Patent Description:
Electronic cigarettes typically have a housing to accommodate working components, including a battery and electronic control circuitry (e.g. printed circuit board, puff sensors, switches). Such housings are generally elongate in shape for a user to hold, similar to conventional cigarettes, and can be made by extruding a material (plastic or metallic) through a die. The working components are generally provided on a drawer insert which is then introduced into the housing from one of its ends. An example of such an assembly is disclosed in <CIT>. <CIT> describes a hand-held personal vaporizer in the art, which includes a button with a display screen and a fingerprint scanner all built into one, such that the button may display information thereon, may scan a finger pressed onto the button and may activate when pressed (as a button). Furthermore <CIT> describes an ergonomic aerosol-generating device comprising a button and a LED located on one side of a housing, and a biosensor located within a recessed surface on the opposite side of the housing.

An object of the invention is to provide a more reliable and improved electronic cigarette.

The scope of the invention is set out in the appended claims. According to the present invention there is provided an electronic cigarette, comprising: an external housing; a sensor configured to detect a characteristic from the user; a display unit located in an aperture of the external housing and configured to receive user input and display operational status of the device, wherein the sensor is integrated into the display unit; and an additional sensor located on the external housing of the electronic cigarette within a notch or depression on an opposite or opposing surface to the outer surface of the display unit.

In this way the sensor is combined with a display in the display unit to provide a device that is simpler to use as well as allowing increased functionality to be provided to a user within the limited real estate of an electronic cigarette. The sensors may be biometric sensors that gather information from a user in order to improve user experience of the electronic device. By providing sensors in the display unit, the electronic cigarette of the present invention will also be more intuitive for a user to operate.

Preferably the display comprises a plurality of layers, where a first layer is configured to sense an input from the user and activate the sensor. In this way a first sensing layer, which is preferably a touch-screen layer, provides an activation function to the sensor before the sensor can be used to detect user characteristics. The sensing layer may have the same area as the display or have a smaller area, thereby providing the input sensing to a limited zone.

Preferably the electronic cigarette further comprises a second layer which is an input area of the sensor. In this way the sensor is provided as a second layer in the display unit where, following activation, a user characteristic can be detected within the input area of the sensor. By use of known conductive layering techniques the second sensing layer may also be integrated within the area of the display, or may have a smaller area than the display, thereby providing a user characteristic detection zone. Using limited zones to provide different functions (e.g. activation, biometric detection) simplifies the manufacture of a display unit. Each zone may preferably also respond to different commands, for example, an activation zone may require a swiping gesture and a user characteristic detection zone may require a pressing motion for a predetermined time period.

Preferably the second layer is activated based on activation of the first layer. In this way user characteristics are only measured following a discrete activation command. This prevents undesired readings, for example from another person, to be mistakenly detected. Advantageously the activation function provides a lock function to display unit of the electronic cigarette.

Preferably the first layer and the second layer are superposed. In this way multiple layers can be provided on top of each other in an overlapping manner.

Preferably the second layer is a pixeled layer and wherein the first layer defines the reading zone of the pixeled second layer. In this way the pixeled layer can be used as a sensing layer where the first layer is configured to indicate where the reading zone of the second layer, or sensing region, is positioned in the display unit of the electronic cigarette. In other words information from the first layer is sent to the controller which then defines the reading zone of the second layer.

Preferably the sensor is configured to detect a movement or position in space of the electronic cigarette. In this way the sensor can detect user motion and display operational information when it detects that the electronic cigarette is being used according to a pre-set manner. For example the sensor can be an accelerometer.

Preferably the electronic cigarette according to any one of the preceding claims, wherein the sensor is a biometric sensor. In this way the sensor can detect biometric information of a user, such as pulse/heart-rate, blood oxygen levels and/or user temperature. This information may be used to activate the electronic cigarette device and/or display the information to the user.

The sensor may be an optical sensor. In this way the sensor can detect light to activate and/or operate the display unit. The sensor may be a fingerprint reader. In this way the sensor can detect fingerprint biometrics to activate the device. Other biometric sensing functions may also be provided via a fingerprint reader, such as pulse or blood-oxygen monitoring. The sensor may preferably be provided as a sensing layer comprising an array of finger biometric pixels. The sensor may be a heart rate sensor.

The electronic cigarette comprises an additional sensor located on the external housing of the electronic cigarette. In this way multiple sensors can be incorporated into the electronic cigarette, where the additional sensor is configured to communicate with the display unit. The additional sensor is located within a notch or depression on an opposite or opposing surface to the outer surface of the display unit. This allows a user to operate both the display unit and the additional sensor with one hand, for example by gripping the electronic cigarette between a finger and a thumb. Preferably the external housing comprises an electrically conductive material and is connected to a circuit registering a heartbeat.

Preferably the electronic cigarette according further comprises a controller configured to retrieve information from the sensor and control the operation of the device. In this way the controller can operate the electronic cigarette based on information received from the sensor. For instance, there can be a plurality of users associated with the device and the e-cig can calibrate the device (vapor volume, allowable timings and nicotine intake etc.) after detecting the specific user or person using the device. The controller may preferably provide a lock mechanism to the electronic cigarette which must be de-activated before the e-cig can be used. Of course, one major advantage of the fingerprint authorization for example is to avoid child or underage use of the device.

Preferably the display unit is provided as an exterior surface, such as a top surface on an insert, comprising at least one electronic component. In this way the display unit can be placed into the external housing in a mounted arrangement. By using a mounted arrangement the manufacturing process is simplified, thereby reducing the risk of damage during production.

In the present disclosure there is provided an electronic cigarette, comprising: an insert comprising at least one electronic component; a housing sleeve comprising a body with a first end and a second end, wherein the housing sleeve comprises an opening along a length of the body between the first end and the second end, and wherein the opening is arranged to receive the insert within the housing sleeve.

In this way the opening allows electronic components to be placed into a housing sleeve in a mounted arrangement. This minimises the risk of damaging electronic components which are introduced into the housing sleeve, as compared to inserting electronic components via an end of a sleeve in a sliding manner where the components may be damaged as they are pushed into position. Providing an opening along the length of the housing sleeve allows aerosol generation devices to be easily and reliably manufactured, reworked or repaired in a cost-effective way. For example a battery can be easily replaced, or access to a printed circuit board, PCB, for reworking is improved by providing access along the length of the housing sleeve.

Preferably the insert further comprises a lid sized and shaped to match the opening. In this way the lid reliably closes the opening and provides protection to the at least one electronic component. The lid may have a rim having a geometry configured to engage with the circumferential edge of the opening in the housing. The outer surface of the lid may be flush with the outer surface of the housing sleeve, or be textured (to provide additional grip) according to design requirements. Alternatively the outer surface of the lid may not be flush in order to include further features (e.g. magnetic or mechanical push-fit connections) which interact with other components, such as a stand or case for the electronic cigarette.

Preferably the lid comprises a display. In this way the lid provides additional display functionality to the aerosol generation device. For example the display may indicate the battery power level of the device, or user information such as puff count or duration of use. The electronic cigarette may also be wirelessly connected to a third party device, such as a smartphone, and provide notifications from the third party device.

The at least one electronic component may comprise one or more of: a battery, a printed circuit board, PCB, and a sensor. In this way different electronic components can be introduced into a housing sleeve via the insert.

The at least one electronic component may be an airflow sensor. In this way the insert can be configured to further interact with a capsule or pod to calculate the amount of aerosol inhaled by a user. The insert may further comprise a housing for the airflow sensor, the housing being configured to receive a portion of the airflow sensor and provide a reduced pressure space.

Preferably the lid comprises a material of higher flexibility than the housing sleeve. In this way the lid and/or display can clip or snap onto the housing via a push-fit connection. For example the lid material may be made of plastic such as polymethyl methacrylate, glass or a combination thereof.

Preferably the display has a connection rim, preferably in metal. The connection rim may be configured to receive a fastener configured to attach the metallic connection rim to the circumferential edge or rim of the housing.

Preferably the insert comprises a wireless antenna positioned below the lid and that is arranged to communicate data therethrough. In this way the lid can be easily constructed at low cost and is also suitable for display and wireless communication purposes. The aerosol generation device can communicate with a user device via a wireless antenna, and where the lid allows wireless communication to easily pass through.

Preferably the housing sleeve comprises a metallic material. In this way transmission of wireless data occurs preferentially through the lid of the device. Hence, the lid provides a surface that facilitates the transmission of radio waves.

Preferably the housing sleeve has a closed end and an open end. In this way the housing sleeve can be easily constructed, for example by extrusion or injection moulding. The housing sleeve may have a cross-sectional shape which is substantially rhombus shaped, oval, circular, square or rectangular.

Preferably the opening is located at a major surface or at a side of the housing sleeve. In this way the insert can be easily introduced within the housing sleeve and away from the ends of the housing sleeve thereby reducing the risk of damage to the at least one electronic component.

The electronic cigarette may further comprise a closing element at the first end. In this way the closing element, for example a plug, provides a seal at the first end of the aerosol generation device.

Preferably the closing element comprises a port, the port configured to provide electrical or data communication access to the at least one electronic component. In this way the first end can be used as an access point to the at least one electronic component of the mounted insert. The port may be made from a radio transparent material similar to that of the display. The port may also comprise embedded magnets which may be used as connections to further enhance the functionality of the electronic cigarette.

Preferably the electronic cigarette further comprises a cartridge seating or a liquid store at the second end. In this way a cartridge or liquid store may be received in the housing sleeve in order for the electronic components to provide electrical energy to a heating element in the cartridge or take measurements, such as a heating element temperature or aerosol generating liquid volume, from the cartridge.

There is also provided a method of manufacturing the electronic cigarette according any of the preceding claims, comprising: providing an insert comprising at least one electronic component; providing a housing sleeve comprising a body with a first end and a second end, wherein the housing sleeve comprises an opening along a length of the body between the first end and the second end, and wherein the opening is arranged to receive the insert within the housing sleeve; and mounting the insert within the housing sleeve via the opening. In this way electronic components can be placed into a housing sleeve using a mounted arrangement, which simplifies the assembly process and reduces the risk of damage to electronic components.

Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:.

<FIG> show an electronic cigarette <NUM> known from the prior art. The electronic cigarette includes a sleeve <NUM> with a mouthpiece end <NUM> and a charging end <NUM>. A capsule, or pod, <NUM> is provided at the mouthpiece end <NUM>, and electronic components, which include a battery <NUM> and a printed circuit board <NUM>, are provided on a drawer <NUM> for insertion via the charging end <NUM> into the sleeve <NUM>. The drawer <NUM> has a capsule contact portion <NUM> and a plug portion <NUM> arranged such that the capsule contact portion <NUM> is slidingly inserted into the sleeve <NUM> through the charging end <NUM> as shown in <FIG>.

The sleeve <NUM> has a closed end at the charging end <NUM> and an open end at the mouthpiece end <NUM> when the drawer <NUM> is fully inserted into the sleeve <NUM>. In other words, the capsule contact portion <NUM> does not extend through to the mouthpiece end <NUM> when the drawer <NUM> is in position within the sleeve <NUM>. This allows a capsule portion of the capsule <NUM> to be received into the open end for connection with the capsule contact portion <NUM>.

The capsule contact portion <NUM> has spring contacts (not shown) which are configured to provide electrical energy from the battery <NUM> to a heater element in the capsule <NUM> when the electronic cigarette <NUM> is in use. The plug portion <NUM> has electrical contacts (not shown) which allow the electronic cigarette <NUM> to be plugged into a charging port for the battery <NUM> to be recharged.

The sleeve <NUM> is made by extrusion of a metallic material through a die to form the tubular body. A hole (not shown) is drilled into the sleeve <NUM> to allow LED indication, such as device charging information, to be provided in the electronic cigarette <NUM>.

The cross-section of the sleeves in the drawings is substantially oval-shaped with flat sides, but it should be understood that any shape could be used (for example rhombus-shaped, oval, circular, square or rectangular). The sleeve may also be made from other materials and processes, for example plastics, ceramics or a combination thereof and vacuum-forming, injection moulding or casting processes. A cast or moulded sleeve could be manufacture with one or both ends closed which may be subsequently machined to provide access to the inner space in the sleeve.

<FIG> shows a perspective view of an assembled electronic cigarette <NUM> in an embodiment of the present invention. The electronic cigarette <NUM> has a sleeve <NUM> with a mouthpiece end <NUM> for receiving the capsule <NUM> and a charging end <NUM> for battery recharging purposes. The sleeve <NUM> has a lid <NUM> which covers a chamber section <NUM> as shown in <FIG>. Similar to the electronic cigarette in the art (shown in <FIG>) the sleeve <NUM> is preferably made as a single piece (e.g. by extrusion). The chamber section <NUM> comprises an opening configured to receive components.

The chamber section may be created by cutting a section out of the sleeve <NUM> to provide access to the inside of the sleeve <NUM> from its top side or a major surface of the sleeve <NUM>. It is also possible to cast, injection-mould or vacuum-form a sleeve or housing with the chamber section provided, or alternatively a solid block of material can be machined into shape as required to provide the chamber section and holes for electrical and charging access and/or airflow. <FIG> shows the sleeve <NUM> with the chamber section <NUM> in its top major surface to allow electronic components including a battery <NUM>, PCB <NUM> and control circuitry <NUM> to be placed into the chamber section <NUM>, as shown in <FIG>. The electronic components can be assembled on an insert (<NUM>) that is lowered into the chamber section <NUM> or alternatively each component can be individually placed into the sleeve <NUM>. After the insert <NUM> and electronic components are placed into the sleeve <NUM> the lid <NUM> is placed over the opening of the chamber section <NUM>.

The electronic cigarette <NUM> is configured to receive a pod <NUM>, where the pod <NUM> contains an aerosol forming material and a heating element. However it should be understood that in an alternative configuration the heating element can be part of the electronic cigarette <NUM> and provided as an isolated component among the electronic components to be placed in the sleeve <NUM>.

As shown in <FIG>, the lid <NUM> has a connection rim that is sized and shaped to match the circumferential edge of the opening. This has an advantage that the components housed in the sleeve <NUM> are sealed off and protected from external debris. The lid <NUM> may be attached onto the sleeve <NUM> in a friction fit connection. The friction fit connection can be achieved by using a push-fit mechanism with preferably a rubberised ring provided in the connection rim to seal the joint and provide shock-protection. Alternatively a magnetic connection can also be used. Optionally a groove (not shown) can be provided at the edge of the lid <NUM> and/or chamber section <NUM> for a tool to remove the lid <NUM> for repair or rework purposes. The lid <NUM> can also be configured as a door (e.g. a hinged connection) that allows a user to open in order to replace a battery or any other faulty electronic component.

<FIG> shows an alternative embodiment in which an electronic module <NUM> is provided as a single unit that is placed into the sleeve <NUM>. The electronic module <NUM> comprises parts of or all electrical circuitry required to operate the electronic cigarette. The electronic module <NUM> has an outer frame structure, or chassis, <NUM> in which electrical components including the battery <NUM>, PCB <NUM>, control circuitry and any other electronic components are provided. <FIG> shows a perspective view of the electronic module <NUM> from the bottom of the module <NUM>, where the electronic module <NUM> is shown to include a base plate <NUM> having a fastener <NUM> configured to guide or attach to corresponding contacts <NUM> in the chamber section <NUM> of the sleeve <NUM>. In an embodiment, the fastener <NUM> may be in the form of magnetic contacts <NUM> and <NUM>, which may optionally also act as electrical contacts for charging and heater power delivery purposes.

The lid <NUM> may advantageously be fixedly attached to the electronic module <NUM> prior to the electronic module <NUM> being inserted into the sleeve <NUM>. This can be achieved using a friction fit (such as a push-fit) or screw fastening mechanism for example. By fixing the lid <NUM> to the electronic module <NUM> the entire modular unit can be easily removed from the electronic cigarette <NUM> for any repair works.

As an illustrative example <FIG>, <FIG> show a lid <NUM> and display <NUM> in accordance with the present invention. It should be understood that the lid <NUM> can be manufactured separately from the sleeve of an electronic cigarette, which therefore allows the lid to be made from a different material, such as plastic (e.g. polymethyl methacrylate), glass, metal or a combination thereof. For example a laminated structure may be used in which a smaller glass layer is inset from and layered above or below a larger plastic layer. The outline or outer edge of the glass layer can have a rubber joint with mechanical clip features disposed around it, which acts as a seal and fastening mechanism to keep the glass and plastic layers in place and together.

The electronic cigarette may further comprise a display <NUM>. The display <NUM> can be a separate component positioned over an opening in the body of the electronic cigarette <NUM>. Hence, the display <NUM> of the present disclosure can be provided without the beforementioned advantageous manufacturing method including a top-mounted insert <NUM>.

However, in a preferred embodiment, the digital display <NUM>, such as an OLED display, liquid crystal, or electronic ink (e-ink) display for example, is integrated into the lid which is connected to the PCB or control electronics within the device. The display <NUM> can provide a user and/or device operational information such as puff count, duration of use, battery status and/or external information and notifications from a connected third party device, such as a calendar or other application in a smartphone.

Additional components can also be attached or integrated into the display <NUM> by using a plurality of different layers in the display <NUM> as shown in <FIG>, or alternatively the additional components can be set apart from the display <NUM> as depicted in <FIG>. The additional components may include sensorial or biometric trackers <NUM>, <NUM> to detect one or more characteristics from a user (e.g. motion sensors, fingerprint sensors, heart-rate or blood oxygen monitors), airflow sensors <NUM>, wireless antennas <NUM> for data or power communication, etc. The additional components may also include sensors that detect environmental conditions, such as temperature or humidity. In further example the additional components may be provided on the sleeve of the electronic cigarette.

A touch panel, which may be made of a thin glass sheet, can be placed on top of the display <NUM>, where the touch panel can be silkscreened to hide the additional components below the display <NUM>. It should therefore be understood that the display <NUM> can act as both an input device and an image display (i.e. similar to a touchscreen display in other electronic devices).

The display <NUM> can be made up of multiple layers, including one or more image display layers for providing information to a user and one or more transparent conductive layers for detecting user input, such as user touch commands or gestures, fingerprints, pulse, or other known biometrics. The conductive layers may include separate layers for authentication and sensing, where the authentication layer must provide a valid authentication to the control electronics before the sensing layer is activated. A user may provide authentication by inputting a PIN number, swipe pattern or other command to a touch panel. Alternatively authentication may be provided via fingerprint validation. A haptic indication may also be provided at the start or end of a user input recording to notify a user that an authentication or reading of biometric information (e.g. a fingerprint biometric heart signature) was successful.

Each of the layers in a biometric display may have substantially the same area, with each layer covering or superposed on a next layer. Alternatively the different conductive layers may have different sizes superposed to provide different zones for reading, authentication and sensing, where some zones may provide combined functions. For example a display may have a distinct zone for fingerprint authentication, and a separate zone for heart-rate monitoring, where the two zones are both provided under the display layer and general touch control layer.

Fingerprint authorization can also be integrated. This can be achieved by arranging a fingerprint scanner below the surface of the display. In order to enhance the readability, the display surface is advantageously configured with a geometry (curved radius) that ensures a sufficiently large contact zone between a user's finger and the display. The fingerprint recognition can also be used to read different commands as different fingers or portions of a single finger, like a "footprint", can be read. In other words different angles and combinations of fingers can be used in the fingerprint scanner to control different functions provided by the electronic device.

The properties of the material(s) of the lid should be selected in order for the functions of such additional components to be integrated or function through the lid; for example selecting a plastic lid that would allow preferential radiofrequency, RF, data transmission through the lid from an antenna in the device as compared to the RF transmissibility through the surrounding metal sleeve body, or configuring a portion of the lid to allow biometric scanning (e.g. heartbeat, fingerprint, etc.) to occur. <FIG> shows the underside of the lid <NUM> to which sensors and/or any other additional electronic components can be attached so that the body of a bulkier component can be stored in the chamber section of a device. This allows the top outer surface of the lid to be substantially flush with the outer surface of the sleeve when assembled.

<FIG> shows a schematic of another embodiment in which an additional sensor <NUM> is located in the sleeve <NUM> of the electronic cigarette, on a face of the sleeve opposite to the display <NUM>. The additional sensor <NUM> may be a biometric sensor such as a heart-rate monitor or other biometric scanning device as described above. This additional sensor <NUM> is aligned with the sensor region, for example a fingerprint sensor <NUM>, in the display <NUM> such that a user can easily place their finger or thumb on either sensor <NUM>, <NUM>. A weakening, for example a indented region, depression or notch, can also be provided around the additional sensor <NUM> to make the additional sensor <NUM> easier to locate.

In this embodiment it is possible for one sensor to be used as an activation or authentication sensor and the other sensor to function as a reading or data collection sensor. For example the sensor <NUM> in the display <NUM> may be a touch panel through which a user selects and activates a pulse or heart-rate monitoring function, whereby the user then places their thumb on the additional sensor <NUM> for the pulse to be read.

Different configurations for arranging components in the device and the lid would readily occur to a person skilled in the art. Importantly it should be understood that the lid allows an electronic cigarette to provide increased functionality to the user and protects the electronic components under the lid and in the sleeve.

<FIG> shows an electronic cigarette <NUM> in another embodiment of the invention. In this arrangement the electronic components are inserted into the electronic cigarette <NUM> from a side entry chamber <NUM> in the sleeve <NUM>. The side entry chamber <NUM> may be created in a similar way as the previously described top entry chamber <NUM>. Hence, the side entry chamber <NUM> can be created by cutting a section out of the sleeve <NUM> in a similar way to the top entry embodiment of the invention. A plug <NUM> is preferably inserted at a charging end <NUM> of the device <NUM>, and a pod <NUM> is inserted at a mouthpiece end <NUM> of the device <NUM>. The plug <NUM> can be made of a RF transmissive material and/or include access ports (not shown) for electrical or data communication access. The access ports may also include embedded magnets for connection to other devices such as a docking or charging hub, or other electronic add-ons that may enhance the device (e.g. additional display or light feature, power bank or external storage).

Claim 1:
An electronic cigarette (<NUM>), comprising:
an external housing (<NUM>);
a sensor (<NUM>) configured to detect a characteristic from the user;
a display unit (<NUM>, <NUM>) located in an aperture (<NUM>) of the external housing and configured to receive user input and display operational status of the device, wherein the sensor is integrated into the display unit; and
an additional sensor (<NUM>) located on the external housing of the electronic cigarette within a notch or depression on an opposite or opposing surface to the outer surface of the display unit.