U.S. patent application number 17/697136 was filed with the patent office on 2022-06-30 for smoking substitute component.
The applicant listed for this patent is Nerudia Limited. Invention is credited to Pete Lomas, Molly McGuinness.
Application Number | 20220202077 17/697136 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-30 |
United States Patent
Application |
20220202077 |
Kind Code |
A1 |
McGuinness; Molly ; et
al. |
June 30, 2022 |
SMOKING SUBSTITUTE COMPONENT
Abstract
Disclosed is a smoking substitute component comprising a housing
having a base portion, a mouthpiece portion, one or more walls
extending longitudinally from the base portion to the mouthpiece
portion, and an air inlet formed in a wall of the housing and
spaced longitudinally from the base portion. The component further
comprises an air outlet formed in the mouthpiece portion and an
airflow path extending from the air inlet to the air outlet. The
airflow path comprises a first portion downstream of the air inlet
and extending longitudinally towards the base portion of the
housing, and a transversely extending second portion that is
downstream of the first portion. The component further comprises a
vaporizer comprising a wick and a heating element for heating the
wick, the wick extending across the first portion of the airflow
path.
Inventors: |
McGuinness; Molly;
(Liverpool, GB) ; Lomas; Pete; (Liverpool,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nerudia Limited |
Liverpool |
|
GB |
|
|
Appl. No.: |
17/697136 |
Filed: |
March 17, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/EP20/76035 |
Sep 17, 2020 |
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17697136 |
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International
Class: |
A24F 40/10 20060101
A24F040/10; A24F 40/42 20060101 A24F040/42; A24F 40/44 20060101
A24F040/44; A24F 40/70 20060101 A24F040/70; A24F 40/65 20060101
A24F040/65 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 20, 2019 |
EP |
19198599.3 |
Sep 20, 2019 |
EP |
19198612.4 |
Sep 20, 2019 |
EP |
19198615.7 |
Claims
1. An aerosol-delivery component comprising: a housing comprising a
base portion, a mouthpiece portion and one or more walls extending
longitudinally from the base portion to the mouthpiece portion; an
air inlet formed in a wall of the housing and spaced longitudinally
from the base portion; an air outlet formed in the mouthpiece
portion; an airflow path extending from the air inlet to the air
outlet, the airflow path comprising a first portion downstream of
the air inlet and extending longitudinally towards the base portion
of the housing, and a transversely extending second portion that is
downstream of the first portion; and a vaporizer comprising a wick
and a heating element for heating the wick, the wick extending
across the second portion of the airflow path.
2. A component according to claim 1 wherein the first portion of
the airflow path extends longitudinally from the air inlet towards
the base portion of the housing.
3. A component according to claim 1 or 2 wherein the air inlet is
longitudinally spaced from the base portion of the housing by a
distance that is greater than 8 mm.
4. A component according to any one of the preceding claims wherein
the airflow path comprises a third portion extending longitudinally
from the second portion to the air outlet.
5. A component according to claim 4 comprising a tank for housing a
liquid aerosol precursor, the tank disposed between the first and
third airflow path portions.
6. A component according to claim 5 wherein the second airflow path
portion is disposed between the tank and the base portion of the
housing.
7. A component according to claim 5 or 6 wherein the housing
comprises opposing front and rear walls spaced by opposing first
and second side walls extending therebetween, the first portion of
the airflow path being defined between the first side wall and a
first longitudinally extending wall of the tank.
8. A component according to claim 7 wherein the distance between
the front and rear walls defines a depth of the housing and the
distance between the side walls defines a width of the housing that
is greater than the depth of the housing.
9. A component according to claim 8 wherein the wick is elongate
and extends in the direction of the depth of the housing.
10. A component according to claim 9 wherein the wick is
cylindrical.
11. A component according to any one of claims 7 to 10 wherein the
third portion of the airflow path is defined between the second
side wall and a second longitudinally extending wall of the
tank.
12. A component according to claim 11 wherein the first and second
tank walls extend from, and are integrally formed with, the
mouthpiece.
13. A component according to any one of claims 5 to 12 wherein the
vaporizer is disposed in a vaporizing chamber that forms part of
the second portion of the airflow path, the vaporizing chamber
defined by an insert received in an open end of the housing.
14. A component according to any one of the preceding claims which
a consumable component for receipt in a smoking substitute
device.
15. An aerosol-delivery system comprising a component according to
any one of the preceding claims and a device comprising a power
source.
16. A smoking substitute component comprising: a housing comprising
a base portion, a mouthpiece portion, and one or more walls
extending longitudinally from the base portion to the mouthpiece
portion; an airflow path extending from an air inlet formed in a
wall of the housing and spaced longitudinally from the base portion
to an air outlet formed in the mouthpiece portion, a first portion
of the airflow path being defined by a first passage extending
longitudinally from the air inlet towards the base portion; a
vaporizer in the airflow path downstream of the first passage; and
an absorbent element disposed in the first passage.
17. A component according to claim 16 wherein a cross-sectional
area of the absorbent element is less than a cross-sectional area
of the passage.
18. A component according to claim 17 wherein the absorbent element
comprises a longitudinally extending groove partly defining the
portion of the airflow path.
19. A component according to any one of claims 16-18 wherein the
absorbent element is formed of a porous material.
20. A component according to any one of claims 16-19 wherein the
absorbent element extends for substantially the entire length of
the passage.
21. A component according to any one of claims 16-20 wherein a void
is defined between an end of the absorbent element and a
corresponding end of the passage proximate the vaporizer.
22. A component according to any one of claims 16-21 wherein the
airflow path comprises a transversely extending second portion
downstream of the first portion, the vaporizer disposed in the
second portion.
23. A component according to claim 22 wherein the airflow path
comprises a third portion extending longitudinally from the second
portion to the air outlet, and wherein the passage is a first
passage and a second passage defines the third portion of the
airflow path.
24. A component according to claim 23 wherein the absorbent element
is a first absorbent element and a second elongate absorbent
element is disposed in the second passage.
25. A component according to claim 24 wherein the second absorbent
element at least partly obstructs the air outlet.
26. A component according to any one of claims 16-25 comprising a
tank, wherein the or each passage is defined between a wall of the
housing and a wall of the tank.
27. A component according to claim 26 wherein the vaporizer is
disposed in a vaporizing chamber defined by one or more chamber
walls, the or each absorbent element spaced from the one or more
chamber walls.
28. A component according to claim 27 wherein the one or more
chamber walls comprises a transverse chamber wall separating the
vaporizing chamber from the tank, the or each absorbent element
being spaced from the transverse chamber wall.
29. A component according to any one of claims 16-28 which a
consumable component for receipt in a smoking substitute
device.
30. An aerosol-delivery system comprising a component according to
any one of claims 16-29 and a device comprising a power source.
31. An aerosol delivery component comprising: a housing comprising
a mouthpiece portion and inlet side and outlet side spaced walls
extending longitudinally from the mouthpiece portion so as to
define an internal space therebetween; an outlet side tank wall
integrally formed with the mouthpiece portion and extending
longitudinally into the internal space from the mouthpiece portion,
the outlet side tank wall spaced from the outlet side wall so as to
define an outlet passage extending to an outlet formed in the
mouthpiece portion; and a tank for storing aerosol precursor, the
tank at least partly defined by the outlet side tank wall.
32. A component according to claim 31 wherein the inlet side wall
and/or outlet side wall are integrally formed with the mouthpiece
portion.
33. A component according to claim 31 or 32 further comprising an
inlet side tank wall integrally formed with the mouthpiece portion
and extending longitudinally into the internal space from the
mouthpiece portion.
34. A component according to claim 33, wherein the inlet side tank
wall and the inlet side wall are integrally formed with the
mouthpiece portion.
35. A component according to claim 33 or 34 wherein all of the
outlet side tank wall, inlet side tank wall, outlet side wall and
inlet side wall are integrally formed with the mouthpiece
portion.
36. A component according to any one of claims 33 to 35, wherein
the inlet side tank wall is spaced from the outlet side tank wall
so as to define the tank therebetween.
37. A component according to any one of claims 33 to 36, wherein
the inlet side tank wall is spaced from the inlet side wall so as
to define an inlet passage extending from an inlet formed in the
inlet side wall.
38. A component according to any one of claims 31 to 37 wherein the
mouthpiece portion is provided at a first lateral end of the
housing, and wherein a base portion is provided at a second,
opposing lateral end, the base portion comprising an insert for
sealing the tank.
39. A component according to claim 38 wherein a terminal end of the
or each tank wall is received in a respective groove on an upper
transverse surface of the insert to seal the tank.
40. A component according to any of claims 31 to 39 wherein the
component is a smoking substitute component.
41. A component according to claim 40 which is a consumable
component for receipt in a smoking substitute device.
42. An aerosol delivery system, comprising: a component as defined
in any of the claims 31 to 41; and a device comprising a power
source.
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/EP2020/076035
filed on Sep. 17, 2020, which claims priority to EP 19198612.4
filed on Sep. 20, 2019, EP 19198615.7 filed on Sep. 20, 2019, and
EP 19198599.3 filed on Sep. 20, 2019. The entire contents of each
of the above-referenced applications are hereby incorporated herein
by reference in their entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to an aerosol-delivery
component, which may be a consumable for receipt in an
aerosol-delivery device to form an aerosol-delivery system (e.g., a
smoking substitute system).
BACKGROUND
[0003] The smoking of tobacco is generally considered to expose a
smoker to potentially harmful substances. It is generally thought
that a significant amount of the potentially harmful substances are
generated through the heat caused by the burning and/or combustion
of the tobacco and the constituents of the burnt tobacco in the
tobacco smoke itself.
[0004] 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 order to avoid
the smoking of tobacco.
[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] Smoking substitute systems, which may also be known as
electronic nicotine delivery systems, may comprise electronic
systems that permit a user to simulate the act of smoking by
producing an aerosol, also referred to as a "vapor", which is drawn
into the lungs through the mouth (inhaled) and then exhaled. The
inhaled aerosol typically bears nicotine and/or flavorings without,
or with fewer of, the odor and health risks associated with
traditional 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 experience and satisfaction to those
experienced with traditional smoking and 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. Some smoking substitute
systems are designed to resemble a traditional cigarette and are
cylindrical in form with a mouthpiece at one end. Other smoking
substitute systems do not generally resemble a cigarette (for
example, the smoking substitute device may have a generally
box-like form).
[0009] There are a number of different categories of smoking
substitute systems, each utilizing a different smoking substitute
approach. A smoking substitute approach corresponds to the manner
in which the substitute system operates for a user.
[0010] One approach for a smoking substitute system is the
so-called "vaping" approach, in which a vaporizable liquid,
typically referred to (and referred to herein) as "e-liquid", is
heated by a heater to produce an aerosol vapor which is inhaled by
a user. An e-liquid typically includes a base liquid as well as
nicotine and/or flavorings. The resulting vapor therefore typically
contains nicotine and/or flavorings. The base liquid may include
propylene glycol and/or vegetable glycerin.
[0011] A typical vaping smoking substitute system includes a
mouthpiece, a power source (typically a battery), a tank or liquid
reservoir for containing e-liquid, as well as a heater. In use,
electrical energy is supplied from the power source to the heater,
which heats the e-liquid to produce an aerosol (or "vapor") which
is inhaled by a user through the mouthpiece.
[0012] Vaping smoking substitute systems can be configured in a
variety of ways. For example, there are "closed system" vaping
smoking substitute systems which typically have a heater and a
sealed tank which 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 device which includes the
power source, wherein the device is configured to be physically and
electrically coupled to a consumable including the tank and the
heater. In this way, when the tank of a consumable has been
emptied, the device can be reused by connecting it to a new
consumable. Another subset of closed system vaping smoking
substitute systems are completely disposable, and intended for
one-use only.
[0013] There are also "open system" vaping smoking substitute
systems which typically have a tank that is configured to be
refilled by a user, so the system can be used multiple times.
[0014] An example vaping smoking substitute system is the Myblu.TM.
e-cigarette. The Myblu.TM. e cigarette is a closed system which
includes a device and a consumable. The device and consumable are
physically and electrically coupled together by pushing the
consumable into the device. The device includes a rechargeable
battery. The consumable includes a mouthpiece, a sealed tank which
contains e-liquid, as well as a vaporizer, which for this system is
a heating filament coiled around a portion of a wick which is
partially immersed in the e-liquid. The system is activated when a
microprocessor on board the device detects a user inhaling through
the mouthpiece. When the system is activated, electrical energy is
supplied from the power source to the vaporizer, which heats
e-liquid from the tank to produce a vapor which is inhaled by a
user through the mouthpiece.
[0015] Another example vaping smoking substitute system is the blu
PRO.TM. e-cigarette. The blu PRO.TM. e cigarette is an open system
which includes a device, a (refillable) tank, and a mouthpiece. The
device and tank are physically and electrically coupled together by
screwing one to the other. The mouthpiece and refillable tank are
physically coupled together by screwing one into the other, and
detaching the mouthpiece from the refillable tank allows the tank
to be refilled with e-liquid. The system is activated by a button
on the device. When the system is activated, electrical energy is
supplied from the power source to a vaporizer, which heats e-liquid
from the tank to produce a vapor which is inhaled by a user through
the mouthpiece.
[0016] As the vapor passes through the consumable (entrained in the
airflow) from the location of vaporization to an air outlet of the
consumable (e.g., a mouthpiece), the vapor cools and condenses to
form an aerosol for inhalation by the user. The aerosol may contain
nicotine and/or flavor compounds.
[0017] One issue with such systems is that e-liquid in the
vaporizer (i.e., received from the tank) can leak from the system
via an air inlet or air outlet of the system. Such leakage may
occur whilst the system is not in use. For example, leakage can
occur when the system (e.g., consumable) is stored in a user's
pocket, which may stain a user's clothing and is thus
undesirable.
[0018] Thus, it may be desirable to provide an arrangement having
reduced leakage of e-liquid from the system.
SUMMARY
[0019] According to a first aspect, there is provided a smoking
substitute component comprising: [0020] a housing comprising a base
portion, a mouthpiece portion, and one or more walls extending
longitudinally from the base portion to the mouthpiece portion;
[0021] an airflow path extending from an air inlet formed in a wall
of the housing and spaced longitudinally from the base portion to
an air outlet formed in the mouthpiece portion, the airflow path
comprising a first portion downstream of the air inlet and
extending longitudinally towards the base portion of the housing,
and a transversely extending second portion that is downstream of
the first portion; and [0022] a vaporizer comprising a wick and a
heating element for heating the wick, the wick extending across the
second portion of the airflow path.
[0023] The provision of an airflow path portion that extends
towards the base portion of the housing to a transverse portion in
which the vaporizer is provided may help to prevent or reduce
leakage from the housing. Such an arrangement means that the
airflow path includes at least two turns/deflections between the
air inlet and the vaporizer. This makes it more difficult for any
liquid in the vaporizer to pass from the vaporizer to the air
inlet.
[0024] According to a second aspect there is a provided a smoking
substitute component, comprising: [0025] a housing comprising a
base portion, a mouthpiece portion, and one or more walls extending
longitudinally from the base portion to the mouthpiece portion;
[0026] an airflow path extending from an air inlet formed in a wall
of the housing and spaced longitudinally from the base portion to
an air outlet formed in the mouthpiece portion, a first portion of
the airflow path being defined by a first passage extending
longitudinally from the air inlet towards the base portion;
[0027] a vaporizer in the airflow path downstream of the first
passage; and
[0028] an absorbent element disposed in the first passage.
[0029] The provision of an airflow path portion that extends
longitudinally from an air inlet formed in a side wall towards a
base portion of the housing may help to prevent or reduce leakage
from the housing. This arrangement makes it more difficult for any
liquid in the vaporizer to pass from the vaporizer to the air
inlet. The provision an absorbent element in the passage within the
longitudinal portion of the airflow path may further reduce or
prevent leakage of liquid from the component.
[0030] Further, in either of the first or second aspects, the base
portion may represent an in use lower end of the component and
therefore, in a normal orientation of the component, gravity may
prevent liquid from travelling up the (first) portion of the
airflow path from the vaporizer to the air inlet.
[0031] According to a third aspect there is a provided an
aerosol-delivery (e.g., a smoking substitute) component,
comprising: [0032] a housing comprising a mouthpiece portion and
inlet side and outlet side spaced walls extending longitudinally
from the mouthpiece portion so as to define an internal space
therebetween; [0033] an outlet side tank wall integrally formed
with the mouthpiece portion and extending longitudinally into the
internal space from the mouthpiece portion, the outlet side tank
wall spaced from the outlet side wall so as to define an outlet
passage extending to an outlet formed in the mouthpiece portion;
and [0034] a tank for storing aerosol precursor, the tank at least
partly defined by the outlet side tank wall.
[0035] Advantageously, the aerosol delivery component of the third
aspect has a tank wall integrally formed with the housing. Only a
single die is necessary to injection mold such a housing, despite
the fact that it comprises complex internal geometry. The
disclosure effectively removes the need for preparing additional
dies, as no sub-components need to be molded and pre-assembled in
order to define the internal geometry. In that way, the aerosol
delivery component may be more easily manufactured using injection
molding.
[0036] Optional features will now be set out. These are applicable
singly or in any combination with any aspect.
[0037] Embodiments of the third aspect comprise an airflow path
that extends from the air inlet to the air outlet. The air outlet
is provided in the mouthpiece portion. The air outlet in the
mouthpiece portion may be in fluid communication with a mouthpiece
attachment. The airflow path passes a vaporizer between the air
inlet to the air outlet. The mouthpiece portion may be provided at
a first lateral end of the housing, and a base portion may be
provided at a second, opposing lateral end. The air flow path may
comprise a first portion extending from the air inlet towards the
base portion.
[0038] In embodiments of any of the aspects, the first portion of
the airflow path may extend substantially longitudinally (away from
the mouthpiece portion) from the air inlet towards the base portion
of the housing.
[0039] Embodiments of the third aspect comprise an air inlet
provided in the inlet side wall, longitudinally spaced (towards the
mouthpiece portion) from the base portion.
[0040] The air inlet (in any aspect) may be longitudinally spaced
from the base portion (e.g., from the lowermost surface of the base
portion) of the housing by a distance that is greater than 8 mm.
The distance may be greater than 10 mm, or, e.g., greater than 13
mm.
[0041] Embodiments of the second or third aspect may further
comprise a transversely extending second portion of the airflow
path. The second portion (in any aspect) may be perpendicular to
the first portion. The second portion may be downstream of the
first portion (e.g., immediately downstream).
[0042] The vaporizer in embodiments of the second or third aspect
may be disposed in the second portion of the airflow path. The
vaporizer may comprise a heating element for heating a wick. The
wick may be elongate and may extend across the second (transverse)
portion of the airflow path.
[0043] The airflow path in any aspect may comprise a third portion
extending longitudinally from the second portion to the air outlet
(formed in the mouthpiece portion). In this respect, a user may
draw fluid (e.g., air) into and along the airflow path by inhaling
at the air outlet (i.e., using the mouthpiece portion).
[0044] The third portion of the airflow path may be substantially
parallel to the first portion of the airflow path. The third
portion of the airflow path may be longer (i.e., in a longitudinal
direction) than the first airflow path. The second portion of the
airflow path may be substantially perpendicular to the first and/or
third portions of the airflow path.
[0045] The airflow path (in any aspect) may be generally U-shaped
(the first and third portions forming stems of the "U" and the
second portion forming the base of the "U"). The first portion
extends from the air inlet towards the base portion (i.e., away
from the mouthpiece portion). The second portion of the airflow
path may connect the first and third portions of the airflow path.
The airflow path may comprise at least two turns (e.g., each around
90.degree.) between the vaporizer and the air inlet. The airflow
path may comprise at least one turn between the vaporizer and the
air outlet.
[0046] References to "downstream" in relation to the air flow path
are intended to refer to the direction towards the air
outlet/mouthpiece portion. Thus, the second and third portions of
the air flow path are downstream of the first portion of the air
flow path. Conversely, references to "upstream" are intended to
refer to the direction towards the air inlet. Thus, the first
portion of the air flow path (and the air inlet) is upstream of the
second/third portions of the air flow path (and the air
outlet/mouthpiece portion).
[0047] The component of the first or second aspect may comprise a
tank for housing an aerosol precursor (e.g., a liquid aerosol
precursor). In embodiments of any of the first to third aspects,
the aerosol precursor may comprise an e-liquid, for example,
comprising a base liquid and, e.g., nicotine. The base liquid may
include propylene glycol and/or vegetable glycerin. Hence, the
component may be a vaping smoking substitute component.
[0048] The second portion of the airflow path (in any of the first
to third aspects) may be disposed between (i.e.,
axially/longitudinally between) the tank and the base portion of
the housing. The tank may be disposed between (in a transverse
direction) the first and the third portions of the airflow path.
The vaporizer may be disposed in the second portion of the air flow
path. The vaporizer may be disposed between the tank and the base
portion of the housing. Thus, the wick may be disposed between the
tank and the base portion of the housing.
[0049] The component (e.g., the housing) may comprise a width,
length and depth dimensions. The depth may be smaller than each of
the width and the length. The wick may be oriented in the direction
of the depth dimension of the component.
[0050] The length of the housing may be greater than the width of
the housing. The housing may be elongate, and the elongate axis may
be in the length direction.
[0051] The housing may comprise opposing front and rear walls
spaced by opposing first (inlet) and second (outlet) side walls
extending therebetween. In the first and second embodiments, the
first and second side walls may extend longitudinally from the
mouthpiece portion so as to define an internal space
therebetween.
[0052] The distance between the side walls of the housing may
define a width of the housing. The distance between the front and
rear walls may define a depth of the housing. The width of the
housing may be greater than the depth of the housing. The wick may
be elongate and may be oriented so as to extend in a direction from
the front wall to the rear wall, i.e., it may be oriented in a
direction of the depth dimension of the housing. Accordingly, the
elongate wick may extend across the second portion of the airflow
path in the direction of the depth of the housing. Thus, the wick
may extend in a direction perpendicular to the direction of air
flow in the second portion of the air flow path.
[0053] The length of the housing may be greater than the width of
the housing. The depth of the housing may be smaller than each of
the width and the length.
[0054] The first portion of the airflow path in the first or third
aspects may be defined within a first (inlet) passage.
[0055] The first airflow path portion (in any aspect) may have a
substantially rectangular transverse cross-sectional shape.
[0056] The first/inlet passage may be between a first (inlet side)
tank wall and the first (inlet) side wall of the housing. The first
(inlet side) tank wall may extend longitudinally into the internal
space from the mouthpiece portion. The first (inlet) side wall and
the first (inlet side) tank wall may be integrally formed with one
another whilst defining the first/inlet passage therebetween. This
enables injection molding the inlet passage simultaneously with the
rest of the housing.
[0057] The first (inlet) side wall may be integrally formed with
the mouthpiece portion.
[0058] The first (inlet side) tank wall and the first (inlet) side
wall may be parallel to each other. They are preferably parallel to
the longitudinal axis of the component. Hence, the first (inlet)
passage defined between these walls may have a substantially
uniform profile and/or cross-sectional area along this
direction.
[0059] In the second aspect, there is an absorbent element disposed
in the first passage.
[0060] The first absorbent element may extend along the first tank
wall. The first absorbent element may be spaced from the first side
wall. The first portion of the airflow path may be defined between
the first absorbent element and the first side wall.
[0061] The absorbent element may be elongate (i.e., in the
longitudinal direction). An end (e.g., that is distal from the base
portion) of the absorbent element may be tapered.
[0062] The absorbent element may be formed of a porous material
(i.e., configured to capture/absorb liquid leaking into the first
passage).
[0063] The absorbent element may have a transverse cross-sectional
area that is less than a transverse cross-sectional area of the
first passage (i.e., for a given axial/longitudinal location). That
is, the absorbent element may be configured so as to only extend
only partway across the first passage (i.e., so as to only partly
fill the first passage). Thus, the first airflow path portion may
be defined between the absorbent element and a wall of the first
passage.
[0064] The absorbent element may have a longitudinally extending
groove or recess formed therein. Thus, for example, the absorbent
element may have substantially the same transverse cross-sectional
shape as the first passage, except for a cut-out defined by the
recess or groove formed therein. The recess or groove may define
the first airflow path portion (with one or more walls of the first
passage).
[0065] A portion of the absorbent element may be adjacent the air
inlet. The absorbent element may extend within a portion of the
first passage at which the air inlet joins the first passage.
[0066] The absorbent element may be disposed on an opposite side
(i.e., in a transverse direction) of the first passage to the air
inlet.
[0067] A portion the first passage may extend longitudinally from
the air inlet in a direction away from the base portion (i.e.,
towards the mouthpiece portion). In this respect, the air inlet may
be disposed partway along the length of the first passage.
[0068] The absorbent element may extend for substantially the
entire length of the first passage. For example, the length of the
absorbent element may be greater than 90% of the length of the
first passage, or, e.g., greater than 95% of the length of the
first passage.
[0069] An end of the absorbent element (e.g., proximate the
vaporizer) may be spaced from a corresponding end (e.g., proximate
the vaporizer) of the first passage. In this way, a void may be
defined between the end of the absorbent element and the end of the
first passage. The void may be located at an end of the first
passage proximate the vaporizer. That is, the absorbent element may
be spaced from the end of the first passage proximate the
vaporizer. Thus, the void may prevent liquid from travelling along
the absorbent element from the vaporizer (e.g., to the air inlet).
The first passage may, for example, comprise a retaining portion
(e.g., a protrusion) for retaining the absorbent element in this
position (i.e., defining the void).
[0070] The third portion of the airflow path in any aspect may be
defined within a second (outlet) passage. The third airflow path
portion may have a substantially rectangular transverse
cross-sectional shape.
[0071] The second/outlet passage may extend longitudinally from the
mouthpiece portion towards the base portion of the housing.
[0072] The previously mentioned absorbent element in the second
aspect may be a first absorbent element and the embodiments of the
second aspect may further comprise a second absorbent element
disposed in the second passage.
[0073] The second absorbent element may be elongate (i.e., in the
longitudinal direction). An end (e.g., that is distal from the base
portion) of the second absorbent element may be tapered. The
tapered end of the second absorbent element may be proximate (or
adjacent to) the air outlet/mouthpiece portion. The second
absorbent element may at least partly obstruct the air outlet. The
second absorbent element may extend across the air outlet.
[0074] The second absorbent element may have a transverse
cross-sectional area that is less than a transverse cross-sectional
area of the second passage. That is, the second absorbent element
may be configured so as to only extend only partway across the
second passage (i.e., so as to only partly fill the second
passage). Thus, the third airflow path portion may be defined
between the second absorbent element and a wall of the second
passage.
[0075] The second absorbent element may have a longitudinally
extending groove or recess formed therein. Thus, for example, the
second absorbent element may have substantially the same transverse
cross-sectional shape as the second passage, except for a cut-out
defined by the recess or groove formed therein. The recess or
groove may define the third airflow path portion (with one or more
walls of the second passage).
[0076] The second absorbent element may extend for substantially
the entire length of the second passage. For example, the length of
the second absorbent element may be greater than 90% of the length
of the second passage, or, e.g., greater than 95% of the length of
the second passage.
[0077] An end of the second absorbent element may be spaced from a
corresponding (i.e., proximate) end of the second passage. In this
way, a void may be defined between the end of the second absorbent
element and the end of the second passage. The void may be located
at an end of the second passage proximate the vaporizer. That is,
the second absorbent element may be spaced from the end of the
second passage proximate the vaporizer. Thus, the void may prevent
liquid from travelling along the absorbent element from the
vaporizer (e.g., to the air outlet).
[0078] The second/outlet passage (in any aspect) may be defined
between a second (outlet side) tank wall and the second (outlet)
side wall of the housing. Thus the third portion of the airflow
path may be defined between the second (outlet side) tank wall and
the second (outlet) side wall. The second (outlet) side wall and
the second (outlet side) tank wall may be integrally formed with
one another. The second (outlet side) tank wall and the second
(outlet) side wall may be parallel to each other. They are
preferably parallel to the longitudinal axis of the component.
Hence, the second/outlet passage defined between these walls may
have a substantially uniform profile and/or cross-sectional area
along this direction.
[0079] The second absorbent element in embodiments of the second
aspect may extend along the second tank wall. The second absorbent
element may be spaced from the second side wall. The third portion
of the airflow path may be defined between the second absorbent
element and the second side wall.
[0080] In the third aspect, the outlet side tank wall is integrally
formed with the mouthpiece portion. In some embodiments, the outlet
side wall may be integrally formed with the mouthpiece portion.
Advantageously, the outlet side tank wall and the outlet side wall
are integrally formed whilst defining the outlet passage
therebetween. This enables injection molding the outlet passage
simultaneously with the rest of the housing.
[0081] In the first and second aspects, all of the first side wall,
second side wall, first tank wall and second tank wall may all be
integrally formed and may additionally be integrally formed with
the mouthpiece portion. In that way, the component may be easily
manufactured using injection molding.
[0082] References to "upper", "lower", "above" or "below" are
intended to refer to the component when in an upright/vertical
orientation, i.e., with elongate (longitudinal/length) axis of the
component vertically aligned and with the mouthpiece portion
vertically uppermost and the base portion lowermost.
[0083] The tank (in any aspect) may be disposed between (in a
transverse direction) the first and the third portions of the
airflow path.
[0084] The first (inlet side) and second (outlet side) tank walls
may be spaced from one another so as to define the tank
therebetween. Thus, it is not necessary to dispose a pre-assembled
tank structure within the housing in order to define a fluid
storage space. The tank can be formed by injection molding
simultaneously with the rest of the housing.
[0085] The first (inlet side) and second (outlet side) tank walls
may extend longitudinally from the mouthpiece portion towards the
base of the housing. The first (inlet side) and second (outlet
side) tank walls may be substantially parallel. They are preferably
parallel to the longitudinal axis of the component. Each of the
first (inlet side) and second (outlet side) tank walls may extend
between (and span) the front and rear walls of the housing.
[0086] Each of the first (inlet side) and second (outlet side) tank
walls may extend from the mouthpiece portion (i.e., internally in
the housing). Each of the first (inlet side) and second (outlet
side) tank walls may be integrally formed with the mouthpiece
portion.
[0087] All of the first (inlet) side wall, second (outlet) side
wall, first (inlet side) tank wall and second (outlet side) tank
wall may be integrally formed with the mouthpiece portion.
[0088] The tank may be partly defined by a wall of the housing
(e.g., the front or rear wall). At least a portion of one of the
walls defining the tank may be translucent. That is, the tank may
comprise a window to allow a user to visually assess the quantity
of e-liquid in the tank. The tank may be referred to as a
"clearomizer" if it includes a window, or a "cartomizer" if it does
not.
[0089] The vaporizer may be disposed in a vaporizing chamber. The
vaporizing chamber may form part of the airflow path (i.e., the
second portion of the airflow path).
[0090] The wick may extend across the second (transverse) portion
of the air flow path. The wick may be oriented so as to extend in a
direction from the front wall to the rear wall of the housing,
i.e., it may be oriented in the direction of the depth dimension of
the component. Thus, the wick may extend in a direction
perpendicular to the direction of air flow in the second portion of
the air flow path.
[0091] The vaporizing chamber may be defined by one or more chamber
walls. In embodiments of the second aspect, each of the absorbent
elements discussed above may be spaced from the one or more chamber
walls (i.e., so as to avoid liquid being transported along the
absorbent element from the chamber wall).
[0092] The wick may extend between first and second opposing
chamber walls. The first and second chamber walls may separate
(i.e., partially separate) the vaporizing chamber from aerosol
precursor in the tank. The first and second chambers walls may each
comprise a respective opening through which a respective end of the
wick projects such that the wick is fluid communication with
aerosol precursor in the tank. In this way a central portion of the
wick may be exposed to fluid flow in airflow path and end portions
of the wick may be in contact with aerosol precursor (e.g.,
e-liquid) stored in the tank. The wick may comprise a porous
material. Thus, aerosol precursor may be drawn (e.g., by capillary
action) along the wick, from the tank to the exposed portion of the
wick.
[0093] A transverse chamber wall (e.g., a third wall) may separate
the vaporizing chamber from aerosol precursor in the tank. In this
respect, the transverse chamber wall may partly define the tank. An
opening/vent may be provided in the transverse chamber wall for the
flow of air into the aerosol precursor tank (i.e., so as to allow
for pressure equalization in the tank).
[0094] The vaporizing chamber may be defined by an insert (e.g., an
insert at least partly formed of silicone) received into an open
(e.g., lower) end of the housing. The chamber walls may be walls of
the insert.
[0095] The insert may define the base portion.
[0096] As discussed above, the component housing comprises the
mouthpiece portion (with the air outlet) at the first lateral end
and the base portion (e.g., the insert) at the opposing lateral
end.
[0097] The insert (e.g., an upper transverse surface of the insert)
may engage the second (outlet side) tank wall and/or the first
(inlet side) tank wall such that the first (outlet side) tank wall
and/or the second (inlet side) tank wall seal against the
insert.
[0098] More specifically, each tank wall comprises a terminal
portion distal from the mouthpiece portion, which terminal portions
engage the (upper transverse surface of the) insert such that they
seal against the insert.
[0099] The upper transverse surface of the insert may an inlet side
groove for receiving the terminal portion of the first (inlet side)
tank wall. The upper transverse surface of the insert may an outlet
side groove for receiving the terminal portion of the second
(outlet side) tank wall.
[0100] To accommodate the insert, the length of the first (inlet
side) tank wall and the second (outlet side) tank wall is less than
the length of the first (inlet) side wall and the second (outlet)
side wall, so as to enable disposal of the insert within the
internal space.
[0101] The insert may comprise opposing transverse side surfaces
which may engage with the first (inlet) side wall and second
(outlet) side wall.
[0102] The wick may have an elongate shape. The wick may be
cylindrical. The heating element may be in the form of a filament
wound about the wick (e.g., the filament may extend helically about
the wick). The filament may be wound about the exposed portion of
the wick (i.e., the portion of the wick extending across the
airflow path). The heating element may be electrically connected
(or connectable) to a power source. Thus, in operation, the power
source may supply electricity to (i.e., apply a voltage across) the
heating element so as to heat the heating element. 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 fluid flowing along
the airflow path. This vapor may subsequently cool to form an
aerosol in the airflow path (e.g., the third portion of the airflow
path).
[0103] In a fourth aspect there is provided an aerosol-delivery
system (e.g., a smoking substitute system) comprising a component
according to the first, second or third aspect and an
aerosol-delivery (e.g., smoking substitute) device.
[0104] The component may be an aerosol-delivery (e.g., a smoking
substitute) consumable, i.e., in some embodiments the component may
be a consumable component for engagement with the aerosol-delivery
(e.g., a smoking substitute) device to form the aerosol-delivery
(e.g., s smoking substitute) system.
[0105] The device may be configured to receive the consumable
component. For example, the device and the consumable component may
be configured to be physically coupled together. For example, the
consumable component may be at least partially received in a recess
of the device, such that there is snap engagement between the
device and the consumable component. Alternatively, the device and
the consumable component may be physically coupled together by
screwing one onto the other, or through a bayonet fitting.
[0106] Thus, the consumable component may comprise one or more
engagement portions for engaging with the device. In this way, one
end of the consumable component (i.e., the inlet end) may be
coupled with the device, while an opposing end (i.e., the outlet
end) of the consumable component may define a mouthpiece.
[0107] The consumable component may comprise an electrical
interface for interfacing with a corresponding electrical interface
of the device. One or both of the electrical interfaces may include
one or more electrical contacts. Thus, when the device is engaged
with the consumable component, the electrical interface may be
configured to transfer electrical power from the power source to a
heating element of the consumable component. The electrical
interface may also be used to identify the consumable component
from a list of known types. The electrical interface may
additionally or alternatively be used to identify when the
consumable component is connected to the device.
[0108] The device may alternatively or additionally be able to
detect information about the consumable component via an RFID
reader, a barcode or QR code reader. This interface may be able to
identify a characteristic (e.g., a type) of the consumable. In this
respect, the consumable component 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.
[0109] In other embodiments, the component may be integrally formed
with the aerosol-delivery (e.g., a smoking substitute) device to
form the aerosol-delivery (e.g., s smoking substitute) system.
[0110] In such embodiments, the aerosol former (e.g., e-liquid) may
be replenished by re-filling a tank that is integral with the
device (rather than replacing the consumable). Access to the tank
(for re-filling of the e-liquid) may be provided via, e.g., an
opening to the tank that is sealable with a closure (e.g., a
cap).
[0111] Further features of the device are described below. These
are applicable to both the device for receiving a consumable
component and to the device integral with the component.
[0112] The device may comprise a power source. The device may
comprise a controller.
[0113] 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. The
device 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.RTM. 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.
[0114] An airflow (i.e., puff) sensor may be provided that is
configured to detect a puff (i.e., inhalation from a user). The
airflow 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 airflow sensor
may, for example, be in the form of a pressure sensor or an
acoustic sensor. The controller may control power supply to a
heating element in response to airflow detection by the sensor. The
control may be in the form of activation of the heating element in
response to a detected airflow. The airflow sensor may form part of
the device.
[0115] In a fifth aspect there is provided a method of using the
aerosol-delivery (e.g., smoking substitute) consumable component
according to the first, second or third aspect, the method
comprising engaging the consumable component with an
aerosol-delivery (e.g., smoking substitute) device (as described
above) having a power source so as to electrically connect the
power source to the consumable component (i.e., to the vaporizer of
the consumable component).
[0116] In a sixth aspect there is provided a method of forming a
consumable component according to the second aspect, the method
comprising providing a housing, inserting an absorbent element into
the first passage defined by the housing, and inserting the insert
into an open end of the housing.
[0117] The housing may be formed by way of injection molding.
[0118] 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
[0119] So that further aspects and features thereof may be
appreciated, embodiments will now be discussed in further detail
with reference to the accompanying figures, in which:
[0120] FIG. 1A is a front schematic view of a smoking substitute
system;
[0121] FIG. 1B is a front schematic view of a device of the
system;
[0122] FIG. 1C is a front schematic view of a consumable of the
system;
[0123] FIG. 2A is a schematic of the components of the device;
[0124] FIG. 2B is a schematic of the components of the
consumable;
[0125] FIG. 3A is a front section view of a consumable;
[0126] FIG. 3B is a perspective section view of the consumable of
FIG. 3A;
[0127] FIG. 3C is a side section view of the consumable of FIG.
3A;
[0128] FIG. 4A is a front section view of a second consumable;
and
[0129] FIG. 4B is a top section view of the consumable of FIG.
4A.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0130] Aspects and embodiments will now be discussed with reference
to the accompanying figures. Further aspects and embodiments will
be apparent to those skilled in the art.
[0131] FIG. 1A shows a smoking substitute system 100. In this
example, the smoking substitute system 100 includes a device 101
and an aerosol delivery consumable component 102. The consumable
component 102 may alternatively be referred to as a "pod",
"cartridge" or "cartomizer". It should be appreciated that in other
examples (i.e., open systems), the device may be integral with the
consumable. In such systems, a tank of the aerosol delivery system
may be accessible for refilling the device.
[0132] In this example, the smoking substitute system 100 is a
closed system vaping system, wherein the consumable component 102
includes a sealed tank 103 and is intended for single-use only. The
consumable component 102 is removably engageable with the device
101 (i.e., for removal and replacement). FIG. 1A shows the smoking
substitute system 100 with the device 101 physically coupled to the
consumable component 102, FIG. 1B shows the device 101 of the
smoking substitute system 100 without the consumable component 102,
and FIG. 1C shows the consumable component 102 of the smoking
substitute system 100 without the device 101.
[0133] The device 101 and the consumable component 102 are
configured to be physically coupled together by pushing the
consumable component 102 into a cavity at an upper end 104 of the
device 101, such that there is an interference fit between the
device 101 and the consumable component 102. In other examples, the
device 101 and the consumable component 102 may be coupled by
screwing one onto the other, or through a bayonet fitting.
[0134] The consumable component 102 comprises a housing 105 having
a base portion 106 (at a lower end), a mouthpiece portion 107 (at
an upper end), and walls extending longitudinally from the base
portion 106 to the mouthpiece portion 107. In particular, the
consumable component 102 comprises front 108a and rear 108b walls
spaced by opposing first (inlet) 108c and second (outlet) 108d side
walls. The distance between the front 108a and rear 108b walls
defines a depth of the housing 105 and the distance between the
side walls 108c, 108d defines a width of the housing 105. The width
of the housing 105 is greater than the depth of the housing
105.
[0135] The tank 103 of the consumable component 102 comprises a
window 109, which allows the quantity of e-liquid remaining in the
tank 103 to be visually assessed. The device 101 includes a slot
110 so that the window 109 of the consumable component 102 can be
seen whilst the rest of the tank 103 is obscured from view when the
consumable component 102 is inserted into the cavity at the upper
end 108 of the device 102.
[0136] A lower end 111 of the device 101 includes a light 112
(e.g., an LED) located behind a small translucent cover. The light
112 may be configured to illuminate when the smoking substitute
system 100 is activated. Whilst not shown, the consumable component
102 may identify itself to the device 101, via an electrical
interface, RFID chip, or barcode.
[0137] FIGS. 2A and 2B are schematic drawings of the device 101 and
consumable component 102. These figures provide an overview of the
components that form part of the consumable component 102 and
device 101. As is apparent from FIG. 2A, the device 101 includes a
power source 113, a controller 114, a memory 115, a wireless
interface 116, an electrical interface 117, and, optionally, one or
more additional components 118.
[0138] The power source 113 is a battery (e.g., a rechargeable
battery). The controller 114 may, for example, include a
microprocessor. The memory 115 may include non-volatile memory. The
memory 115 may include instructions which, when implemented, cause
the controller 114 to perform certain tasks or steps of a
method.
[0139] The wireless interface 116 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 116 could
include a Bluetooth.RTM. antenna. Other wireless communication
interfaces, e.g., WIFI.RTM., are also possible. The wireless
interface 116 may also be configured to communicate wirelessly with
a remote server.
[0140] The electrical interface 117 of the device 101 may include
one or more electrical contacts. The electrical interface 117 may
be located in a base of the cavity formed in the upper end 104 of
the device 101. When the device 101 is physically coupled to the
consumable component 102, the electrical interface 117 of the
device 101 is configured to transfer electrical power from the
power source 113 to the consumable component 102 (i.e., upon
activation of the smoking substitute system 100).
[0141] The electrical interface 117 may be configured to receive
power from a charging station when the device 101 is not physically
coupled to the consumable component 102 and is instead coupled to
the charging station. The electrical interface 117 may also be used
to identify the consumable component 102 from a list of known
consumables. For example, the consumable component 102 may include
e-liquid having a particular flavor and/or having a certain
concentration of nicotine (which may be identified by the
electrical interface 117). This can be indicated to the controller
114 of the device 101 when the consumable component 102 is
connected to the device 101. Additionally, or alternatively, there
may be a separate communication interface provided in the device
101 and a corresponding communication interface in the consumable
component 102 such that, when connected, the consumable component
102 can identify itself to the device 101.
[0142] The additional components 118 of the device 101 may comprise
an indicator (e.g., the light 112 discussed above), a charging
portion, a battery charging control circuit, a sensor or, e.g.,
user input.
[0143] The charging port (e.g., USB or micro-USB port) may be
configured to receive power from the charging station (i.e., when
the power source 118 is a rechargeable battery). This may be
located at the lower end 111 of the device 101. Alternatively, the
electrical interface 117 discussed above may be configured to act
as a charging port configured to receive power from the charging
station such that a separate charging port is not required.
[0144] The battery charging control circuit may be configured for
controlling the charging of the rechargeable battery. However, a
battery charging control circuit could equally be located in the
charging station (if present).
[0145] The sensor may be, e.g., an airflow (i.e., puff) sensor for
detecting airflow in the smoking substitute system 100, e.g.,
caused by a user inhaling through a mouthpiece 107 of the
consumable component 102. The smoking substitute system 100 may be
configured to be activated when airflow is detected by the airflow
sensor. This sensor could alternatively be included in the
consumable component 102. The airflow sensor can be used to
determine, for example, how heavily a user draws on the mouthpiece
107 or how many times a user draws on the mouthpiece 107 in a
particular time period.
[0146] The user input may be a button. The smoking substitute
system 100 may be configured to be activated when a user interacts
with the user input (e.g., presses the button). This provides an
alternative to the airflow sensor as a mechanism for activating the
smoking substitute system 100.
[0147] The consumable component 102, which is shown in FIG. 2B,
includes the tank 103, an electrical interface 119, a vaporizer
120, an air inlet 121, an air outlet 122 (e.g., formed in the
mouthpiece 107), and one or more additional components 123.
[0148] The electrical interface 119 of the consumable component 102
may include one or more electrical contacts. The electrical
interface 117 of the device 101 and the electrical interface 119 of
the consumable component 102 may be configured to contact each
other and thereby electrically couple the device 101 to the
consumable component 102 when the base portion 106 of the
consumable component 102 is inserted into the cavity formed in the
upper end 104 of the device 101 (as shown in FIG. 1A). In this way,
electrical energy (e.g., in the form of an electrical current) is
able to be supplied from the power source 113 in the device 101 to
the vaporizer 120 in the consumable component 102.
[0149] The vaporizer 120 is configured to heat and vaporize
e-liquid contained in the tank 103 using electrical energy supplied
from the power source 113. As will be described further below, the
vaporizer 120 heats the e-liquid received from the tank 103 to
vaporize the e-liquid. The air inlet 121 is configured to allow air
to be drawn into the smoking substitute system 100 when a user
inhales using the air outlet 122 formed in the mouthpiece 107, such
that the vaporized e-liquid is drawn through the consumable
component 102 for inhalation by the user.
[0150] In operation, a user activates the smoking substitute system
100, e.g., through interaction with a user input forming part of
the device 101 or by inhaling through the air outlet 122 as
described above. Upon activation, the controller 114 may supply
electrical energy from the power source 113 to the vaporizer 120
(via electrical interfaces 117, 119), which may cause the vaporizer
120 to heat e-liquid drawn from the tank 103 to produce a vapor
which is inhaled by a user through the mouthpiece 107.
[0151] An example of one of the one or more additional components
123 of the consumable component 102 is an interface for obtaining
an identifier of the consumable component 102. As discussed above,
this interface may be, for example, an RFID reader, a barcode, a QR
code reader, or an electronic interface which is able to identify
the consumable component 102. The consumable component 102 may,
therefore include any one or more of an RFID chip, a barcode or QR
code, or memory within which is an identifier and which can be
interrogated via the electronic interface 117 in the device
101.
[0152] It should be appreciated that the smoking substitute system
100 shown in FIGS. 1A to 2B is just one exemplary implementation of
a smoking substitute system 100. For example, the system could
otherwise be in the form of an entirely disposable (single-use)
system or an open system in which the tank is refillable (rather
than replaceable).
[0153] FIGS. 3A, 3B and 3C are section views of a consumable
component 102 described above and FIGS. 4A and 4B are section views
of a further consumable component 102'. The air inlet 121 of the
consumable component 102/102' is in the form of an aperture formed
in the first (inlet) side wall 108c of the housing 105. In
particular, the air inlet 121 is spaced along the first (inlet)
side wall 108c (in a longitudinal direction) from the base portion
106 of the housing 105 so as to be partway along the first (inlet)
side wall 108c from the base portion 106. The air outlet 122 is
formed in the mouthpiece 107 and an airflow path 124 extends from
the air inlet 121 to the air outlet 122, such that a user can draw
air through the airflow path 124 by inhaling at the air outlet 122.
As will be described in more detail below, the airflow path 124
follows a generally U-shaped path through the consumable component
102/102'.
[0154] The airflow path 124 comprises first 138a, second 138b and
third 138c airflow path portions. The first airflow path portion
138a is defined by a first (inlet) passage 125a extending
longitudinally from the air inlet 121 towards the base portion 106
of the consumable component 102/102'. This first portion 138a of
the air flow path extends from the air inlet 121 away from the
mouthpiece portion 107. This first (inlet) passage 125a is defined
between a first (inlet side) tank wall 126a that is laterally
(i.e., transversely) spaced from the first (inlet) side wall 108c
(in which the air inlet 121 is formed) and that extends
longitudinally from an internal surface of the mouthpiece 107.
[0155] The third airflow path portion 138c is similarly defined by
a second (outlet) passage 125b that is formed between a second
(outlet side) tank wall 126b and the second (outlet) side wall
108d. The second (outlet side) tank wall 126b extends
longitudinally from an internal surface of the mouthpiece 107 and
is laterally spaced from the second (outlet) side wall 108d. Both
the first (inlet side) 126a and second (outlet side) 126b tank
walls span the front 108a and rear 108b (see FIG. 3B) walls of the
housing 105. In this way, the tank 103 is partly defined between
the first (inlet side) and second (outlet side) tank walls 126a,
126b, the front 108a and rear 108b walls, and an internal surface
of the mouthpiece 107.
[0156] The tank walls 126a, 126b, side walls 108c, 108d and the
mouthpiece 107 are integrally formed with each other so as to form
a single unitary component that may, e.g., be formed by way of an
injection molding process. Such a component may be formed of a
thermoplastic material such as polypropylene. To facilitate this
(e.g., to allow removal from a mold), each of the tank walls 126a,
126b is tapered from a proximal end at which it is connected to the
mouthpiece 107 to an opposing distal end.
[0157] The second airflow path portion 138b is in the form of a
vaporizing chamber 127 that extends transversely across the housing
105 so as to connect lower ends of the first (inlet) 125a and
second (outlet) 125b passages. Thus, upon inhalation by a user, air
may flow into the air inlet 121, through the first (inlet) passage
125a, through the vaporizing chamber 127 (where vapor may be
entrained in the air) and subsequently through the second (outlet)
passage 125b where it is discharged (into a user's mouth) from the
air outlet 122 at an upper end of the second (outlet) passage 125b.
Thus, the airflow path 124 comprises at least two turns (at the air
inlet 121 and the connection between the vaporizing chamber 127 and
the first (inlet) passage 125a) between the vaporizer chamber 127
and the air inlet 121. This may reduce the propensity for leakage
of e-liquid out of the air inlet 121 (i.e., from the vaporizing
chamber 127).
[0158] The vaporizer 120 (briefly discussed with reference to FIG.
2B) is located in the vaporizing chamber 127 and comprises a porous
wick 128 and a heater filament 129 coiled around the porous wick
128. The wick 128 extends across the vaporizing chamber 127
(perpendicular to the direction of airflow through the chamber
127). That is, the wick 128 extends in the depth direction of the
housing 105.
[0159] The vaporizing chamber 127 is formed within an insert 130
that is received in an open lower end of the housing 105 so as to
define the base portion 106 of the consumable component 102/102'.
The insert 130 seals against the walls of the housing 105 so as to
define a lower end of the tank 103. Thus, the walls of the insert
130 (defining the vaporizing chamber 127) separate the vaporizing
chamber 127 from the tank 126. In particular, an upper transverse
wall 133 of the insert 130 extends from the first (inlet side) tank
wall 126a to the second (outlet side) tank wall 126b so as to
separate the vaporizing chamber 127 from the tank 103 (and so as to
define a lower surface of the tank 103).
[0160] To form a seal with the tank walls 126a, 126b, the upper
wall comprises grooves 134a, 134b that extend in a direction of the
depth of the housing 105 and receive distal ends of the tank walls
126a, 126b. This arrangement also seals the tank 103 from the air
passages 125a, 125b, which connect to the vaporizing chamber 127
via respective channels 135a, 135b formed in the insert 130.
[0161] The insert 130 comprises two apertures 131a, 131b formed in
opposing walls of the insert 130 for receipt of respective ends of
the wick 128 therethrough. The insert 130 is spaced from each of
the front 108a and rear 108b walls, such that gaps 132a, 132b are
formed between the insert 130 and each of the front 108a and rear
108b walls. These gaps 132a, 132b are arranged such that the ends
of the wick 128 projecting through the apertures 131a, 131b in the
insert 134 are received in the gaps 132a, 132b. In this way, the
ends of the wick 128 are in contact with aerosol precursor
(e-liquid) stored in the tank 106. This e-liquid is transported
along the wick 128 (e.g., by capillary action) to a central portion
of the wick 128 that is exposed to airflow flowing through the
vaporizing chamber 127. The transported e-liquid is heated by the
heater filament 129 (when activated, e.g., by detection of
inhalation), which causes the e-liquid to be vaporized and to be
entrained in air flowing across the wick 128. This vaporized liquid
may cool to form an aerosol in the passage 140, which may then be
inhaled by a user.
[0162] The insert also 130 accommodates the electrical interface
119 of the consumable component 102/102'. The electrical interface
119 comprises two electrical contacts 136a, 136b that are
electrically connected to the heating filament 129. In this way,
when the consumable component 102/102' is engaged with the device
101, power can be supplied from the power source 113 of the device
to the heating filament 129.
[0163] In the embodiment shown in FIGS. 4A/4B, the component 102'
comprises first 137a and second 137b elongate absorbent elements
that are respectively disposed in the first 125a and second 125b
passages. Each absorbent 137a, 137b element is formed of a porous
material (e.g., a foam) so as to be suitable for capturing liquid
that leaks into the passages 125a, 125b. As is apparent from FIG.
4B in particular, each of the absorbent elements 137a, 137b has a
cross-sectional area that is less than the cross-sectional area of
the passage 125a, 125b within which it is received. That is,
neither absorbent element 137a, 137b fills the cross-section of its
respective passage 125a, 125b. Each absorbent element 137a, 137b
comprises a longitudinally extending groove 139a, 139b that,
together with the respective side wall 108c, 108d of the housing
105 defines a corresponding portion 138a, 138c of the airflow path
124.
[0164] The first (inlet) passage 125a, in addition to having a
portion (defining the first airflow path portion 138a) that extends
from the air inlet 121 towards the base portion 106, includes a
portion that extends from the air inlet towards the mouthpiece
portion 107. Thus, the air inlet 121 joins with the first (inlet)
passage 125a partway along the first (inlet) passage 125a. The
first absorbent member 137a extends longitudinally along the first
(inlet side) tank wall 126a for substantially the entire length of
the first (inlet) passage 125a to an end proximate the mouthpiece
portion 107 that is tapered. In this way, a portion of the first
absorbent member 137a is adjacent (albeit on an opposite side of
the first (inlet) passage 125a) to the air inlet 121.
[0165] Similar to the first absorbent member 137a, the second
absorbent member 137b extends longitudinally along the second
(outlet side) tank wall 126b for substantially the entire length of
the second (outlet) passage 125b.
[0166] Both of the first 137a and second 137b absorbent members are
spaced from the insert 130 (i.e., from the upper transverse wall
133 of the insert 130). Thus, a void is formed between each
absorbent member 137a, 137b and the insert 130. This ensures that
liquid on the surface of the insert 130 is not transported along
the absorbent members 137a, 137b (and to the air inlet 121 or air
outlet 122).
[0167] While exemplary embodiments have been described above, many
equivalent modifications and variations will be apparent to those
skilled in the art when given this disclosure. Accordingly, the
exemplary embodiments set forth above are considered to be
illustrative and not limiting.
[0168] 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.
[0169] 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%.
[0170] 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.
* * * * *