SMOKING SUBSTITUTE COMPONENT

Abstract

Disclosed is an aerosol-delivery component comprising a vaporiser and having an airflow path extending from at least one upstream air inlet to a downstream air outlet. The airflow path comprises a vaporiser portion extending past (e.g., through a hole in) the vaporiser. The vaporiser portion of the airflow path is at least partly defined by an air tube, e.g., a metal air tube. The air tube has an inlet in fluid communication with the at least one air inlet, and an outlet which is downstream of the vaporiser.

Claims

1. An aerosol-delivery component comprising: a vaporiser and having an airflow path extending from at least one upstream air inlet to a downstream air outlet, wherein the airflow path comprises a vaporiser portion extending past the vaporiser, the vaporiser portion of the airflow path being at least partly defined by an air tube, the air tube having an inlet in fluid communication with the at least one air inlet and an outlet, wherein the air tube outlet is downstream of the vaporiser.

2. A component according to claim 1 further comprising a conduit extending towards the air outlet from a conduit opening proximal the vaporiser.

3. A component according to claim 2 wherein the air tube extends concentrically within the conduit.

4. A component according to any one of the preceding claims wherein the vaporiser comprises a planar porous substrate.

5. A component according to claim 4 wherein the substrate is a ceramic substrate.

6. A component according to claim 4 or 5 wherein the substrate comprises a longitudinal through hole and the air tube passes through the longitudinal through hole.

7. A component according to claim 6 further comprising at least one further air inlet and at least one further airflow path wherein the or each further airflow path comprises a vaporiser portion extending through the substrate.

8. A component according to claim 7 wherein the or each vaporiser portion extends through a gap provided around the air tube within the longitudinal through hole.

9. A component according to claim 7 or 8 wherein the vaporiser comprises a heating track and wherein the or each further airflow path comprises a radial portion extending adjacent the heating track.

10. A component according to claim 9 wherein the heating track is provided on an upstream face of the substrate and the radial portion of the at least one further air flow path passes over the upstream face of the substrate.

11. A component according to any one of the preceding claims further comprising a base supporting the vaporiser, the at least one air inlet being provided in the base.

12. A component according to claim 11 further comprising a sealing plate with the vaporiser interposed between the base the sealing plate.

13. A component according to claim 12 wherein the sealing plate comprises at least one feed channel in fluid communication with a tank for containing an aerosol precursor, for delivering aerosol precursor to the vaporiser.

14. A component according to any one of the preceding claims which a consumable component for receipt in a smoking substitute device.

15. An aerosol-delivery system comprising a component according to any one of the preceding claims and a device comprising a power source.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0078] So that further aspects and features thereof may be appreciated, embodiments will now be discussed in further detail with reference to the accompanying figures, in which:

[0079] FIG. 1A is a front schematic view of an exemplary embodiment of a smoking substitute system;

[0080] FIG. 1B is a front schematic view of an exemplary embodiment of a device of the system;

[0081] FIG. 1C is a front schematic view of an exemplary embodiment of a consumable of the system;

[0082] FIG. 2A is a schematic of an exemplary embodiment of the components of the device;

[0083] FIG. 2B is a schematic of an exemplary embodiment of the components of the consumable;

[0084] FIG. 3 is a first example of a consumable component;

[0085] FIG. 4A is a second example of a consumable component; and

[0086] FIG. 4B shows the airflow path in the second example.

DETAILED DESCRIPTION

[0087] Aspects and embodiments will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.

[0088] FIG. 1A shows a smoking substitute system 100. In this example, the smoking substitute system 100 includes a device 102 and an aerosol delivery consumable component 104. The consumable component 104 may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the device may be integral with the component. In such systems, a tank of the aerosol delivery component may be accessible for refilling the system.

[0089] In this example, the smoking substitute system 100 is a closed system vaping system, wherein the consumable component 104 includes a sealed tank and is intended for single-use only. The consumable component 104 is removably engageable with the device 101 (i.e., for removal and replacement). FIG. 1A shows the smoking substitute system 100 with the device 102 physically coupled to the consumable component 104, FIG. 18 shows the device 102 of the smoking substitute system 100 without the consumable component 104, and FIG. 1C shows the consumable component 104 of the smoking substitute system 100 without the device 101.

[0090] The device 102 and the consumable component 104 are configured to be physically coupled together by pushing the consumable component 104 into a cavity at an upper end 108 of the device 102, such that there is an interference fit between the device 102 and the consumable component 104. In other examples, the device 102 and the consumable component 104 may be coupled by screwing one onto the other, or through a bayonet fitting.

[0091] The consumable component 104 comprises a housing 106 having a base portion 111 (at a lower end), an outlet portion 109 (at an upper end), and walls extending longitudinally from the base portion 111 to the outlet portion 109. In particular, the consumable component 104 comprises front and rear walls spaced by opposing first and second side walls. The distance between the front and rear walls defines a depth of the housing 106 and the distance between the side walls defines a width of the housing 106. The width of the housing 106 is greater than the depth of the housing 106.

[0092] The tank 106 of the consumable component 104 comprises a window 112, which allows the quantity of e-liquid remaining in the tank to be visually assessed. The device 102 includes a slot 114 so that the window 112 of the consumable component 104 can be seen whilst the rest of the tank is obscured from view when the consumable component 104 is inserted into the cavity at the upper end 108 of the device 102.

[0093] A lower end of the device 102 includes a light 116 (e.g., an LED) located behind a small translucent cover. The light 116 may be configured to illuminate when the smoking substitute system 100 is activated. Whilst not shown, the consumable component 104 may identify itself to the device 102, via an electrical interface, RFID chip, or barcode.

[0094] FIGS. 2A and 2B are schematic drawings of the device 102 and consumable component 104. These figures provide an overview of the components that form part of the consumable component 104 and device 102. As is apparent from FIG. 2A, the device 102 includes a power source 118, a controller 120, a memory 122, a wireless interface 124, an electrical interface 126, and, optionally, one or more additional components 128.

[0095] The power source 118 is a battery (e.g., a rechargeable battery). The controller 120 may, for example, include a microprocessor. The memory 122 may include non-volatile memory. The memory 122 may include instructions which, when implemented, cause the controller 120 to perform certain tasks or steps of a method.

[0096] The wireless interface 124 may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124 could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., WiFi®, are also possible. The wireless interface 124 may also be configured to communicate wirelessly with a remote server.

[0097] The electrical interface 130 of the device 102 may include one or more electrical contacts. The electrical interface 130 may be located in a base of the cavity formed in the upper end 108 of the device 102. When the device 102 is physically coupled to the consumable component 104, the electrical interface 130 of the device 102 is configured to transfer electrical power from the power source 118 to the consumable component 104 (i.e., upon activation of the smoking substitute system 100).

[0098] The electrical interface 130 may be configured to receive power from a charging station when the device 102 is not physically coupled to the consumable component 104 and is instead coupled to the charging station. The electrical interface 130 may also be used to identify the consumable component 104 from a list of known consumables. For example, the consumable component 104 may include e-liquid having a particular flavour and/or having a certain concentration of nicotine (which may be identified by the electrical interface 130).

[0099] This can be indicated to the controller 120 of the device 102 when the consumable component 104 is connected to the device 102. Additionally, or alternatively, there may be a separate communication interface provided in the device 102 and a corresponding communication interface in the consumable component 104 such that, when connected, the consumable component 104 can identify itself to the device 102.

[0100] The additional components 138 of the device 102 may comprise an indicator (e.g., the light 116 discussed above), a charging portion, a battery charging control circuit, a sensor or, e.g., user input.

[0101] The charging port 115 (e.g., USB or micro-USB port) may be configured to receive power from the charging station (i.e., when the power source 118 is a rechargeable battery). This may be located at the lower end of the device 102. Alternatively, the electrical interface 126 discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

[0102] The battery charging control circuit may be configured for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

[0103] The sensor may be, e.g., an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100, e.g., caused by a user inhaling through a mouthpiece attachment (not shown) fitted to the outlet portion 109 of the consumable component 104. The smoking substitute system 100 may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable component 104. The airflow sensor can be used to determine, for example, how heavily a user draws on the outlet portion 109 (through the affixed or integral mouthpiece) or how many times a user draws on the outlet portion 109 in a particular time period.

[0104] The user input may be a button. The smoking substitute system 100 may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100.

[0105] The consumable component 104, which is shown in FIG. 2B, includes the tank 106, an electrical interface 130, a vaporiser 132, an air inlet 134, an air outlet 136 (e.g., formed in the outlet portion 109), and one or more additional components 138

[0106] The electrical interface 130 of the consumable component 104 may include one or more electrical contacts. The electrical interface 126 of the device 102 and the electrical interface 130 of the consumable component 104 may be configured to contact each other and thereby electrically couple the device 102 to the consumable component 104 when the base portion 111 of the consumable component 104 is inserted into the cavity formed in the upper end 108 of the device 102 (as shown in FIG. 1A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 in the device 102 to the vaporiser 132 in the consumable component 104.

[0107] The vaporiser 132 is configured to heat and vaporise e-liquid contained in the tank 106 using electrical energy supplied from the power source 118. As will be described further below, the vaporiser 132 heats the e-liquid received from the tank 106 to vaporise the e-liquid. The air inlet 134 is configured to allow air to be drawn into the smoking substitute system 100 when a user inhales using the air outlet 136 formed in the outlet portion 109, such that the vaporised e-liquid is drawn through the consumable component 104 for inhalation by the user.

[0108] In operation, a user activates the smoking substitute system 100, e.g., through interaction with a user input forming part of the device 102 or by inhaling through the air outlet 136 as described above. Upon activation, the controller 120 may supply electrical energy from the power source 118 to the vaporiser 132 (via electrical interfaces 126, 130), which may cause the vaporiser 132 to heat e-liquid drawn from the tank 106 to produce a vapour which is inhaled by a user through the mouthpiece which is affixed to or integral with the outlet portion 109.

[0109] An example of one of the one or more additional components 138 of the consumable component 104 is an interface for obtaining an identifier of the consumable component 104. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable component 104. The consumable component 104 may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electrical interface 126 in the device 102.

[0110] It should be appreciated that the smoking substitute system 100 shown in FIGS. 1A to 2B is just one exemplary implementation of a smoking substitute system 100. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

[0111] FIG. 3 shows a first example of a consumable component 104 within the cavity of a device 102.

[0112] The consumable component 104 comprises a vaporiser 132 which is formed of a planar ceramic substrate 132a with a metal heating track 132b screen printed onto the upstream surface 133 of the substrate 132a.

[0113] The consumable component 104 has a linear, axial airflow path extending from a centrally positioned upstream air inlet 134 to a downstream air outlet 136 provided in a mouthpiece portion 135 provided at the outlet portion 109 of the component 104.

[0114] The air inlet 134 is formed in a base 145 and a metal air tube 137 extends from the base 145 in fluid communication with the air inlet 134.

[0115] The air tube 137 passes through a longitudinal through hole 139 in the substrate 132a so that the outlet 141 of the air tube 137 is downstream of the vaporiser 132.

[0116] The component further comprises a conduit 143 which extends from proximal the vaporiser 132 to the outlet portion 109 of the component 104. The outlet 141 of the air tube 137 is within the conduit 143, i.e., a downstream portion of the air tube 137 extends concentrically within an upstream portion of the conduit 143.

[0117] The component has a housing 153 comprising laterally opposed first and second side walls 149a, 149b.

[0118] The housing 153 further comprises opposing front and rear walls (not shown) spaced by the laterally opposed first and second side walls 149a, 149b. The distance between the first and second side walls 149a, 149b of the housing 153 may define a width of the housing 153. The distance between the front and rear walls may define a depth of the housing 153. The width of the housing 153 is greater than the depth of the housing 153. The length of the housing 153 may be greater than the width of the housing 153. The depth of the housing 153 may be smaller than each of the width and the length.

[0119] The conduit 143 is substantially parallel to the first and second side walls 149a, 149b of the housing 153.

[0120] The component 104′ comprises a tank 106 housing the liquid aerosol precursor (e-liquid).

[0121] The tank 106 (e.g., an outer region of the tank 106) is defined between the first and second side walls 149a, 149b and the front/rear walls.

[0122] The conduit 143 extends through the tank 106 with the conduit walls 143a defining an inner region of the tank 106.

[0123] The substrate 132a extends transversely across component between the first and second side walls 149a, 149b of the housing 153. It also extends between the front and rear walls of the housing 153.

[0124] A lower end of the tank 106 is in fluid communication with the substrate 132a such that e-liquid from the tank can permeate the substrate 132a.

[0125] The substrate 132a is supported on a support surface of the base 145. The base 145 also comprises a sleeve portion 145b upstanding from the support surface which abuts the perimeter of the substrate 132a. The sleeve portion 145b further seals against the side walls 149a, 149b and front/rear walls of the component housing 153.

[0126] The consumable component 104 comprises an electrical interface 130 for interfacing with a corresponding electrical interface 126 of the device 102. The electrical interface 130 includes two electrical contacts which extend through the base 145 to make contact with corresponding electrical contacts 126 in the device 102.

[0127] In use, power is supplied to the heating track 132b via the electrical contacts of the component electrical interface 130. This heats the upstream surface 133 of the substrate 132a so that e-liquid contained within the substrate 132a at the upstream surface 133 is vaporised.

[0128] The airflow path comprises a first portion extending from the air inlet 134 to the inlet of the air tube 137, i.e., extending through the base 145 from the air inlet 134 to the inlet of the air tube 137. A second (vaporiser) portion of the airflow path extends within the air tube 137 (from the air tube inlet to the air tube outlet 141) and a third portion extends from the air tube outlet 141 to the air outlet 136 (through the conduit 143).

[0129] Upon inhalation by the user, air flow is pulled through the air inlet 134 via two side air inlets (not shown) provided in the device. The air passes through the air tube 137 to the outlet 141 of the air tube.

[0130] As the airflow continues from the outlet 141 of the air tube 137 to the air outlet 136, vaporised e-liquid in pulled into the airflow path downstream of the air tube outlet 141 towards the air outlet 136 for inhalation by the user

[0131] By providing the air tube 137 which defines the airflow path past the vaporiser and has an outlet 141 downstream of the vaporiser 132, unvaporised e-liquid from the vaporiser 132 is less likely to pass to and thus out of the air inlet 134 thus reducing leakage and user contamination.

[0132] FIGS. 4A and 4B show a further example of a consumable component 104′ which is similar to the first example (and uses common reference numerals).

[0133] The component 104′ further comprises two further air inlets 151a, 151b which are diametrically opposed across the central air inlet 134.

[0134] As shown in FIG. 4B, there are two further air flow paths each comprising a radial portion 153a, 153b that extends along the upstream surface 133 of the vaporiser substrate 132a. Thus, in use, e-liquid is entrained in the radial portions 153a, 153b of the further air flow paths.

[0135] The further air flow paths each comprise a vaporiser portion that passes through an annular gap 155 in the substrate 132a around the air tube 137.

[0136] The component 104′ further comprises a sealing plate 157 with the substrate 132a interposed between the base 145 and the sealing plate 157.

[0137] The sealing plate 157 seals against the walls 149a, 149b of the housing 153 to form the lower end of the tank 106. It engages with the sleeve portion 145b of the base 145. The sealing plate 157 comprises two feed channels 157a, 157b in fluid communication with the tank 106 and extending to the substrate 132a to provide the e-liquid to the substrate 132a. The downstream surface of the substrate 132a comprises two wells 161a, 161b in fluid communication with a respective feed channel 157a, b for pooling of e-liquid in the substrate.

[0138] The sealing plate 157 furthers comprise a gasket 163 for sealing against the conduit 143 proximal a conduit opening 165.

[0139] The further airflow paths join the airflow path downstream of the outlet 141 of the air tube 137.

[0140] In this way, the (cooler) air from the air tube 137 will mix with the (hotter) vapour-laden air from the further airflow path and this may impact, e.g., increase, the particle size within the resulting aerosol for inhalation at the air outlet 136.

[0141] While exemplary embodiments have been described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments set forth above are considered to be illustrative and not limiting.

[0142] 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.

[0143] 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%.

[0144] The words “preferred” and “preferably” are used herein refer to embodiments of the disclosure 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.