Producing an aerosol-forming composition

Abstract

There is provided a machine for producing an aerosol-forming composition for an aerosol-generating system, the machine including a plurality of reservoirs configured to contain components of an aerosol-forming composition; a mixing mechanism in communication with the plurality of reservoirs; a controller connected to, and configured to control, the mixing mechanism; a user interface connected to the controller for a user to operate the machine, the mixing mechanism being configured to mix selective quantities of components from the plurality of reservoirs according to specified ratios to create an aerosol-forming composition; a testing mechanism including a heater assembly configured to vaporize a test sample to form an aerosol, and at least one outlet configured to deliver the aerosol to the user; and a transfer mechanism configured to deliver the test sample to the testing mechanism. There is also provided a machine and process for producing and delivering the test sample.

Claims

1. A machine for producing an aerosol-forming composition for an aerosol-generating system, the machine comprising: a main housing and a handheld electrically-operated aerosol-generating device, the main housing comprising a housing containing: a plurality of reservoirs configured to contain components of an aerosol-forming composition; a mixer in communication with the plurality of reservoirs, the mixer being configured to mix selective quantities of components from the plurality of reservoirs according to specified ratios to create an aerosol-forming composition: a controller connected to, and being configured to control, the mixer; and a transfer head configured to deliver a test sample of the aerosol-forming composition to the aerosol-generating device; the main housing further comprising: a user interface connected to the controller and being configured for a user to operate the machine; and a docking station for the aerosol-generating device; the aerosol-generating device comprising: a heater assembly configured to vaporize the test sample to form an aerosol, the heater assembly comprising a heating element formed from an electrically resistive material; an aerosol-forming chamber to form an aerosol from the vaporized test sample; and an air inlet and an air outlet, wherein an airflow route is defined from the air inlet to the air outlet via the aerosol-forming chamber for delivering the aerosol to the air outlet, wherein the aerosol-generating device is coupled to the main housing, the coupling providing an electrical connection between the main housing and the aerosol-generating device.

2. The machine according to claim 1, further comprising a heater supply containing a plurality of heater assemblies configured for the aerosol-generating device.

3. The machine according to claim 2, wherein the transfer head is further configured to select a heater assembly from among the plurality of heater assemblies of the heater supply, to apply the aerosol-forming composition on one or more surfaces of the heater assembly, and to deliver the heater assembly to the aerosol-generating device.

4. The machine according to claim 1, wherein the plurality of reservoirs is housed in the main housing.

5. The machine according to claim 1, further comprising: a mouthpiece supply containing a plurality of mouthpieces configured to removably couple with the at least one outlet of the aerosol-generating device; and a mouthpiece delivery mechanism configured to deliver a mouthpiece from the mouthpiece supply for subsequent coupling to the at least one outlet.

6. The machine according to claim 1, further comprising a dispensing port configured to receive an unfilled cartridge for the aerosol-generating system and a dispensing mechanism connected to the controller and in communication with the mixer, wherein the mixer is further configured to mix the selective quantities of components from the plurality of reservoirs according to the specified ratios to create the aerosol-forming composition for filling into the unfilled cartridge, and wherein the dispensing mechanism is configured to fill into the unfilled cartridge.

7. The machine according to claim 6, further comprising a cartridge supply containing a plurality of unfilled cartridges for the aerosol-generating system and a cartridge delivery mechanism configured to deliver the unfilled cartridge from the cartridge supply to the dispensing port for subsequent filling.

8. The machine according to claim 7, wherein the cartridge supply contains a plurality of cartridges of different types for different types of aerosol-generating systems, and wherein the cartridge delivery mechanism is configured to select a cartridge of a particular type from the cartridge supply based on a desired type of an aerosol-generating system.

9. The machine according to claim 1, wherein the mixer is further configured to mix the selective quantities of components from the plurality of reservoirs to create the aerosol-forming composition test sample having a volume of about 0.5 ml or less.

10. The machine according to claim 1, wherein the mixer is further configured to mix the selective quantities of components from the plurality of reservoirs to create the aerosol-forming composition test sample having a volume of about 0.05 ml to about 0.15 ml.

11. A method for producing an aerosol-forming composition for an aerosol-generating system, the method comprising: receiving a testing instruction, via a user interface, at a machine for producing an aerosol-forming composition, the machine comprising a main housing and a handheld electrically-operated aerosol-generating device, the main housing comprising a controller connected to the user interface, the controller actuating a mixer in fluid communication with a plurality of reservoirs containing components of an aerosol-forming composition; creating an aerosol-fonning composition by mixing selective quantities of components from the plurality of reservoirs according to ratios specified by the testing instruction; delivering a test sample comprising the aerosol-forming composition to, via a transfer head, an aerosol-generating device comprising a heater assembly. an aerosol-forming chamber, an air inlet, and an air outlet, wherein an airflow route is defined from the air inlet to the air outlet via the aerosol-forming chamber for delivering the aerosol to the air outlet, the aerosol-generating device being located at a docking station and being coupled to the main housing, the coupling providing an electrical connection between the main housing and the aerosol-generating device; vaporizing the test sample using the heater assembly to form an aerosol in the aerosol-forming chamber; and delivering the aerosol to the user via the at least one air outlet.

12. The method according to claim 11, wherein the delivering the test sample to the aerosol-generating device comprises actuating the transfer head to select a heater assembly from a heater supply, applying the test sample on one or more surfaces of the heater assembly, and delivering the heater assembly to the aerosol-generating device.

13. The method according to claim 11, further comprising: receiving a dispensing instruction via the user interface; creating an aerosol-forming composition for filling a cartridge for the aerosol-generating system by mixing the selective quantities of components from the plurality of reservoirs according to the ratios specified by the dispensing instruction; and actuating a dispensing mechanism to dispense the aerosol-forming composition to a dispensing port and into a cartridge held in the dispensing port.

14. The method according to claim 11, wherein the aerosol-forming composition test sample has a volume of from about 0.5 ml or less.

15. The method according to claim 11, wherein the aerosol-forming composition test sample has a volume of from about 0.05 ml to about 0.15 ml.

Description

(1) The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

(2) FIG. 1 shows a front view of a machine according to a first embodiment;

(3) FIG. 2 shows an enlarged view of the testing mechanism of FIG. 1;

(4) FIG. 3 shows a functional schematic view of the machine of FIG. 1;

(5) FIG. 4 shows an operational flow chart of the machine of FIG. 1;

(6) FIG. 5 shows an example selection screen for display on the user interface of the machine of FIG. 1;

(7) FIG. 6 shows a front view of a machine according to a second embodiment;

(8) FIG. 7 shows a functional schematic view of the machine of FIG. 6; and

(9) FIG. 8 shows an operational flow chart of the machine of FIG. 6.

(10) Referring to FIGS. 1 to 3, there is shown a machine 10 according to a first embodiment for producing an aerosol-forming liquid for use in an electrically operated aerosol-generating system, such as a smoking system. The machine 10 comprises a main unit 12 and a testing mechanism in the form of a handheld electrically operated aerosol-generating device 14. The aerosol-generating device 14 is external to the main unit 12 and is coupled to the main unit by a flexible electrical cable 16.

(11) The main unit 12 comprises a housing 18 within which is provided a plurality of reservoirs 20. The reservoirs 20 each contain a liquid component of the aerosol-forming liquid. The reservoirs 20 may each contain a different liquid component. Alternatively, the same liquid component may be contained in two or more of the reservoirs 20. In this example, the machine 10 comprises three reservoirs respectively containing nicotine, an aerosol former and a flavourant, although it will be appreciated that the machine may comprise fewer or more reservoirs, for example four, five, six, seven, eight, nine, ten, or more reservoirs containing different liquid components of an aerosol-forming liquid.

(12) The main unit 12 includes a mixing mechanism 22 in fluid communication with each of the reservoirs 20 by supply tubes 24. Each supply tube 24 includes an electrically operated valve 26 to control the flow of the liquid component from the reservoir 20 to the mixing mechanism 22.

(13) The main unit 12 also includes a user interface 28 and a controller 30 connected to the mixing mechanism 22 and to the user interface 28. The user interface 28 is operable by a user to operate the machine, as described below in relation to FIGS. 3 and 4. In this example, the user interface 28 comprises a touch-sensitive display screen, although it could comprise a display in combination with a keyboard, keypad, touch-sensitive pad or other similar input device. The user interface 28 may also comprise a card payment device (not shown), or other payment means for taking payment from a user. The user interface 28 may also comprise a reader (not shown), such as an user-ID card reader or passport reader for verifying a user's age.

(14) The controller 30 is connected to the supply valves 26 and is configured to operate the valves 26 in response to a testing instruction from a user via the user interface 28 to dispense to the mixing mechanism 22 a particular quantity of each liquid component stored in the reservoirs 20 according to the desired ratios specified by the user testing instruction. The mixing mechanism 22 is configured to mix the dispensed quantities of the liquid components to create an aerosol-liquid test sample for transfer to the aerosol-generating device 14.

(15) The main unit 12 includes a docking station 32 having a docking port 34 for receiving the aerosol-generating device. The docking station 32 includes a docking sensor (not shown) operable to detect whether the aerosol-generating device 14 is correctly positioned in the docking port 34. The docking sensor is connected to the controller 30 and the controller 30 is arranged to prevent operation of the machine 10 if the docking sensor detects that the device 14 is not correctly positioned in the docking port 34. The device 14 may be held in the docking port 34 by a releasable coupling, such as a clip. Alternatively, or in addition, the docking port 34 may include a shaped recess arranged to receive and hold at least part of the device 14.

(16) The machine 10 further includes a mouthpiece supply 42 containing a plurality of disposable mouthpieces for use with the aerosol-generating device 14 and a mouthpiece delivery mechanism 44 connected to the controller 30. The mouthpiece delivery mechanism 44 is arranged to remove a mouthpiece from the mouthpiece supply 42 and to deliver the mouthpiece to a mouthpiece supply port 46 provided in the housing of the main unit 12 based on an instruction from the controller 30. The mouthpiece can then be removed from the mouthpiece port 46 by a user and coupled to the aerosol-generating device 14. The main unit 12 also includes a mouthpiece disposal port 48 into which used mouthpieces can be placed by a user for disposal after use.

(17) In this example, the disposable mouthpieces contained in the mouthpiece supply 42 have an outer diameter which corresponds to the inner diameter of the outlet at the downstream end of the aerosol-generating device 14, so that a mouthpiece from the supply can be removably coupled to the outlet by placing the upstream end of the mouthpiece into the outlet. In other examples, each mouthpiece may be arranged to couple to the device 14 via a removable coupling, such as a screw thread, clip, or bayonet fitting.

(18) FIG. 4 is a flow chart showing the operation of the machine 10.

(19) At step S1, the user uses the user interface to activate the machine 10 and initiate a testing procedure. At step S2, the machine 10 performs a start-up procedure to check that a testing operation can be carried out. For example, during this step, the controller 30 may communicate with the docking sensor to confirm whether the aerosol-generating device 14 is correctly positioned in the docking port 34. The controller 30 may also communicate with sensors associated with the reservoirs 20 to confirm whether sufficient levels of e-liquid component are stored in the reservoirs 20. If the controller 30 determines during the start-up procedure that a testing operation cannot be carried out, an error message is displayed on the user interface 28, at step S3, requesting that the user addresses the reason for the halted testing operation, for example by ensuring that the device 14 is correctly positioned in the docking port 34.

(20) At step S4, the user enters user information, including user age information, via the user interface 28, for example by allowing a reader in the user interface to read a user ID, or by entering the information manually. At step S5, the controller 30 determines whether the user age information is valid. If the user age information is not valid, an error message is displayed on the user interface 28 at step S6 to inform the user that the testing procedure will not proceed without valid user age information.

(21) At step S7, the user uses the user interface to input a testing instruction. The testing instruction specifies the desired ratios of each of the liquid components of the aerosol-forming liquid which are stored in the reservoirs 20. The testing instruction may be entered directly by the user via the user interface 28, for example as described below in relation to FIG. 5. Alternatively, the testing instruction can be entered indirectly by the user via the user interface 28 by selecting an e-liquid mix, with predefined component ratios, from a list of suggested mixes or from a list of e-liquid mixes associated with the user. For example, the user interface 28 may display e-liquid formulations previously tested by the user, or previously entered by the user using a remote device and saved to the user's account. As a further alternative, the machine 10 may include a cartridge sensor for reading e-liquid formulation information from a cartridge placed in close proximity to the cartridge sensor by the user, the controller determining the testing instruction based on the e-liquid formulation information on the cartridge.

(22) At step S8, the controller 30 determines whether the quantities of liquid component specified in the testing instruction are within predetermined limits stored on the memory. For example, the controller 30 may determine whether the quantity of nicotine specified in the testing instruction exceeds a maximum regulatory limit. Alternatively, or in addition, the controller 30 may determine whether the quantities of one or more of the components specified in the testing instruction exceed a guideline amount stored on the memory and display a warning message on the user interface 28 to inform the user. For example, the controller 30 may determine whether the quantity of glycerin exceeds a guideline amount, since too much glycerin may impair correct functioning of an aerosol-generating device in which the resulting liquid is intended for use. Alternatively, or in addition, the controller 30 may determine whether the quantities of one or more e-liquid components specified in the testing instruction would lead to an undesirable flavour or flavour combination. If the quantities of e-liquid component specified in the testing instruction are outside of predetermined limits, or outside of guideline amounts, an error message is displayed on the user interface 28 at step S9 to inform the user and to request confirmation of the testing instruction with quantities of e-liquid components that are within predetermined limits.

(23) At step S10, once the controller 30 has determined that the quantities of e-liquid components specified by the user in the testing instruction are within predetermined limits stored on the memory, the machine 10 creates the e-liquid test sample according to the ratios specified in the testing instruction. During this step, the controller 30 operates the supply valves 26 in response to the testing instruction to dispense the quantity of each e-liquid component specified in the testing instruction from the reservoir 20 in which it is stored to the mixing mechanism 22 via the supply tubes 26 to form the e-liquid test sample.

(24) At step S11, once the e-liquid test sample has been mixed according to the user testing instruction, the controller 30 operates the transfer mechanism 36 to select a disposable heater assembly from the heater supply 38 and to apply the e-liquid test sample onto the selected disposable heater assembly

(25) At step S12, the controller 30 actuates the mouthpiece delivery mechanism 44 to select a disposable mouthpiece from the mouthpiece supply 42 and to deliver the selected mouthpiece to the mouthpiece supply port 46.

(26) At step S13, the controller 30 operates the device 14 to heat the heater assembly in order to vapourise the e-liquid test sample applied on the heater assembly to form an aerosol.

(27) As step S14, the controller 30 displays a message on the user interface 28 to inform the user that the test sample has been vapourised and is ready for testing and to instruct the user to remove the mouthpiece from the mouthpiece supply port and to place it on the device 14.

(28) At step S15, once the aerosol has been tested, the user deactivates the testing device 14 via the user interface 28.

(29) At step S16, the controller 30 displays a message on the user interface 28 requesting feedback on the tested aerosol and instructing the user to remove the mouthpiece from the device, dispose of the mouthpiece in the mouthpiece disposal port 48 and to return the device 14 to the docking station 32. The controller 30 then saves the e-liquid formulation and feedback information to the user's registered account and displays a message, at step S17, asking the user whether further testing operations are required. If further testing operations are required, the controller returns to step S7 and requests that the user enters a testing instruction via the user interface 28. If no further testing operations are required, the procedure ends at step S18.

(30) In some examples the volume of the composition formed in the mixing mechanism 22 from the components delivered from the reservoirs is greater than is required for the test sample. In this case, only a portion of the composition is delivered to the testing mechanism. The remaining composition not delivered to the testing mechanism may be later dispensed into a cartridge, for example if the user decides to purchase that composition. The remaining composition not delivered to the testing mechanism may be held in the machine, either in the mixing mechanism 22 or in a separate storage unit, and may be dispensed to a subsequent user for example as a test sample or in a cartridge.

(31) In a further example of an aspect of the invention, a test sample of the composition is delivered from the mixing mechanism 22 to a test cartridge. The volume of liquid delivered to the test cartridge may be for example less than about 0.5 ml, for example about 0.1 ml. The cartridge may comprise a liquid storage container. In other examples, the cartridge may include other components for example a heater and optionally a liquid transfer substrate for transferring liquid from the liquid storage container to the heater. In some examples, the cartridge comprises a cartomiser for an e-cigarette device. The cartridge may for example be a low-volume cartomiser which the user may use in combination with their own e-cigarette system to try a new composition. The machine for filling the test cartridge may include one or more of the features described below in relation to FIGS. 6 and 7.

(32) FIG. 5 is an example selection screen 100 for display on the user interface 28 by which user may select mix ratios and thereby input a testing instruction. The selection screen 100 includes a slider bar 102 for each e-liquid component stored in the reservoirs 20. The user can then increase the quantity of a particular e-liquid component by sliding the respective slider bar 102 towards the right. The selection screen 100 also includes warning indicators 104 for one or more of the e-liquid components. In this example, the warning indicators 104 are each in the form of a light bulb. The warning indicator 104 for a particular e-liquid component can be illuminated by the controller 30 if the quantity of that component specified by the user is outside of a predetermined limit to provide a warning to the user.

(33) Referring to FIGS. 6 and 7, there is shown a machine 210 according to a further embodiment. The machine 210 is substantially the same as the machine 10 according to the first embodiment, as described above in relation to FIGS. 1 to 3, with the exception that the machine 210 is further arranged to prepare and dispense an aerosol-forming liquid, or e-liquid, to fill an empty cartridge for use in an aerosol-generating system. In the below description, like reference numerals have been used to designate those parts in common with the machine 10 shown in FIGS. 1 to 3.

(34) In addition to the components discussed above in relation to the machine 10 according to the first embodiment, the main unit 212 of the machine 210 further includes a dispensing port 250 configured to receive an e-liquid cartridge and a dispensing mechanism 252 associated with the dispensing port 250 and connected to the controller 230. The dispensing mechanism 252 is in fluid communication with the mixing mechanism 222, via a dispensing tube 253 and is configured to fill a cartridge received in the dispensing port 250 with e-liquid mixed by the mixing mechanism 222.

(35) The machine 210 further includes a cartridge supply 254, containing a plurality of cartridges for use with one or more types of aerosol-generating device, and a cartridge delivery mechanism 256 connected to the controller 230. The cartridge delivery mechanism 256 is arranged to select and remove a cartridge from the cartridge supply 254 and to deliver the selected cartridge to the dispensing port 250 for subsequent filling by the dispensing mechanism 252. The machine may also include a cartridge marking mechanism (not shown) for applying machine-readable e-liquid formulation information to the cartridge, either by printing the information onto a label on the cartridge, by applying a printed label on to the cartridge, or by applying an RFID tag to the cartridge.

(36) FIG. 8 is a flow chart showing the operation of the machine 210.

(37) Steps S1-S18 (not shown), which relate to the testing procedure, are the same as described above in relation to FIG. 4.

(38) At step S19, the user initiates an e-liquid dispensing operation by inputting a dispensing instruction via the user interface 28. The dispensing instruction specifies the desired ratios of each of the e-liquid components stored in the reservoirs 220 and the type of cartridge which is to be filled by the dispensing operation. The dispensing instruction may be entered directly by the user via the user interface 228, for example as described above in relation to FIGS. 4 and 5. Alternatively, the user may enter the dispensing instruction indirectly via the user interface 228 by selecting the e-liquid formulation tested during steps S1-S18, or by selecting an e-liquid mix from a list of suggested mixes or from a list of e-liquid mixes associated with the user. For example, the user interface 228 may display e-liquid formulations previously tested by the user, or previously entered by the user using a remote device and saved to the user's account. As a further alternative, the machine 210 may include a cartridge sensor for reading e-liquid formulation information from a cartridge placed in close proximity to the cartridge sensor by the user, the controller determining the dispensing instruction based on the e-liquid formulation information on the cartridge.

(39) At step S20, the controller 230 determines whether the quantities of e-liquid component specified in the dispensing instruction are within predetermined limits stored on the memory in the same way as described above in relation to step S8 in FIG. 4. If the quantities of e-liquid component specified in the dispensing instruction are outside of predetermined limits, or outside of guideline amounts, an error message is displayed on the user interface 228 at step S21 to inform the user and to request confirmation or revision of the dispensing instruction so that the specified quantities of e-liquid components are within predetermined limits.

(40) At step S22, the controller 230 queries whether the user has their own cartridge to be refilled, or requires a new cartridge to be provided by the machine 210. If the user has their own cartridge to be refilled, the controller 230, via the user interface 228, requests that the user places the cartridge to be refilled into the dispensing port, at step S23. If a new cartridge is required, the controller 230 operates the cartridge delivery mechanism 256 at step S24 to select and remove a cartridge from the cartridge supply 254 and to deliver the selected cartridge to the dispensing port 250 for subsequent filling by the dispensing mechanism 252.

(41) At step S25, the controller 230 checks whether the cartridge to be filled is correctly placed in the dispensing port 250 using one or more sensors (not shown) associated with the dispensing port 250. If the cartridge is not correctly positioned in the dispensing port 250, the controller 230 displays an error message on the user interface 228 at step S26 requesting the user to correctly place the cartridge in the dispensing port 250. This repeats until the controller 230 determines that the cartridge has been correctly positioned in the dispensing port 250.

(42) At step S27, the user operates the user interface 228 to effect payment for dispensing the selected e-liquid. If a new cartridge is required, the payment required may be more than if the user supplies their own cartridge.

(43) At step S28, the machine 210 creates the e-liquid for filling the cartridge according to the ratios specified in the dispensing instruction. During this step, the controller 230 operates the supply valves 226 in response to the dispensing instruction to dispense the desired quantity of each e-liquid component from the reservoir 220 in which it is stored to the mixing mechanism 222 via the supply tubes 226. The mixing mechanism 222 then mixes together the e-liquid components to form the selected e-liquid.

(44) At step S29, the dispensing mechanism 252 withdraws the e-liquid from the mixing mechanism 222 via the dispensing tube 253 and dispenses the e-liquid into the cartridge received in the dispensing port 250 to fill the cartridge.

(45) At step S30, the machine 210 determines whether the cartridge has been filled with the e-liquid, either by detecting when a predetermined volume of e-liquid has been dispensed by the dispensing mechanism 252 or by detecting the e-liquid level within the cartridge.

(46) At step S31, after the cartridge has been filled, the controller 230 operates the cartridge marking mechanism to apply e-liquid formulation information to the cartridge, either by printing the information onto a label on the cartridge, by applying a printed label on to the cartridge, or by applying an RFID tag to the cartridge.

(47) The controller 230 then displays an end message on the user interface 228, at step S32, indicating that the user may remove the filled cartridge from the dispensing port 250.

(48) The dispensing operation ends at step S33.

(49) The exemplary embodiments described above illustrate but are not limiting. In view of the above discussed exemplary embodiments, other embodiments consistent with the above exemplary embodiments will now be apparent to one of ordinary skill in the art.