Patent ID: 12200821

DETAILED DESCRIPTION

Various example embodiments will now be described more fully with reference to the accompanying drawings in which some example embodiments are shown. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Thus, the embodiments may be embodied in many alternate forms and should not be construed as limited to only example embodiments set forth herein. Therefore, it should be understood that there is no intent to limit example embodiments to the particular forms disclosed, but on the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope. In the drawings, the thicknesses of layers and regions may be exaggerated for clarity, and like numbers refer to like elements throughout the description of the figures.

Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that, if an element is referred to as being “connected” or “coupled” to another element, it can be directly connected, or coupled, to the other element or intervening elements may be present. In contrast, if an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” if used herein, specify the presence of stated features, integers, steps, operations, and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or groups thereof.

Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper” and the like) may be used herein for ease of description to describe one element or a relationship between a feature and another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, for example, the term “below” can encompass both an orientation that is above, as well as, below. The device may be otherwise oriented (rotated 90 degrees or viewed or referenced at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.

Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, may be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle may have rounded or curved features and/or a gradient (e.g., of implant concentration) at its edges rather than an abrupt change from an implanted region to a non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation may take place. Thus, the regions illustrated in the figures are schematic in nature and their shapes do not necessarily illustrate the actual shape of a region of a device and do not limit the scope.

It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed substantially concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.

Although corresponding plan views and/or perspective views of some cross-sectional view(s) may not be shown, the cross-sectional view(s) of device structures illustrated herein provide support for a plurality of device structures that extend along two different directions as would be illustrated in a plan view, and/or in three different directions as would be illustrated in a perspective view. The two different directions may or may not be orthogonal to each other. The three different directions may include a third direction that may be orthogonal to the two different directions. The plurality of device structures may be integrated in a same electronic device. The plurality of device structures may be arranged in an array and/or in a two-dimensional pattern.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In order to more specifically describe example embodiments, various features will be described in detail with reference to the attached drawings. However, example embodiments described are not limited thereto.

FIG.1ais a schematic illustration of a two element vaping device in a disassembled state. The device comprises a main unit100, comprising a battery120and control circuitry130, and an aerosol-generating element200, referred to as a cartomiser, comprising an reservoir of liquid230, an electrically powered heater220and a mouthpiece240.

FIG.1bis a schematic illustration of the device ofFIG.1ain an assembled state, with the housing110of the main unit100fixed to the housing205of the aerosol-generating element200. Power is provided from the battery120in the main unit100to the heater220in aerosol-generating element200, under the control of the control circuitry130. When the main unit100is connected to the aerosol-generating element200, electrical connection terminals210,215mate with electrical contacts140,145on the main unit100. Electrical current can be supplied through the electrical contacts and connection terminals. Although it is illustrated only schematically, the connection between the main unit100and the aerosol-generating element200is made by a screw connection. Both the electrical connection terminals and the electrical contacts can be arranged as annular, coaxial connectors so that the relative rotational position of the main unit and the aerosol-generating element is not critical to provide an effective electrical connection.

The liquid in the reservoir230is delivered to the heater220by a capillary wick225. The capillary wick225extends across an airflow passage235through a tube245running through the centre of the aerosol-generating element. The heater220comprises a heater filament, coiled around the capillary wick225within the airflow passage. The heater220is electrically connected to the electrical connection terminals210,215.

The device illustrated inFIGS.1aand1boperates as follows. When the mouthpiece240is drawn upon, air is drawn into the airflow passage235through inlet holes (not shown) in the housing of the main unit and the aerosol-generating element. An airflow sensor, such as a microphone (not shown) is provided in the main unit and senses the flow of air. When a sufficient airflow is detected, the control circuitry130supplies power to the heater220. This causes the heater220to heat up and vapourise the liquid in the immediate vicinity of the heater. The resulting vapour is cooled in the air flowing past the heater and condenses to form an aerosol. The aerosol is then drawn out through the mouthpiece240. When air is no longer drawn through the mouthpiece, and the airflow past the airflow sensor drops below a threshold level, the control circuitry130cuts power to the heater220. The liquid in the capillary wick is replenished by capillary action from the liquid reservoir.

However, as will be described, in example embodiments, the aerosol-generating element performs another function, additional to atomising the substrate, and an additional electrical element or electrical elements, described in detail with respect toFIGS.2-6, are provided for that function. The additional function may be to identify to the control circuitry the type of liquid in the cartomiser, or may be to provide the control circuitry with a measurement of a parameter of the system, such as heater temperature or liquid level within the liquid storage portion, or may be to record usage data for the cartomiser. Alternatively, the additional function may be to disable the cartomiser in certain conditions, such as a malfunction or after a certain period of use.

Ordinarily, in order to provide such additional functionality in a cartomiser, it is necessary to provide further, function specific, electrical connections between the main unit and the cartomiser. So one pair of connection terminals may be used to connect the atomiser to the control circuitry, and another pair of electrical connections may be used to transfer power or data between the additional electrical elements in the cartomiser and the control circuitry in the main unit. This significantly increases the complexity and cost of the main unit. It also increases the probability of a malfunction of breakage, and reduces the reliability of the connection between the main unit and the cartomiser.

However, it is possible to provide for additional functions using just the single pair of electrical connections between the main unit and the cartomiser.FIG.2illustrates a basic circuit arrangement for providing an identifying resistor in the cartomiser that can be measured by the control circuitry in the main unit before power is supplied to the heater. This is useful because different liquid compositions in different cartomisers or different arrangements of heater and airflow in different cartomisers may require different management of power supplied to the heater in order to provide an optimal experience. By identifying the type of cartomiser connected to the main unit before application of power to the heater, an appropriate power management program can be selected. It may also be beneficial for detecting counterfeit cartomisers. If an identifying resistor is not present or is not of a recognised value, the control circuitry may be configured to prevent the supply of power to the cartomiser.

In the arrangement ofFIG.2, the electrical connection terminals210,215are labelled T1and T2respectively. The heater220is connected directly to T1and is connected to T2through a first diode300. The first diode prevents a flow of current from T2to T1through the heater220. The identifying resistor320is connected to the connection terminals in parallel with the heater. The identifying resistor is connected directly to T2and is connected to T1through a second diode310. The second diode prevents a flow of current from T1to T2through the resistor320.

The first and second diodes inFIG.2are simple p-n junction diodes. However, one or both diode may be light emitting diodes or diodes of another type.

So, in order to measure the resistance of the identifying resistor320without activating the heater, the control circuitry130applies current to the connection terminals so that current can pass through the identifying resistor, shown as arrow B. In order to activate the heater without dissipating power in the resistor320, the control circuitry130applies current to the connection terminals in the reverse direction, shown as arrow A. The arrangement shown inFIG.2effectively enables two separate and independent circuits to be created using a single pair of electrical connections, in a simple and inexpensive manner. The resistor320can be replaced by an identifying electrical element of another type, such as a capacitor or inductor.

FIGS.3,4,5and6illustrate similar circuit arrangements to that shown inFIG.2, but are configured to provide different secondary functions. InFIG.3a fuse330is provided in place of the resistor320ofFIG.2. A fuse may be provided to prevent reuse of the cartomiser after the supply of aerosol-forming substrate has been exhausted. For example, the control circuitry130may be configured to count the number of times the heater has been activated following connection of a new cartomiser to the main unit, and when the count reaches a desired (or, alternatively a predetermined) number, the control circuitry130may be configured to apply a current through the fuse330, sufficient to blow the fuse. When a new cartomiser is connected to the main unit, the control circuitry130may be configured to pass a smaller current from T2to T1, insufficient to blow the fuse330, to check that a fuse is present and intact. If no current can flow from T2to T1, then a fuse is not present or has blown and the control circuitry130may be configured to prevent the supply of power to the cartomiser.

InFIG.4, the resistor ofFIG.2is replaced by a sensor340. The sensor340may be a liquid level sensor that allows liquid level to be checked before each heater activation or before each vaping session. If the level of liquid in the liquid reservoir is below a threshold, the control circuitry130may be configured to prevent the supply of power to the heater.

InFIG.5, the resistor ofFIG.2is replaced by a memory350. The memory may be used to store usage data for the consumable. The usage data may include, for example, usage time, number of puffs, number of vaping sessions and estimated liquid use or estimated liquid remaining. After each puff, the control circuitry130may update the record stored in the memory. The provision of a memory is particularly useful for refillable cartomisers that can be swapped. By storing the data on the cartomiser, each cartomiser retains a record of its use. This has advantages over storing usage data on the main unit, as that would require the main unit to uniquely identify each cartomiser before use and maintain a record for each cartomiser used.

InFIG.6, the resistor ofFIG.2is replaced by a second heater360. A second heater may be provided in the same location as the first heater220in order to give rise to a different heating effect. Alternatively, a second heater may be provided in a different location within the cartomiser in order to heat a different liquid or in order to allow more time for liquid at the first heater to be replenished following activation of the first heater. The control circuitry130may be configured to activate each heater on different but alternate puffs. Alternatively, heater to be used for a particular vaping session may be selectable.

Example embodiments allow a cartomiser to have two separate and independent functions whilst only having a standard two terminal connection. By maintaining only two connections, the device can remain simple to construct, cheap to make and/or more reliable than more complicated solutions having more than two connection terminals.

It should be clear that the examples described herein are simple examples, and that modifications may be made to the illustrated circuits to provide different or more sophisticated functionality. For example, in each of the illustrated circuits the barrier elements are simple diodes, which has the advantage of being simple and inexpensive. However, it is possible to use another element, such as a transistor, or a combination of elements, to provide the same function.

It should also be clear that types of aerosol-generating systems different to that illustrated inFIG.1could incorporate the invention. In particular, vaping systems that operate by heating a solid aerosol-forming substrate may usefully be made in accordance with the invention.