Field of the Invention
[0001] The present invention relates to an aerosol delivery device and to an aerosol-generation
apparatus for an aerosol delivery device. The present invention preferably relates
to an aerosol delivery device including a heater arranged to heat an aerosol precursor
to generate an aerosolised composition for inhalation by a user, and to an aerosol-generation
apparatus therefor.
Background
[0002] A smoking-substitute device or system is an electronic device that permits the user
to simulate the act of smoking by producing an aerosol mist or vapour that is drawn
into the lungs through the mouth and then exhaled. The inhaled aerosol mist or vapour
typically bears nicotine and/or other flavourings without the odour and health risks
associated with traditional smoking and tobacco products. In use, the user experiences
a similar satisfaction and physical sensation to those experienced from a traditional
smoking or tobacco product, and exhales an aerosol mist or vapour of similar appearance
to the smoke exhaled when using such traditional smoking or tobacco products.
[0003] 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. The
e-liquid typically includes a base liquid as well as nicotine and/or flavourings.
The resulting vapour therefore also typically contains nicotine and/or flavourings.
The base liquid may include propylene glycol and/or vegetable glycerine.
[0004] A typical vaping smoking substitute device includes a mouthpiece, a power source
(typically a battery), a tank 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.
[0005] 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 sealed tank and heating element. The tank 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. The consumable may also be referred to as a cartomizer.
In this way, when the tank of a consumable has been emptied, that consumable is disposed
of. The main body can be reused by connecting it to a new, replacement, consumable.
Another subset of closed system vaping smoking substitute devices are completely disposable,
and intended for one-use only.
[0006] There are also "open system" vaping smoking substitute devices which typically have
a tank that is configured to be refilled by a user. In this way the device can be
used multiple times.
[0007] 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 (also
referred to as an aerosol precursor), as well as a heater, which for this device is
a heating filament coiled around a portion of a wick. The wick is partially immersed
in the e-liquid, and conveys e-liquid from the tank to the heating filament. 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 heater, which heats e-liquid from the tank to produce
a vapour which is inhaled by a user through the mouthpiece.
[0008] For a smoking substitute device it is desirable to deliver nicotine into the user's
lungs, where it can be absorbed into the bloodstream. As explained above, in the so-called
"vaping" approach, "e-liquid" is heated by a heating device to produce an aerosol
vapour which is inhaled by a user. Many e-cigarettes also deliver flavour to the user,
to enhance the experience. Flavour compounds are contained in the e-liquid that is
heated. Heating of the flavour compounds may be undesirable as the flavour compounds
are inhaled into the user's lungs. Toxicology restrictions are placed on the amount
of flavour that can be contained in the e-liquid. This can result in some e-liquid
flavours delivering a weak and underwhelming taste sensation to consumers in the pursuit
of safety.
[0009] In aerosol delivery devices, it is desirable to avoid large liquid droplets reaching
a user's mouth.
[0010] The present invention has been devised in light of the above considerations.
Summary of the Invention
[0011] At its most general, the present invention proposes that an aerosol-generation apparatus
has a reservoir for holding aerosol precursor, a wick arranged to receive aerosol
precursor from the reservoir, and a wick support element between the reservoir and
the wick. The wick support element has at least one capillary bore therethrough for
the passage of aerosol precursor from the reservoir to the wick in a capillary manner.
The reservoir, the wick and the wick support element may form parts of a fluid-transfer
article, and the aerosol generation apparatus may also include a heater, which heater
makes abutting unbonded contact with an activation surface of the wick to interact
thermally therewith.
[0012] Thus, when aerosol precursor has passed to the wick, through the or each capillary
bore, the aerosol precursor may be heated by the heater to form a vapour which may
then pass to a user of the aerosol-generation apparatus.
[0013] The use of one or more capillary bores permit aerosol precursor to pass from the
reservoir to the wick without the amount of aerosol precursor reaching the wick being
excessive.
[0014] Thus, the present invention may provide an aerosol-generation apparatus comprising
a heater and a fluid-transfer article, the fluid-transfer article comprising a reservoir
for holding an aerosol precursor, a wick arranged to receive aerosol precursor from
said reservoir, and a wick support element; wherein said wick support element is arranged
to support said wick such that said heater makes abutting unbonded contact with an
activation surface of said wick so as to interact thermally with said activation surface;
and wherein said wick support element is between said reservoir and said wick and
has at least one capillary bore therethrough for passage of said aerosol precursor
from said reservoir to said wick in a capillary manner.
[0015] Preferably, the or each capillary bore has a diameter of at least 0.3mm, more preferably
at least 0.5mm. It is also preferable that the or each capillary bore has a diameter
not greater than 2mm. Thus, the or each capillary bore may have a diameter of 0.8
to 1.5mm.
[0016] With such capillary bores, the wick support element may have a thickness of at least
0.5, more preferably 1 mm, between the reservoir and the wick. It is also desirable
that the wick support element is not thicker than 5mm.
[0017] Preferably, the activation surface of the wick is planar, as this assists in ensuring
efficient interaction with the heater. The wick support element may form an end wall
of the reservoir of the reservoir. It is preferable that the wick support element
is resilient, so that it biases the wick towards the heater to ensure good contact
therebetween. For this purpose, the wick support element may be made of rubber material.
The wick itself may be of silica material, or may be fibrous, woven or of porous ceramic
material.
[0018] According to a second aspect of the invention, the aerosol-generation apparatus discussed
above may form part of an aerosol delivery device, also comprising first and second
casings. The first casing contains the reservoir and supports the wick and the wick
support element, and the second casing supports the heater. The first and second casings
may then be separably interconnected.
[0019] In such an arrangement, it is preferable that the first casing has an outlet, which
may form a mouthpiece for the user, and there is a first air-flow pathway from the
activation surface to the outlet. For convenience, part of that first air-flow pathway
may be formed by aligned openings in the wick and wick support element, which allows
the passage of air from the activation surface, which may contain vaporised aerosol
precursor may pass to the user. In a similar way the second casing may have an inlet,
with there being a second air-flow pathway from the inlet to the activation surface.
Thus, when the user draws on the mouthpiece, air is drawn into the inlet of the device,
through the second air-flow pathway to the activation surface where it may be mixed
with vaporised aerosol precursor generated by heating of the wick by the heater. The
resulting mixture of air and vapour may then pass through the aligned openings in
the wick and wick support element and along the first air-flow pathway to the outlet,
and hence to the user.
[0020] 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
[0021] 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 1 shows a schematic drawing of a first arrangement of a smoking substitute system;
Figure 2 shows another schematic drawing of the first arrangement of the smoking substitute
system;
Figure 3 shows a schematic drawing of a second arrangement of a smoking substitute system;
Figure 4 shows another schematic drawing of the second arrangement of the smoking substitute
system;
Figure 5 shows a cutaway view of part of a third arrangement of a smoking substitute system;
Figure 6 shows a cross-sectional view of an arrangement of a flavour pod;
Figure 7 shows in detail parts of another arrangement of a smoking substitute system;
Figure 8 shows detail of the heater and the heater support in the arrangement of Figure 7;
Figure 9 shows another arrangement of a smoking substitute system;
Figure 10 shows detail of part of a smoking substitute system;
Figure 11 shows detail of a heater support which may be used in a smoking substitute system;
Figure 12 shows detail of an alternative heater support which may be used in a smoking substitute
system;
Figure 13 shows detail of a heater which may be used in a smoking substitute system;
Figure 14 shows yet another arrangement of a smoking substitute system;
Figure 15 shows a detailed schematic sectional view of a part of a smoking substitute system;
Figure 16 shows another arrangement of a smoking substitute system;
Figure 17 shows a consumable part of another smoking substitute system.
Figure 18 shows another consumable part of a smoking substitute system; and
Figure 19 shows detail of the consumable part of Figure 18.
Detailed Description of the Invention
[0022] 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.
[0023] Referring to Figures 1 and 2, there is shown a smoking substitute system comprising
a smoking substitute device 100. In this example, the substitute smoking system comprises
a cartomiser 101 and a flavour pod 102. The cartomiser 101 may engage with the smoking
substitute device 100 via a push-fit engagement, a screw-thread engagement, or a bayonet
fit, for example. A cartomiser may also be referred to as a "pod". The smoking substitute
system may be an aerosol delivery device according to the present invention.
[0024] The flavour pod 102 is configured to engage with the cartomiser 101 and thus with
the substitute smoking device 100. The flavour pod 102 may engage with the cartomiser
101 via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example.
Fig. 2 illustrates the cartomiser 101 engaged with the substitute smoking device 100,
and the flavour pod 102 engaged with the cartomiser 101. As will be appreciated, in
this example, the cartomiser 101 and the flavour pod 102 are distinct elements. Each
of the cartomiser 101 and the flavour pod may be an aerosol delivery device.
[0025] As will be appreciated from the following description, the cartomiser 101 and the
flavour pod 102 may alternatively be combined into a single component that implements
the functionality of the cartomiser 101 10 and flavour pod 102. Such a single component
may also be an aerosol delivery device according to the present invention. In other
examples, the cartomiser may be absent, with only a flavour pod 102 present or vice
versa.
[0026] A "consumable" component may mean that the component is intended to be used once
until exhausted, and then disposed of as waste or returned to a manufacturer for reprocessing.
[0027] Referring to Figures 3 and 4, there is shown a smoking substitute system comprising
a smoking substitute device 100 and a consumable 103. The consumable 103 combines
the functionality of the cartomiser 101 and the flavour pod 102. In Figure 3, the
consumable 103 and the smoking substitute device 100 are shown separated from one
another. In Figure 4, the consumable 103 and the smoking substitute device 100 are
engaged with each other.
[0028] Referring to Figure 5, there is shown a consumable 103 engaged with a smoking substitute
device 100 via a push-fit engagement. The consumable 103 may be considered to have
two portions - a cartomiser portion 104 and a flavour pod portion 105, both of which
are located within a single component (as in Figures 3 and 4).
[0029] The consumable 103 includes an upstream airflow inlet 106 and a downstream airflow
outlet 107. In other examples a plurality of inlets and/or outlets are included. Between
and fluidly connecting the inlet 106 and the outlet 107 there is an airflow passage
108. The outlet 107 is located at the mouthpiece 109 of the consumable 103, and is
formed by a mouthpiece aperture.
[0030] As above, the consumable 103 includes a flavour pod portion 105. The flavour pod
portion 105 is configured to generate a first (flavour) aerosol for output from the
outlet 107 of the mouthpiece 109 of the consumable 103. The flavour pod portion 105
of the consumable 103 includes a member 115. The member 115 acts as a passive aerosol
generator (i.e. an aerosol generator which does not use heat to form the aerosol,
also referred to as a "first aerosol generator" in this example), and is formed of
a porous material. The member 115 comprises a supporting portion 117, which is located
inside a housing, and an aerosol generator portion 118, which is located in the airflow
passage 108. In this example, the aerosol generator portion 118 is a porous nib.
[0031] A first storage reservoir 116 (in this example a tank) for storing a first aerosol
precursor (i.e. a flavour liquid) is fluidly connected to the member 115. The porous
nature of the member 115 means that flavour liquid from the first storage 116 is drawn
into the member 115. As the first aerosol precursor in the member 115 is depleted
in use, further flavour liquid is drawn from the first storage reservoir 116 into
the member 115 via a wicking action.
[0032] As described above, the aerosol generator portion 118 is located within the airflow
passage 108 through the consumable 103. The aerosol generator portion 118 therefore
constricts or narrows the airflow passage 108. The aerosol generator portion 118 occupies
some of the area of the airflow passage, resulting in constriction of the airflow
passage 108. The airflow passage 108 is narrowest adjacent to the aerosol generator
portion 118. Since the constriction results in increased air velocity and corresponding
reduction in air pressure at the aerosol generator portion 118, the constriction is
a Venturi aperture 119.
[0033] The cartomiser portion 104 of the consumable 103 includes a second storage reservoir
110 (in this example a tank) for storing a second aerosol precursor (i.e. e-liquid,
which may contain nicotine). At one end of the second storage reservoir 110 is a wick
support element 120, which supports a wick 111. As will be described in more detail
later, aerosol precursor passes through one or more bores (not shown in Fig.5) in
the wick support element 120 to reach the wick 111. The surface of the wick furthest
from the reservoir then acts as an activation surface from which aerosol precursor
will be released in the form of a vapour, or a mixture of vapour and aerosol.
[0034] A heater 112 is a configured to heat the wick 111. The heater 112 may be in the form
of one or more resistive heating filaments that abut the wick 111. The wick 111, the
heater 112 and the e-liquid storage reservoir 110 together act as an active aerosol
generator (i.e. an aerosol generator which uses heat to form the aerosol, referred
to as a "second aerosol generator" in this example). The second storage reservoir
110, the wick support element, and the wick 111 form a fluid-transfer article, as
they transfer aerosol precursor to the activation surface to be heated by the heater
112.
[0035] The heater 112 is supported in the smoking substitute device 100 by a heater support
element 130. There may be one or more passages (not shown in Figure 5) through the
heater support element 130 to allow air to reach the activation surface of the wick
111 from an inlet (again not shown in Figure 5) of the smoking substitute device.
[0036] The smoking substitute device 100 includes an electrical power source (not shown),
for example a battery. That battery is then connected via suitable electrical connections
to the heater 112. The heater 112, the battery, and other components of the smoking
substitute system device 100 form a non-consumable part of the device from which the
consumable may be connected and disconnected.
[0037] In the arrangement of the smoking substitute device 100 of Figure 5, and in the arrangement
to be described later, the consumable 103 is separable from the rest of the smoking
substitute device 100. This allows the consumable 103 to be replaced, or possibly
refilled, when the first and/or second aerosol precursor have been consumed by the
user. Since the consumable 103 includes the wick 111 and the wick support element
120, these components will be removed when the consumable 103 is separated from the
rest of the smoking substitute device 100. The heater 112, on the other hand, will
remain when the consumable 103 is removed, so that it is non-consumable.
[0038] In use, a user draws (or "sucks", or "pulls") on the mouthpiece 109 of the consumable
103, which causes a drop in air pressure at the outlet 107, thereby generating air
flow through the inlet, through the passages in the heater support element 130, past
the activation surface of the wick 111, along the airflow passage 108, out of the
outlet 107 and into the user's mouth.
[0039] When the heater 112 is activated (by passing an electric current through one or more
heating filaments in response to the user drawing on the mouthpiece 109) the e-liquid
(aerosol precursor) located in the wick 111 at the activation surface adjacent to
the or each heating filament is heated and vaporised to form a vapour. The vapour
condenses to form the second aerosol within the airflow passage 108. Accordingly,
the second aerosol is entrained in an airflow along the airflow flow passage 108 to
the outlet 107 and ultimately out from the mouthpiece 109 for inhalation by the user
when the user 10 draws on the mouthpiece 109.
[0040] The substitute smoking device 100 supplies electrical current to the heating filament
or filaments of the heater 112 and the heating filament or filaments heat up. As described,
the heating of the heating filament or filaments causes vaporisation of the e-liquid
in the wick 111 to form the second aerosol.
[0041] As the air flows up through the airflow passage 108, it encounters the aerosol generator
portion 118. The constriction of the airflow passage 108 caused by the aerosol generator
portion 118 results in an increase in air velocity and corresponding decrease in air
pressure in the airflow in the vicinity of the porous surface 118 of the aerosol generator
portion 115. The corresponding low pressure region causes the generation of the first
(flavour) aerosol from the porous surface 118 of the aerosol generator portion 118.
The first (flavour) aerosol is entrained into the airflow and ultimately is output
from the outlet 107 of the consumable 103 and thus from the mouthpiece 109 into the
user's mouth.
[0042] The first aerosol may be sized to inhibit pulmonary penetration. The first aerosol
may be formed of particles with a mass median aerodynamic diameter that is greater
than or equal to 15 microns, in particular, greater than 30 microns, more particularly
greater than 50 microns, yet more particularly greater than 60 microns, and even more
particularly greater than 70 microns.
[0043] The first aerosol may be sized for transmission within at least one of a mammalian
oral cavity and a mammalian nasal cavity. The first aerosol may be formed by particles
having a maximum mass median aerodynamic diameter that is less than 300 microns, in
particular less than 200 microns, yet more particularly less than 100 microns. Such
a range of mass median aerodynamic diameter will produce aerosols which are sufficiently
small to be entrained in an airflow caused by a user drawing air through the flavour
element and to enter and extend through the oral and or nasal cavity to activate the
taste and/or olfactory receptors.
[0044] The second aerosol generated may be sized for pulmonary penetration (i.e. to deliver
an active ingredient such as nicotine to the user's lungs). The second aerosol may
be formed of particles having a mass median aerodynamic diameter of less than or equal
to 10 microns, preferably less than 8 microns, more preferably less than 5 microns,
yet more preferably less than 1 micron. Such sized aerosols tend to penetrate into
a human user's pulmonary system, with smaller aerosols generally penetrating the lungs
more easily. The second aerosol may also be referred to as a vapour.
[0045] The size of aerosol formed without heating is typically smaller than that formed
by condensation of a vapour.
[0046] As a brief aside, it will be appreciated that the mass median aerodynamic diameter
is a statistical measurement of the size of the particles/droplets in an aerosol.
That is, the mass median aerodynamic diameter quantifies the size of the droplets
that together form the aerosol. The mass median aerodynamic diameter may be defined
as the diameter at which 50% of the particles/droplets by mass in the aerosol are
larger than the mass median aerodynamic diameter and 50% of the particles/droplets
by mass in the aerosol are smaller than the mass median aerodynamic diameter. The
"size of the aerosol", as may be used herein, refers to the size of the particles/droplets
that are comprised in the particular aerosol.
[0047] Referring to Fig. 6, there is shown a flavour pod portion 202 of a consumable, the
consumable providing an aerosol delivery device in accordance with the invention.
The consumable further comprises a cartomiser portion (not shown in Fig. 6) having
all of the features of the cartomiser portion 104 described above with respect to
Fig. 5.
[0048] The flavour pod portion 202 comprises an upstream (i.e. upstream with respect to
flow of air in use) inlet 204 and a downstream (i.e. downstream with respect to flow
of air in use) outlet 206. Between and fluidly connecting the inlet 204 and the outlet
206 the flavour pod portion 204 comprises an airflow passage 208. The airflow passage
208 comprises a first airflow branch 210 and a second airflow branch 212, each of
the first airflow branch 210 and the second airflow branch 212 fluidly connecting
the inlet 204 and the outlet 206. In other examples the airflow passage 208 may have
an annular shape. The outlet 206 is located at the mouthpiece 209 of the consumable
103, and is also referred to as a mouthpiece aperture 206.
[0049] The flavour pod portion 202 comprises a storage 214, which stores a first aerosol
precursor. The storage 214 comprises a reservoir 216 located within a chamber 218.
The reservoir 216 is formed of a first porous material.
[0050] The flavour pod portion 202 comprises a member 220, which comprises an aerosol generator
portion 222 and a supporting portion 223. The aerosol generator portion 222 is located
at a downstream end (an upper end in Fig. 6) of the member 220, while the supporting
portion 223 makes up the rest of the member 220. The supporting portion 223 is elongate
and substantially cylindrical. The aerosol generator portion 222 is bulb-shaped, and
comprises a portion which is wider than the supporting portion 223. The aerosol generator
portion 222 tapers to a tip at a downstream end of the aerosol generator portion 222.
[0051] The member 220 extends into and through the storage 214. The member 220 is in contact
with the reservoir 216. More specifically, the supporting portion 223 extends into
and through the storage 204 and is in contact with the reservoir 216. The member 220
is located in a substantially central position within the reservoir 216 and is substantially
parallel to a central axis of the consumable. The member 220 is formed of a second
porous material.
[0052] The first and second airflow branches 210, 212 are located on opposite sides of the
member 220. Additionally, the first and second airflow branches 210, 212 are located
on opposite sides of the reservoir 216. The first and second airflow branches 210,
212 branch in a radial outward direction (with respect to the central axis of the
consumable 200) downstream of the inlet 204 to reach the opposite sides of the reservoir
216.
[0053] The aerosol generator portion 222 is located in the airflow passage 208 downstream
of the first and second airflow branches 210, 212. The first and second airflow branches
210, 212 turn in a radially inward direction to merge at the member 220, at a point
upstream of the aerosol generator portion 222.
[0054] The aerosol generator portion 222 is located in a narrowing section 224 of the airflow
passage 208. The narrowing section 224 is downstream of the point at which the first
and second airflow branches 210 212 merge, but upstream of the mouthpiece aperture
207. The mouthpiece aperture 207 flares outwardly in the downstream direction, such
that a width of the mouthpiece aperture 207 increases in the downstream direction.
[0055] In use, when a user draws on the mouthpiece 209, air flow is generated through the
air flow passage 208. Air (comprising the second aerosol from the cartomiser portion
as explained above with respect to Fig. 5) flows through the inlet 204 before the
air flow splits to flow through the first and second airflow branches 210, 212. Further
downstream, the first and second airflow branches 210, 212 provide inward airflow
towards the member 220 and the aerosol generator portion 222.
[0056] As air flows past the aerosol generator portion in the narrowing section 224, the
velocity of the air increases, resulting in a drop in air pressure. This means that
the air picks up the first aerosol precursor from the aerosol generator portion 222
to form the first aerosol. The first aerosol has the particle size and other properties
described above with respect to Fig. 5.
[0057] As the first aerosol precursor is picked up by the air, the member 220 transfers
further first aerosol precursor from the storage 214 to the aerosol generator portion
222. More specifically, the member 220 wicks the first aerosol precursor from the
storage 214 to the aerosol generator portion 223.
[0058] In other examples, the storage 214 comprises a tank containing the first aerosol
precursor as free liquid, rather than the reservoir 216 and the chamber 218. In such
examples, the member 220 still extends into the tank to transfer first aerosol precursor
from the tank to the aerosol generator portion 223.
[0059] Further arrangements of the present invention will now be described, which arrangements
incorporate one or more features of the aspects of the present invention. In the subsequent
arrangements, the smoking substitute device 100 includes a consumable 103 in the form
of a cartomiser, but does not include a flavour pod. However the smoking substitute
device 100 of the subsequent arrangements may be modified to incorporate a flavour
pod in a way similar to the arrangement of Figures 5 and 6.
[0060] As mentioned above, the wick 111 is supported by a wick support element 120. Figure
7 illustrates an arrangement of a smoking substitute system in which these components
are illustrated in more detail, and in an exploded view. The wick support element
120 is mounted at an end of the second storage reservoir 111 and has bores 122 therethrough
to allow aerosol precursor in the second storage reservoir 110 to pass to the wick
110. These bores may be sized so that aerosol precursor may flow therethrough in a
non-capillary manner. Although, two bores 122 are visible in Figure 7, there may be
more arranged around the wick support element 120.
[0061] In the arrangement of Figure 7, the wick support element 120 is made of a resilient
material, such as rubber, and thus may deform when force is applied thereto. In particular,
when the consumable 103 is mounted on the main body 100, the wick 111 is brought into
contact with the heater 112, and is held thereto by the resilience of the wick support
element 120. The wick support element 120 may be sized so that it deforms slightly
when the wick 111 is in contact with the heater 112, so as to provide a biasing force
to urge the wick 111 into firm contact with the heater 112.
[0062] The wick 111 has an opening 124 at its centre, which is aligned with a passageway
126 through the wick support element 122. The passageway 126 communicates with the
air-flow passage 108 shown in Fig. 5 so that air, together with vapour or a mixture
of vapour and aerosol, will pass to the user. The surface of the wick 111 closest
to the heater 112 acts as an activation surface for the aerosol precursor and, as
the wick 111 is heated by the heater 112, aerosol precursor is released from the activation
surface in the form of vapour or a mixture of vapour and aerosol, it can then pass
through the opening 124 and the passageway 126 into the air-flow passage 108.
[0063] As illustrated in Figure 7, the heater 112 is mounted on a heater support element
130, which may act as an end wall of a battery housing and which may itself be supported
by a support wall 132. The casing of the main body 100 (not shown in Figure 7) will
enclose the support wall 132 and parts of the heater support element 130. In order
for air to flow from the activation surface of the wick 111 through the opening 124
and into the passage 126, air must first reach the activation surface of the wick
111. The support wall 132 may thus have a bore 134 therethrough, which communicates
with passages 136 (not shown in Figure 7) through the heater support element 130.
Figure 8 illustrates these passages 136 and shows that they open immediately adjacent
the heater 112 and hence adjacent the activation surface of the wick 111. The casing
of the main body 100 may be provided with an inlet at a suitable location, to allow
air to reach the bore 134, and hence to flow to the passages 136 in the heater support
element 130. Hence, when the user draws on the mouthpiece 109 of the consumable 103,
air is drawn into the casing of the main body 100 through the bore 134 and the passages
136 to reach the activation surface of the wick 111 adjacent the heater 112. That
air then passes, together with vapour or mixture of aerosol and vapour generated by
heating of the aerosol precursor by the heater 112, through the opening 124 in the
wick 111 to the passage 126, and hence to the air-flow passage 108, and then to user,
as has previously been described.
[0064] Note that in the arrangement of Figures 7 and 8, the heater 112 will need to be connected
to a power source, such as a battery, and there may then need to be additional bores
(not shown in Figures 7 and 8) through the heater support element 130 and the support
wall 132 to allow electrical leads to pass therethrough.
[0065] Figure 9 illustrates another arrangement of a smoking substitute system, in which
the consumable has a single reservoir for aerosol precursor which corresponds to the
second storage reservoir 110 in the embodiment of Figure 5. In this arrangement, the
consumable does not have a flavour pod portion. For simplicity, parts corresponding
to those of Figures 5 to 8 are indicated by the same reference numerals. Note that
in Figure 9, the support wall 132 has multiple bores 134 therethrough, aligned with
the passages 136 in the heater support element 130.
[0066] Figure 9 also shows the casings of the device. In particular, there is a casing 300
(the "first" casing), being a casing of the consumable 103. That casing contains the
reservoir 110 for aerosol precursor, and also supports the wick support element 120
and the wick 111. A tube 302 within that first casing 300 forms a bounding wall of
the air-flow passage 108, and the mouthpiece 109 is formed at an end of the first
casing 300. The main device 100 also has a casing 310 (the "second" casing on which
are mounted the support wall 132 and the heater support element 130. There is a space
312 within the second casing 310 for a battery and other electronic components used
to power the heater 112, and the second casing 310 may also have an inlet 314 to allow
air to enter the space 312 and hence pass to the bores 134 and the passages 136 to
enable it to reach the activation surface of the wick 110.
[0067] Figure 9 also shows electrical leads 138 which extend through the support wall 132
and the heater support element 130 to enable the heater 112 to be connected to a battery
in space 312. Small bores may be formed in the heater support element 130 and the
support wall 132 through which the leads 138 may pass. The first and second casings
300, 310 are separable and held together by a "click" engagement 316. When the two
casings 300,310. are interconnected, as shown in Fig.9, the wick 111 is forced into
contact with the heater 112 by the resilience of the wick support element 120, so
that good heating of the activation surface of the wick 111 will occur when the heater
112 is active. The separability of the two casing 300, 310 allows the consumable 103
to be removed from the main body 100, and replaced, e.g. when the aerosol precursor
in the reservoir 110 is exhausted.
[0068] Figure 10 shows a perspective view of the consumable 103 in Figure 9, with the part
of the first casing 300 removed so that the wick 111 and the wick support element
120 are clearly visible. It can be seen from Figure 10 that the wick 111 is flat and
so has a planar activation surface (the exposed surface of the wick 111 in Figure
10). Figure 10 also shows clearly the opening 124 in the wick 111, which allows communication
with the passageway 126 through the wick support element 120. The wick support element
120 in this embodiment, and in some other embodiments, is preferably made of rubber
material. In a similar way, the wick 111 is preferably made of silica material, which
material is suitably porous to allow the aerosol precursor to pass therethrough. Alternatively,
the wick may be of fibrous material, woven material or porous ceramic material.
[0069] Figures 11 and 12 illustrate two alternative configurations of a heater support element
130 which may be used in the present invention. They differ in the shape of the mouth
of the passage 136 through the heater support element 130 which allows air to pass
through the heater support element from e.g. the interior of the casing of the main
body 100 to the vicinity of the heater 112 and the activation surface of the wick
111. Note that, in Figures 11 and 12, the heater itself is not shown and there is
a single passage 134 through the heater support element 132. In each of the alternative
configurations, the heater support element 130 is preferably made of resilient material,
which must also be suitable to resist the heat generated by the heater 112.
[0070] In Figure 11, the heater support element 130 comprises a body part 500 which has
a peripheral seal surface 502 which seals to the casing 310 (not shown in Figure 11).
The seal between the seal surface 502 and the casing 310 needs to be sufficiently
strong to prevent, or at least significantly resist, movement of the heater support
element 130 in the casing 310, particularly when the consumable 103 is removed from
the main body 100.
[0071] A projecting part 504 projects from the body part 500, terminating in a flat heater
support face 506. The periphery of the projecting part 504 seals to the casing 300
of the consumable 103, and for this purpose may have ribs 508 on its side surface.
However, unlike the sealing of the seal surface 502 to the casing 310 of the main
body 100, the sealing of the projecting part 504 to the casing 300 of the consumable
103 needs to allow the consumable 103 to be removed to allow another consumable 103
to be mounted thereon without too much resistance. Nevertheless, the sealing must
be sufficiently good to limit leakage of any aerosol precursor which has passed through
the wick 111 but has not been vaporised by the heater 112. As in the arrangement of
Figure 9, the passage 136 passes through the heater support element 130 to enable
air to pass towards the heater 112 and the wick 111. In the heater support element
130 shown in Figure 11, the passage 136 terminates in a splayed or funnelled mouth
510, which opens into a slot 512 in the heater support surface 506, so that air which
has passed through the bore 136 can expand in the funnelled mouth 510 before reaching
the heater 112.
[0072] Figure 11 also shows bores 514 through which pass leads from the heater 112, which
leads will provide electrical connection to the battery.
[0073] The heater support element 130 shown in Figure 11 is resilient and is preferably
made of silicone material, with provision to resist high temperatures which may be
generated by the heater 112. For example, the material known as Polygraft HT-3120
silicone, which is a two-part mix, may be a suitable material from which the heater
support element 132 may be made. The configuration shown in Figure 11 will normally
be made by moulding the silicone material in a suitable mould.
[0074] Figure 12 illustrates an alternative heater support element 130. It is generally
similar to the heater support element 130 shown in Figure 11 and the same reference
numerals indicate corresponding parts. It may be made of the same materials as the
heater support element 130 of Figure 11. The heater support element 130 of Figure
12 differs from that of Figure 11 in that the passage 136 opens directly into the
channel 512 in the heater support surface 506. There is thus a flat face 516 at the
bottom of the channel 516, rather than the funnel mouth 510 shown in Figure 11.
[0075] Figure 13 shows a heater that may be used with the heater support element 130 shown
in Figure 11 or Figure 12. The heater comprises a heater filament 520 which is generally
flat and rests on the heater support face 506 of the heater support element 130. For
this reason, the filament 520 is not straight but meanders in its plane. Figure 13
also shows the leads 138 which extend through the bores 514 of the heater support
130 shown in Figure 11 or Figure 12, to enable the heater 112 to be connected to a
battery.
[0076] Figure 14 illustrates an arrangement of a smoking substitute system which incorporates
the heater support element 132 of Figure 11, and also the heater 112 of Figure 13.
The arrangement of Figure 14 is generally similar to that of Figure 9, and corresponding
parts are indicated by the same reference numerals. As mentioned previously, when
the heater support element 132 of Figure 11 is used, there is only a single bore 136
therein for air, hence there is only a single bore 134 in the support 132 in the main
body 100. The bore 136 extends to the funnelled mouth 510 which opens into the slot
512 directly below the heater 112. Note that the leads 138 of the heater 112 are not
visible in Figure 14.
[0077] Figure 14 illustrates how the seal surface 502 of the main body 500 seals to the
second casing 310, and the projecting part 504 seals to the first casing 300. This
sealing is illustrated in more detail in the enlarged view of Figure 15. In particular,
the first casing 300 of the consumable 103 extends sufficiently far within the second
casing 310 of the main body 100 so as to contact the projecting part 504 of the heater
support element 130 at a sealing interface 518. Similarly, the main body 500 of the
heater support element 130 seals at a sealing interface 520 with the casing 310 of
the main body 100. As mentioned previously, the degrees of sealing at these two sealing
interfaces 518 and 520 are preferably different, since the heater support element
130 does not normally release from the second casing 310, but must release from the
first casing 300 when the consumable 103 is removed.
[0078] Figure 15 also shows how the funnelled mouth 510 of the passage 136 opens within
the heater support element 130 towards the heater 112 and the wick 111. This causes
the airflow from the passage 136 to expand, as illustrated by the arrows 522, so that
there is a good air flow where the heater 112 meets the wick 111, to entrain vapour
therein prior to flow to the passage 126 in the wick support element 120.
[0079] With the arrangement shown in Figure 15, as in the other arrangements, the sealing
between the first casing 300 and the heater support element 130 at the sealing interface
518 prevents any leakage of aerosol precursor which has come from the wick 111 and
has not been vaporised by the heater 112. Hence, when the consumable 103 is fitted
in place on the main body 100, the only escape route for the aerosol precursor is
via the air flow passage 108 and the mouthpiece 109. This helps to ensure efficient
consumption of the aerosol precursor.
[0080] The arrangement of Figure 14 also differs from the arrangement of Figure 9 (and also
that of Figure 15), in that the wick 111 extends across the whole of the end face
of the wick support element 120, as in the arrangement of Figure 10. As before, the
wick 111 has an opening 124 therein to allow air to pass through the wick 111 and
into the passage 126, and hence through the air-flow passage 108 so that it can reach
the outlet 109 and thus pass to the user.
[0081] Figure 16 shows another arrangement of a smoking substitute system, which is generally
similar to that of the embodiment of Figs. 9 and 10 and corresponding parts are indicated
by the same reference numerals. In the embodiment of Fig.16, however, there is no
heater support element 130, and instead the heater 112 is a coil or other filament
held within the second casing 310, which has a space 400 adjacent thereto. The space
400 communicates with inlets (not shown in Figure 16) which allow air to enter the
casing 310 and pass to the activation surface of the wick 111. Again, the wick 111
is forced into contact with the heater 112 by the resilience of the wick support element
120. In this arrangement, the flow of air to the activation surface is not restricted
by the size of the passage or passages through the heater support element 130. In
this arrangement the heater 112 needs to be sufficiently stiff that it is not deformed
when the wick 111 is urged into contact therewith by the resilient wick support element
120.
[0082] In the arrangements of the smoking substitute system described above, the wick support
element 120 is a separate element from the first casing 300 of the consumable 103.
Figure 17 illustrates an alternative arrangement, in which the wick support element
is integral with part of the first casing 300.
[0083] In the arrangement of Figure 17, parts which correspond to arrangements described
previously are indicated by the same reference numerals. Note that, in Figure 17,
the main body 100 is not shown. It may be the same as in the other arrangements of
a smoking substitute system described previously.
[0084] In the arrangement of Figure 17, the first casing 300 has a lower part 300a and an
upper part 300b. The mouthpiece 109 is in the upper part 300b, and the tube 302 is
also integral with that upper part 300b. The lower part 300a has an upper rim which
meets a lower rim of the upper part 300b at a sealing surface 600, and has an internal
flange 602 adjacent its lower end. The internal flange 602 corresponds to the wick
support element 120 of the arrangements previously described. The internal flange
602 has a central bore forming passage 126, which passage is aligned with the passage
108 within the tube 302. The end of the tube 302 furthest from the mouth piece 109
engages the flange 602 and is sealed thereto.
[0085] The interiors of the upper and lower parts 300b and 300a of the casing 300 are hollow,
and form the reservoir 110. There are bores 122 in the flange 602 to allow the reservoir
110 to communicate with the wick 111, in the same way as the bores 122 in the earlier
arrangements described previously. Thus, aerosol precursor in the reservoir 110 may
pass through the bores 122 to saturate the wick 111, and then be heated by the heater
112 (not visible in Figure 17). The arrangement of Figure 17 prevents any leakage
of aerosol precursor between the wick support element 120 and the casing 300. Whilst
there could be leakage between the upper and lower parts 300b, 300a of the casing
300, this can be prevented by suitable configuration of the sealing interface 600.
However, if the sealing of the reservoir 110 is too good, air may not be able to enter
it to replace aerosol precursor which has been consumed.
[0086] Therefore, Figure 17 shows that there may be at least one additional bore 604 in
the flange 602, to allow passage of air to the reservoir 110 from outside the first
casing. The or each additional bore 604 needs to be sufficiently small that it will
not allow a significant amount of aerosol precursor to pass therethrough. For example,
the or each additional bore 604 may be e.g. 0.2 to 0.5mm in diameter, more preferably
0.32 to 0.5mm, even more preferably 0.32 to 0.4mm. If the flange has a thickness of
e.g. 0.5 to 5mm, preferably 1 to 5mm, aerosol precursor should not be able to escape
reservoir 110 through the or each additional bore 604. In general, the thicker the
flange 602, the greater the possible diameter of the or each additional bore 604 may
be, without it allowing aerosol precursor to flow therethrough. A thin flange 602
(which thinness may be desirable for manufacture) will thus need the diameter of the
or each additional bore to be small.
[0087] The upper and lower parts 300a, 300b of the casing 300 may be separable to allow
for refiling of the reservoir 110 once the aerosol precursor wherein has been consumed.
In such an arrangement, the sealing at the sealing surface 640 needs to be sufficiently
good to prevent leakage of aerosol precursor therethrough when the smoking substitute
system is in use. Alternatively, the seal at the sealing surface 600 may be a permanent
one, with the upper and lower parts 300a and 300b if the casing bonded together. In
such an arrangement, the reservoir 110 may not be refillable, and the consumable 101
would need to be replaced once the aerosol precursor in the reservoir 110 had been
consumed.
[0088] In the arrangements described previously, the bores 122 in the wick support element
120 (or in the flange 602 in the case of Figure 17) were described as being sized
so that aerosol precursor may flow therethrough in a non-capillary manner. In an alternative,
applicable to all the arrangements described previously, the bores 122 may be capillary
ducts (hereinafter referred to as capillary bores) which allow aerosol precursor to
flow therethrough in a capillary manner. The capillary bores allow the flow of aerosol
precursor to the wick 111, in a controlled manner, so that there is less chance of
there being excess aerosol precursor at the wick 111. In general, the capillary bores
may have a diameter range of 0.3mm to 2mm, as a diameter of less than 0.3mm will generally
not allow sufficient aerosol precursor to pass to the wick 111. Preferably, the diameter
is at least 0.5mm, preferably 0.8 to 1.5mm, and more preferably 1 mm or 1.3mm. In
practice, the diameter of the capillary bores may be affected by the thickness of
the wick support element 120, which can have a thickness of e.g. 0.5mm to 5mm, more
preferably 1 to 5mm, such as 4mm, 3mm, 2mm and 1mm. In general, the width of the capillary
bores will need to be greater with greater thickness of the wick support element 120.
[0089] In the arrangements of Figures 6 to 16, the wick support element 120 is made of resilient
material such as rubber. In the arrangement of Figure 17 on the other hand, the support
for the wick 111 is rigid, because it was formed by the internal flange 602 which
was integral with, and therefore made of the same material as, the casing 300. Figures
18 and 19 then illustrate another arrangement in which the wick is supported by a
rigid element. Unlike the arrangement of Figure 17, however, in the arrangement of
Figures 18 and 19, that rigid element is a separate wick support element 720. In Figures
18 and 19, parts which correspond to parts of earlier arrangements are indicated by
the same reference numerals. Moreover, as in Figure 17, only the consumable 103 is
illustrated. The main part 100 may be the same as in earlier arrangements.
[0090] In particular, in the arrangements of Figures 18 and 19, the rigid wick support element
720 is formed at an end of the reservoir 110, within the first casing 300. Bores 122
through the wick support element 720 allow aerosol precursor from the reservoir 110
to pass to wick 111. Whilst the bores 122 may be non-capillary bores, they are preferably
capillary bores. The diameter of the capillary bores may be as previously described,
as may the thickness of the wick support element 720. Although not illustrated in
Figures 18 and 19, there may need to be an additional bore or bores in the wick support
element 720 to allow passage of air to the reservoir 110, corresponding to the at
least one additional bore 604 in Figure 17.
[0091] In order to prevent escape of liquid from the reservoir, the wick support element
720 is preferably sealed to the first casing 300 by seals 610. For example, the seals
610 may be O-ring seals extending around the wick support element 120. The seals can
be seen clearly in Figure 19, as can the opening 124 in the wick 111, which leads
to the passage 126 through the wick support element 720 to the air-flow passage 108.
The wick support element 720 also needs to be sealed to the tube 302, to prevent escape
of aerosol precursor from the reservoir 110. To achieve this, the wick support element
720 may have an upstanding ring 612, which then seals (e.g. by O-rings and/or an interference
fit) to the tube 302. Grooves for those O-rings are illustrated in Figure 19. Another
possibility is for the tube 302 to be integral with the wick support element 720,
with the end of the tube 302 being sealed to the casing 300 adjacent the mouthpiece
109.
[0092] The rigidity of the wick support element 720 and the tube 302 means that the positioning
of the wick support element 720 on the tube 302 and the positioning of the tube 302
relative to the casing 300 may be determined to good precision. This ensures that
the wick 111 is accurately positioned relative to the casing 300, and hence accurately
positioned relative to the casing 310 and the heater 112.
[0093] In the arrangement of Figures 18 and 19, the wick support element 720 may be made
of the same material as the casing 300 (and the casing 310) such as being made from
moulded polypropylene plastics material. Other suitable materials to form the wick
support element 720 include ABS and PEAK materials. The seals 610 may be O-rings of
e.g. rubber material or silicone seals co-moulded with the wick support element 720,
but preferably are nitrile or thermoplastic polymer O-ring seals. The moulding of
the wick support element 720 and the first and second casings 300, 310 simplifies
manufacture.
[0094] Because the wick support element 720 is rigid in the arrangement of Figures 18 and
19, it may be thinner than the resilient wick support elements 120 described with
reference to e.g. Figures 5 to 16. Thus, it may then be possible to have a wick support
element 720 with a thickness of e.g. 0.5 to 2mm, preferably 1mm, allowing the bores
122 to have a small diameter, and still provide a capillary effect. The same is true
in the arrangement of Figure 17. Thus, at least in the arrangements of Figures 17
to 19, the bores 122 may have a diameter of 0.3mm to 2mm, most preferably 0.5mm. If
one or more additional bores are provided, corresponding to the additional bores 604
in the arrangement of Figure 18, to allow air to enter the reservoir volume to replace
aerosol precursor which has passed to the wick 111, those additional bores will have
small diameters, due to the reduced thickness of the wick support element 720, so
e.g. less than 0.3mm. The diameter of the additional bores will always be less than
the diameter of the capillary bores. It should be noted that, even in the arrangements
of Figures 5 to 16, it may be possible to have small diameter capillary bores, if
the wick support element 120 s thin enough.
[0095] In the arrangements of Figures 17 to 19, the position of the wick 111 is precisely
determined, relative to the casing 300, either because the wick support element is
part of the casing itself, as in the arrangement of Figure 17, or because the position
of the wick support element 720 is determined by a component of the casing such as
the tube 302, as in the arrangement of Figures 18 and 19. This precise positioning
of the wick 111 in the casing 300 means that manufacture will be consistent and hence
replacement of one consumable with another will not alter the relationship between
the wick 111 and the heater 112, and so will not affect the efficiency of the smoking
substitute device.
[0096] The use of capillary bores 122 in the wick support element 720 in the arrangements
of Figures 17 to 19 mean that it is possible to optimise the flow of aerosol precursor
to the wick 111 to minimise leakage. The length and diameter of the capillary bores
122 may be chosen to control the flow of a specific aerosol precursor formulation
to the wick 111, based on the viscosity and liquid characteristics of that aerosol
precursor. When aerosol precursor is vaporised from the wick 111 by the heater 112,
there will be an available volume of air in the wick 111 allowing additional aerosol
precursor to flow into the wick 111, so that the wick 111 is maintained in a saturated
state when the device is in use. The rigid nature of the wick support element 720
improves the consistency of liquid flow to the wick 111, compared to a wick support
element 120 of resilient material, so that efficient operation may be achieved.
[0097] The sealing configuration in the arrangement of Figures 18 and 19 makes use of O-rings,
with the effect of minimising leakage in use and in transit, as a robust seal is created
between the wick support element 720 and the casing 300, so that there is no leakage
path therebetween. O-ring technology is well established, so it is straight forward
to put in to practice in the smoking substitute device to reduce or eliminate variation
between parts, improving repeatability of manufacture.
[0098] The use of a rigid wick support element 720 in the arrangements of Figures 17 to
19 means that the wick support element 720 is easy to manufacture with high precision,
and the assembly of the consumable may easily be automated. This ensures efficient
manufacture, thereby reducing costs.
[0099] 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.
[0100] 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.
[0101] 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.
[0102] Any section headings used herein are for organizational purposes only and are not
to be construed as limiting the subject matter described.
[0103] 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.
[0104] 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%.
[0105] 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.