumable;
Figure 3A is a section view of the consumable;
Figure 3B is a detailed section view of a vaporising chamber of the consumable; and
Figure 4 is a section view of a manufacturing assembly for manufacturing the consumable.
Detailed Description of the Invention
[0061] Aspects and embodiments of the present invention will now be discussed with reference
to the accompanying figures. Further aspects and embodiments will be apparent to those
skilled in the art. All documents mentioned in this text are incorporated herein by
reference.
[0062] Figure 1A shows a first embodiment of a smoking substitute system 100. In this example,
the smoking substitute system 100 includes a main body 102 and an aerosol delivery
device in the form of a consumable 104. The consumable 104 may alternatively be referred
to as a "pod", "cartridge" or "cartomizer". It should be appreciated that in other
examples (i.e. open systems), the main body may be integral with the consumable such
that the aerosol delivery device incorporates the main body. In such systems, a tank
of the aerosol delivery device may be accessible for refilling the device.
[0063] In this example, the smoking substitute system 100 is a closed system vaping system,
wherein the consumable 104 includes a sealed tank 106 and is intended for single-use
only. The consumable 104 is removably engageable with the main body 102 (i.e. for
removal and replacement). Figure 1A shows the smoking substitute device 100 with the
main body 102 physically coupled to the consumable 104, Figure 1B shows the main body
102 of the smoking substitute system 100 without the consumable 104, and Figure 1C
shows the consumable 104 of the smoking substitute system 100 without the main body
102.
[0064] The main body 102 and the consumable 104 are configured to be physically coupled
together by pushing the consumable 104 into a cavity at an upper end 108 of the main
body 102, such that there is an interference fit between the main body 102 and the
consumable 104. In other examples, the main body 102 and the consumable may be coupled
by screwing one onto the other, or through a bayonet fitting.
[0065] The consumable 104 includes a mouthpiece (not shown in Figure 1A, 1B or 1C) at an
upper end 109 of the consumable 104, and one or more air inlets (not shown) in fluid
communication with the mouthpiece such that air can be drawn into and through the
consumable 104 when a user inhales through the mouthpiece. The tank 106 containing
e-liquid is located at the lower end 111 of the consumable 104.
[0066] The tank 106 includes a window 112, which allows the amount of e-liquid in the tank
106 to be visually assessed. The main body 102 includes a slot 114 so that the window
112 of the consumable 104 can be seen whilst the rest of the tank 106 is obscured
from view when the consumable 104 is inserted into the cavity at the upper end 108
of the main body 102.
[0067] The lower end 110 of the main body 102 also includes a light 116 (e.g. an LED) located
behind a small translucent cover. The light 116 may be configured to illuminate when
the smoking substitute system 100 is activated. Whilst not shown, the consumable 104
may identify itself to the main body 102, via an electrical interface, RFID chip,
or barcode.
[0068] Figures 2A and 2B are schematic drawings of the main body 102 and consumable 104.
As is apparent from Figure 2A, the main body 102 includes a power source 118, a controller
120, a memory 122, a wireless interface 124, an electrical interface 126, and, optionally,
one or more additional components 128.
[0069] The power source 118 is preferably a battery, more preferably a rechargeable battery.
The controller 120 may include a microprocessor, for example. The memory 122 preferably
includes non-volatile memory. The memory may include instructions which, when implemented,
cause the controller 120 to perform certain tasks or steps of a method.
[0070] The wireless interface 124 is preferably configured to communicate wirelessly with
another device, for example a mobile device, e.g. via Bluetooth
®. To this end, the wireless interface 124 could include a Bluetooth
® antenna. Other wireless communication interfaces, e.g. WiFi
®, are also possible. The wireless interface 124 may also be configured to communicate
wirelessly with a remote server.
[0071] The electrical interface 126 of the main body 102 may include one or more electrical
contacts. The electrical interface 126 may be located in a base of the aperture in
the upper end 108 of the main body 102. When the main body 102 is physically coupled
to the consumable 104, the electrical interface 126 is configured to transfer electrical
power from the power source 118 to the consumable 104 (i.e. upon activation of the
smoking substitute system 100).
[0072] The electrical interface 126 may be configured to receive power from a charging station
when the main body 102 is not physically coupled to the consumable 104 and is instead
coupled to the charging station. The electrical interface 126 may also be used to
identify the consumable 104 from a list of known consumables. For example, the consumable
104 may be a particular flavour and/or have a certain concentration of nicotine (which
may be identified by the electrical interface 126). This can be indicated to the controller
120 of the main body 102 when the consumable 10nected to the main body 102. Additionally,
or alternatively, there may be a separate communication interface provided in the
main body 102 and a corresponding communication interface in the consumable 104 such
that, when connected, the consumable 104 can identify itself to the main body 102.
[0073] The additional components 128 of the main body 102 may comprise the light 116 discussed
above.
[0074] The additional components 128 of the main body 102 may also comprise a charging port
(e.g. USB or micro-USB port) configured to receive power from the charging station
(i.e. when the power source 118 is a rechargeable battery). This may be located at
the lower end 110 of the main body 102. Alternatively, the electrical interface 126
discussed above may be configured to act as a charging port configured to receive
power from the charging station such that a separate charging port is not required.
[0075] The additional components 128 of the main body 102 may, if the power source 118 is
a rechargeable battery, include a battery charging control circuit, for controlling
the charging of the rechargeable battery. However, a battery charging control circuit
could equally be located in the charging station (if present).
[0076] The additional components 128 of the main body 102 may include a sensor, such as
an airflow (i.e. puff) sensor for detecting airflow in the smoking substitute system
100, e.g. caused by a user inhaling through a mouthpiece 136 of the consumable 104.
The smoking substitute system 100 may be configured to be activated when airflow is
detected by the airflow sensor. This sensor could alternatively be included in the
consumable 104. The airflow sensor can be used to determine, for example, how heavily
a user draws on the mouthpiece or how many times a user draws on the mouthpiece in
a particular time period.
[0077] The additional components 128 of the main body 102 may include a user input, e.g.
a button. The smoking substitute system 100 may be configured to be activated when
a user interacts with the user input (e.g. presses the button). This provides an alternative
to the airflow sensor as a mechanism for activating the smoking substitute system
100.
[0078] As shown in Figure 2B, the consumable 104 includes the tank 106, an electrical interface
130, a vaporiser 132, one or more air inlets 134, a mouthpiece 136, and one or more
additional components 138.
[0079] The electrical interface 130 of the consumable 104 may include one or more electrical
contacts. The electrical interface 126 of the main body 102 and an electrical interface
130 of the consumable 104 are configured to contact each other and thereby electrically
couple the main body 102 to the consumable 104 when the lower end 111 of the consumable
104 is inserted into the upper end of the main body 102 (as shown in Fig. 1A). In
this way, electrical energy (e.g. in the form of an electrical current) is able to
be supplied from the power source 118 in the main body 102 to the vaporiser 132 in
the consumable 104.
[0080] The vaporiser 132 is configured to heat and vaporise e-liquid contained in the tank
106 using electrical energy supplied from the power source 118. As will be described
further below, the vaporiser 132 includes a heating filament and a wick. The wick
draws e-liquid from the tank 106 and the heating filament heats the e-liquid to vaporise
the e-liquid.
[0081] The one or more air inlets 134 are preferably configured to allow air to be drawn
into the smoking substitute system 100, when a user inhales through the mouthpiece
136. When the consumable 104 is physically coupled to the main body 102, the air inlets
134 receive air, which flows to the air inlets 134 along a gap between the main body
102 and the lower end 111 of the consumable 104.
[0082] In operation, a user activates the smoking substitute device 110, e.g. through interaction
with a user input forming part of the main body 102 or by inhaling through the mouthpiece
136 as described above. Upon activation, the controller 120 may supply electrical
energy from the power source 118 to the vaporiser 132 (via electrical interfaces 126,
130), which may cause the vaporiser 132 to heat e-liquid drawn from the tank 106 to
produce a vapour which is inhaled by a user through the mouthpiece 136.
[0083] An example of one of the one or more additional components 138 of the consumable
104 is an interface for obtaining an identifier of the consumable 104. As discussed
above, this interface may be, for example, an RFID reader, a barcode, a QR code reader,
or an electronic interface which is able to identify the consumable. The consumable
104 may, therefore include any one or more of an RFID chip, a barcode or QR code,
or memory within which is an identifier and which can be interrogated via the electronic
interface in the main body 102.
[0084] It should be appreciated that the smoking substitute system 100 shown in figures
1A to 2B is just one exemplary implementation of a smoking substitute system. For
example, the system could otherwise be in the form of an entirely disposable (single-use)
system or an open system in which the tank is refillable (rather than replaceable).
[0085] Figure 3A is a section view of the consumable 104 described above. The consumable
104 comprises a tank 106 for storing e-liquid, a mouthpiece 136 and a passage 140
extending along a longitudinal axis of the consumable 104. In the illustrated embodiment
the passage 140 is in the form of a tube having a substantially circular transverse
cross-section (i.e. transverse to the longitudinal axis). The tank 106 surrounds the
passage 140, such that the passage 140 extends centrally through the tank 106.
[0086] A tank housing 142 of the tank 106 defines an outer casing of the consumable 104,
whilst a passage wall 144 defines the passage 140. The tank housing 142 extends from
the lower end 111 of the consumable 104 to the mouthpiece 136 at the upper end 109
of the consumable 104. At the junction between the mouthpiece 136 and the tank housing
142, the mouthpiece 136 is wider than the tank housing 142, so as to define a lip
146 that overhangs the tank housing 142. This lip 146 acts as a stop feature when
the consumable 104 is inserted into the main body 102 (i.e. by contact with an upper
edge of the main body 102).
[0087] The tank 106, the passage 140 and the mouthpiece 136 are integrally formed with each
other so as to form a single unitary component. As will be described further below
with respect to Figure 4, this component may be formed by way of an injection moulding
process and, for example, may be formed of a thermoplastic material such as polypropylene.
[0088] Although not immediately apparent from the figures, the tank housing 142 tapers,
such that the thickness of the tank housing 142 decreases in a first demoulding direction
(as will be discussed further with respect to Figure 4). In Figure 3A the first demoulding
direction is in a downward direction away from the mouthpiece 136. This means that,
aside from a small number of indents (which provide physical connection between the
consumable 104 and the main body 102), the thickness of the tank housing 142 decreases
with increasing distance away from the mouthpiece 136. In particular, the tank housing
142 tapers in this way, because internal and external surfaces of the tank housing
142 are angled with respect to the first demoulding direction. This tapering assists
in forming the tank housing 142 and passage wall 144 as a single (i.e. unitary) component.
[0089] Like the tank housing 142, the passage wall 144 is also tapered such that the thickness
of the passage wall 144 decreases along the first demoulding direction. Again, the
thickness of the passage wall 144 decreases due to internal and external surfaces
of the passage wall 144 being angled with respect to the first demoulding direction.
As a result of the tapering of the passage wall 144, the passage 140 has an internal
diameter that decreases in a downstream direction (i.e. an upward direction in Figure
3A). For example, the passage 140 has an internal width less than 4.0 mm and greater
than 3.0 mm at an upstream end of the passage 140 (e.g. approximately 3.6 mm). On
the other hand, the passage 140 has an internal width of less than 3.8 mm and greater
than 2.8 mm at the downstream end of the passage 140 (e.g. approximately 3.4 mm).
[0090] The mouthpiece 136 comprises a mouthpiece aperture 148 defining an outlet of the
passage 140. The mouthpiece aperture 148 has a radially inwardly directed inner surface
150, which joins an outer surface 152 of the mouthpiece 136 (i.e. a surface which
contacts a user's lips in use) at an outer edge 154 of the mouthpiece aperture 148.
At this outer edge 154, the included angle between the inner surface 150 of the mouthpiece
aperture 148 and the outer surface 152 of the mouthpiece 136 (i.e. the "mouthpiece
angle") is greater than 90 degrees. In the illustrated embodiment, this is due to
the outer edge 154 being rounded. This edge 154 may otherwise be chamfered or bevelled.
[0091] The vaporiser 132 is located in a vaporising chamber 156 of the consumable 104. This
is best shown in Figure 3B, which provides a detailed view of the vaporising chamber
156. The vaporising chamber 156 is downstream of the inlet 134 of the consumable 104
and is fluidly connected to the mouthpiece aperture 148 (i.e. outlet) by the passage
140. In particular, the passage 140 extends between the mouthpiece aperture 148 and
an opening 158 from the chamber 156. This opening 158 is formed in a downstream (i.e.
upper) wall 160 of the chamber 156.
[0092] The vaporiser 132 comprises a porous wick 162 and a heater filament 164 coiled around
the porous wick 162. As is apparent from Figures 3A and 3B, the wick 162 extends transversely
across the chamber 156 between sidewalls 166 of the chamber 156 which form part of
an inner sleeve 168 of an insert 170 that defines the lower end 111 of the consumable
104 that connects with the main body 102. The insert 170 is inserted into an open
lower end of the tank 106 so as to seal against the tank housing 142.
[0093] In this way, the inner sleeve 168 projects into the tank 106 and seals with the passage
140 (around the passage wall 144) so as to separate the chamber 156 from the e-liquid
in the tank 106. Ends of the wick 162 project through apertures in the inner sleeve
168 and into the tank 106 so as to be in contact with the e-liquid in the tank 106.
In this way, e-liquid is transported along the wick 162 (e.g. by capillary action)
to a central portion of the wick 162. The transported e-liquid is heated by the heater
filament 164 (when activated e.g. by detection of inhalation), which causes the e-liquid
to be vaporised and to be entrained in air flowing in the vaporising chamber 156.
This vaporised liquid may cool to form an aerosol in the passage 140, which may then
be inhaled by a user.
[0094] In some cases, unvaporised liquid can be carried by air flowing through the chamber
156. This may be undesirable for a user. To reduce or avoid this, the consumable 104
comprises a baffle 172, which is shown in more detail in Figure 3B. The baffle 172
extends across the chamber 156 so as to be interposed between the vaporiser 132 and
the passage opening 158. In this way, unvaporised liquid from the wick 162 may collect
on an upstream (i.e. lower) planar surface 174 of the baffle 172 rather than entering
the passage opening 158. The baffle 172 also causes airflow from the vaporiser 132
to the passage opening 158 to be redirected around the baffle 172. The baffle 172
comprises two opposing upstream edges 176 around which the airflow is redirected.
These upstream edges 176 and the sidewalls 166 of the chamber 156 define two respective
apertures 178 spaced either side of the baffle 172. The baffle further comprises two
downstream edges 179.
[0095] The chamber air flow path i.e. the airflow through the vaporising chamber 156 from
proximal the vaporiser 132 to the passage opening 158 extends is bifurcated and has
two branches extending through the apertures 178 in a generally longitudinal direction
between the upstream edges 176 and the downstream edges 179. The transverse cross-sectional
area of the chamber air flow path as it passes between the upstream and downstream
edges 176, 179 is constant within each branch and equal between the two branches.
Furthermore, the transverse cross-sectional area of the chamber airflow path between
the upstream and downstream edges 176, 179 in each branch is equal to the minimum
(smallest) cross-sectional area of the chamber airflow path downstream of the downstream
edges 179 i.e. between the downstream edges 179 and the passage opening 158. In fact,
the chamber airflow path between the apertures 178 and the passage opening 158 is
constant. The chamber airflow path will deflect radially towards the passage opening
158 at the downstream edges 179.
[0096] Although not clear from Figure 3B, the transverse width of the apertures 178 equals
the longitudinal spacing between the downstream edges 179 of the baffle 172 and the
end wall 160 of the vaporising chamber 156. Furthermore, the transverse width of the
end wall 160 of the vaporising chamber 156 between the passage opening 158 and the
sidewall 166 of the vaporising chamber 156 (measured between the radially outermost
limit of the passage opening 158 and the proximal sidewall 166) is less than the length
of the chamber airflow path between the upstream edges 176 and the downstream edges
179 of the baffle 172.
[0097] Upon inhalation by a user at the mouthpiece aperture 148, air flows along the bifurcated
chamber airflow path around the wick 162, through the apertures 178 and into the passage
140 via the passage opening 158.
[0098] Figure 4 shows a drawing of a manufacturing assembly 282 which is used to manufacture
the consumable 104. The manufacturing assembly 282 comprises a first mould 284 and
a second mould 286.
[0099] The first mould 284 has a shape which complements that of a first end of the integrally
formed tank housing 142 and mouthpiece 136. The first mould 284 therefore has a shape
which matches the inner surfaces defining the tank 106.
[0100] The second mould 286 has a shape which complements that of a second end of the integrally
formed tank housing 142 and mouthpiece 136. The second mould 286 has a shape which
matches the outer surface of the mouthpiece 136 and the inner surface of the mouthpiece
aperture 148.
[0101] When the first mould 284 and the second mould 286 are brought together, they define
a closed cavity which has the shape of the tank housing 142, the mouthpiece 136 and
the passage walls 144.
[0102] To manufacture these components, heated material is injected into the cavity between
the first mould 284 and the second mould 286. At this point, the first mould 284 and
the second mould 286 meet at a boundary between external surfaces of the mouthpiece
136 and the tank housing 142.
[0103] The material is subsequently cooled, and the first mould 284 and the second mould
286 are separated, with the first mould 284 travelling in the first demoulding direction
288 (i.e. away from the second mould 286) and the second mould 286 travelling in a
second demoulding direction 290 (i.e. away from the first mould 284 and opposite to
the first demoulding direction 288). For a particular component, a demoulding direction
is a direction along which a mould which contacts that component is removed during
an injection moulding process.
[0104] The insert 170 and any additional components are subsequently inserted into the tank
106.
[0105] The features disclosed in the foregoing description, or in the following claims,
or in the accompanying drawings, expressed in their specific forms or in terms of
a means for performing the disclosed function, or a method or process for obtaining
the disclosed results, as appropriate, may, separately, or in any combination of such
features, be utilised for realising the invention in diverse forms thereof.
[0106] While the invention has been described in conjunction with the exemplary embodiments
described above, many equivalent modifications and variations will be apparent to
those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments
of the invention set forth above are considered to be illustrative and not limiting.
Various changes to the described embodiments may be made without departing from the
spirit and scope of the invention.
[0107] For the avoidance of any doubt, any theoretical explanations provided herein are
provided for the purposes of improving the understanding of a reader. The inventors
do not wish to be bound by any of these theoretical explanations.
[0108] Any section headings used herein are for organizational purposes only and are not
to be construed as limiting the subject matter described.
[0109] Throughout this specification, including the claims which follow, unless the context
requires otherwise, the words "have", "comprise", and "include", and variations such
as "having", "comprises", "comprising", and "including" will be understood to imply
the inclusion of a stated integer or step or group of integers or steps but not the
exclusion of any other integer or step or group of integers or steps.
[0110] It must be noted that, as used in the specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless the context clearly
dictates otherwise. Ranges may be expressed herein as from "about" one particular
value, and/or to "about" another particular value. When such a range is expressed,
another embodiment includes from the one particular value and/or to the other particular
value. Similarly, when values are expressed as approximations, by the use of the antecedent
"about," it will be understood that the particular value forms another embodiment.
The term "about" in relation to a numerical value is optional and means, for example,
+/- 10%.
[0111] The words "preferred" and "preferably" are used herein refer to embodiments of the
invention that may provide certain benefits under some circumstances. It is to be
appreciated, however, that other embodiments may also be preferred under the same
or different circumstances. The recitation of one or more preferred embodiments therefore
does not mean or imply that other embodiments are not useful, and is not intended
to exclude other embodiments from the scope of the disclosure, or from the scope of
the claims.
[0112] The following numbered clauses may be useful in understanding the disclosure herein:
- 1. An aerosol delivery device having a chamber airflow path through a vaporising chamber
housing a vaporiser, the chamber airflow path extending through at least one aperture
defined by an upstream edge of a transverse baffle mounted downstream from the vaporiser,
wherein the chamber airflow path through the at least one aperture has a transverse
cross-sectional area that is substantially equal or less than a minimum transverse
cross-sectional area of the chamber airflow path downstream from the at least one
aperture.
- 2. A device according to clause 1 wherein the chamber airflow path has a portion extending
from the aperture to a downstream edge of the transverse baffle, wherein the chamber
airflow path at the downstream edge of the transverse baffle has a transverse cross-sectional
area that is substantially equal or less than a minimum transverse cross-sectional
area of the chamber airflow path downstream from the downstream edge of the transverse
baffle.
- 3. A device according to clause 2 wherein the portion of the chamber airflow path
extending from the aperture to the downstream edge of the transverse baffle has a
constant transverse cross-sectional area.
- 4. A device according to clause 2 or 3 wherein the chamber airflow path is partly
defined by an end wall of the vaporising chamber and wherein a transverse width of
the aperture equals or is less than the longitudinal spacing between the downstream
edge of the baffle and the end wall of the vaporising chamber.
- 5. A device according to clause 4 further comprising a passage extending longitudinally
from the vaporising chamber to the outlet of the device wherein the chamber airflow
path extends to a passage opening and wherein the transverse width of the end wall
of the vaporising chamber between the passage opening and a sidewall of the vaporising
chamber is less than the length of the chamber airflow path between the upstream edge
and the downstream edge of the baffle.
- 6. An aerosol delivery component according to any one of the preceding clauses wherein
the device further comprises an insert defining a device inlet, wherein the insert
is configured to support the vaporiser within the vaporising chamber and the insert
and the baffle are integrally formed.
- 7. A device according to clause 6 further comprising a tank for housing the vaporisable
liquid wherein the insert defines the vaporising chamber and is configured to seal
the open end of the tank, and wherein the insert comprises an inner sleeve projecting
into the tank so as to seal against the passage, the inner sleeve defining the sidewalls
of the vaporising chamber.
- 8. A device according to clause 7 wherein the or each aperture is further defined
by the sidewalls of the vaporising chamber.
- 9. A device according to any one of clauses 5 to 8 wherein the aperture is offset
laterally from the longitudinal axis of the passage.
- 10. A device according to any one of the preceding clauses wherein the baffle has
two laterally opposed upstream edges that at least partly define two laterally opposed
apertures such that the chamber airflow path is bifurcated into two branches.
- 11. A device according to clause 10 wherein the both branches of the bifurcated chamber
airflow path have a transverse cross-sectional area that is substantially equal or
less than a minimum transverse cross-sectional area of the chamber airflow path downstream
from the apertures.
- 12. A device according to any one of the preceding clauses wherein the transverse
cross-sectional area of the or each aperture is less than the transverse cross-sectional
area of the passage opening.
- 13. A smoking substitute system comprising:
a main body comprising a power source; and
a device according to any one of the preceding clauses, the device being engageable
with the main body such that the vaporiser of the device is electrically connected
to the power source of the main body.