U.S. patent application number 17/695423 was filed with the patent office on 2022-06-30 for smoking substitute apparatus.
The applicant listed for this patent is Nerudia Limited. Invention is credited to Nikhil Aggarwal, Benjamin Astbury, Benjamin Illidge, James Keefe, Andrew Lacey, Huanghai Lu, Matthew Pilkington.
Application Number | 20220202074 17/695423 |
Document ID | / |
Family ID | 1000006239557 |
Filed Date | 2022-06-30 |
United States Patent
Application |
20220202074 |
Kind Code |
A1 |
Illidge; Benjamin ; et
al. |
June 30, 2022 |
SMOKING SUBSTITUTE APPARATUS
Abstract
A smoking substitute apparatus. The smoking substitute apparatus
comprising at least one air inlet and an air inlet passage, an
aerosol generator and an outlet, the aerosol generator comprising a
heater and being operable to generate an aerosol by vaporizing a
liquid aerosol precursor, air flowing in use through said at least
one air inlet and air inlet passage, entraining the aerosol and
flowing to the outlet when a user draws on the apparatus. A
partition wall is provided between the aerosol generator and air
inlet passage, in use the partition wall being heated by the heater
of the aerosol generator and thereby heating the air in the air
inlet passage before entraining the aerosol. The partition wall is
formed at least in part by an electrical contact for the
heater.
Inventors: |
Illidge; Benjamin;
(Liverpool, GB) ; Astbury; Benjamin; (Liverpool,
GB) ; Lu; Huanghai; (Liverpool, GB) ;
Aggarwal; Nikhil; (Liverpool, GB) ; Pilkington;
Matthew; (Liverpool, GB) ; Keefe; James;
(Liverpool, GB) ; Lacey; Andrew; (Liverpool,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nerudia Limited |
Liverpool |
|
GB |
|
|
Family ID: |
1000006239557 |
Appl. No.: |
17/695423 |
Filed: |
March 15, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/EP20/76285 |
Sep 21, 2020 |
|
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|
17695423 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 40/44 20200101;
A24F 40/465 20200101; A24F 40/485 20200101; A24F 40/10
20200101 |
International
Class: |
A24F 40/10 20060101
A24F040/10; A24F 40/44 20060101 A24F040/44; A24F 40/465 20060101
A24F040/465; A24F 40/485 20060101 A24F040/485 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 20, 2019 |
EP |
19198625.6 |
Claims
1. A smoking substitute apparatus comprising at least one air inlet
and an air inlet passage, an aerosol generator and an outlet, the
aerosol generator comprising a heater and being operable to
generate an aerosol by vaporizing a liquid aerosol precursor, air
flowing in use through said at least one air inlet and air inlet
passage, entraining the aerosol and flowing to the outlet when a
user draws on the apparatus, characterized in that a partition wall
is provided between the aerosol generator and air inlet passage, in
use the partition wall being heated by the heater of the aerosol
generator and thereby heating the air in the air inlet passage
before entraining the aerosol, and wherein the partition wall is
formed at least in part by an electrical contact for the
heater.
2. The smoking substitute apparatus according to claim 1, wherein
at least where the partition wall is formed by the electrical
contact, the total thickness of the partition wall is defined by
the electrical contact.
3. The smoking substitute apparatus according to any preceding
claim, wherein the partition wall presents a heat-absorbing surface
to the heater, the heat-absorbing surface having an area of at
least 15 mm.sup.2.
4. The smoking substitute apparatus according to any preceding
claim, wherein the partition wall presents a heat-transmitting
surface to the air inlet passage, the heat-transmitting surface
having an area of at least 15 mm.sup.2.
5. The smoking substitute apparatus according to any preceding
claim, wherein, in use, a proportion of the air flow from the air
inlet to the outlet bypasses the aerosol generator.
6. The smoking substitute apparatus according to claim 5 wherein
substantially all of the air flow from the air inlet to the outlet
bypasses the aerosol generator.
7. The smoking substitute apparatus of any preceding claim, wherein
the aerosol generator includes a wick, which has a longitudinal
axis which is coextensive with a width of the partition wall.
8. The smoking substitute apparatus of any preceding claim, wherein
the aerosol generator and partition wall are located within a
vaporization chamber having an oval cross-section, and wherein the
partition wall is substantially aligned with a long axis of the
oval cross-section.
9. The smoking substitute apparatus according to any preceding
claim, wherein the air inlet is a first air inlet, and the smoking
substitute apparatus further comprises a second partition wall
provided between the aerosol generator and a second air inlet, the
second partition wall and second air inlet being located on an
opposite side of the heater to the first partition wall and first
air inlet.
10. The smoking substitute apparatus of any preceding claim,
wherein the heater is a coil heater, which helically encompasses a
wick, and wherein the helical axis of the helical coil heater is
substantially aligned with the partition wall.
11. The smoking substitute apparatus according to any preceding
claim, wherein the smoking substitute apparatus is comprised by or
within a cartridge configured for engagement with a base unit, the
cartridge and base unit together forming a smoking substitute
system.
12. A smoking substitute system comprising: a base unit; and a
smoking substitute apparatus according to claim 11, wherein the
smoking substitute apparatus is removably engaged with the base
unit.
13. A method of using the smoking substitute apparatus of any of
claims 1 to 11 to generate an aerosol.
14. A method according to claim 13, wherein the heater heats air in
the air inlet passage to at least 50.degree. C. before entraining
the aerosol.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE
STATEMENT
[0001] This application is a non-provisional application claiming
benefit to the international application no. PCT/EP2020/076262
filed on Sep. 21, 2020, which claims priority to EP 19198625.6
filed on Sep. 20, 2019. The entire contents of each of the
above-referenced applications are hereby incorporated herein by
reference in their entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to a smoking substitute
apparatus and, in particular, a smoking substitute apparatus that
is able to deliver nicotine to a user in an effective manner.
BACKGROUND
[0003] The smoking of tobacco is generally considered to expose a
smoker to potentially harmful substances. It is thought that a
significant amount of the potentially harmful substances are
generated through the burning and/or combustion of the tobacco and
the constituents of the burnt tobacco in the tobacco smoke
itself.
[0004] Low temperature combustion of organic material such as
tobacco is known to produce tar and other potentially harmful
by-products. There have been proposed various smoking substitute
systems in which the conventional smoking of tobacco is
avoided.
[0005] Such smoking substitute systems can form part of nicotine
replacement therapies aimed at people who wish to stop smoking and
overcome a dependence on nicotine.
[0006] Known smoking substitute systems include electronic systems
that permit a user to simulate the act of smoking by producing an
aerosol (also referred to as a "vapor") that is drawn into the
lungs through the mouth (inhaled) and then exhaled. The inhaled
aerosol typically bears nicotine and/or a flavorant without, or
with fewer of, the health risks associated with conventional
smoking.
[0007] In general, smoking substitute systems are intended to
provide a substitute for the rituals of smoking, whilst providing
the user with a similar, or improved, experience and satisfaction
to those experienced with conventional smoking and with combustible
tobacco products.
[0008] The popularity and use of smoking substitute systems has
grown rapidly in the past few years. Although originally marketed
as an aid to assist habitual smokers wishing to quit tobacco
smoking, consumers are increasingly viewing smoking substitute
systems as desirable lifestyle accessories. There are a number of
different categories of smoking substitute systems, each utilizing
a different smoking substitute approach. Some smoking substitute
systems are designed to resemble a conventional cigarette and are
cylindrical in form with a mouthpiece at one end. Other smoking
substitute devices do not generally resemble a cigarette (for
example, the smoking substitute device may have a generally
box-like form, in whole or in part).
[0009] One approach is the so-called "vaping" approach, in which a
vaporizable liquid, or an aerosol former, sometimes typically
referred to herein as "e-liquid", is heated by a heating device
(sometimes referred to herein as an electronic cigarette or
"e-cigarette" device) to produce an aerosol vapor which is inhaled
by a user. The e-liquid typically includes a base liquid, nicotine
and may include a flavorant. The resulting vapor therefore also
typically contains nicotine and/or a flavorant. The base liquid may
include propylene glycol and/or vegetable glycerin.
[0010] A typical e-cigarette device includes a mouthpiece, a power
source (typically a battery), a tank for containing e-liquid and a
heating device. In use, electrical energy is supplied from the
power source to the heating device, which heats the e-liquid to
produce an aerosol (or "vapor") which is inhaled by a user through
the mouthpiece.
[0011] E-cigarettes can be configured in a variety of ways. For
example, there are "closed system" vaping smoking substitute
systems, which typically have a sealed tank and heating element.
The tank is pre-filled with e-liquid and is not intended to be
refilled by an end user. One subset of closed system vaping smoking
substitute systems include a main body which includes the power
source, wherein the main body is configured to be physically and
electrically couplable to a consumable including the tank and the
heating element. In this way, when the tank of a consumable has
been emptied of e-liquid, that consumable is removed from the main
body and disposed of. The main body can then be reused by
connecting it to a new, replacement, consumable. Another subset of
closed system vaping smoking substitute systems are completely
disposable, and intended for one-use only.
[0012] There are also "open system" vaping smoking substitute
systems which typically have a tank that is configured to be
refilled by a user. In this way the entire device can be used
multiple times.
[0013] An example vaping smoking substitute system is the myblu.TM.
e-cigarette. The myblu.TM. e-cigarette is a closed system which
includes a main body and a consumable. The main body and consumable
are physically and electrically coupled together by pushing the
consumable into the main body. The main body includes a
rechargeable battery. The consumable includes a mouthpiece and a
sealed tank which contains e-liquid. The consumable further
includes a heater, which for this device is a heating filament
coiled around a portion of a wick. The wick is partially immersed
in the e-liquid, and conveys e-liquid from the tank to the heating
filament. The system is controlled by a microprocessor on board the
main body. The system includes a sensor for detecting when a user
is inhaling through the mouthpiece, the microprocessor then
activating the device in response. When the system is activated,
electrical energy is supplied from the power source to the heating
device, which heats e-liquid from the tank to produce a vapor which
is inhaled by a user through the mouthpiece.
SUMMARY OF THE DISCLOSURE
[0014] For a smoking substitute system, it is desirable to deliver
nicotine into the user's lungs, where it can be absorbed into the
bloodstream. However, the present disclosure is based in part on a
realization that some prior art smoking substitute systems, such
delivery of nicotine is not efficient. In some prior art systems,
the aerosol droplets have a size distribution that is not suitable
for delivering nicotine to the lungs. Aerosol droplets of a large
particle size tend to be deposited in the mouth and/or upper
respiratory tract. Aerosol particles of a small (e.g., sub-micron)
particle size can be inhaled into the lungs but may be exhaled
without delivering nicotine to the lungs. As a result, the user
would require drawing a longer puff, more puffs, or vaporizing
e-liquid with a higher nicotine concentration in order to achieve
the desired experience.
[0015] Accordingly, there is a need for improvement in the delivery
of nicotine to a user in the context of a smoking substitute
system.
[0016] The present disclosure has been devised in the light of the
above considerations.
[0017] According to a first preferred aspect there is provided a
smoking substitute apparatus comprising at least one air inlet and
an air inlet passage, an aerosol generator, and an outlet, the
aerosol generator comprising a heater and being operable to
generate an aerosol by vaporizing a liquid aerosol precursor, air
flowing in use through said at least one air inlet and air inlet
passage, entraining the aerosol and flowing to the outlet when a
user draws on the apparatus, [0018] wherein a partition wall is
provided between the aerosol generator and air inlet passage, in
use the partition wall being heated by the heater of the aerosol
generator and thereby heating the air in the air inlet passage
before entraining the aerosol, [0019] and wherein the partition
wall is formed at least in part by an electrical contact for the
heater.
[0020] Such a smoking substitute apparatus promotes heating of the
incoming air using the partition wall. This facilitates the
generation of an aerosol with the desired particles sizes, as the
cooling rate is slowed relative to a smoking substitute apparatus
in which the incoming air is not heated using the partition
wall.
[0021] The partition wall may be a heat shield, to an enclosure at
least partially formed of plastics material and containing the
aerosol generator from the heater. In use, the heater generates
heat energy. Some of this energy heats and the aerosol precursor so
as to generate an aerosol, with the remainder of the heat energy
being excess heat energy. Some of the excess heat energy, in the
absence of the heat shield, would disadvantageously heat the part
of the enclosure formed of plastics material. Advantageously, the
heat shield, which is provided between the heater and said part of
the enclosure, intercepts and absorbs a significant proportion of
the excess heat directed towards said part of the enclosure and
reduces heating thereof. This reduces the risk of thermal
degradation of said part of the enclosure. Note that, because a
significant part of the air flow may bypass the vaporization
chamber, the typical cooling effect of the bypass airflow through
the vaporization chamber is not provided. Therefore, the material
of the enclosure is particularly at risk of thermal degradation in
the absence of the features of the present disclosure.
Additionally, the aerosol generator and the enclosure can be
positioned closer together than a corresponding case in which the
heat shield is absent. Furthermore, the arrangement of the heat
shield to include a heat insulating gap between the heat shield and
said part of the enclosure, further reduces the risk of thermal
degradation of said part of the enclosure, by limiting transfer of
heat energy from the heat shield to said part of the enclosure via
thermal conduction.
[0022] At least where the partition wall is formed by the
electrical contact, the total thickness of the partition wall may
be defined by the electrical contact.
[0023] The heater may be configured to heat air in the air inlet
passage to at least 50.degree. C. before entraining the
aerosol.
[0024] The partition wall presents a heat-absorbing surface to
heater, and the heat-absorbing surface may have an area of at least
15 mm.sup.2. The partition wall presents a heat-transmitting
surface to the air inlet passage, and the heat-transmitting surface
may have an area of at least 15 mm.sup.2.
[0025] The partition wall may be formed of a material selected from
metals, thermosetting polymers and ceramics and composites
thereof.
[0026] In use, a proportion of the air flow from the air inlet to
the outlet may bypass the aerosol generator. Such an example may be
referred to as a bypass smoking substitute apparatus, and said
apparatus can advantageously reduce the average and/or maximum air
flow velocity of air past the aerosol generator, which can lead to
an aerosol with larger droplet sizes being formed. In some
examples, substantially all of the air flow from the air inlet to
the outlet may bypass the aerosol generator. Such an example may be
referred to as a stagnant vaporization chamber, and said chamber
advantageously reduces the average and/or maximum air flow velocity
of air past the aerosol generator which can lead to an aerosol with
larger droplet sizes being formed.
[0027] The aerosol generator may include a wick, which has a
longitudinal axis which is coextensive with a width of the
partition wall.
[0028] The aerosol generator and partition wall may be located
within a vaporization chamber having an oval cross-section, and the
partition wall may be substantially aligned with a long axis of the
oval cross-section.
[0029] The air inlet may be a first air inlet, and the smoking
substitute apparatus may further comprise a second partition wall
provided between the aerosol generator and a second air inlet
passage, the second partition wall and second air inlet being
located on an opposite side of the heater to the first partition
wall and first air inlet.
[0030] The heater may be a coil heater, which may helically
encompass a wick, and the helical axis of the helical coil heater
may be substantially aligned with the partition wall.
[0031] The smoking substitute apparatus may be comprised by or
within a cartridge configured for engagement with a base unit, the
cartridge and base unit together forming a smoking substitute
system.
[0032] The smoking substitute apparatus may be in the form of a
consumable. The consumable may be configured for engagement with a
main body. When the consumable is engaged with the main body, the
combination of the consumable and the main body may form a smoking
substitute system such as a closed smoking substitute system. For
example, the consumable may comprise components of the system that
are disposable, and the main body may comprise non-disposable or
non-consumable components (e.g., power supply, controller, sensor,
etc.) that facilitate the generation and/or delivery of aerosol by
the consumable. In such an embodiment, the aerosol precursor (e.g.,
e-liquid) may be replenished by replacing a used consumable with an
unused consumable.
[0033] Alternatively, the smoking substitute apparatus may be a
non-consumable apparatus (e.g., that is in the form of an open
smoking substitute system). In such embodiments an aerosol former
(e.g., e-liquid) of the system may be replenished by re-filling,
e.g., a reservoir of the smoking substitute apparatus, with the
aerosol precursor (rather than replacing a consumable component of
the apparatus).
[0034] In light of this, it should be appreciated that some of the
features described herein as being part of the smoking substitute
apparatus may alternatively form part of a main body for engagement
with the smoking substitute apparatus. This may be the case in
particular when the smoking substitute apparatus is in the form of
a consumable.
[0035] Where the smoking substitute apparatus is in the form of a
consumable, the main body and the consumable may be configured to
be physically coupled together. For example, the consumable may be
at least partially received in a recess of the main body, such that
there is an interference fit between the main body and the
consumable. Alternatively, the main body and the consumable may be
physically coupled together by screwing one onto the other, or
through a bayonet fitting, or the like.
[0036] Thus, the smoking substitute apparatus may comprise one or
more engagement portions for engaging with a main body. In this
way, one end of the smoking substitute apparatus may be coupled
with the main body, whilst an opposing end of the smoking
substitute apparatus may define a mouthpiece of the smoking
substitute system.
[0037] The smoking substitute apparatus may comprise a reservoir
configured to store an aerosol precursor, such as an e-liquid. The
e-liquid may, for example, comprise a base liquid. The e-liquid may
further comprise nicotine. The base liquid may include propylene
glycol and/or vegetable glycerin. The e-liquid may be substantially
flavorless. That is, the e-liquid may not contain any deliberately
added additional flavorant and may consist solely of a base liquid
of propylene glycol and/or vegetable glycerin and nicotine.
[0038] The reservoir may be in the form of a tank. At least a
portion of the tank may be light-transmissive. For example, the
tank may comprise a window to allow a user to visually assess the
quantity of e-liquid in the tank. A housing of the smoking
substitute apparatus may comprise a corresponding aperture (or
slot) or window that may be aligned with a light-transmissive
portion (e.g., window) of the tank. The reservoir may be referred
to as a "clearomizer" if it includes a window, or a "cartomizer" if
it does not.
[0039] The smoking substitute apparatus may comprise a passage for
fluid flow therethrough. The passage may extend through (at least a
portion of) the smoking substitute apparatus, between openings that
may define an inlet and an outlet of the passage. The outlet may be
at a mouthpiece of the smoking substitute apparatus. In this
respect, a user may draw fluid (e.g., air) into and through the
passage by inhaling at the outlet (i.e., using the mouthpiece). The
passage may be at least partially defined by the tank. The tank may
substantially (or fully) define the passage, for at least a part of
the length of the passage. In this respect, the tank may surround
the passage, e.g., in an annular arrangement around the
passage.
[0040] The smoking substitute apparatus may comprise an aerosol
generator. The aerosol generator may comprise a wick. The aerosol
generator may further comprise a heater. The wick may comprise a
porous material, capable of wicking the aerosol precursor. A
portion of the wick may be exposed to air flow in the passage. The
wick may also comprise one or more portions in contact with liquid
stored in the reservoir. For example, opposing ends of the wick may
protrude into the reservoir and an intermediate portion (between
the ends) may extend across the passage so as to be exposed to air
flow in the passage. Thus, liquid may be drawn (e.g., by capillary
action) along the wick, from the reservoir to the portion of the
wick exposed to air flow.
[0041] The heater may comprise a heating element, which may be in
the form of a filament wound about the wick (e.g., the filament may
extend helically about the wick in a coil configuration). The
heating element may be wound about the intermediate portion of the
wick that is exposed to air flow in the passage. The heating
element may be electrically connected (or connectable) to a power
source. Thus, in operation, the power source may apply a voltage
across the heating element so as to heat the heating element by
resistive heating. This may cause liquid stored in the wick (i.e.,
drawn from the tank) to be heated so as to form a vapor and become
entrained in air flowing through the passage. This vapor may
subsequently cool to form an aerosol in the passage, typically
downstream from the heating element.
[0042] The smoking substitute apparatus may comprise a vaporization
chamber. The vaporization chamber may form part of the passage in
which the heater is located. The vaporization chamber may be
arranged to be in fluid communication with the inlet and outlet of
the passage. The vaporization chamber may be an enlarged portion of
the passage. In this respect, the air as drawn in by the user may
entrain the generated vapor in a flow away from heater. The
entrained vapor may form an aerosol in the vaporization chamber, or
it may form the aerosol further downstream along the passage. The
vaporization chamber may be at least partially defined by the tank.
The tank may substantially (or fully) define the vaporization
chamber. In this respect, the tank may surround the vaporization
chamber, e.g., in an annular arrangement around the vaporization
chamber.
[0043] In use, the user may puff on a mouthpiece of the smoking
substitute apparatus, i.e., draw on the smoking substitute
apparatus by inhaling, to draw in an air stream therethrough. A
portion, or all, of the air stream (also referred to as a "main air
flow") may pass through the vaporization chamber so as to entrain
the vapor generated at the heater. That is, such a main air flow
may be heated by the heater (although typically only to a limited
extent) as it passes through the vaporization chamber.
Alternatively, or in addition, a portion of the air stream (also
referred to as a "dilution air flow" or "bypass air flow") may
bypass the vaporization chamber and be directed to mix with the
generated aerosol downstream from the vaporization chamber. That
is, the dilution air flow may be an air stream at an ambient
temperature and may not be directly heated at all by the heater.
The dilution air flow may combine with the main air flow for
diluting the aerosol contained therein. The dilution air flow may
merge with the main air flow along the passage downstream from the
vaporization chamber. Alternatively, the dilution air flow may be
directly inhaled by the user without passing though the passage of
the smoking substitute apparatus.
[0044] As a user puffs on the mouthpiece, vaporized e-liquid
entrained in the passing air flow may be drawn towards the outlet
of the passage. The vapor may cool, and thereby nucleate and/or
condense along the passage to form a plurality of aerosol droplets,
e.g., nicotine-containing aerosol droplets. A portion of these
aerosol droplets may be delivered to and be absorbed at a target
delivery site, e.g., a user's lung, whilst a portion of the aerosol
droplets may instead adhere onto other parts of the user's
respiratory tract, e.g., the user's oral cavity and/or throat.
Typically, in some known smoking substitute apparatuses, the
aerosol droplets as measured at the outlet of the passage, e.g., at
the mouthpiece, may have a droplet size, d.sub.50, of less than 1
.mu.m.
[0045] In some embodiments of the disclosure, the d.sub.50 particle
size of the aerosol particles is preferably at least 1 .mu.m.
Typically, the d.sub.50 particle size is not more than 10 .mu.m,
preferably not more than 9 .mu.m, not more than 8 .mu.m, not more
than 7 .mu.m, not more than 6 .mu.m, not more than 5 .mu.m, not
more than 4 .mu.m or not more than 3 .mu.m. It is considered that
providing aerosol particle sizes in such ranges permits improved
interaction between the aerosol particles and the user's lungs.
[0046] The particle droplet size, d.sub.50, of an aerosol may be
measured by a laser diffraction technique. For example, the stream
of aerosol output from the outlet of the passage may be drawn
through a Malvern Spraytec laser diffraction system, where the
intensity and pattern of scattered laser light are analyzed to
calculate the size and size distribution of aerosol droplets. As
will be readily understood, the particle size distribution may be
expressed in terms of d.sub.10, d.sub.50 and d.sub.90, for example.
Considering a cumulative plot of the volume of the particles
measured by the laser diffraction technique, the d.sub.10 particle
size is the particle size below which 10% by volume of the sample
lies. The d.sub.50 particle size is the particle size below which
50% by volume of the sample lies. The d.sub.90 particle size is the
particle size below which 90% by volume of the sample lies. Unless
otherwise indicated herein, the particle size measurements are
volume-based particle size measurements, rather than number-based
or mass-based particle size measurements.
[0047] The spread of particle size may be expressed in terms of the
span, which is defined as (d.sub.90-d.sub.10)/d.sub.50. Typically,
the span is not more than 20, preferably not more than 10,
preferably not more than 8, preferably not more than 4, preferably
not more than 2, preferably not more than 1, or not more than
0.5.
[0048] The smoking substitute apparatus (or main body engaged with
the smoking substitute apparatus) may comprise a power source. The
power source may be electrically connected (or connectable) to a
heater of the smoking substitute apparatus (e.g., when the smoking
substitute apparatus is engaged with the main body). The power
source may be a battery (e.g., a rechargeable battery). A connector
in the form of, e.g., a USB port may be provided for recharging
this battery.
[0049] When the smoking substitute apparatus is in the form of a
consumable, the smoking substitute apparatus may comprise an
electrical interface for interfacing with a corresponding
electrical interface of the main body. One or both of the
electrical interfaces may include one or more electrical contacts.
Thus, when the main body is engaged with the consumable, the
electrical interface of the main body may be configured to transfer
electrical power from the power source to a heater of the
consumable via the electrical interface of the consumable.
[0050] The electrical interface of the smoking substitute apparatus
may also be used to identify the smoking substitute apparatus (in
the form of a consumable) from a list of known types. For example,
the consumable may have a certain concentration of nicotine and the
electrical interface may be used to identify this. The electrical
interface may additionally or alternatively be used to identify
when a consumable is connected to the main body.
[0051] Again, where the smoking substitute apparatus is in the form
of a consumable, the main body may comprise an identification
means, which may, for example, be in the form of an RFID reader, a
barcode or QR code reader. This identification means may be able to
identify a characteristic (e.g., a type) of a consumable engaged
with the main body. In this respect, the consumable may include any
one or more of an RFID chip, a barcode or QR code, or memory within
which is an identifier and which can be interrogated via the
identification means.
[0052] The smoking substitute apparatus or main body may comprise a
controller, which may include a microprocessor. The controller may
be configured to control the supply of power from the power source
to the heater of the smoking substitute apparatus (e.g., via the
electrical contacts). A memory may be provided and may be
operatively connected to the controller. The memory may include
non-volatile memory. The memory may include instructions which,
when implemented, cause the controller to perform certain tasks or
steps of a method.
[0053] The main body or smoking substitute apparatus may comprise a
wireless interface, which may be configured to communicate
wirelessly with another device, for example a mobile device, e.g.,
via Bluetooth.RTM.. To this end, the wireless interface could
include a Bluetooth.degree. antenna. Other wireless communication
interfaces, e.g., WIFI.RTM., are also possible. The wireless
interface may also be configured to communicate wirelessly with a
remote server.
[0054] A puff sensor may be provided that is configured to detect a
puff (i.e., inhalation from a user). The puff sensor may be
operatively connected to the controller so as to be able to provide
a signal to the controller that is indicative of a puff state
(i.e., puffing or not puffing). The puff sensor may, for example,
be in the form of a pressure sensor or an acoustic sensor. That is,
the controller may control power supply to the heater of the
consumable in response to a puff detection by the sensor. The
control may be in the form of activation of the heater in response
to a detected puff. That is, the smoking substitute apparatus may
be configured to be activated when a puff is detected by the puff
sensor. When the smoking substitute apparatus is in the form of a
consumable, the puff sensor may be provided in the consumable or
alternatively may be provided in the main body.
[0055] According to a second preferred aspect there is provided a
smoking substitute system comprising: a base unit; and the smoking
substitute apparatus according to the first aspect, wherein the
smoking substitute apparatus is removably engaged with the base
unit.
[0056] According to a third preferred aspect there is provided a
method of using the smoking substitute apparatus of the first
aspect to generate an aerosol.
[0057] The term "flavorant" is used to describe a compound or
combination of compounds that provide flavor and/or aroma. For
example, the flavorant may be configured to interact with a sensory
receptor of a user (such as an olfactory or taste receptor). The
flavorant may include one or more volatile substances.
[0058] The flavorant may be provided in solid or liquid form. The
flavorant may be natural or synthetic. For example, the flavorant
may include menthol, licorice, chocolate, fruit flavor (including,
e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon)
and tobacco flavor. The flavorant may be evenly dispersed or may be
provided in isolated locations and/or varying concentrations.
[0059] The present inventors consider that a flow rate of 1.3 L
min.sup.-1 is towards the lower end of a typical user expectation
of flow rate through a conventional cigarette and therefore through
a user-acceptable smoking substitute apparatus. The present
inventors further consider that a flow rate of 2.0 L min.sup.-1 is
towards the higher end of a typical user expectation of flow rate
through a conventional cigarette and therefore through a
user-acceptable smoking substitute apparatus. Embodiments of the
present disclosure therefore provide an aerosol with advantageous
particle size characteristics across a range of flow rates of air
through the apparatus.
[0060] The aerosol may have a Dv50 of at least 1.1 .mu.m, at least
1.2 .mu.m, at least 1.3 .mu.m, at least 1.4 .mu.m, at least 1.5
.mu.m, at least 1.6 .mu.m, at least 1.7 .mu.m, at least 1.8 .mu.m,
at least 1.9 .mu.m or at least 2.0 .mu.m.
[0061] The aerosol may have a Dv50 of not more than 4.9 .mu.m, not
more than 4.8 .mu.m, not more than 4.7 .mu.m, not more than 4.6
.mu.m, not more than 4.5 .mu.m, not more than 4.4 .mu.m, not more
than 4.3 .mu.m, not more than 4.2 .mu.m, not more than 4.1 .mu.m,
not more than 4.0 .mu.m, not more than 3.9 .mu.m, not more than 3.8
.mu.m, not more than 3.7 .mu.m, not more than 3.6 .mu.m, not more
than 3.5 .mu.m, not more than 3.4 .mu.m, not more than 3.3 .mu.m,
not more than 3.2 .mu.m, not more than 3.1 .mu.m or not more than
3.0 .mu.m.
[0062] A particularly preferred range for Dv50 of the aerosol is in
the range 2-3 .mu.m.
[0063] When the air flow rate inhaled by the user through the
apparatus is 1.3 L min.sup.-1, the average magnitude of velocity of
air in the vaporization chamber may be not more than 0.001
ms.sup.-1, or not more than 0.005 ms.sup.-1, or not more than 0.01
ms.sup.-1, or not more than 0.05 ms.sup.-1.
[0064] Alternatively, when the air flow rate inhaled by the user
through the apparatus is 1.3 L min.sup.-1, the average magnitude of
velocity of air in the vaporization chamber may be at least 0.001
ms.sup.-1, or at least 0.005 ms.sup.-1, or at least 0.01 ms.sup.-1,
or at least 0.05 ms.sup.-1. When the air flow rate inhaled by the
user through the apparatus is 1.3 L min.sup.-1, the average
magnitude of velocity of air in the vaporization chamber may be at
most 1.2 ms.sup.-1, at most 1.1 ms.sup.-1, at most 1.0 ms.sup.-1,
at most 0.9 ms.sup.-1, at most 0.8 ms.sup.-1, at most 0.7 ms.sup.-1
or at most 0.6 ms.sup.-1. When the air flow rate inhaled by the
user through the apparatus is 2.0 L min.sup.-1, the average
magnitude of velocity of air in the vaporization chamber may be at
least 0.001 ms.sup.-1, or at least 0.005 ms.sup.-1, or at least
0.01 ms.sup.-1, or at least 0.05 ms.sup.-1. When the air flow rate
inhaled by the user through the apparatus is 2.0 L min.sup.-1, the
average magnitude of velocity of air in the vaporization chamber
may be at most 1.2 ms.sup.-1, at most 1.1 ms.sup.-1, at most 1.0
ms.sup.-1, at most 0.9 ms.sup.-1, at most 0.8 ms.sup.-1, at most
0.7 ms.sup.-1 or at most 0.6 ms.sup.-1.
[0065] The aerosol generator may comprise a vaporizer element
loaded with aerosol precursor, the vaporizer element being heatable
by a heater and presenting a vaporizer element surface to air in
the vaporization chamber. A vaporizer element region may be defined
as a volume extending outwardly from the vaporizer element surface
to a distance of 1 mm from the vaporizer element surface.
[0066] The air inlet, flow passage, outlet and the vaporization
chamber may be configured so that, when the air flow rate inhaled
by the user through the apparatus is 1.3 L min.sup.-1, the average
magnitude of velocity of air in the vaporizer element region is in
the range 0-1.2 ms.sup.-1. The average magnitude of velocity of air
in the vaporizer element region may be calculated using
computational fluid dynamics.
[0067] When the air flow rate inhaled by the user through the
apparatus is 1.3 L min.sup.-1, the average magnitude of velocity of
air in the vaporizer element region may be not more than 0.001
ms.sup.-1, or not more than 0.005 ms.sup.-1, or not more than 0.01
ms.sup.-1, or not more than 0.05 ms.sup.-1.
[0068] Alternatively, when the air flow rate inhaled by the user
through the apparatus is 1.3 L min.sup.-1, the average magnitude of
velocity of air in the vaporizer element region may be at least
0.001 ms.sup.-1, or at least 0.005 ms.sup.-1, or at least 0.01
ms.sup.-1, or at least 0.05 ms.sup.-1. When the air flow rate
inhaled by the user through the apparatus is 1.3 L min.sup.-1, the
average magnitude of velocity of air in the vaporizer element
region may be at most 1.1 ms.sup.-1, at most 1.0 ms.sup.-1, at most
0.9 ms.sup.-1, at most 0.8 ms.sup.-1, at most 0.7 ms.sup.-1 or at
most 0.6 ms.sup.-1. When the air flow rate inhaled by the user
through the apparatus is 2.0 L min.sup.-1, the average magnitude of
velocity of air in the vaporizer element region may be at least
0.001 ms.sup.-1, or at least 0.005 ms.sup.-1, or at least 0.01
ms.sup.-1, or at least 0.05 ms.sup.-1. When the air flow rate
inhaled by the user through the apparatus is 2.0 L min.sup.-1, the
average magnitude of velocity of air in the vaporizer element
region may be at most 1.1 ms.sup.-1, at most 1.0 ms.sup.-1, at most
0.9 ms.sup.-1, at most 0.8 ms.sup.-1, at most 0.7 ms.sup.-1 or at
most 0.6 ms.sup.-1.
[0069] When the average magnitude of velocity of air in the
vaporizer element region is in the ranges specified, it is
considered that the resultant aerosol particle size is
advantageously controlled to be in a desirable range. It is further
considered that the velocity of air in the vaporizer element region
is more relevant to the resultant particle size characteristics
than consideration of the velocity in the vaporization chamber as a
whole. This is in view of the significant effect of the velocity of
air in the vaporizer element region on the cooling of the vapor
emitted from the vaporizer element surface.
[0070] Additionally, or alternatively is it relevant to consider
the maximum magnitude of velocity of air in the vaporizer element
region.
[0071] Therefore, the air inlet, flow passage, outlet and the
vaporization chamber may be configured so that, when the air flow
rate inhaled by the user through the apparatus is 1.3 L min.sup.-1,
the maximum magnitude of velocity of air in the vaporizer element
region is in the range 0-2.0 ms.sup.-1.
[0072] When the air flow rate inhaled by the user through the
apparatus is 1.3 L min.sup.-1, the maximum magnitude of velocity of
air in the vaporizer element region may be not more than 0.001
ms.sup.-1, or not more than 0.005 ms.sup.-1, or not more than 0.01
ms.sup.-1, or not more than 0.05 ms.sup.-1.
[0073] Alternatively, when the air flow rate inhaled by the user
through the apparatus is 1.3 L min.sup.-1, the maximum magnitude of
velocity of air in the vaporizer element region may be at least
0.001 ms.sup.-1, or at least 0.005 ms.sup.-1, or at least 0.01
ms.sup.-1, or at least 0.05 ms.sup.-1. When the air flow rate
inhaled by the user through the apparatus is 1.3 L min.sup.-1, the
maximum magnitude of velocity of air in the vaporizer element
region may be at most 1.9 ms.sup.-1, at most 1.8 ms.sup.-1, at most
1.7 ms.sup.-1, at most 1.6 ms.sup.-1, at most 1.5 ms.sup.-1, at
most 1.4 ms.sup.-1, at most 1.3 ms.sup.-1 or at most 1.2 ms.sup.-1.
When the air flow rate inhaled by the user through the apparatus is
2.0 L min.sup.-1, the maximum magnitude of velocity of air in the
vaporizer element region may be at least 0.001 ms.sup.-1, or at
least 0.005 ms.sup.-1, or at least 0.01 ms.sup.-1, or at least 0.05
ms.sup.-1. When the air flow rate inhaled by the user through the
apparatus is 2.0 L min.sup.-1, the maximum magnitude of velocity of
air in the vaporizer element region may be at most 1.9 ms.sup.-1,
at most 1.8 ms.sup.-1, at most 1.7 ms.sup.-1, at most 1.6
ms.sup.-1, at most 1.5 ms.sup.-1, at most 1.4 ms.sup.-1, at most
1.3 ms.sup.-1 or at most 1.2 ms.sup.-1.
[0074] It is considered that configuring the apparatus in a manner
to permit such control of velocity of the airflow at the vaporizer
permits the generation of aerosols with particularly advantageous
particle size characteristics, including Dv50 values.
[0075] Additionally, or alternatively is it relevant to consider
the turbulence intensity in the vaporizer chamber in view of the
effect of turbulence on the particle size of the generated aerosol.
For example, the air inlet, flow passage, outlet and the
vaporization chamber may be configured so that, when the air flow
rate inhaled by the user through the apparatus is 1.3 L min.sup.-1,
the turbulence intensity in the vaporizer element region is not
more than 1%.
[0076] When the air flow rate inhaled by the user through the
apparatus is 1.3 L min.sup.-1, the turbulence intensity in the
vaporizer element region may be not more than 0.95%, not more than
0.9%, not more than 0.85%, not more than 0.8%, not more than 0.75%,
not more than 0.7%, not more than 0.65% or not more than 0.6%.
[0077] It is considered that configuring the apparatus in a manner
to permit such control of the turbulence intensity in the vaporizer
element region permits the generation of aerosols with particularly
advantageous particle size characteristics, including Dv50
values.
[0078] Following detailed investigations, the inventors consider,
without wishing to be bound by theory, that the particle size
characteristics of the generated aerosol may be determined by the
cooling rate experienced by the vapor after emission from the
vaporizer element (e.g., wick). In particular, it appears that
imposing a relatively slow cooling rate on the vapor has the effect
of generating aerosols with a relatively large particle size. The
parameters discussed above (velocity and turbulence intensity) are
considered to be mechanisms for implementing a particular cooling
dynamic to the vapor.
[0079] More generally, it is considered that the air inlet, flow
passage, outlet and the vaporization chamber may be configured so
that a desired cooling rate is imposed on the vapor. The particular
cooling rate to be used depends of course on the nature of the
aerosol precursor and other conditions. However, for a particular
aerosol precursor it is possible to define a set of testing
conditions in order to define the cooling rate, and by extension
this imposes limitations on the configuration of the apparatus to
permit such cooling rates as are shown to result in advantageous
aerosols. Accordingly, the air inlet, flow passage, outlet and the
vaporization chamber may be configured so that the cooling rate of
the vapor is such that the time taken to cool to 50.degree. C. is
not less than 16 ms, when tested according to the following
protocol. The aerosol precursor is an e-liquid consisting of 1.6%
freebase nicotine and the remainder a 65:35 propylene glycol and
vegetable glycerin mixture, the e-liquid having a boiling point of
209.degree. C. Air is drawn into the air inlet at a temperature of
25.degree. C. The vaporizer is operated to release a vapor of total
particulate mass 5 mg over a 3 second duration from the vaporizer
element surface in an air flow rate between the air inlet and
outlet of 1.3 L min.sup.-1.
[0080] Additionally, or alternatively, the air inlet, flow passage,
outlet and the vaporization chamber may be configured so that the
cooling rate of the vapor is such that the time taken to cool to
50.degree. C. is not less than 16 ms, when tested according to the
following protocol. The aerosol precursor is an e-liquid consisting
of 1.6% freebase nicotine and the remainder a 65:35 propylene
glycol and vegetable glycerin mixture, the e-liquid having a
boiling point of 209.degree. C. Air is drawn into the air inlet at
a temperature of 25.degree. C. The vaporizer is operated to release
a vapor of total particulate mass 5 mg over a 3 second duration
from the vaporizer element surface in an air flow rate between the
air inlet and outlet of 2.0 L min.sup.-1.
[0081] Cooling of the vapor such that the time taken to cool to
50.degree. C. is not less than 16 ms corresponds to an equivalent
linear cooling rate of not more than 10.degree. C./ms.
[0082] The equivalent linear cooling rate of the vapor to
50.degree. C. may be not more than 9.degree. C./ms, not more than
8.degree. C./ms, not more than 7.degree. C./ms, not more than
6.degree. C./ms or not more than 5.degree. C./ms.
[0083] Cooling of the vapor such that the time taken to cool to
50.degree. C. is not less than 32 ms corresponds to an equivalent
linear cooling rate of not more than 5.degree. C./ms.
[0084] The testing protocol set out above considers the cooling of
the vapor (and subsequent aerosol) to a temperature of 50.degree.
C. This is a temperature which can be considered to be suitable for
an aerosol to exit the apparatus for inhalation by a user without
causing significant discomfort. It is also possible to consider
cooling of the vapor (and subsequent aerosol) to a temperature of
75.degree. C. Although this temperature is possibly too high for
comfortable inhalation, it is considered that the particle size
characteristics of the aerosol are substantially settled by the
time the aerosol cools to this temperature (and they may be settled
at still higher temperature).
[0085] Accordingly, the air inlet, flow passage, outlet and the
vaporization chamber may be configured so that the cooling rate of
the vapor is such that the time taken to cool to 75.degree. C. is
not less than 4.5 ms, when tested according to the following
protocol. The aerosol precursor is an e-liquid consisting of 1.6%
freebase nicotine and the remainder a 65:35 propylene glycol and
vegetable glycerin mixture, the e-liquid having a boiling point of
209.degree. C. Air is drawn into the air inlet at a temperature of
25.degree. C. The vaporizer is operated to release a vapor of total
particulate mass 5 mg over a 3 second duration from the vaporizer
element surface in an air flow rate between the air inlet and
outlet of 1.3 L min.sup.-1.
[0086] Additionally, or alternatively, the air inlet, flow passage,
outlet and the vaporization chamber may be configured so that the
cooling rate of the vapor is such that the time taken to cool to
75.degree. C. is not less than 4.5 ms, when tested according to the
following protocol. The aerosol precursor is an e-liquid consisting
of 1.6% freebase nicotine and the remainder a 65:35 propylene
glycol and vegetable glycerin mixture, the e-liquid having a
boiling point of 209.degree. C. Air is drawn into the air inlet at
a temperature of 25.degree. C. The vaporizer is operated to release
a vapor of total particulate mass 5 mg over a 3 second duration
from the vaporizer element surface in an air flow rate between the
air inlet and outlet of 2.0 L min.sup.-1.
[0087] Cooling of the vapor such that the time taken to cool to
75.degree. C. is not less than 4.5 ms corresponds to an equivalent
linear cooling rate of not more than 30.degree. C./ms.
[0088] The equivalent linear cooling rate of the vapor to
75.degree. C. may be not more than 29.degree. C./ms, not more than
28.degree. C./ms, not more than 27.degree. C./ms, not more than
26.degree. C./ms, not more than 25.degree. C./ms, not more than
24.degree. C./ms, not more than 23.degree. C./ms, not more than
22.degree. C./ms, not more than 21.degree. C./ms, not more than
20.degree. C./ms, not more than 19.degree. C./ms, not more than
18.degree. C./ms, not more than 17.degree. C./ms, not more than
16.degree. C./ms, not more than 15.degree. C./ms, not more than
14.degree. C./ms, not more than 13.degree. C./ms, not more than
12.degree. C./ms, not more than 11.degree. C./ms or not more than
10.degree. C./ms.
[0089] Cooling of the vapor such that the time taken to cool to
75.degree. C. is not less than 13 ms corresponds to an equivalent
linear cooling rate of not more than 10.degree. C./ms.
[0090] It is considered that configuring the apparatus in a manner
to permit such control of the cooling rate of the vapor permits the
generation of aerosols with particularly advantageous particle size
characteristics, including Dv50 values.
[0091] The disclosure includes the combination of the aspects and
preferred features described except where such a combination is
clearly impermissible or expressly avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0092] So that the disclosure may be understood, and so that
further aspects and features thereof may be appreciated,
embodiments illustrating the principles of the disclosure will now
be discussed in further detail with reference to the accompanying
figures, in which:
[0093] FIG. 1 illustrates a set of rectangular tubes for use in
experiments to assess the effect of flow and cooling conditions at
the wick on aerosol properties. Each tube has the same depth and
length but different width.
[0094] FIG. 2 shows a schematic perspective longitudinal cross
sectional view of an example rectangular tube with a wick and
heater coil installed.
[0095] FIG. 3 shows a schematic transverse cross sectional view an
example rectangular tube with a wick and heater coil installed. In
this example, the internal width of the tube is 12 mm.
[0096] FIGS. 4A-4D show air flow streamlines in the four devices
used in a turbulence study.
[0097] FIG. 5 shows the experimental set up to investigate the
influence of inflow air temperature on aerosol particle size, in
order to investigate the effect of vapor cooling rate on aerosol
generation.
[0098] FIG. 6 shows a schematic longitudinal cross sectional view
of a first smoking substitute apparatus (pod 1) used to assess
influence of inflow air temperature on aerosol particle size.
[0099] FIG. 7 shows a schematic longitudinal cross sectional view
of a second smoking substitute apparatus (pod 2) used to assess
influence of inflow air temperature on aerosol particle size.
[0100] FIG. 8A shows a schematic longitudinal cross sectional view
of a third smoking substitute apparatus (pod 3) used to assess
influence of inflow air temperature on aerosol particle size.
[0101] FIG. 8B shows a schematic longitudinal cross sectional view
of the same third smoking substitute apparatus (pod 3) in a
direction orthogonal to the view taken in FIG. 8A.
[0102] FIG. 9 shows a plot of aerosol particle size (Dv50)
experimental results against calculated air velocity.
[0103] FIG. 10 shows a plot of aerosol particle size (Dv50)
experimental results against the flow rate through the apparatus
for a calculated air velocity of 1 m/s.
[0104] FIG. 11 shows a plot of aerosol particle size (Dv50)
experimental results against the average magnitude of the velocity
in the vaporizer surface region, as obtained from CFD
modelling.
[0105] FIG. 12 shows a plot of aerosol particle size (Dv50)
experimental results against the maximum magnitude of the velocity
in the vaporizer surface region, as obtained from CFD
modelling.
[0106] FIG. 13 shows a plot of aerosol particle size (Dv50)
experimental results against the turbulence intensity.
[0107] FIG. 14 shows a plot of aerosol particle size (Dv50)
experimental results dependent on the temperature of the air and
the heating state of the apparatus.
[0108] FIG. 15 shows a plot of aerosol particle size (Dv50)
experimental results against vapor cooling rate to 50.degree.
C.
[0109] FIG. 16 shows a plot of aerosol particle size (Dv50)
experimental results against vapor cooling rate to 75.degree.
C.
[0110] FIG. 17 is a schematic front view of a smoking substitute
system, according to a first embodiment, in an engaged
position.
[0111] FIG. 18 is a schematic front view of the smoking substitute
system of the first embodiment in a disengaged position.
[0112] FIG. 19 is a schematic longitudinal cross sectional view of
a smoking substitute apparatus which is an embodiment of the
present disclosure.
[0113] FIG. 20 is an enlarged schematic cross sectional view of
part of the air passage and vaporization chamber of the smoking
substitute apparatus of FIG. 19.
[0114] FIG. 21 is a cross sectional view of the vaporization
chamber of an alternative embodiment.
[0115] FIG. 22 is a perspective section view of the vaporization
chamber and air passage of FIG. 21.
[0116] FIG. 23 is a schematic longitudinal cross sectional view of
a smoking substitute apparatus which is an embodiment of the
present disclosure.
DETAILED DESCRIPTION
[0117] Further background to the present disclosure and further
aspects and embodiments of the present disclosure will now be
discussed with reference to the accompanying figures. Further
aspects and embodiments will be apparent to those skilled in the
art. The contents of all documents mentioned in this text are
incorporated herein by reference in their entirety.
[0118] FIGS. 17 and 18 illustrate a smoking substitute system in
the form of an e-cigarette system 110. The system 110 comprises a
main body 120 of the system 110, and a smoking substitute apparatus
in the form of an e-cigarette consumable (or "pod") 150. In the
illustrated embodiment the consumable 150 (sometimes referred to
herein as a smoking substitute apparatus) is removable from the
main body 120, so as to be a replaceable component of the system
110. The e-cigarette system 110 is a closed system in the sense
that it is not intended that the consumable should be refillable
with e-liquid by a user.
[0119] As is apparent from FIGS. 17 and 18, the consumable 150 is
configured to engage the main body 120. FIG. 17 shows the main body
120 and the consumable 150 in an engaged state, whilst FIG. 18
shows the main body 120 and the consumable 150 in a disengaged
state. When engaged, a portion of the consumable 150 is received in
a cavity of corresponding shape in the main body 120 and is
retained in the engaged position by way of a snap-engagement
mechanism. In other embodiments, the main body 120 and consumable
150 may be engaged by screwing one into (or onto) the other, or
through a bayonet fitting, or by way of an interference fit.
[0120] The system 110 is configured to vaporize an aerosol
precursor, which in the illustrated embodiment is in the form of a
nicotine-based e-liquid 160. The e-liquid 160 comprises nicotine
and a base liquid including propylene glycol and/or vegetable
glycerin. In the present embodiment, the e-liquid 160 is flavored
by a flavorant. In other embodiments, the e-liquid 160 may be
flavorless and thus may not include any added flavorant.
[0121] FIG. 19 shows a schematic longitudinal cross sectional view
of the smoking substitute apparatus forming part of the smoking
substitute system shown in FIGS. 17 and 18. In FIG. 19, the
e-liquid 160 is stored within a reservoir in the form of a tank 152
that forms part of the consumable 150. In the illustrated
embodiment, the consumable 150 is a "single-use" consumable 150.
That is, upon exhausting the e-liquid 160 in the tank 152, the
intention is that the user disposes of the entire consumable 150.
The term "single-use" does not necessarily mean the consumable is
designed to be disposed of after a single smoking session. Rather,
it defines the consumable 150 is not arranged to be refilled after
the e-liquid contained in the tank 152 is depleted. The tank may
include a vent (not shown) to allow ingress of air to replace
e-liquid that has been used from the tank. The consumable 150
preferably includes a window 158 (see FIGS. 17 and 18), so that the
amount of e-liquid in the tank 152 can be visually assessed. The
main body 120 includes a slot 157 so that the window 158 of the
consumable 150 can be seen whilst the rest of the tank 152 is
obscured from view when the consumable 150 is received in the
cavity of the main body 120. The consumable 150 may be referred to
as a "clearomizer" when it includes a window 158, or a "cartomizer"
when it does not.
[0122] In other embodiments, the e-liquid (i.e., aerosol precursor)
may be the only part of the system that is truly "single-use". That
is, the tank may be refillable with e-liquid or the e-liquid may be
stored in a non-consumable component of the system. For example, in
such other embodiments, the e-liquid may be stored in a tank
located in the main body or stored in another component that is
itself not single-use (e.g., a refillable cartomizer).
[0123] The external wall of tank 152 is provided by a casing of the
consumable 150. The tank 152 annularly surrounds, and thus defines
a portion of, a passage 170 that extends between a vaporizer inlet
172 and an outlet 174 at opposing ends of the consumable 150. In
this respect, the passage 170 comprises an upstream end at the end
of the consumable 150 that engages with the main body 120, and a
downstream end at an opposing end of the consumable 150 that
comprises a mouthpiece 154 of the system 110.
[0124] When the consumable 150 is received in the cavity of the
main body 120 as shown in FIG. 3, a plurality of device air inlets
176 are formed at the boundary between the casing of the consumable
and the casing of the main body. The device air inlets 176 are in
fluid communication with the vaporizer inlet 172 through an inlet
flow channel 178 formed in the cavity of the main body which is of
corresponding shape to receive a part of the consumable 150. Air
from outside of the system 110 can therefore be drawn into the
passage 170 through the device air inlets 176 and the inlet flow
channels 178.
[0125] When the consumable 150 is engaged with the main body 120, a
user can inhale (i.e., take a puff) via the mouthpiece 154 so as to
draw air through the passage 170, and so as to form an airflow
(indicated by the dashed arrows in FIG. 3) in a direction from the
vaporizer inlet 172 to the outlet 174. Although not illustrated,
the passage 170 may be partially defined by a tube (e.g., a metal
tube) extending through the consumable 150. In FIG. 19, for
simplicity, the passage 170 is shown with a substantially circular
cross-sectional profile with a constant diameter along its length.
In other embodiments, the passage may have other cross-sectional
profiles, such as oval shaped or polygonal shaped profiles.
Further, in other embodiments, the cross sectional profile and the
diameter (or hydraulic diameter) of the passage may vary along its
longitudinal axis.
[0126] The smoking substitute system 110 is configured to vaporize
the e-liquid 160 for inhalation by a user. To provide this
operability, the consumable 150 comprises a heater having a porous
wick 162 and a resistive heating element in the form of a heating
filament 164 that is helically wound (in the form of a coil) around
a portion of the porous wick 162. The porous wick 162 extends
across the passage 170 (i.e., transverse to a longitudinal axis of
the passage 170 and thus also transverse to the air flow along the
passage 170 during use) and opposing ends of the wick 162 extend
into the tank 152 (so as to be immersed in the e-liquid 160). In
this way, e-liquid 160 contained in the tank 152 is conveyed from
the opposing ends of the porous wick 162 to a central portion of
the porous wick 162 so as to be exposed to the airflow in the
passage 170.
[0127] The helical filament 164 is wound about the exposed central
portion of the porous wick 162 and is electrically connected to an
electrical interface in the form of electrical contacts 156 mounted
at the end of the consumable that is proximate the main body 120
(when the consumable and the main body are engaged). When the
consumable 150 is engaged with the main body 120, electrical
contacts 156 make contact with corresponding electrical contacts
(not shown) of the main body 120. The main body electrical contacts
are electrically connectable to a power source (not shown) of the
main body 120, such that (in the engaged position) the filament 164
is electrically connectable to the power source. In this way, power
can be supplied by the main body 120 to the filament 164 in order
to heat the filament 164. This heats the porous wick 162 which
causes e-liquid 160 conveyed by the porous wick 162 to vaporize and
thus to be released from the porous wick 162. The vaporized
e-liquid becomes entrained in the airflow and, as it cools in the
airflow (between the heated wick and the outlet 174 of the passage
170), condenses to form an aerosol. This aerosol is then inhaled,
via the mouthpiece 154, by a user of the system 110. As e-liquid is
lost from the heated portion of the wick, further e-liquid is drawn
along the wick from the tank to replace the e-liquid lost from the
heated portion of the wick.
[0128] The filament 164 and the exposed central portion of the
porous wick 162 are positioned across the passage 170. More
specifically, the part of passage that contains the filament 164
and the exposed portion of the porous wick 162 forms a vaporization
chamber. In the illustrated example, the vaporization chamber has
the same cross-sectional diameter as the passage 170. However, in
other embodiments the vaporization chamber may have a different
cross sectional profile compared with the passage 170. For example,
the vaporization chamber may have a larger cross sectional diameter
than at least some of the downstream part of the passage 170 so as
to enable a longer residence time for the air inside the
vaporization chamber.
[0129] FIG. 20 illustrates in more detail the vaporization chamber
and therefore the region of the consumable 150 around the wick 162
and filament 164. The helical filament 164 is wound around a
central portion of the porous wick 162. The porous wick extends
across passage 170. E-liquid 160 contained within the tank 152 is
conveyed as illustrated schematically by arrows 401, i.e., from the
tank and towards the central portion of the porous wick 162.
[0130] When the user inhales, air is drawn from through the inlets
176 shown in FIG. 19, along inlet flow channel 178 to vaporization
chamber inlet 172 and into the vaporization chamber containing
porous wick 162. The porous wick 162 extends substantially
transverse to the airflow direction. The airflow passes around the
porous wick, at least a portion of the airflow substantially
following the surface of the porous wick 162. In examples where the
porous wick has a cylindrical cross-sectional profile, the airflow
may follow a curved path around an outer periphery of the porous
wick 162.
[0131] At substantially the same time as the airflow passes around
the porous wick 162, the filament 164 is heated so as to vaporize
the e-liquid which has been wicked into the porous wick. The
airflow passing around the porous wick 162 picks up this vaporized
e-liquid, and the vapor-containing airflow is drawn in direction
403 further down passage 170.
[0132] The power source of the main body 120 may be in the form of
a battery (e.g., a rechargeable battery such as a lithium-ion
battery). The main body 120 may comprise a connector in the form
of, e.g., a USB port for recharging this battery. The main body 120
may also comprise a controller that controls the supply of power
from the power source to the main body electrical contacts (and
thus to the filament 164). That is, the controller may be
configured to control a voltage applied across the main body
electrical contacts, and thus the voltage applied across the
filament 164. In this way, the filament 164 may only be heated
under certain conditions (e.g., during a puff and/or only when the
system is in an active state). In this respect, the main body 120
may include a puff sensor (not shown) that is configured to detect
a puff (i.e., inhalation). The puff sensor may be operatively
connected to the controller so as to be able to provide a signal,
to the controller, which is indicative of a puff state (i.e.,
puffing or not puffing). The puff sensor may, for example, be in
the form of a pressure sensor or an acoustic sensor.
[0133] Although not shown, the main body 120 and consumable 150 may
comprise a further interface which may, for example, be in the form
of an RFID reader, a barcode or QR code reader. This interface may
be able to identify a characteristic (e.g., a type) of a consumable
150 engaged with the main body 120. In this respect, the consumable
150 may include any one or more of an RFID chip, a barcode or QR
code, or memory within which is an identifier and which can be
interrogated via the interface.
[0134] FIG. 21 is a cross section view of a vaporization chamber
200 of an apparatus, showing further features than shown in FIG.
20. As can be seen, the vaporization chamber includes wick 162 and
coil 164. The wick extends axially into the plane of the image.
Adjacent to the wick, on opposing sides, are first 201a and second
201b partition walls which extend from a base of the vaporization
chamber up to at least a point adjacent to the wick 162. The first
partition wall 201a has a height which is less than the uppermost
portion of the wick, whereas the second partition wall 201b has a
height which is greater than the uppermost portion of the wick. The
first and second partition walls are also referred to as a contact
air vane.
[0135] Adjacent to the first partition wall 201a, on a side of the
wall opposite to the wick, is a first air inlet 202a. In use, air
passes through the first air inlet and up through first air inlet
passage 203a, so as to contact a heat-transmitting surface of the
first partition wall 201a. When the coil is activated, it heats the
first partition wall 201a on a heat-absorbing side (proximal to the
coil) which allows the first partition wall to heat the air flow
passing along the first air flow passage 203a.
[0136] Similarly, adjacent to the second partition wall 201b, on a
side of the wall opposite to the wick 162, is a second air inlet
202b. In use, air passes through the second air inlet and up
through second air inlet passage 203b, so as to contact a
heat-transmitting surface of the second partition wall 201b. When
the coil is activated, it heats the second partition wall 201b on a
heat-absorbing side (proximal to the coil) which allows the second
partition wall to heat air flow passing along the second air flow
passage 203b. The partition walls 201a and 201b form at least a
part of a pair of electrical contacts for the heater.
[0137] Advantageously, the air entering the vaporization chamber
200 is thereby heated to a temperature above ambient. This reduces
a temperature difference between aerosol precursor vaporized by the
coil 164 and wick 162 and the air in which the vaporized precursor
is entrained. This reduction in the temperature difference results
in a reduction in the cooling rate of the vaporized precursor,
which yields an aerosol with a larger droplet size. The heater
and/or partition walls are configured to heat the air in the air
inlet passage(s) to a temperature of at least 50.degree. C. before
entraining the aerosol.
[0138] FIG. 22 is a perspective section view of the vaporization
chamber 200. Like features are shown by like reference
numerals.
[0139] Whilst not shown, the partition walls may extend
significantly further than the uppermost surface of the wick
162.
[0140] In both FIGS. 21 and 22, the wick is in effect located
within a `stagnant` vaporization chamber as discussed above. In
such examples, there may be essentially no or very limited air flow
past the wick and coil. In further examples, not shown, there may
be only a single partition wall 201a or 201b.
[0141] FIG. 23 illustrates a schematic longitudinal cross sectional
view of a bypass smoking substitute apparatus forming part of the
smoking substitute system shown in FIGS. 17 and 18. The smoking
substitute apparatus illustrated in FIG. 23 differs from that
illustrated in FIG. 19 in that the substitute smoking apparatus
includes two bypass passages 180 in addition to the vaporizer
passage 170. The bypass air passages extend between the plurality
of device air inlets 176 and two outlets 184. In other variations,
the number of bypass passages 180 and corresponding outlets 184 may
be greater or smaller than in the illustrated example. Furthermore,
there may be more or fewer air inlets and there may be more or
fewer outlets.
[0142] In FIG. 23, for simplicity, the bypass passage 180 is shown
with a substantially circular cross-sectional profile with a
constant diameter along its length. In some variations, the bypass
passage 180 may have other cross-sectional profiles, such as oval
shaped or polygonal shaped profiles. Further, in some variations,
the cross sectional profile and the diameter (or hydraulic
diameter) of the bypass passage 180 may vary along its longitudinal
axis.
[0143] The provision of a bypass passage 180 means that a part of
the air drawn through the smoking substitute apparatus 150a when a
user inhales via the mouthpiece 154 is not drawn through the
vaporization chamber. This has the effect of reducing the flow rate
through the vaporization chamber in correspondence with the
respective flow resistances presented by the vaporizer passage 170
and the bypass passage 180. This can reduce the correlation between
the flow rate through the smoking substitute apparatus 150a (i.e.,
the user's draw rate) and the particle size generated when the
e-liquid 160 is vaporized and subsequently forms an aerosol.
Therefore, the smoking substitute apparatus 150a shown in FIG. 23
can deliver a more consistent aerosol to a user.
[0144] Furthermore, the smoking substitute apparatus 150a is
capable of producing an increased particle droplet size, d.sub.50,
based on typical inhalation rates undertaken by a user, compared to
the smoking substitute apparatus of FIG. 19. Such larger droplet
sizes may be beneficial for the delivery of vapor to a user's
lungs. The preferred ratio between the dimensions of the bypass
passage 180 and the dimensions of the vaporizer passage 170, and
hence flow rate in the respective passages may be determined from
representative user inhalation rates and from the required air flow
rate through the vaporization chamber to deliver a desired droplet
size. For example, an average total flow rate of 1.3 liters per
minute may be split such that 0.8 liters per minute passes through
the bypass air channel 180, and 0.5 liters per minute passes
through the vaporizer channel 170, a bypass:vaporizer flow rate
ratio of 1.6:1. Such a flow rate may provide a droplet size,
d.sub.50, of 1-3 .mu.m (more preferably 2-3 .mu.m) with a span of
not more than 20 (preferably not more than 10). Alternative flow
rate ratios may be provided based on calculations and measurements
of user flow rate, vaporizer flow rate, and average droplet size
d.sub.50. A bypass:vaporizer flow rate ratio of between 0.5:1 and
20:1, typically at an average total flow rate of 1.3 liters per
minute may be advantageous depending on the configuration of the
smoking substitute apparatus.
[0145] The bypass passage and vaporizer passage extend from a
common device inlet 176. This has the benefit of ensuring more
consistent airflow through the bypass passage 180 and vaporizer
passage 170 across the lifetime of the smoking substitute apparatus
150a, since any obstruction that impinges on an air inlet 176 will
affect the airflow through both passages equally. The impact of
inlet manufacturing variations can also be reduced for the same
reason. This can therefore improve the user experience for the
smoking substitute apparatus 150a. Furthermore, the provision of a
common device inlet 176 simplifies the construction and external
appearance of the device.
[0146] The bypass passage 180 and vaporizer passage 170 separate
upstream of the vaporization chamber. Therefore, no vapor is drawn
through the bypass passage 180. Furthermore, because the bypass
passage leads to outlet 184 that is separate from outlet 174 of the
vaporizer passage, substantially no mixing of the bypass air and
vaporizer air occurs within the smoking substitute apparatus 150a.
Such mixing could otherwise lead to excessive cooling of the vapor
and hence a build-up of condensation within the smoking substitute
apparatus 150a. Such condensation could have adverse implications
for delivering vapor to the user, for example by causing the user
to draw liquid droplets rather than vapor when "puffing" on the
mouthpiece 154.
[0147] The features disclosed in the foregoing description, or in
the following claims, or in the accompanying drawings, expressed in
their specific forms or in terms of a means for performing the
disclosed function, or a method or process for obtaining the
disclosed results, as appropriate, may, separately, or in any
combination of such features, be utilized for realizing the
disclosure in diverse forms thereof.
[0148] There now follows a disclosure of certain experimental work
undertaken to determine the effects of certain conditions in the
smoking substitute apparatus on the particle size of the generated
aerosol.
EXAMPLES
[0149] There now follows a disclosure of certain examples of
experimental work undertaken to determine the effects of certain
conditions in the smoking substitute apparatus on the particle size
of the generated aerosol. However, the present disclosure is to be
understood to not be limited in its application to the specific
experimentation, results, and laboratory procedures disclosed
herein after. Rather, the Examples are simply provided as one of
various embodiments and are meant to be exemplary, not
exhaustive.
[0150] The experimental results described in these examples is
relevant to the embodiments disclosed above in view of the control
demonstrated over the particle size of the generated aerosol in
view of the cooling rate of the vapor emitted from the wick and the
flow conditions at the wick.
Introduction
[0151] Aerosol droplet size is a considered to be an important
characteristic for smoking substitution devices. Droplets in the
range of 2-5 .mu.m are preferred in order to achieve improved
nicotine delivery efficiency and to minimize the hazard of
second-hand smoking. However, at the time of writing (September
2019), commercial EVP devices typically deliver aerosols with
droplet size averaged around 0.5 .mu.m, and to the knowledge of the
inventors not a single commercially available device can deliver an
aerosol with an average particle size exceeding 1 .mu.m.
[0152] The present inventors speculate, without themselves wishing
to be bound by theory, that there has to date been a lack of
understanding in the mechanisms of e-liquid evaporation, nucleation
and droplet growth in the context of aerosol generation in smoking
substitute devices. The present inventors have therefore studied
these issues in order to provide insight into mechanisms for the
generation of aerosols with larger particles. The present inventors
have carried out experimental and modelling work alongside
theoretical investigations, leading to significant achievements as
now reported.
[0153] This disclosure considers the roles of air velocity, air
turbulence and vapor cooling rate in affecting aerosol particle
size.
Experiments
[0154] In the following examples, a Malvern PANalytical Spraytec
laser diffraction system was employed for the particle size
measurement. In order to limit the number of variables, the same
coil and wick (1.5 ohms Ni--Cr coil, 1.8 mm Y07 cotton wick), the
same e-liquid (1.6% freebase nicotine, 65:35 propylene glycol
(PG)/vegetable glycerin (VG) ratio, no added flavor) and the same
input power (10 W) were used in all experiments. Y07 represents the
grade of cotton wick, meaning that the cotton has a linear density
of 0.7 grams per meter.
[0155] Particle sizes were measured in accordance with ISO
13320:2009(E), which is an international standard on laser
diffraction methods for particle size analysis. This is
particularly well suited to aerosols, because there is an
assumption in this standard that the particles are spherical (which
is a good assumption for liquid-based aerosols). The standard is
stated to be suitable for particle sizes in the range 0.1 micron to
3 mm.
[0156] The results presented here concentrate on the volume-based
median particle size Dv50. This is to be taken to be the same as
the parameter d.sub.50 used above.
First Example: Rectangular Tube Testing
[0157] The work of a first example reported here based on the
inventors' insight that aerosol particle size might be related to:
1) air velocity; 2) flow rate; and 3) Reynolds number. In a given
EVP device, these three parameters are inter-linked to each other,
making it difficult to draw conclusions on the roles of each
individual factor. In order to decouple these factors, experiments
of a first example were carried out using a set of rectangular
tubes having different dimensions. These were manufactured by 3D
printing. The rectangular tubes were 3D printed in an MJP 2500 3D
printer. FIG. 1 illustrates the set of rectangular tubes. Each tube
has the same depth and length but different width. Each tube has an
integral end plate in order to provide a seal against air flow
outside the tube. Each tube also has holes formed in opposing side
walls in order to accommodate a wick.
[0158] FIG. 2 shows a schematic perspective longitudinal cross
sectional view of an example rectangular tube 1170 with a wick 1162
and heater coil 1164 installed. The location of the wick is about
half way along the length of the tube. This is intended to allow
the flow of air along the tube to settle before reaching the
wick.
[0159] FIG. 3 shows a schematic transverse cross sectional view an
example rectangular tube 1170 with a wick 1162 and heater coil 1164
installed. In this example, the internal width of the tube is 12
mm.
[0160] The rectangular tubes were manufactured to have same
internal depth of 6 mm in order to accommodate the standardized
coil and wick, however the tube internal width varied from 4.5 mm
to 50 mm. In this disclosure, the "tube size" is referred to as the
internal width of rectangular tubes.
[0161] The rectangular tubes with different dimensions were used to
generate aerosols that were tested for particle size in a Malvern
PANalytical Spraytec laser diffraction system. An external digital
power supply was dialed to 2.6 A constant current to supply 10 W
power to the heater coil in all experiments. Between two runs, the
wick was saturated manually by applying one drop of e-liquid on
each side of the wick.
[0162] Three groups of experiments were carried out in this study
of a first example: [0163] 1. 1.3 lpm (liters per minute, L
min.sup.-1 or LPM) constant flow rate on different size tubes
[0164] 2. 2.0 lpm constant flow rate on different size tubes [0165]
3. 1 m/s constant air velocity on 3 tubes: i) 5 mm tube at 1.4 lpm
flow rate; ii) 8 mm tube at 2.8 lpm flow rate; and iii) 20 mm tube
at 8.6 lpm flow rate.
[0166] Table 1 shows a list of experiments of a first example. The
values in "calculated air velocity" column were obtained by simply
dividing the flow rate by the intersection area at the center plane
of wick. Reynolds numbers (Re) were calculated through the
following equation:
R .times. e = .rho. .times. v .times. L .mu. , ##EQU00001##
[0167] where: .rho. is the density of air (1.225 kg/m.sup.3); .nu.
is the calculated air velocity in table 1; .mu. is the viscosity of
air (1.48.times.10.sup.-5 m.sup.2/s); L is the characteristic
length calculated by:
L = 4 .times. P A , ##EQU00002##
[0168] where: P is the perimeter of the flow path's intersection,
and A is the area of the flow path's intersection.
TABLE-US-00001 TABLE 1 List of experiments in the rectangular tube
study Calculated air Tube size Flow rate Reynolds velocity [mm]
[lpm] number [m/s] 1.3 lpm 4.5 1.3 153 1.17 constant flow 6 1.3 142
0.71 rate 7 1.3 136 0.56 8 1.3 130 0.47 10 1.3 120 0.35 12 1.3 111
0.28 20 1.3 86 0.15 50 1.3 47 0.06 2.0 lpm 4.5 2.0 236 1.81
constant flow 5 2.0 230 1.48 rate 6 2.0 219 1.09 8 2.0 200 0.72 12
2.0 171 0.42 20 2.0 132 0.23 50 2.0 72 0.09 1.0 m/s 5.0 1.4 155
1.00 constant air 8 2.8 279 1.00 velocity 20 8.6 566 1.00
[0169] Five repetition runs were carried out for each tube size and
flow rate combination. Between adjacent runs there were at least 5
minutes wait time for the Spraytec system to be purged. In each
run, real time particle size distributions were measured in the
Spraytec laser diffraction system at a sampling rate of 2500 per
second, the volume distribution median (Dv50) was averaged over a
puff duration of 4 seconds. Measurement results were averaged and
the standard deviations were calculated to indicate errors as shown
in section 4 below.
Second Example: Turbulence Tube Testing
[0170] The Reynolds numbers in Table 1 are all well below 1000,
therefore, it is considered fair to assume all the experiments of a
first example would be under conditions of laminar flow. Further
experiments (of a second example) were carried out and reported in
this section to investigate the role of turbulence.
[0171] Turbulence intensity was introduced as a quantitative
parameter to assess the level of turbulence. The definition and
simulation of turbulence intensity is discussed below.
[0172] Different device designs were considered in order to
introduce turbulence. In the experiments of the second example
reported here, jetting panels were added in the existing 12 mm
rectangular tubes upstream of the wick. This approach enables
direct comparison between different devices as they all have highly
similar geometry, with turbulence intensity being the only
variable.
[0173] FIGS. 4A-4D show air flow streamlines in the four devices
used in this turbulence study of the second example. FIG. 4A is a
standard 12 mm rectangular tube with wick and coil installed as
explained previously, with no jetting panel. FIG. 4B has a jetting
panel located 10 mm below (upstream from) the wick. FIG. 4C has the
same jetting panel 5 mm below the wick. FIG. 4D has the same
jetting panel 2.5 mm below the wick. As can be seen from FIGS.
4B-4D, the jetting panel has an arrangement of apertures shaped and
directed in order to promote jetting from the downstream face of
the panel and therefore to promote turbulent flow. Accordingly, the
jetting panel can introduce turbulence downstream, and the panel
causes higher level of turbulence near the wick when it is
positioned closer to the wick. As shown in FIGS. 4A-4D, the four
geometries gave turbulence intensities of 0.55%, 0.77%, 1.06% and
1.34%, respectively, with FIG. 4A being the least turbulent, and
FIG. 4D being the most turbulent.
[0174] For each of FIGS. 4A-4D, there are shown three modelling
images. The image on the left shows the original image (color in
the original), the central image shows a greyscale version of the
image and the right hand image shows a black and white version of
the image. As will be appreciated, each version of the image
highlights slightly different features of the flow. Together, they
give a reasonable picture of the flow conditions at the wick.
[0175] These four devices were operated to generate aerosols
following the procedure explained above (the first example) using a
flow rate of 1.3 lpm and the generated aerosols were tested for
particle size in the Spraytec laser diffraction system.
Third Example: High Temperature Testing
[0176] This experiment of a third example aimed to investigate the
influence of inflow air temperature on aerosol particle size, in
order to investigate the effect of vapor cooling rate on aerosol
generation.
[0177] The experimental set up of the third example is shown in
FIG. 5. The testing used a Carbolite Gero EHA 12300B tube furnace
3210 with a quartz tube 3220 to heat up the air. Hot air in the
tube furnace was then led into a transparent housing 3158 that
contains the EVP device 3150 to be tested. A thermocouple meter
3410 was used to assess the temperature of the air pulled into the
EVP device. Once the EVP device was activated, the aerosol was
pulled into the Spraytec laser diffraction system 3310 via a
silicone connector 3320 for particle size measurement.
[0178] Three smoking substitute apparatuses (referred to as "pods")
were tested in the study: pod 1 is the commercially available
"myblu optimised" pod (FIG. 6); pod 2 is a pod featuring an
extended inflow path upstream of the wick (FIG. 7); and pod 3 is
pod with the wick located in a stagnant vaporization chamber and
the inlet air bypassing the vaporization chamber but entraining the
vapor from an outlet of the vaporization chamber (FIGS. 8A and
8B).
[0179] Pod 1, shown in longitudinal cross sectional view (in the
width plane) in FIG. 6, has a main housing that defines a tank 160x
holding an e-liquid aerosol precursor. Mouthpiece 154x is formed at
the upper part of the pod. Electrical contacts 156x are formed at
the lower end of the pod. Wick 162x is held in a vaporization
chamber. The air flow direction is shown using arrows.
[0180] Pod 2, shown in longitudinal cross sectional view (in the
width plane) in FIG. 7, has a main housing that defines a tank 160y
holding an e-liquid aerosol precursor. Mouthpiece 154y is formed at
the upper part of the pod. Electrical contacts 156y are formed at
the lower end of the pod. Wick 162y is held in a vaporization
chamber. The air flow direction is shown using arrows. Pod 2 has an
extended inflow path (plenum chamber 157y) with a flow conditioning
element 159y, configured to promote reduced turbulence at the wick
162y.
[0181] FIG. 8A shows a schematic longitudinal cross sectional view
of pod 3. FIG. 8B shows a schematic longitudinal cross sectional
view of the same pod 3 in a direction orthogonal to the view taken
in FIG. 8A. Pod 3 has a main housing that defines a tank 160z
holding an e-liquid aerosol precursor. Mouthpiece 154z is formed at
the upper part of the pod. Electrical contacts 156z are formed at
the lower end of the pod. Wick 162z is held in a vaporization
chamber. The air flow direction is shown using arrows. Pod 3 uses a
stagnant vaporizer chamber, with the air inlets bypassing the wick
and picking up the vapor/aerosol downstream of the wick.
[0182] All three pods were filled with the same e-liquid (1.6%
freebase nicotine, 65:35 PG/VG ratio, no added flavor). Three
experiments of the third example were carried out for each pod: 1)
standard measurement in ambient temperature; 2) only the inlet air
was heated to 50 .degree. C.; and 3) both the inlet air and the
pods were heated to 50.degree. C. Five repetition runs were carried
out for each experiment and the Dv50 results were taken and
averaged.
Modelling Work
[0183] In the following examples, modelling work was performed
using COMSOL Multiphysics 5.4, engaged physics include: 1) laminar
single-phase flow; 2) turbulent single-phase flow; 3) laminar
two-phase flow; 4) heat transfer in fluids; and (5) particle
tracing. Data analysis and data visualization were mostly completed
in MATLAB R2019a.
Fourth Example: Velocity Modelling
[0184] Air velocity in the vicinity of the wick is believed to play
an important role in affecting particle size. In the first example,
the air velocity was calculated by dividing the flow rate by the
intersection area, which is referred to as "calculated velocity" in
a fourth example. This involves a very crude simplification that
assumes velocity distribution to be homogeneous across the
intersection area.
[0185] In order to increase reliability of the fourth example,
computational fluid dynamics (CFD) modelling was performed to
obtain more accurate velocity values: [0186] 1) The average
velocity in the vicinity of the wick (defined as a volume from the
wick surface to 1 mm away from the wick surface) [0187] 2) The
maximum velocity in the vicinity of the wick (defined as a volume
from the wick surface to 1 mm away from the wick surface)
TABLE-US-00002 [0187] TABLE 2 Average and maximum velocity in the
vicinity of wick surface obtained from CFD modelling. Calculated
Average Maximum Tube size Flow rate velocity* velocity** Velocity**
[mm] [lpm] [m/s] [m/s] [m/s] 1.3 lpm 4.5 1.3 1.17 0.99 1.80
constant 6 1.3 0.71 0.66 1.22 flow rate 7 1.3 0.56 0.54 1.01 8 1.3
0.47 0.46 0.86 10 1.3 0.35 0.35 0.66 12 1.3 0.28 0.27 0.54 20 1.3
0.15 0.15 0.32 50 1.3 0.06 0.05 0.12 2.0 lpm 4.5 2.0 1.81 1.52 2.73
constant 5 2.0 1.48 1.31 2.39 flow rate 6 2.0 1.09 1.02 1.87 8 2.0
0.72 0.71 1.31 12 2.0 0.42 0.44 0.83 20 2.0 0.23 0.24 0.49 50 2.0
0.09 0.08 0.19 *Calculated by dividing flow rate with intersection
area **Obtained from CFD modelling
[0188] The CFD model uses a laminar single-phase flow setup. For
each experiment, the outlet was configured to a corresponding
flowrate, the inlet was configured to be pressure-controlled, the
wall conditions were set as "no slip". A 1 mm wide ring-shaped
domain (wick vicinity) was created around the wick surface, and
domain probes were implemented to assess the average and maximum
magnitudes of velocity in this ring-shaped wick vicinity
domain.
[0189] The CFD model of the fourth example outputs the average
velocity and maximum velocity in the vicinity of the wick for each
set of experiments carried out in the first example. The outcomes
are reported in Table 2.
Fifth Example: Turbulence Modelling
[0190] Turbulence intensity (I) is a quantitative value that
represents the level of turbulence in a fluid flow system. It is
defined as the ratio between the root-mean-square of velocity
fluctuations, u', and the Reynolds-averaged mean flow velocity,
U:
I = u ' U = 1 3 .times. ( u x ' 2 + u y ' 2 + u z ' 2 ) u x _ 2 + u
y _ 2 + u z _ 2 = 1 3 .function. [ ( u x - u x _ ) 2 + ( u y - u y
_ ) 2 + + ( u z - u z _ ) 2 ] u x _ 2 + u y _ 2 + u z _ 2 ,
##EQU00003##
[0191] where u.sub.x, u.sub.y and u.sub.z are the x-, y- and
z-components of the velocity vector, u.sub.x, u.sub.y, and u.sub.z
represent the average velocities along three directions.
[0192] Higher turbulence intensity values represent higher levels
of turbulence. As a rule of thumb, turbulence intensity below 1%
represents a low-turbulence case, turbulence intensity between 1%
and 5% represents a medium-turbulence case, and turbulence
intensity above 5% represents a high-turbulence case.
[0193] In a fifth example, turbulence intensity was obtained from
CFD simulation using turbulent single-phase setup in COMSOL
Multiphysics. For each of the four experiments explained in the
second example, above, the outlet was set to 1.3 lpm, the inlet was
set to be pressure-controlled, and all wall conditions were set to
be "no slip".
[0194] Turbulence intensity of the fifth example was assessed
within the volume up to 1 mm away from the wick surface (defined as
the wick vicinity domain). For the four experiments explained in
the second example, the turbulence intensities are 0.55%, 0.77%,
1.06% and 1.34%, respectively, as also shown in FIGS. 4A-4D.
Sixth Example: Cooling Rate Modelling
[0195] The cooling rate modelling of the sixth example involves
three coupling models in COMSOL Multiphysics: 1) laminar two-phase
flow; 2) heat transfer in fluids, and 3) particle tracing. The
model is setup in three steps:
(1) Set Up Two Phase Flow Model
[0196] Laminar mixture flow physics was selected for the sixth
example. The outlet was configured in the same way as in the fourth
example. However, this model of the sixth example includes two
fluid phases released from two separate inlets: the first one is
the vapor released from wick surface, at an initial velocity of
2.84 cm/s (calculated based on 5 mg total particulate mass over 3
seconds puff duration) with initial velocity direction normal to
the wick surface; the second inlet is air influx from the base of
tube, the rate of which is pressure-controlled.
(2) Set Up Two-Way Coupling with Heat Transfer Physics
[0197] The inflow and outflow settings in heat transfer physics was
configured in the same way as in the two-phase flow model. The air
inflow was set to 25.degree. C., and the vapor inflow was set to
209.degree. C. (boiling temperature of the e-liquid formulation).
In the end, the heat transfer physics is configured to be two-way
coupled with the laminar mixture flow physics. The above model
reaches steady state after approximately 0.2 second with a step
size of 0.001 second.
(3) Set Up Particle Tracing
[0198] A wave of 2000 particles were release from wick surface at
t=0.3 second after the two-phase flow and heat transfer model has
stabilized. The particle tracing physics has one-way coupling with
the previous model, which means the fluid flow exerts dragging
force on the particles, whereas the particles do not exert
counterforce on the fluid flow. Therefore, the particles function
as moving probes to output vapor temperature at each timestep.
[0199] The model of the sixth example outputs average vapor
temperature at each time steps. A MATLAB script was then created to
find the time step when the vapor cools to a target temperature
(50.degree. C. or 75.degree. C.), based on which the vapor cooling
rates were obtained (Table 3).
TABLE-US-00003 TABLE 3 Average vapor cooling rate obtained from
Multiphysics modelling. Cooling rate Cooling rate Tube size Flow
rate to 50.degree. C. to 75.degree. C. [mm] [lpm] [.degree. C./ms]
[.degree. C./ms] 1.3 lpm 4.5 1.3 11.4 44.7 constant flow 6 1.3 5.48
14.9 rate 7 1.3 3.46 7.88 8 1.3 2.24 5.15 10 1.3 1.31 2.85 12 1.3
0.841 1.81 20 1.3 0* 0.536 50 1.3 0 0 2.0 lpm 4.5 2.0 19.9 670
constant flow 5 2.0 13.3 67 rate 6 2.0 8.83 26.8 8 2.0 3.61 8.93 12
2.0 1.45 3.19 20 2.0 0.395 0.761 50 2.0 0 0 *Zero cooling rate when
the average vapor temperature is still above target temperature
after 0.5 second
Results and Discussions
[0200] Particle size measurement results for the rectangular tube
testing example above (the first example) are shown in Table 4. For
every tube size and flow rate combination, five repetition runs
were carried out in the Spraytec laser diffraction system. The Dv50
values from five repetition runs were averaged, and the standard
deviations were calculated to indicate errors, as shown in Table
4.
[0201] In this section, the roles of different factors affecting
aerosol particle size will be discussed based on experimental and
modelling results.
TABLE-US-00004 TABLE 4 Particle size measurement results for the
rectangular tube testing. Dv50 standard Tube size Flow rate Dv50
average deviation [mm] [lpm] [.mu.m] [.mu.m] 1.3 lpm 4.5 1.3 0.971
0.125 constant flow 6 1.3 1.697 0.341 rate 7 1.3 2.570 0.237 8 1.3
2.705 0.207 10 1.3 2.783 0.184 12 1.3 3.051 0.325 20 1.3 3.116
0.354 50 1.3 3.161 0.157 2.0 lpm 4.5 2.0 0.568 0.039 constant flow
5 2.0 0.967 0.315 rate 6 2.0 1.541 0.272 8 2.0 1.646 0.363 12 2.0
3.062 0.153 20 2.0 3.566 0.260 50 2.0 3.082 0.440 1.0 m/s 5.0 1.4
1.302 0.187 constant air 8 2.8 1.303 0.468 velocity 20 8.6 1.463
0.413
Seventh Example: Decouple the Factors Affecting Particle Size
[0202] The particle size (Dv50) experimental results of a seventh
example are plotted against calculated air velocity in FIG. 9. The
graph shows a strong correlation between particle size and air
velocity.
[0203] Different size tubes were tested at two flow rates: 1.3 lpm
and 2.0 lpm. Both groups of data show the same trend that slower
air velocity leads to larger particle size. The conclusion was made
more convincing by the fact that these two groups of data overlap
well in FIG. 9: for example, the 6 mm tube delivered an average
Dv50 of 1.697 .mu.m when tested at 1.3 lpm flow rate, and the 8 mm
tube delivered a highly similar average Dv50 of 1.646 .mu.m when
tested at 2.0 lpm flow rate, as they have similar air velocity of
0.71 and 0.72 m/s, respectively.
[0204] In addition, FIG. 10 shows the results of three experiments
of the seventh example, with highly different setup arrangements:
1) 5 mm tube measured at 1.4 lpm flow rate with Reynolds number of
155; 2) 8 mm tube measured at 2.8 lpm flow rate with Reynolds
number of 279; and 3) 20 mm tube measured at 8.6 lpm flow rate with
Reynolds number of 566. It is relevant that these setup
arrangements have one similarity: the air velocities are all
calculated to be 1 m/s. FIG. 10 shows that, although these three
sets of experiments have different tube sizes, flow rates and
Reynolds numbers, they all delivered similar particle sizes, as the
air velocity was kept constant. These three data points were also
plotted out in FIG. 9 (1 m/s data with star marks) and they tie in
nicely into particle size-air velocity trendline.
[0205] The above results of the seventh example lead to a strong
conclusion that air velocity is an important factor affecting the
particle size of EVP devices. Relatively large particles are
generated when the air travels with slower velocity around the
wick. It can also be concluded that flow rate, tube size and
Reynolds number are not necessarily independently relevant to
particle size, providing the air velocity is controlled in the
vicinity of the wick.
Eighth Example: Further Consideration of Velocity
[0206] In FIG. 9 the "calculated velocity" was obtained by dividing
the flow rate by the intersection area, which is a crude
simplification that assumes a uniform velocity field. In order to
increase reliability of the work, CFD modelling has been performed
to assess the average and maximum velocities in the vicinity of the
wick. In an eighth example, the "vicinity" was defined as a volume
from the wick surface up to 1 mm away from the wick surface.
[0207] The particle size measurement data of the eighth example
were plotted against the average velocity (FIG. 11) and maximum
velocity (FIG. 12) in the vicinity of the wick, as obtained from
CFD modelling.
[0208] The data in these two graphs indicates that in order to
obtain an aerosol with Dv50 larger than 1 .mu.m, the average
velocity should be less than or equal to 1.2 m/s in the vicinity of
the wick and the maximum velocity should be less than or equal to
2.0 m/s in the vicinity of the wick.
[0209] Furthermore, in order to obtain an aerosol with Dv50 of 2
.mu.m or larger, the average velocity should be less than or equal
to 0.6 m/s in the vicinity of the wick and the maximum velocity
should be less than or equal to 1.2 m/s in the vicinity of the
wick.
[0210] It is considered that typical commercial EVP devices deliver
aerosols with Dv50 around 0.5 .mu.m, and there is no commercially
available device that can deliver aerosol with Dv50 exceeding 1
.mu.m. It is considered that typical commercial EVP devices have
average velocity of 1.5-2.0 m/s in the vicinity of the wick.
Ninth Example: The Role of Turbulence
[0211] The role of turbulence has been investigated in terms of
turbulence intensity in a ninth example, which is a quantitative
characteristic that indicates the level of turbulence. In the ninth
example, four tubes of different turbulence intensities were used
to general aerosols which were measured in the Spraytec laser
diffraction system. The particle size (Dv50) experimental results
of the ninth example are plotted against turbulence intensity in
FIG. 13.
[0212] The graph suggests a correlation between particle size and
turbulence intensity, that lower turbulence intensity is beneficial
for obtaining larger particle size. It is noted that when
turbulence intensity is above 1% (medium-turbulence case), there
are relatively large measurement fluctuations. In FIG. 13, the tube
with a jetting panel 10 mm below the wick has the largest error
bar, because air jets become unpredictable near the wick after
traveling through a long distance.
[0213] The results of the ninth example clearly indicate that
laminar air flow is favorable for the generation of aerosols with
larger particles, and that the generation of large particle sizes
is jeopardized by introducing turbulence. In FIG. 13, the 12 mm
standard rectangular tube (without jetting panel) delivers above 3
.mu.m particle size (Dv50). The particle size values reduced by at
least a half when jetting panels were added to introduce
turbulence.
Tenth Example: Vapor Cooling Rate
[0214] FIG. 14 shows the high temperature testing results of a
tenth example. Larger particle sizes were observed from all 3 pods
when the temperature of inlet air increased from room temperature
(23.degree. C.) to 50.degree. C. When the pods were heated as well,
two of the three pods saw even larger particle size measurement
results, while pod 2 was unable to be measured due to significant
amount of leakage.
[0215] Without wishing to be bound by theory, the results of the
tenth example are in line with the inventors' insight that control
over the vapor cooling rate provides an important degree of control
over the particle size of the aerosol. As reported above, the use
of a slow air velocity can have the result of the formation of an
aerosol with large Dv50. It is considered that this is due to
slower air velocity allowing a slower cooling rate of the
vapor.
[0216] Another conclusion related to laminar flow can also be
explained by a cooling rate theory of the tenth example: laminar
flow allows slow and gradual mixing between cold air and hot vapor,
which means the vapor can cool down in slower rate when the airflow
is laminar, resulting in larger particle size.
[0217] The results in FIG. 14 further validate this cooling rate
theory of the tenth example: when the inlet air has higher
temperature, the temperature difference between hot vapor and cold
air becomes smaller, which allows the vapor to cool down at a
slower rate, resulting in larger particle size; when the pods were
heated as well, this mechanism was exaggerated even more, leading
to an even slower cooling rate and an even larger particle
size.
Eleventh Example: Further Consideration of Vapor Cooling Rate
[0218] In the sixth example, the vapor cooling rates for each tube
size and flow rate combination were obtained via multiphysics
simulation. In FIG. 15 and FIG. 16, the particle size measurement
results were plotted against vapor cooling rate to 50.degree. C.
and 75.degree. C., respectively.
[0219] The data in these graphs indicates that in order to obtain
an aerosol with Dv50 larger than 1 .mu.m, the apparatus should be
operable to require more than 16 ms for the vapor to cool to
50.degree. C., or an equivalent (simplified to an assumed linear)
cooling rate being slower than 10 .degree. C./ms. From an
alternative viewpoint, in order to obtain an aerosol with Dv50
larger than 1 .mu.m, the apparatus should be operable to require
more than 4.5 ms for the vapor to cool to 75.degree. C., or an
equivalent (simplified to an assumed linear) cooling rate slower
than 30.degree. C./ms.
[0220] Furthermore, in order to obtain an aerosol with Dv50 of 2
.mu.m or larger, the apparatus should be operable to require more
than 32 ms for the vapor to cool to 50.degree. C., or an equivalent
(simplified to an assumed linear) cooling rate being slower than
5.degree. C./ms. From an alternative viewpoint, in order to obtain
an aerosol with Dv50 of 2 .mu.m or larger, the apparatus should be
operable to require more than 13 ms for the vapor to cool to
75.degree. C., or an equivalent (simplified to an assumed linear)
cooling rate slower than 10.degree. C./ms.
Conclusions of Particle Size Experimental Work
[0221] In the above example, particle size (Dv50) of aerosols
generated in a set of rectangular tubes was studied in order to
decouple different factors (flow rate, air velocity, Reynolds
number, tube size) affecting aerosol particle size. It is
considered that air velocity is an important factor affecting
particle size--slower air velocity leads to larger particle size.
When air velocity was kept constant, the other factors (flow rate,
Reynolds number, tube size) has low influence on particle size.
[0222] The role of turbulence was also investigated in the above
examples. It is considered that laminar air flow favors generation
of large particles, and introducing turbulence deteriorates
(reduces) the particle size.
[0223] Modelling methods were used in some of the above examples to
simulate the average air velocity, the maximum air velocity, and
the turbulence intensity in the vicinity of the wick. A COMSOL
model with three coupled physics has also been developed to obtain
the vapor cooling rate.
[0224] All experimental and modelling results of the above examples
support a cooling rate theory that slower vapor cooling rate is a
significant factor in ensuring larger particle size. Slower air
velocity, laminar air flow and higher inlet air temperature lead to
larger particle size, because they all allow vapor to cool down at
slower rates.
[0225] While the disclosure has been described in conjunction with
the exemplary embodiments and examples described above, many
equivalent modifications and variations will be apparent to those
skilled in the art when given this disclosure. Accordingly, the
exemplary embodiments and examples of the disclosure set forth
above are considered to be illustrative and not limiting. Various
changes to the described embodiments may be made without departing
from the spirit and scope of the disclosure.
[0226] For the avoidance of any doubt, any theoretical explanations
provided herein are provided for the purposes of improving the
understanding of a reader. The inventors do not wish to be bound by
any of these theoretical explanations.
[0227] Any section headings used herein are for organizational
purposes only and are not to be construed as limiting the subject
matter described.
[0228] 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.
[0229] 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%.
[0230] 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.
* * * * *