Abstract
An electronic cigarette is described which comprises an outer housing sleeve having an open end and a closed end and a functional insert comprising electrical components, wherein the functional insert is arranged to be introduced through the open end of the outer housing sleeve and is held within the outer housing sleeve. By grouping the functional electronic components together on the functional insert and by providing the device housing in the form of a sleeve, the assembly process is simplified as the functional components can be assembled in a first assembly step and then subsequently sleeved within the outer housing in a single step, thus reducing the complexity of the assembly procedure.
Claims
1. An electronic cigarette comprising: an outer housing sleeve having an open end and a closed end; a functional insert comprising a battery and electronic circuitry for supplying power from the battery to a cartridge during use; wherein the functional insert is arranged to be introduced through the open end of the outer housing sleeve and is held within the outer housing sleeve.
2. The electronic cigarette of claim 1 wherein the functional insert comprises a cartridge seating for receiving a removable cartridge containing a liquid to be vaporized.
3. The electronic cigarette of claim 2 wherein the cartridge seating is arranged such that a cartridge lies fully within the outer housing sleeve when received in the cartridge seating during use.
4. The electronic cigarette of claim 1 wherein the functional insert comprises a first end positioned at the open end of the housing sleeve and a second end positioned towards the closed end of the housing sleeve, the electronic cigarette further comprising: a mouthpiece at the first end of the functional insert, the mouthpiece moveable between an open position and a closed position.
5. The electronic cigarette of claim 4 wherein the mouthpiece is moveable by a hinge mechanism connecting the mouthpiece to the first end of the functional insert.
6. The electronic cigarette of claim 5 wherein the hinge mechanism comprises an L-shaped lever which connects a central point on the mouthpiece to a point near the an edge of the first end of the functional insert.
7. The electronic cigarette of claim 1 wherein the outer housing sleeve further comprises a rim extending circumferentially around an inner surface of the sleeve at the open end, and wherein the functional insert is configured to engage with the rim.
8. The electronic cigarette of claim 7 wherein the functional insert comprises a circumferential rim extending around the outer surface of the functional insert, wherein the circumferential rim of the functional insert is arranged to contact the rim of the housing sleeve to hold the functional insert in position within the housing sleeve.
9. The electronic cigarette of claim 1 wherein the housing sleeve comprises a first aperture on an inner surface at the open end and the functional insert comprises a second, corresponding, aperture arranged to align with the first aperture to allow the housing sleeve and functional insert to be attached with a fastener through the aligned apertures.
10. The electronic cigarette of claim 1, wherein the functional insert comprises a first shell portion and a second shell portion, and wherein the first and second shell portions are configured to connect along a longitudinal interface to enclose the electronic circuitry within.
11. The electronic cigarette of claim 10, wherein the first shell portion and the second shell portion are offset in relation to each other, such that one shell portion extends further than the other in a direction towards the closed end of the housing sleeve.
12. The electronic cigarette of claim 10, wherein the first and second shell portions comprise a thermoplastic material suitable for thermoplastic or ultrasonic welding.
13. The electronic cigarette of claims10 wherein the first shell portion and the second shell portion comprise engaging structures configured to attach to each other, wherein the engaging structures provide a snap-lock or friction fit connection.
14. The electronic cigarette of claim 1, wherein the housing sleeve further comprises at least one guide rail arranged along an inner surface and the functional insert comprises a slot configured to engage with the guide rail.
15. The electronic cigarette of claim 14 wherein the guide rail further comprises an aperture for receiving a fastener to attach the insert to the housing sleeve.
16. The electronic cigarette of claim 2 wherein the functional insert comprises a first end comprising an opening to the cartridge seating and a second end at the opposite end of the functional insert, and wherein the first end of the functional insert is angled such that the functional insert has an increased length along a longitudinal line passing through the cartridge seating.
17. The electronic cigarette of claim 1 wherein the functional insert is elongate and the functional insert comprises a battery and a cartridge seating, and wherein the battery and the cartridge are positioned side-by-side along the elongate axis of the functional insert.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The invention will now be described with reference to the appended drawings, which by way of example illustrate embodiments of the present invention and in which like features are denoted with the same reference numerals, and wherein:
[0040] FIGS. 1A and 1B respectively illustrate a functional insert and an outer housing sleeve according to the present invention;
[0041] FIGS. 2A and 2B illustrate an electronic cigarette according to the present invention;
[0042] FIG. 3 schematically illustrates a mouthpiece portion for an electronic cigarette according to the present invention;
[0043] FIG. 4 schematically illustrates an electronic cigarette according to the present invention;
[0044] FIGS. 5A and 5B schematically illustrate a functional insert for an electronic cigarette according to the present invention;
[0045] FIGS. 5C and 5D schematically illustrate alternative arrangements of the functional insert for an electronic cigarette according to the present invention;
[0046] FIG. 6 schematically illustrates an outer housing sleeve for an electronic cigarette according to the present invention;
[0047] FIGS. 7A and 7B respectively schematically illustrate a functional insert and a corresponding outer housing sleeve according to the present invention;
[0048] FIG. 8 schematically illustrates an electronic cigarette according to the present invention;
[0049] FIG. 9 schematically illustrates a portion of an electronic cigarette according to the present invention.
DETAILED DESCRIPTION
[0050] FIGS. 1 and 2 schematically illustrate an electronic cigarette 1 which comprises an outer housing sleeve 10 having an open end 11 and a closed end 12 and a functional insert 20 which comprises the electrical components of the device. The functional insert 20 is arranged to be introduced to the open end 11 of the outer housing sleeve 10 and is held within the outer housing sleeve 10. These features provide a number of advantages. In particular, this structure allows for a modular assembly process in which the functional electronic components of the device can be assembled into a single integral assembly, the functional insert 20, and this can be simply introduced into the housing sleeve 10 to form the completed device 1, shown in FIG. 2A. The source allows for the device to be disassembled and repaired when needed by simply removing the outer housing sleeve. Further advantages in terms of temperature management may be achieved by suspending the functional insert within the outer housing sleeve 10 to minimize heat conduction from the heater components to the outer shell. Furthermore, the outer housing sleeve 10 may be formed as a single integral component, providing enhanced strength and resistance to breakage. A number of further technical advantages are described with respect to the specific components of the device, described below.
[0051] FIGS. 1A and 1B schematically illustrate an exemplary embodiment of the functional insert 20 and the outer housing sleeve 10 respectively. FIGS. 2A and 2B schematically illustrate the electronic cigarette formed from the functional insert 20 held within the outer housing sleeve 10 in an outer and cross sectional view. As shown in FIG. 2A, the electronic cigarette 1 has a substantially elongate body running from a base end 2 to a mouthpiece end 3, with a mouthpiece portion 30 positioned at the mouthpiece end 3. As shown in FIG. 1A, the functional insert 20 comprises the functional components of the device 1, i.e. the electronic components which provide the aerosol generation function of the device 1. In particular, the functional insert includes a first cartridge seating 21 for receiving a first removable cartridge 40 a power supply in a form of a battery 22 and electronic circuitry for controllably supplying power from the battery 22 to a cartridge 40 received in the cartridge seating 21 during use.
[0052] The electronic cigarette 1 comprises a mouthpiece portion 30 connected to the functional insert 20, wherein the mouthpiece portion 30 is moveable relative to the functional insert 20 by the connection mechanism 31 between an open position in which the first cartridge seating 21 is exposed such that a first cartridge 40 can be received; and a closed position in which the first cartridge seating 21 is enclosed in the electronic cigarette 1. In this way, the mouthpiece portion 30 may be moved to the open position while remaining connected to the functional insert 20 via the connection mechanism 31 to allow a cartridge 40 to be inserted into the first cartridge seating 21 of the functional insert 20. The mouthpiece portion 30 may then be returned to the closed position to enclose the received first cartridge 40 in the device 12.
[0053] The electronic cigarette 1 is assembled by placing the functional insert 20 within the outer housing speed 10 to form the complete electronic cigarette 1 shown in FIG. 2A. During use, the user inhales through the mouthpiece portion 30 whilst power is supplied to a cartridge received in the cartridge seating 21 to heat a heating element and vaporize an aerosol generating liquid contained in the cartridge 40 whereby the aerosol is inhaled by the user through the mouthpiece 30. The device illustrated in the figures further includes a second cartridge seating 32 provided in the mouthpiece 30. The second cartridge seating is arranged to receive a second cartridge 41. The first and second cartridge seatings 21, 32 and the mouthpiece are arranged such that when the mouthpiece is closed, a first cartridge 40 received in the first cartridge seating 21 forms a sealed fluidic passage through the second cartridge 41 received in the second cartridge seating 32 to the mouthpiece such that the inhaled vapor may comprise components from both the first cartridge 40 and the second cartridge 41. As shown in FIGS. 1A, 2A and 2B the second cartridge 41 is arranged so as to protrude from the mouthpiece 30 when received in the mouthpiece such that a portion of the second cartridge 41 provides part of the mouthpiece from which the user may inhale the generated vapor.
[0054] The various features of the functional insert 20 are shown in the cross sectional diagram of FIG. 2B. In particular, FIG. 2B illustrates the battery 22 and the electronic circuitry 23 arranged to supply power from the battery to a cartridge 40 received in the first (main) cartridge seating 21. FIG. 2B further shows how, when the mouthpiece 30 is in the closed configuration, a second cartridge 41 received in the second cartridge seating 32 within the mouthpiece 30 is brought into sealed engagement with the first cartridge 40 received in the first cartridge seating 21. In this way, an aerosol generated within the first cartridge is drawn through the second cartridge 41 through an air outlet 42 positioned in a protruding portion of the second cartridge 41 which acts as the mouthpiece, such that the inhaled aerosol includes components from both the first and second cartridges 40, 41.
[0055] As shown in FIGS. 1 and 2, the functional insert 20 and housing sleeve 10 both comprise a corresponding elongate shape of substantially similar dimensions such that when the electronic cigarette 1 is assembled the functional insert 20 lies fully within the outer housing sleeve 10 as shown in FIGS. 2A and 2B. The body of the functional insert 20 extends between a first end 24 comprising the opening to the first cartridge seating 21 and a second, base end 25. The electronic cigarette 1 is arranged such that the first end 24 of the functional insert 20 is arranged at the open end 11 of the outer housing sleeve 10 and the second, base end 25 of the functional insert 20 is arranged at the closed end 12 of the outer housing sleeve 10. The mouthpiece 30 of the electronic cigarette 1 is connected to the first end 24 of the functional insert 20 by a movement mechanism 31.
[0056] As shown most clearly in FIG. 3, the connecting mechanism 31 between the mouthpiece portion 30 and functional insert 20 is preferably configured as a hinge mechanism 70. As seen in FIGS. 1A, 2B and 4, the hinge mechanism 70 is connected to the first end 24 of the functional insert 20 and is arranged so as to be fully enclosed within the electronic cigarette 1 when the mouthpiece is in the closed configuration. This is advantageous as the hinge mechanism 70 is invisible from the outside of the electronic cigarette 1 such that a user's hand does not interfere with the hinge mechanism 70 when using the device. Furthermore the hinge mechanism 70 can be protected inside the electronic cigarette 1 when the mouthpiece 30 is in a closed position.
[0057] As best seen in FIGS. 3 and 4, the hinge mechanism 70 comprises a lever 72 comprising a first connection end 74 fixedly connected to the mouthpiece portion 30 and a second connection end 76 rotatably connected to a receiving portion 77 of the functional insert 20. The second connection end 76 can be configured as a rotating joint 76. The rotating joint 76 may be in the form of a pin or axle which is retained within the receiving portion 77 of the functional insert 20 such that the rotating joint 76 defines the axis of rotation about which the lever 72 may rotate.
[0058] It is desirable to create an electronic cigarette device 1 with a compact and ergonomic shape. It is therefore needed to reduce the internal space needed for the hinge mechanism 70. The movement of the lever 72 in the horizontal direction of the electronic cigarette 1 should therefore be reduced. The hinge mechanism 70 may therefore be designed to provide a combined rotary and linear movement of the mouthpiece portion 30 as it is moved to the open position.
[0059] The hinge mechanism 70 can be configured to enable the mouthpiece portion 30 to both rotate and move axially away from the functional insert 20 which allows for the opening 26 of the first cartridge seating 21 to be exposed with a reduced degree of rotation of the mouthpiece portion 30, thereby reducing the space required for the hinge mechanism 70. To achieve the rotation and linear motion of the mouthpiece portion 30, the receiving portion 77 in the form of an elongate axial slot 77, shown in FIG. 2B, in which the rotating joint 76 at the rotating end 76 of the lever 72 is retained. The linear slot 77 and the lever 72 are retained such that the rotating end of the lever 72 may rotate within the slot 77 and move linearly in a direction corresponding to the elongate axis of the slot 77. In this way the lever 72 can both rotate and translate as the mouthpiece portion 30 moves to the open position.
[0060] The linear slot 77 therefore defines end positions comprising the limits of the linear movement, where the end positions correspond to the position of the rotating joint 76 when the mouthpiece portion 30 is located in the closed position and the open position, respectively. Hence the joint 76 at the rotating end of the lever 72 is located in a lower end of the linear slot when the mouthpiece portion is in a closed position, as shown in FIG. 2B, and the joint 76 is located in an upper end of the linear slot 77 when the mouthpiece portion 4 is in an open position, as shown in FIG. 4.
[0061] The limiting surface S, shown in FIG. 2B, can be provided on an axial extension connected to the functional insert 20 and is met by a corresponding surface of the lever 72 when it reaches the fully open position, thus limiting further rotation of the lever 72. In other words, the functional insert 20 comprises an internal surface S arranged to be met by the lever 72 as it rotates to prevent further rotation at a certain point. This surface S may be provided as a portion of the first end 24 of the functional insert that extends in a direction towards the mouthpiece 30 along the elongate axis of the functional insert 20.
[0062] The linear movement of the mouthpiece portion 30 enables the opening 26 of the main cartridge seating 21 to be liberated with a minimal degree of rotation of the mouthpiece portion 30 such that a first cartridge 40 can be introduced. This also reduces the space required in the functional insert 20 for the hinge mechanism 70.
[0063] One or more retaining elements 88, preferable in the form of magnetic elements may be positioned such as to encourage the rotational and linear movement of the mouthpiece portion 30 provided by the hinge mechanism 70. In particular a magnetic element 88b (see FIG. 2B) may be provided on the limiting surface S and corresponding magnetic material 88a on the opposing surface of the lever 72 such that upon the user initially opening the mouthpiece portion 4 the lever 72 is encouraged to rotate and translate upwards linearly such that the corresponding magnets meet, then retaining the mouthpiece portion 30 in a stable, open position.
[0064] The lever 72 is substantially L-shaped and comprises a horizontal portion 73, a vertical portion 75 and the joint 76, as shown in FIG. 3. The L shape allows a point towards the centre of the underside of the mouthpiece portion 30 to be connected to a point near the radial extremity of an upper surface of the first end of the functional insert 20. This allows for an internal lever mechanism to be provided and enhances the displacement of the mouthpiece portion 30 from the functional insert for a smaller degree of rotation.
[0065] FIGS. 5A and 5B show further details of the functional insert 20. As shown in FIGS. 5A and 5B, the functional insert may comprise an outer shell 50 which houses the various electronic components of the functional insert 20. In particular, the shell 50 comprises a first shell portion 51 and a second shell portion 52. The first and second shell portions 51, 52 are arranged such that they connect along a longitudinal interface running along the elongate axis of the functional insert 20. The first and second shell portions 51, 52 thereby enclose the functional electrical components within the shell 50. The first and second shell portions 51, 52 may comprise a thermoplastic material allowing for the first and second shell portions 51, 52 to be welded along the longitudinal interface to seal the shell 50 around the internal electronic components. In other examples of the invention, the first and second shell portions 51, 52 may comprise corresponding engaging structures which are configured to attach to each other, allowing the first and second shell portions 51, 52 to be releasably engaged with each other to seal the electronic components. For example, the engaging structures may allow a snap lock or friction fit connection between the shell portions 51, 52.
[0066] One or more parts of the shell portions 51, 52 may be removable to allow the internal electrical components to be serviced, replaced or repaired. The shell 50 of the functional insert 20 also includes a circumferential rim 53 running around an outer surface of the shell 50 at the first end 24 functional insert 20. The functional insert rim 53 engages with a corresponding feature within the outer housing shell 10 in order to assist in retaining the functional insert 20 at the correct position within the outer housing shell 10, as will be described. As shown in FIG. 5B, the functional insert 20 further includes a longitudinal slot 54 running along an outer surface of the shell in a direction corresponding to the elongate axis of the functional insert 20.
[0067] As illustrated in FIG. 5C, the first shell portion 51 and the second shell portion 52 may be off-set in relation to each other when assembled together. In other words, at least one of distal end of the first shell portion 51 and the second shell portion 52 is offset in relation to the other.
[0068] For example, as illustrated in FIG. 5D, one of the shell portions 51, 52 can be shorter than the other shell portion 51, 52. For instance, the distance in length can be between 50% and 75%. This enables some of the components to remain exposed when the first shell portion 51 and the second shell portion are assembled to each other. The exposed component can be more easily removed if replacement is needed or can be assembled onto the insert after the first shell portion 51 and the second shell portion 52 are attached to each other.
[0069] In this embodiment, only one of the shell portions 51, 52 is touching the bottom portion of the housing sleeve. This also makes is possible to arrange a separate component in the bottom of the housing sleeve, such as for instance an air channel piece or plug 300 as will be described in more detail in connection with FIGS. 7 to 9.
[0070] As shown in FIG. 6, the outer housing sleeve 10 further comprises a circumferential protrusion 13 (i.e. an inner rim on the inner surface of the housing) extending radially inward from an inner surface of the outer housing sleeve 10 and running around the circumference of the inner surface near the first open end 11 of the outer housing sleeve 10. The circumferential protrusion 13 is arranged to meet the corresponding rim 53 of the functional insert 20 as the functional insert 20 is inserted into the outer housing sleeve 10 such that the functional insert 20 is held within the outer housing sleeve 10. This ensures that the functional insert is held at the correct positioned along the length of the housing, for example to ensure the cartridge seating opening 26 is aligned with the open end of the housing 10.
[0071] FIG. 6 also shows a guide rail 14 which runs along the elongate axis of the outer housing 10 along an inner surface from the circumferential protrusion 13 downwards towards the closed end 12 within the outer housing sleeve 10. The guide rail 14 is configured to engage with the corresponding slot 54 in the outer surface of the shell 50 of the functional insert 20 shown in FIG. 5B. In this way, the functional insert 20 must be inserted in the correct orientation within the outer housing 10 such that the guide rail 14 engages with the slot 54 to guide the functional insert 20 into the housing 10 such that it is held at the correct position. This can be used for example to ensure that the functional insert 20 is correctly oriented in the device and, for example, the air inlet within the functional insert and the charging port are correctly aligned with corresponding apertures in the closed end 12 of the outer housing sleeve 10. Multiple guide rails 14 may be positioned around the circumference of the inner surface of the outer housing 10 with corresponding slots 54 arranged on the functional insert 20 to receive the guide rails. In the example of FIGS. 5 and 6, two guide rails 14 are provided on opposing surfaces within the outer housing 10 with corresponding slots 54 provided on opposing surfaces along the elongate axis of the functional insert 20.
[0072] The outer housing sleeve 10 and the functional insert preferably also include means to fasten the functional insert 20 to the outer housing sleeve when it is correctly received at the correct position within the outer housing sleeve 10. In the example shown in FIGS. 5 and 6 the outer housing sleeve 10 and the functional insert both include fastening features in the form of apertures 15, 55. In particular, an aperture 15 is provided on the top surface of the guide rail 14 within the outer housing sleeve and a corresponding aperture 55 is provided on the rim 53 of the functional insert, wherein the apertures 15, 55 are positioned so as to align when the functional insert 20 is received at the correct position within the outer housing sleeve 10. The functional insert 20 can then be secured to the outer housing sleeve by a fastener such as screws which are engaged through both sets of apertures 15, 55. In this way, the functional insert 20 can be secured within the outer housing sleeve 10 with minimal fastening means allowing the functional insert to be removed in a straightforward manner. FIG. 4 shows the fasteners, in this case screws positioned within the functional insert apertures 55 on an upper surface of the functional insert below the mouthpiece 30. In this way, the screws are easily assessable allowing the electronic cigarette 1 to be assembled in a straightforward manner.
[0073] As shown in FIG. 5B, the first end 24 of the functional insert 20 is preferably angled to provide a greater longitudinal length of the functional insert along a portion of the insert 20 comprising the cartridge seating 21. In other words, the functional insert 20 is shaped to have a varying length in the elongate direction from the first end 24 to the second end 25. In particular a sloping surface at the first end 24 provides a greater longitudinal length of the functional insert in a region which includes the cartridge seating 21. This allows the cartridge seating 21 to occupy a greater volume of the device, allowing the device to accept larger cartridges 40 with a longer duration of use. As described above, the first cartridge seating 21 and the battery 22 are preferably positioned side by side in the functional insert 20. The battery and first cartridge seating may be aligned along the elongate axis functional insert 20, providing the most efficient way to maximize the volume of both battery 22 and the elongate cartridge seating 21 in a given sized functional insert 20.
[0074] FIGS. 7 and 8 illustrate an alternative example of the electronic cigarette 1 according to the present invention. As with the previously described examples, the electronic cigarette 1 comprises an outer housing sleeve 100 having an open end and an opposing closed end 102. As with the previously described embodiments, the outer housing sleeve 100 has an air inlet 117 positioned on the closed end. The electronic cigarette 1 also includes a functional insert 200, shown in FIG. 7A which comprises the electronical components including a cartridge seating 221 arranged to receive a movable cartridge 40, wherein the functional insert 200 is arranged to be introduced through the open end 101 of the outer housing sleeve 100 and retained within the housing sleeve 100 to form the electronic cigarette 1.
[0075] The examples of FIGS. 7 to 9 of an differ from the previously described electronic cigarettes 1 in that they further includes an air channel plug 210 which is arranged within the outer housing sleeve 100 between the closed end 102 of the outer housing sleeve 100 and the functional insert 200. The air channel plug 300 comprises an air channel 310 which provides at least a portion of an air flow route connecting the air inlet 117 of the outer housing sleeve 100 to the cartridge seating 221. The air channel plug 300 is a plug of material which occupies a portion of the internal volume of the outer housing sleeve 100 at the first end 102. In particular the air channel plug 300 may comprise a piece of material which substantially fills the internal volume of the closed end 102 of the outer housing sleeve 100 and extends a certain length L1 from the closed end 102 towards the open end 101.
[0076] The air channel plug 300 serves a number of purposes. It firstly acts to only allow air flow into the device 1 through a defined air flow passage way 310. Some devices which do not include such an air channel plug, air can enter the device through openings in the casing, for example the charging port, which lead to reduce the pressure drop when inhaling through the mouthpiece and can have implications for aerosol generation and for the correct triggering of the pressure sensor to activate the device. Furthermore, the air channel plug 300 can act to protect the electrical components of the functional insert 200 by preventing contact between the functional insert 200 and the closed end within the outer housing sleeve 100.
[0077] By managing the air flow route into the device through the air channel 310 within the air channel plug 300 it can be ensured that the air flow pressure exerted from inhaling at the mouthpiece is directed to the sensor and the sensor is not triggered by air flow through the openings at the base of the device over the air flow sensor. It also reduces the free internal volume of the device which can lead to a lack of responsiveness of the sensor. The air channel plug 300 is preferably made of a resilient deformable material such as an elastic material which deforms to the shape of the internal volume within the outer housing sleeve 100 and provides shock absorption within the device to protect the electrical components of the functional insert 200. The air channel plug 300 also provides a seal across the cross section of the internal volume of the outer housing sleeve 100 such that air flow into the outer housing sleeve 100 is restricted other than through passage via the air channel 310. The air channel plug 300 preferably extends over a length L1 from the closed end 102 of the outer housing sleeve towards the open end which corresponds to more than 25% of the total length of the housing L2, as measured from the closed end 102 to the open end 101. This provides sufficient shock absorption to prevent damage from accidental dropping of the device and also the advantage that it is possible to properly position the cartridge seating 221 and arrange the cartridge air inlet within the device.
[0078] The air channel 310 is preferably arranged such that it passes through the air channel plug 300, that is, it passes centrally through the mass of deformable elastomeric material. The air channel 310 and the air channel plug 300 which houses it may extend upwards from the closed end of the device sufficiently to engage with an inlet at the base of the cartridge seating such that the air channel connects the air inlet of the outer housing 100 directly to the air inlet of the cartridge seating 221 (not shown). In other examples, such as that shown in FIG. 7A, the elastomeric material forming the air channel plug 300 may only extend a certain distance up the length of the housing leaving a gap and an internal volume of the housing which is open between the air channel plug 300 and the air inlet to the cartridge seating 221.
[0079] The functional insert 200 preferably contacts the air channel plug 300 within the outer housing sleeve to provide the shock absorption and to prevent significant contact between the functional insert and the outer housing sleeve which might provide sufficient forces to damage the components. More preferably, the functional insert 200 is engaged with the air channel plug 300 such that they are attached together and the functional insert 200 and the air channel plug 300 may be assembled as an integral assembly which can then be inserted and secured within the outer housing sleeve 100. This provides significant advantages in terms of simplicity of manufacture.
[0080] The connection between the functional insert 200 and the air channel plug 300 may be achieved in a number of different ways. In the example of FIG. 7A, the PCB 220 extends along the elongate axis of the device 1 from its connection with the battery 222 and cartridge seating 221 towards the second base end 102, where it engages with a slot 301 provided in the air channel plug 300. In this way, the PCB 220, which is connected to the electronic components of the functional insert 200, extends along the elongate axis downwards towards the closed end of the housing 100 and extends within a slot provided in the air channel plug 300 which retains the PCB providing a mechanical connection between the functional insert 200 and the air channel plug 300.
[0081] The electronic cigarette 1 described above and in respect to the FIGS. 7 and 8 also can include a charging port 302 allowing the device to be connected to a mains power supply to charge the battery 222. In the examples of FIGS. 7 and 8 the charging port 302 is provided within the air channel plug 300 and is connected to the electronic components of the functional insert 200 by electrical circuitry 303. This provides another connection between the air channel plug 300 and the functional insert 200. In particular, the charging port 302 is generally a metallic aperture arranged to receive a mains charger and may be positioned wholly or partially within the elastomeric material of the air channel plug 300 with the open end of the charging port extending out of the base such that it protrudes sufficiently to align with an aperture at the closed end 102 of the outer housing sleeve 100. The charging port 302 may be connected to the PCB 220 within the slot 301 within the air channel plug 300. In this way, a mechanical and electrical connection is provided between the functional insert 200 and the air channel plug 300 using the existing features of these components, i.e. without requiring any additional securing components.
[0082] When the functional insert 200 and connected air channel plug 300 are positioned within the outer housing sleeve 100 shown in FIG. 7B, the lower end 304 of the air channel plug 300, which includes the charging port 302, engages with the inside of the closed end 102 of the outer housing sleeve 100. The charging port 302 aligns with a corresponding opening in the base of the outer housing sleeve 100 and the opening 217 of the air channel 310 of the air channel plug 300 aligns with the air inlet 117 at the base at the closed end 102 of the outer housing sleeve 100.
[0083] As described above, in the examples of FIGS. 7A and 7B a mouthpiece portion 30 is provided at the first end 224 of the functional insert 200 wherein the mouthpiece portion 30 is hingedly connected to the functional insert such that when the functional insert 200 is received within the outer housing sleeve 100 the mouthpiece is moveable between an open position shown in FIG. 7A and a closed position in which the open end 101 of the outer housing sleeve is sealed and the second cartridge seating 32 is connected with the first cartridge seating 221 of the functional insert 200. These components are as described above with respect to FIGS. 1 to 6.
[0084] FIG. 8 schematically illustrates another example of an electronic cigarette 1 including a functional insert 200 and an air channel plug 300 received within the outer housing sleeve 100 to form the e-cigarette 1. As described above, the air channel plug 300 comprises a plug of elastic material positioned within the outer housing sleeve at the closed end to separate the inner surfaces of the closed end from the functional insert 200 and provide shock absorbing properties and control of the air flow route from the air inlet 117 at the closed end 102 of the outer housing sleeve 100 to the first cartridge seating 221. As described above the PCB 220 connected to the functional insert 200 extends downwards along the elongate axis of the electronic cigarette 1 to engage with a slot 301 providing a mechanical connection between the air channel plug 300 and the functional insert 200.
[0085] FIG. 8 further illustrates an air flow sensor housing 240 which houses an air flow sensor (shown in FIG. 9) within an internal cavity arranged to hold the air flow sensor. The internal cavity which holds the air flow sensor is in fluidic communication with the first cartridge seating 221 such that the air flow sensor is triggered when the user inhales at the mouthpiece 30. The air flow sensor is also connected to the power supply to turn on the power to the heater from the battery when a change in air pressure, corresponding to a user inhaling at the device, is detected. As shown in FIG. 8, the air flow sensor housing 240 also includes a separate air flow through channel 241 which is not in connection with the internal chamber. The air flow through channel 241 is connected to the air flow passage 310 within the air channel plug 300. Together therefore, the air flow through channel 241 of the air flow sensor housing 240 and the air channel 310 of the air channel plug provide the air flow route from the air inlet 117 in the outer housing sleeve 100 to the cartridge seating 221. The air flow sensor housing 240 may also comprise a similar material to the air channel plug 300 such as a resilient deformable material such as an elastic material. Together, the air channel plug 300 and the air flow sensor housing 240 provide the air flow route from the inlet to the cartridge seating 221 and ensure that this does not pass over the air flow sensor. This prevents the air flow sensor being triggered via air flow through the inlet 117 but only via the reduction in air pressure from the user inhaling at the mouthpiece which is delivered directly to the internal chamber of the airflow sensor housing. These features are described in more detail with reference to FIG. 9.
[0086] FIG. 9 shows an enlarged portion of the base end 102 of the electronic cigarette 1, opposite to the mouthpiece end 101. FIG. 9 shows the air channel plug 300 positioned between the functional insert 200 and the internal surface of the closed base end 102 of the outer housing shell 100. Again, the PCB 220 connected to the functional insert 200 extends downwardly into a slot 301 in the air channel plug 300 and is connected via electrical circuitry 303 to the charging port 302 which embedded within the air channel plug and is accessible through an aperture at the base of the outer housing sleeve 100.
[0087] FIG. 9 depicts the air flow route from the inlet 117 in the outer housing shell 100 to the cartridge seating 221 with a series of arrows A. FIG. 9 also shows the air flow sensor 242 positioned in an internal cavity 243 within the surrounding air sensor housing 240. As shown in the cross sectional view of FIG. 9, the air flow sensor cavity 243 is connected to the air flow route to the mouthpiece via an air flow cavity inlet 244. The air flow cavity inlet 244 extends upwards from the cavity 243 within the sensor housing 240 towards the cartridge seating 221, such as a change of pressure due to a user inhaling is communicated to the air flow sensor cavity 243.
[0088] FIG. 9 also shows the air flow through channel 241 from the air inlet 117 through the air flow sensor housing 240. As clearly shown the air flow through channel 241 is separated from the airflow sensor chamber 243 such that air flow through this path does not pass over the air flow sensor 242. This ensures improved functioning of the air flow sensor 242, in particular increasing the responsiveness.
[0089] In this example, the air channel plug 300 extends from the closed end 102 of the housing upwards to meet the air flow sensor housing 240. Furthermore, the air flow channel 310 provided in the air channel plug 300 directly connects the air inlet 117 in the outer housing sleeve 100 to the air flow through channel 241 in the air flow sensor housing 240. Therefore, together the air channel plug 300 and the air flow sensor housing 240 form an air flow path from the air inlet to the cartridge seating 221. In particular, as shown by the arrows A, the air enters the air inlet 117 passes through the air flow channel 310 of the air channel plug 300 enters the air flow through channel 241 of the air flow sensor housing 240 and is directed into the base of the cartridge seating 221 to extract the vapour generated therein and carry it to the mouthpiece 30. Because there is no direct air flow from the inlet over the air flow sensor, the air flow sensor is more sensitive to air flow pressure changes due to inhalation at the mouthpiece.
