Patent ID: 12239162

DETAILED DESCRIPTION OF THE EMBODIMENTS

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.

FIG.1Ashows a smoking substitute system100. In this example, the smoking substitute system100includes a device101and an aerosol delivery consumable component102. The consumable component102may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the device may be integral with the component. In such systems, a tank of the aerosol delivery component may be accessible for refilling the system.

In this example, the smoking substitute system100is a closed system vaping system, wherein the consumable component102includes a sealed tank103and is intended for single-use only. The consumable component102is removably engageable with the device101(i.e., for removal and replacement).FIG.1Ashows the smoking substitute system100with the device101physically coupled to the consumable component102,FIG.1Bshows the device101of the smoking substitute system100without the consumable component102, andFIG.1Cshows the consumable component102of the smoking substitute system100without the device101.

The device101and the consumable component102are configured to be physically coupled together by pushing the consumable component102into a cavity at an upper end104of the device101, such that there is an interference fit between the device101and the consumable component102. In other examples, the device101and the consumable component102may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable component102comprises a housing105having a base portion106(at a lower end), a mouthpiece107(at an upper end), and walls extending longitudinally from the base portion106to the mouthpiece107. In particular, the consumable component102comprises front108aand rear walls spaced by opposing first108cand second108dside walls. The distance between the front108aand rear108bwalls defines a depth of the housing105and the distance between the side walls108c,108ddefines a width of the housing105. The width of the housing105is greater than the depth of the housing105.

The tank103of the consumable component102comprises a window109, which allows the quantity of e-liquid remaining in the tank103to be visually assessed. The device101includes a slot110so that the window109of the consumable component102can be seen whilst the rest of the tank103is obscured from view when the consumable component102is inserted into the cavity at the upper end108of the device101.

A lower end111of the device101includes a light112(e.g., an LED) located behind a small translucent cover. The light112may be configured to illuminate when the smoking substitute system100is activated. Whilst not shown, the consumable component102may identify itself to the device101, via an electrical interface, RFID chip, or barcode.

FIGS.2A and2Bare schematic drawings of the device101and consumable component102. These figures provide an overview of the components that form part of the consumable component102and device101. As is apparent fromFIG.2A, the device101includes a power source113, a controller114, a memory115, a wireless interface116, an electrical interface117, and, optionally, one or more additional components118.

The power source113is a battery (e.g., a rechargeable battery). The controller114may, for example, include a microprocessor. The memory115may include non-volatile memory. The memory115may include instructions which, when implemented, cause the controller114to perform certain tasks or steps of a method.

The wireless interface116may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface116could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., WIFI®, are also possible. The wireless interface116may also be configured to communicate wirelessly with a remote server.

The electrical interface117of the device101may include one or more electrical contacts. The electrical interface117may be located in a base of the cavity formed in the upper end104of the device101. When the device101is physically coupled to the consumable component102, the electrical interface117of the device101is configured to transfer electrical power from the power source113to the consumable component102(i.e., upon activation of the smoking substitute system100).

The electrical interface117may be configured to receive power from a charging station when the device101is not physically coupled to the consumable component102and is instead coupled to the charging station. The electrical interface117may also be used to identify the consumable component102from a list of known consumables. For example, the consumable component102may include e-liquid having a particular flavor and/or having a certain concentration of nicotine (which may be identified by the electrical interface117). This can be indicated to the controller114of the device101when the consumable component102is connected to the device101. Additionally, or alternatively, there may be a separate communication interface provided in the device101and a corresponding communication interface in the consumable component102such that, when connected, the consumable component102can identify itself to the device101.

The additional components118of the device101may comprise an indicator (e.g., the light112discussed above), a charging portion, a battery charging control circuit, a sensor or, e.g., user input.

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 source118is a rechargeable battery). This may be located at the lower end111of the device101. Alternatively, the electrical interface117discussed 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.

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).

The sensor may be, e.g., an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system100, e.g., caused by a user inhaling through a mouthpiece107of the consumable component102. The smoking substitute system100may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable component102. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece107or how many times a user draws on the mouthpiece107in a particular time period.

The user input may be a button. The smoking substitute system100may 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 system100.

The consumable component102, which is shown inFIG.2B, includes the tank103, an electrical interface119, a vaporizer120, an air inlet121, an air outlet122(e.g., formed in the mouthpiece107), and one or more additional components123.

The electrical interface119of the consumable component102may include one or more electrical contacts. The electrical interface117of the device101and the electrical interface119of the consumable component102may be configured to contact each other and thereby electrically couple the device101to the consumable component102when the base portion106of the consumable component102is inserted into the cavity formed in the upper end104of the device101(as shown inFIG.1A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source113in the device101to the vaporizer120in the consumable component102.

The vaporizer120is configured to heat and vaporize e-liquid contained in the tank103using electrical energy supplied from the power source113. As will be described further below, the vaporizer120heats the e-liquid received from the tank103to vaporize the e-liquid. The air inlet121is configured to allow air to be drawn into the smoking substitute system100when a user inhales using the air outlet122formed in the mouthpiece107, such that the vaporized e-liquid is drawn through the consumable component102for inhalation by the user.

In operation, a user activates the smoking substitute system100, e.g., through interaction with a user input forming part of the device101or by inhaling through the air outlet122as described above. Upon activation, the controller114may supply electrical energy from the power source113to the vaporizer120(via electrical interfaces117,119), which may cause the vaporizer120to heat e-liquid drawn from the tank103to produce a vapor which is inhaled by a user through the mouthpiece107.

An example of one of the one or more additional components123of the consumable component102is an interface for obtaining an identifier of the consumable component102. 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 component102. The consumable component102may, 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 interface117in the device101.

It should be appreciated that the smoking substitute system100shown inFIGS.1A to2Bis just one exemplary implementation of a smoking substitute system100. 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).

FIGS.3A,3B and3Care section views of the consumable component102described above. The air inlet121of the consumable component102is in the form of an aperture formed in the first side wall108cof the housing105. In particular, the air inlet121is spaced along the first side wall108c(in a longitudinal direction) from the base portion106of the housing105so as to be partway along the first side wall108cfrom the base portion106. The air outlet122is formed in the mouthpiece107and an airflow path124extends from the air inlet121to the air outlet122, such that a user can draw air through the airflow path124by inhaling at the air outlet122. As will be described in more detail below, the airflow path124follows a generally U-shaped path through the consumable component102.

The airflow path124comprises first138a, second and third138cairflow path portions. The first airflow path portion is defined by an inlet passage125aextending longitudinally from the air inlet121towards the base portion106of the consumable component102. This inlet passage125ais defined between a first tank wall126athat is laterally (i.e., transversely) spaced from the first side wall108c(in which the air inlet121is formed) and that extends longitudinally from an internal surface of the mouthpiece107.

The third airflow path is similarly defined by an outlet passage125bthat is formed between a second tank wall126band the second side wall108d. The second tank wall126bextends longitudinally from an internal surface of the mouthpiece107and is laterally spaced from the second side wall108d. Both the first126aand second126btank walls span the front108aand rear108b(seeFIG.3B) walls of the housing105. In this way, the tank103is partly defined between the first and second tank walls126a,126b, the front108aand rear108bwalls, and an internal surface of the mouthpiece107.

The tank walls126a,126band the mouthpiece107are 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 walls126a,126bis tapered from a proximal end at which it is connected to the mouthpiece107to an opposing distal end.

The second airflow path portion is in the form of a vaporizing chamber127that extends transversely across the housing105so as to connect lower ends of the first125aand second125bpassages. Thus, upon inhalation by a user, air may flow into the inlet121, through the inlet passage125a, through the vaporizing chamber127(where vapor may be entrained in the air) and subsequently through the outlet passage125bwhere it is discharged (into a user's mouth) from the outlet122at an upper end of the outlet passage125b. Thus, the airflow path124comprises at least two turns (at the inlet121and the connection between the vaporizing chamber127and the inlet passage125a) between the vaporizer chamber127and the inlet121. This may reduce the propensity for leakage of e-liquid out of the inlet121(i.e., from the vaporizing chamber127).

The vaporizer120is located in the vaporizing chamber127and comprises a porous wick128and a heater filament129coiled around the porous wick128. The wick128extends across the vaporizing chamber127(perpendicular to the direction of airflow through the chamber127). That is, the wick128extends in the depth direction of the housing105.

The vaporizing chamber127is formed within an insert130that is received in an open lower end of the housing105so as to define the base portion106of the consumable component102. The insert130seals against the walls of the housing105so as to define a lower end of the tank103. Thus, the walls of the insert130(defining the vaporizing chamber127) separate the vaporizing chamber127from the tank106. In particular, an upper transverse wall133of the insert130extends from the first tank wall126ato the second tank wall126bso as to separate the vaporizing chamber127from the tank103(and so as to define a lower surface of the tank103).

To form a seal with the tank walls126a,126b, the upper wall comprises grooves134a,134bthat extend in a direction of the depth of the housing105and receive distal ends of the tank walls126a,126b. This arrangement also seals the tank103from the air passages125a,125b, which connect to the vaporizing chamber127via respective channels135a,135bformed in the insert130.

As shown inFIG.3B, the insert130comprises two apertures131a,131bformed in opposing walls of the insert130for receipt of respective ends of the wick128therethrough. The insert130is spaced from each of the front108aand rear108bwalls, such that gaps132a,132bare formed between the insert130and each of the front108aand rear108bwalls. These gaps132a,132bare arranged such that the ends of the wick128projecting through the apertures131a,131bin the insert134are received in the gaps132a,132b. In this way, the ends of the wick128are in contact with aerosol precursor (e-liquid) stored in the tank106. This e-liquid is transported along the wick128(e.g., by capillary action) to a central portion of the wick128that is exposed to airflow flowing through the vaporizing chamber127. The transported e-liquid is heated by the heater filament129(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 wick128. This vaporized liquid may cool to form an aerosol in the passage140, which may then be inhaled by a user.

The insert also130accommodates the electrical interface119of the consumable component102. The electrical interface119comprises two electrical contacts136a,136bthat are electrically connected to the heating filament129. In this way, when the consumable component102is engaged with the device101, power can be supplied from the power source113of the device to the heating filament129.

As shown inFIGS.3A,3B and3C, the upper transverse wall133of the insert130separates the vaporizing chamber127from the tank103and includes a vent channel150. The vent channel150extends through the transverse wall133from a first opening152at the vaporizing chamber127to a second opening154at the tank103. The vent channel150is generally formed as an elongate tubular passage.

The longitudinal axis151of the elongate vent channel150intersects the vaporizer, which in this embodiment, includes an elongate cylindrical wick128with a length128L that is greater than its width128W and its depth128D. The length128L and width128W are both perpendicular to the length128L of the wick. The wick128extends transversely across the component and includes opposing first153aand second153blongitudinal ends.

Accordingly, the vent channel150is vertically above/vertically aligned with the wick128.

The axis151of the vent channel150intersects the wick128at a position that is equally spaced from the first longitudinal end153aand the second longitudinal end153bof the wick128. Thus, the vent channel150is transversely centered along the length128L of the wick128.

The axis151of the vent channel150intersects the longitudinal axis of the wick128such that the axis151of the vent channel150is centered in the width dimension128W of the wick128.

Accordingly, the axis151of the vent channel150is centered in both the length128L and width128W dimensions of the wick128.

The first opening152is positioned such that it overlies the wick128. The entire cross-sectional area of the first opening152overlies the wick128. The maximum dimension of the first opening152is less than the smaller of the width128W and length128L dimension of the wick128.

The first opening152is circular and the diameter of the first opening152is equal to or smaller than the smaller of the width128W and length128L dimensions of the wick128. The second opening154is circular.

The first opening152has a greater cross-sectional area/diameter than the second opening154. In this embodiment, the first opening152has a greater diameter than the second opening154.

The vent channel150tapers evenly/uniformly and constantly outwardly from the second opening154to the first opening152, i.e., the cross-sectional area of the vent channel150(in a plane extending perpendicularly to the longitudinal axis151of the vent channel150) increases toward the first opening152.

The vent channel150has a uniform circular cross-sectional profile, i.e., the cross-sectional profile/shape remains constant along the length of the vent channel150. Accordingly, the vent channel150is frustoconical. The vent channel150is shaped as a hollow conical frustum.

The longitudinal axis151of the elongate vent channel150is coaxial with the elongate axis of the component.

The silicone insert130forms the walls of the vaporizing chamber127and separates the vaporizing chamber127from the tank130. The insert130seals the vaporizing chamber127from the tank103other than at the vent channel150and the openings131a,131bthrough which the ends of the wick128project for contact with the aerosol precursor. The upper transverse wall133of the insert130includes an upper surface156which defines the lower end of the tank103and a lower surface158of the wall133which defines the upper end of the vaporizing chamber127. The first opening152is formed in the lower surface158of the wall and the second opening156is formed in the upper surface156of the wall.

As described above, in use aerosol precursor is drawn from the tank103and into the wick128. As the aerosol precursor is drawn out from the tank103, a pressure differential is created between the inside of the tank103and the vaporizing chamber127. This pressure difference causes air to be drawn into the tank103via the vent channel150.

Air is thus able to enter the tank103and replace the volume created by the vaporized aerosol precursor. By allowing air to enter the tank103, the pressure differential between the tank103and the vaporizing chamber127is equalized. Further aerosol precursor can therefore be released or drawn out from the tank103by the wick128as needed.

As described above, air passes through the vent channel150and into the tank103. Liquid aerosol precursor in the tank103may leak from the tank103through the vent channel150. Any liquid aerosol precursor that leaks from the tank103through the vent channel150is discharged onto the wick128. The aerosol precursor that leaks onto the wick128can be heated and vaporized as described above.

In a further embodiment, in which the component is the same as that shown inFIGS.3A,3B,3C, the second opening154is sized to prevent flow of liquid aerosol precursor therethrough. The second opening154, or specifically the cross-sectional area of the second opening154, may thus be sufficiently small to prevent flow of liquid aerosol precursor through the vent channel150. In practice, the second opening154is sufficiently small such that the surface tension of the liquid aerosol precursor prevents the liquid aerosol precursor from passing through the second opening154. In such an embodiment, the second opening154prevents liquid aerosol precursor from leaking from the tank103and into the vaporizing chamber127. The vent channel150is sized to allow air to pass therethrough. In particular, the first152and second154openings are sized to allow air to pass therethrough. Specifically, the cross-sectional areas of the first152and second154openings are sufficiently large to allow air to pass through them. Air is therefore able to pass freely through the first and second openings152,154of the vent channel150. In other words, air is flowable from the vaporizing chamber127through the first opening152and into the tank through the second opening154.

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.

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.

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%.

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.